KIRLOSKAR GK Series Programming manual

1 IOM/GK/SEP19/00
INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE ‘GK’
KIRLOSKAR BROTHERS LIMITED
REGD. AND HEAD OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002

2 IOM/GK/SEP19/00
WARRANTY
We warrant t at t e pump supplied from us is free from
defective material and faulty workmans ip. T is warranty olds
good for a period of 12 mont s from t e date of commissioning
t e equipment or 18 mont s from t e date of dispatc from our
factory, w ic ever is earlier. Our liability in respect of any
complaint is limited to replacing part/parts free of c arge ex-
works or repairs of t e defective part/parts only to t e extent
t at suc replacement/repairs are attributable or arise solely from
faulty workmans ip or defective material.
T is warranty olds good only for t e products manufactured by us.
KIRLOSKAR BROTHERS LIMITED

3 IOM/GK/SEP19/00
Table f c ntents
Sr. No. Description
Page No.
1.0 General 04
2.0 Safety Instructi ns 05
3.0 Equipment Schedule 09
4.0 Operati n 12
5.0 Maintenance Manual 14
5.1 Maintenance EHS instructi ns 14
5.2 General maintenance d cuments 14
5.3 Overhauling 14
5.3.1 Dismantling 15
5.3.2 Reassembly 18
5.4 Maintenance T ls required 19
5.5 Preventive Maintenance 19
5.5.1 Daily Checks 19
5.5.2 Peri dical Checks 19
5.5.3 Annual Checks 20
5.5.4 Mechanical Seal in Pumps 20
5.6 C rrective Maintenance 21
6.0 Technical Data 21
6.1 Directi n f R tati n 21
6.2 Bearing Details 21
6.3 Bearing Lubricati n 21
6.4.1 Stuffing B x Sealing 22
6.4.2 Stuffing B x packing specificati n 22
6.4.3 Stuffing B x Packing & Lantern Ring 22
6.4.4 Gaskets, O-rings & Wear Ring details 23
6.4.5 Interchangeability Chart f C mp nents 26
6.4.6 Rec mmended Spare Parts 29
7.0 Part Descripti n and Secti nal
Drawings 30
8.0 Expl ded View 36
9.0 General Outline Dimensi ns 37
10.0 Cut secti n View 39

4 IOM/GK/SEP19/00
1.0 GENERAL :
1.1 ‘KIRLOSKAR’ make GK series pumps are f back pull ut design which enables
t rem ve the r tating unit f pump f r inspecti n and repairs with ut
disturbing sucti n and delivery pipe c nnecti ns.
1.2 The b klet c vers instructi ns f r installati n, perati n & maintenance f
f ll wing m dels f GK Pumps:
GK
UNIT – 30
GK
UNIT – 40
GK
UNIT – 50
GK32/13
A
GK40/26B
GK65/32B
GK32/13B
GK50/26A
GK80/32B
GK32/16
GK50/32A
GK80/40B
GK32/20A
GK65/16B
GK100/26B
GK32/20B
GK65/20B
GK100/32B
GK40/13
GK65/26A
GK100/40A
GK40/
16
GK65/26B
GK100/40B
GK40/20A
GK80/16A
GK12
5/26A
GK40/20B
GK
80/20A
GK125/32A
GK50/13
GK80/26A
GK125/32B
GK50/16A
GK100/20A
GK50/20A
GK65/13A
Applicati ns:
GK pumps are mainly used f r clean and clear liquids which are free fr m
suspended s lids/particles. Few f the applicati ns are as bel w:
Water supply, Sprinkling, Air c nditi ning, Industrial water, Swimming p l water,
H t water, Fire fighting, Irrigati n, Drinking water/P table water, C ling water,
C ndensate, Clear juice.
1.3 Nameplate inf rmati n:
Every pump has the f ll wing nameplate fitted t bearing h using
(2400000) pr vided with necessary identificati n f the pump and its
specific hydraulic characteristics. The nameplate must n t be rem ved.
L ss f this plate c uld make identificati n imp ssible. This in turn c uld
affect safety and cause difficulty in btaining spare parts. Such accidental
l ss r damage if ccur, c ntact KBL immediately.

5 IOM/GK/SEP19/00
1.4 Pumps when pr perly installed & given due care in perati n & maintenance
sh uld perate satisfact rily f r a l ng peri d.
1.5 When the pump is received, s metime bef re the actual use f pump, it sh uld
be inspected & l cated in dry place. The shaft sh uld be r tated nce in a
m nth t prevent pitting f bearing surfaces.
2.0 Safety Instructions:
2.1 General Information
Bef re perf rming any acti ns detailed within this instructi n, the site Health
and Safety instructi ns and the instructi ns in this d cument shall be read and
fully underst d.
Whenever the equipment is perated, maintained r used in any way,
the pr cedures detailed within these instructi ns shall be f ll wed. The
pump supplied by Kirl skar Br thers Limited (KBL) has been designed
with safety in mind; where hazards cann t be eliminated, the risk has
been minimized by the use f guards and ther design features. S me
hazards cann t be guarded against and the instructi ns bel w MUST BE
COMPLIED WITH f r safe perati n. These instructi ns cann t c ver all
circumstances. It is the resp nsibility f the user f the equipment f r
maintaining safe w rking practices at all times. The pumps are supplied with
stickers f r hazard, cauti n & safety wherever these are applicable.
2.2.1 Within the manual, safety instructi ns are marked with safety symb ls.
Hazard.
This symb l refers t general mechanical aspects f safety.
Hazard.
This symb l refers t electrical safety.

6 IOM/GK/SEP19/00
This symb l is used t intr duce safety instructi ns wh se
n n bservance may lead t damage t the machine and its
functi ns.
2.1.2 KBL pr ducts are designed f r installati n in designated areas, which are t be
kept clean and free f bstructi ns that may restrict safe access t the c ntr ls
and maintenance access p ints.
2.1.3 Access t the equipment sh uld be restricted t the pers nnel resp nsible f r
installati n, perati n and maintenance and they must be qualified, adequately
trained and supplied with the appr priate t ls f r their respective tasks.
2.1.4 This pr duct must be serviced by qualified pers nnel wh are familiar with
the design and perati n f this pr duct and the system with the
essential safety aspects inv lved.
2.1.5 KBL firmly insists that all pers nnel resp nsible f r installati n, perati n and
maintenance f the equipment must read the manual bef re any w rk is d ne.
2.1.6 Our guarantee will be valid nly if the installati n, perati n,
maintenance and repairs f this pump are carried ut in acc rdance with these
instructi ns. The plant perat r is t make sure that the c ntents f these
instructi ns are fully underst d by the perating pers nnel. During
perati n, peri dic inspecti ns sh uld be made t assure safe perati n
under the prevailing c nditi ns.
2.1.7 Ear defenders sh uld be w rn where the specified equipment n ise level
exceeds l cally defined safe levels. Safety glasses r g ggles sh uld be
w rn where w rking with pressurized systems and hazard us substances.
Other pers nal pr tecti n equipment must be w rn where l cal rules apply.
2.1.8 Any m dificati n may be made t the pr duct nly after c nsultati n
with the manufacturer. Using spare parts and access ries auth rized by
the manufacturer is a relevant safety aspect. Only genuine spare parts
which are in acc rdance with the riginal delivery (in the parts list) are t
be used.
2.2 DO NOT wear l se r frayed cl thing r jewellery, which
c uld catch n the c ntr ls r bec me trapped in the
equipment.
2.3 Operati n f the equipment f r the applicati n ther than f r which it is
supplied can increase the risk fr m hazards. Please c nsult KBL bef re making
such change in the applicati n f the equipment.
2.4 Impr per installati n, perati n and maintenance f the pr duct supplied by KBL
c uld result in injury r death.
2.5 Within the manual, safety instructi ns are marked with safety symb ls.
CAUTION
CA
CACA
CA
UTION
UTIONUTION
UTION

7 IOM/GK/SEP19/00
2.6 Transp rt Handling and St rage Instructi ns:
2.6.1 Transp rt
Pumps are dispatched in duly assembled c nditi n. Lubricating il in the
bearing h using is drained pri r t dispatch f pump. Pumps are pr tected
against c rr si n and packed f r transp rt by n rmal r ad, rail and sea
carriers.
2.6.2 Handling
Crushing Hazard.
When lifting the pump r pump set, use lifting equipment having a safe w rking l ad
rating suitable f r the weight specified. Use suitable slings f r lifting the pump which
is n t pr vided with lifting p ints.
The use f suitable f rklift truck and f ur chain crane sling equipment is rec mmended
but l cally appr ved equipment rating may be used.Pump sh uld be slung as sh wn.
Pump set must be lifted fr m the lifting h les pr vided using suitable f ur chain lifting
equipment.

8 IOM/GK/SEP19/00
2.6.3 St rage:
2.6.3.1Temp rary St rage f r up t six weeks.
If the pump unit is n t t be used immediately it sh uld be st red carefully in a
h riz ntal p siti n, in a sheltered, dry l cati n. Additi nal rust preventive
sh uld be applied t all unpainted carb n steel r cast-ir n parts and sh uld n t
be rem ved until final installati n.
2.6.3.2 L ng Term St rage .
If the pump is n t t be installed and perated s n after arrival, st re it in a
clean, dry place, having sl w, m derate changes in ambient temperature.
Step sh uld be taken t pr tect the pump fr m m isture, dust, dirt, and
f reign b dies. It is rec mmended that the f ll wing precauti ns t be
taken:
a) Ensure that the bearings are packed with the rec mmended grease, t
prevent m isture fr m entering ar und the shaft.
b) Rem ve the glands, packings and lantern rings fr m the stuffing b x
if the pump is equipped in this manner. If the pump is equipped with
mechanical seal, dismantle and c at the seal with light il.
c) Ensure that sucti n and discharge branches f the pump and all ther
penings are c vered with cardb ard, w d r masking tape t
prevent f reign bjects entering the pump.
d) If the pump is t be st red where there is n pr tective c vering, it
is advisable t c ver the unit with a tarpaulin r ther suitable
c vering.
e) The pump shaft sh uld be manually r tated peri dically t prevent
pitting f the bearing surfaces due t m isture.
S earing Hazard.
D NOT place fingers r hands, etc., int the sucti n r discharge pipe utlets
and d NOT t uch impeller, if r tated this may cause severe injury.
Fill the bearing h using with rec mmended grease t ensure that the shaft and
bearings remain rust free.
2.6.3.3 Exp sed r Extreme C nditi ns St rage.
F r exp sed st rage r extreme variants in atm spheric r envir nmental
c nditi ns, please refer t KBL f r special st rage instructi ns t suit the
c nditi ns acceptable.
2.7 Environmental safety
Always keep the stati n clean t av id and/ r disc ver emissi ns.
Waste and emissions regulations :
Observe these safety regulati ns regarding waste and emissi ns:
• Appr priately disp se f all waste.

9 IOM/GK/SEP19/00
• Handle and disp se f the pr cessed liquid in c mpliance with applicable
envir nmental regulati ns.
• Clean up all spills in acc rdance with safety and envir nmental pr cedures.
• Rep rt all envir nmental emissi ns t the appr priate auth rities.
Electrical installation
F r electrical installati n recycling requirements, c nsult y ur l cal electric utility.
Recycling guidelines
Always f ll w l cal laws and regulati ns regarding recycling.
3.0 Equipment Sc edule:
3.1 Installati n:
3.1.1 F r l cati n, preparing f undati n, installati n, alignment, piping, general
maintenance, tr uble sh ting, etc., the instructi ns given in ur publicati n -
’GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION AND
MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is als printed
al ng this b klet must be f ll wed very carefully.
3.1.2 MOUNTING AND ALIGNMENT
A spacer type flexible c upling is used t c nnect pump shaft t the driver. By
using spacer type f c upling, the c mplete r tating unit can be rem ved fr m
the v lute with ut rem ving pump casing r r t r and with ut disc nnecting
piping c nnecti ns. This als av ids any realignment f pump and m t r after
re-assembly f r tating unit.
3.1.3 ALIGNMENT
ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL
JOINT”.
C rrect alignment is essential f r the sm th perati n f the pump. There
are tw types f misalignment between the pump shaft and the drive shaft,
which are:
1) Angular misalignment – Shaft with axis c ncentric, but n t parallel.
Maximum all wable misalignment is 1°.
2) Parallel misalignment – Shaft with axis parallel, but n t c ncentric.

10 IOM/GK/SEP19/00
This misalignment is checked by using a straight edge as sh wn in figure
given ab ve. Bef re c mmissi ning the pump set, please ensure:
3) The pipe c nnecti ns are flushed and tightened pr perly.
4) Alignment is pr per.
5) Auxiliary piping c nnecti ns such as sealing c nnecti ns, c ling
c nnecti ns, etc., are made. Details f sealing liquid are given in ur supply
rder.
FACTORS THAT MAY DISTURB ALIGNMENT
The unit sh uld be peri dically checked f r alignment. If the unit d es n t
stay in line after being pr perly installed, the f ll wing are p ssible reas ns:
a) Setting, Seas ning f the f undati n.
b) Pipe strains, dist rting r shifting f the machines.
c) Wear f the bearings.
3.1.4 Bef re c mmissi ning the pump set, please ensure:
A. The pipe c nnecti ns are flushed and tightened pr perly.
B. Alignment is pr per.
C. Auxiliary piping c nnecti ns such as sealing c nnecti ns, c ling c nnecti ns,
etc., are made.
D. External c nnecti n t the pump if applicable, must be made after installati n
and bef re c mmissi ning f pump.

11 IOM/GK/SEP19/00
F ll wing tapings are pr vided n Pump Casing, Sucti n C ver and bearing
h using:

12 IOM/GK/SEP19/00
4.0 OPERATION:
4.1 EQUIPMENT DESCRIPTION:
End sucti n centrifugal pump type GK is fr m KBL manufactured pump series
which dimensi nally c nf rms t ISO 5199 r EN 22858 . The mechanical
assembly c mprises a rigid shaft, supp rted n deep gr ve ball bearings with a
d uble shr uded impeller m unted in a rem vable bearing h using assembly.
This is attached t an end sucti n v lute casing fitted with wear rings and back
vanes. The bearing h using, shaft and impeller assembly can be withdrawn
fr m the v lute f r maintenance with ut disc nnecti n f pipe w rk.
The discharge branch is p siti ned vertically upwards while sucti n branch is
h riz ntal and is at 90° t discharge n zzle. An additi nal m unting f t is
fitted at the uter bearing p siti n f r stability.
The c mplete assembly is f rigid c nstructi n, being intended f r m unting n
suitable base plate with electric m t r. A suitable c upling is pr vided t
transmit the r tati nal drive between pump and m t r. A spacer c upling must
be used t all w the rem val f the pump r tating assembly with ut
disc nnecting sucti n pipe, discharge pipe and m t r.
A mechanical seal is used t seal the leakage f pumped liquid acr ss the
shaft. Mechanical seal is pti nal supply.
4.2 EQUIPMENT OPERATION:
4.2.1 Bef re starting the pump check the f ll wing:
1) The pump r tates freely by hand.
2) Fill in the grease f r bearing, if n t d ne earlier. The bearings are packed with
grease initially at the fact ry. H wever, if the pump is st red f r a l nger time it
is necessary t refill the grease in bearings.
3) The directi n f r tati n f driver. It sh uld c rresp nd t the directi n f
r tati n f pump.
4) The pump casing and the sucti n pipeline is fully primed with the liquid.
5) Valve n delivery side is cl sed.
6) The c ck f r pressure gauge c nnecti n is cl sed.
4.2.2 Starting the pump.
1) Start the pump. Let the prime m ver pickup its full speed.
2) Open the valve n delivery line gradually.
3) Regulate the required fl w by adjusting the delivery valve.
4) Open the c ck f r pressure gauge c nnecti n.
4.2.3 During running the pump check the f ll wing things and regulate if needed.
1) The pump is running sm th.
2) The fl w f sealing liquid [if external liquid is pr vided f r sealing purp se] is
uninterrupted.
3) Leakage thr ugh stuffing b x is n rmal. There sh uld be 60-80 dr ps per
minute.

13 IOM/GK/SEP19/00
4) The bearings are n t getting abn rmally h t.
5) Head and capacity devel ped by the pump is as specified.
6) P wer c nsumpti n is within limit.
7) Ensure that there is n mechanical fricti n in the pipe.
8) St p the pump immediately, if any defects are detected. D n t start the pump
unless the defects are rectified.
4.2.4 During st pping the pump
1) Cl se the valve n the delivery line.
2) St p the m t r.
3) Cl se the c ling water and sealing liquid c nnecti ns.
4) If the pump is n t required t be perated f r a l ng time, drain the casing
c mpletely. If the pump is required t be st red f r a l ng time, the bearing
h using sh uld be dried internally with h t air and sh uld be flushed with
m isture free pr tective such as light il r ker sene.
Be aware f the hazards relating t the pumped fluid, especially the danger fr m
inhalati n f n xi us and t xic gases, skin and eye c ntact r penetrati n.
Electric S ock and Accidental Starting Hazard:
Is late the equipment bef re any maintenance w rk is d ne. Switch ff the
mains supply, rem ve fuses, apply l ck uts where applicable and affix suitable
is lati n warning signs t prevent inadvertent re-c nnecti n.
In rder t av id the p ssibility f maintenance pers nnel inhaling danger us
fumes r vap urs, it is rec mmended that maintenance w rk be carried ut
away fr m the pump l cati n by rem val f the r tating unit assembly t a
suitable maintenance area.
Failing t f ll w right sh p practices during equipment perati n will result
int failure f pr duct & in turn pr duct warranty gets v id.

14 IOM/GK/SEP19/00
5.0 MAINTENANCE MANUAL:
5.1 MAINTENANCE EHS INSTRUCTIONS:
F ll wing hazards may arise during maintenance w rk.
Fluid Pressure Jet Hazards.
Check and ensure that the pump perates at bel w the maximum
W rking Pressure specified.
Bef re attempting any maintenance n a pump, ensure that the unit is safe
t w rk n. The pump must be flushed th r ughly with suitable cleaner t
purge away any f the pr duct left in the pump c mp nents. The plant
perat r sh uld carry this ut and a certificate f cleanliness btained
bef re starting w rk. T av id any risk t health it is als advisable t
wear pr tective cl thing as rec mmended by the site safety fficer,
especially when rem ving ld packing that may be c ntaminated.
5.2 GENERAL MAINTENANCE DOCUMENTS
Maintenance d cuments:
a) Pump Secti nal assembly drawing with part list
b) Pump Outline dimensi n drawing
c) Mechanical seal assembly / GA drawing
d) F undati n plan drawing
e) Pump data sheet
Specific Maintenance data:
5.3 Over auling:
With n rmal daily perating spell, the pump will be due f r verhaul after
ab ut 5000 w rking h urs. This w rk sh uld be d ne by skilled pers nnel.
Procedure for dismantling and re-assembly
While dismantling and re-assembling, the cr ss-secti nal assembly drawing and
specificati n part list sh uld be referred.
5.3.1 DISMANTLING
F ll w the f ll wing simple steps t dismantle the pump.
5.3.1.1 Is late p wer supply t m t r.
5.3.1.2 Shut ff valves c ntr lling fl w t and fr m the pump.
5.3.1.3 Drain the liquid fr m pump by rem ving the drain plug r pen the pump
casing drain c ck.
5.3.1.4 We rec mmend matching the punch mark f the c upling halves.

15 IOM/GK/SEP19/00
5.3.1.5 In case f the pumps with spacer type flexible c uplings, disc nnect c upling
(pump half and m t r half) fr m the c upling spacer and rem ve c upling
spacer. In case f rdinary flexible c uplings, rem ve the m t r fr m the
base.
5.3.1.6 Rem ve the supp rt f t (25100) h ld d wn b lts.
5.3.1.7 Adjust string r chain tensi n t supp rt the weight f the back pull ut
assembly.
5.3.1.8 Rem ve the hexag nal nuts (58100) fr m casing stud h lding the casing
c ver (22000) t pump casing (10500).
5.3.1.9 Screw the release b lts pr vided in casing c ver. Turn b lts evenly thr ugh a
quarter turn at b th sides.
5.3.1.10 Slightly pull ut the driving unit till impeller (15100) clears the pump casing
(10500).
5.3.1.11 Place this r tating unit n a table r clear place f r further dismantling.
5.3.1.12 Rem ve casing gasket (51100).
5.3.1.13 Unscrew the impeller screw (66900) & rem ve impeller screw gasket
(51500).
5.3.1.14 Take ut the impeller (15100) fr m pump shaft (18000).

16 IOM/GK/SEP19/00
5.3.1.15 Rem val f stuffing b x with gland packing:
F r this, f ll wing steps sh uld be taken: Rem ve the gland (22900) by
taking ut b lts used f r clamping f the gland. Take ut the casing c ver
(22000) al ng with gland packing (43000) and lantern ring (22700).
1) Rem ve the gland packing rings (43000) and lantern ring (22700).
2) Rem ve the shaft sleeve (31000) with ‘O’ring (52500).
3) Rem ve the liquid deflect r (23600).
5.3.1.16 Rem ve the nuts h lding the pump casing/casing c ver (10500/22000) and
bearing h using (24000).
5.3.1.17 Take ut bearing h using (24000).
5.3.1.18 Rem ve pump half c upling after unscrewing grub screw.
C upling half sh uld be rem ved with the help f suitable extracti n
device. T av id damage t the bearings, c upling half sh uld n t be
kn cked ut f shaft.
5.3.1.19 Take ut c upling key (32100).
5.3.1.20 L sen the b lts h lding bearing c ver (27000) (driving end). Rem ve
carefully bearing c ver.
5.3.1.21 F rce shaft (18000) carefully in the directi n f driving end. After DE side
bearing c me ut al ng with shaft unclamp the circlip (48500). N w pull
shaft, it will c me ut al ng with the bearings & circlip.
CA
CACA
CAUTION
UTIONUTION
UTION

17 IOM/GK/SEP19/00
T dismantle shaft seal arrangement:
a) Clamped casing c ver units – The f ll wing pumps have this type f c nstructi n.
100/26B 32/13B 65/13A
125/26A 40/13 65/16B
32/13A 50/13 80/16A
b) S ft packed pumps – Rem ve gland nuts and withdraw gland (22300). Unpack
stuffing b x.
c) Rem ve impeller (15100). Rem ve casing c ver (22000) fr m the bearing
h using. Draw shaft sleeve (31000) ff end f shaft (18000).
d) B lted casing c ver units – The f ll wing pumps have this type f c nstructi n.
65/32B 80/40B 50/16A 50/20A 50/26B
80/32B 100/40A 32/20A 65/20B 65/26A
100/32B 100/40B 32/20B 80/20A 65/26B
125/32A 32/16 40/20A 100/20A 80/26A
125/32B 40/16 40/20B 40/26B 50/32A
e) S ft packed pumps – Rem ve gland nuts and with draw gland (22300).
Unpack stuffing b x. Rem ve impeller (15100) as ab ve. Rem ve casing c ver
(22000) fr m the bearing h using. Draw shaft sleeve (31000) ff end f shaft
(18000).
5.3.1.22 Rem ve screws f r bearing c ver. Draw DE bearing c ver (27000) ut f
bearing h using (24000) and ff shaft.
5.3.1.23 Take ut the driving end bearing (26000) with the help f puller.
1) Push the sleeve n arb ur press with unif rm pressure.
2) Steps 5.2.1.22 t 5.2.1.24 are t be f ll wed nly if bearings
are damaged and t be replaced.
5.3.1.24 The pump shaft (18000) can n w be carefully driven with its bearing
h using (24000), in the directi n f the drive end, f r the DE bearing
(26000) t just clear the bearing h using (24000).
5.3.1.25 The NDE bearing (26000) can be pressed thr ugh the end f the bearing
h using. Care must be taken t ensure the bearing passes centrally thr ugh
the b re f bearing h using.
CAUTION
CAUTIONCAUTION
CAUTION

18 IOM/GK/SEP19/00
5.3.1.26 NDE bearing (26000) can be pressed ff impeller end f shaft (18000).
5.3.1.27 DE bearing (26000) can be pressed ff drive end f shaft (18000), after the
careful rem val f the shaft circlip ring.
During and after dismantling:
1. Wash all ld grease fr m ball bearings and h usings with ker sene r white spirit
and th r ughly dry bearings. Renew them if they d n t r tate sm thly with n
sign f jamming and freely but with slackness, r if running surfaces f balls
sh w any deteri rati n. C at bearing with rust preventive il and wrap in
greasepr f paper.
2. M unt shaft n between p int centres r n r llers and place stem f dial
indicat r in c ntact with the shaft. Set the indicat r dial at zer and turn the shaft
sl wly by hand. Reading at any p int must n t vary m re than 0.05mm.
3. Examine shaft sleeve f r wear and check f r true. It is imp rtant that the surfaces
f the sleeve, which run in the stuffing b x, against s ft packing, are c ncentric
and n t sc red r damaged. If true f shaft is satisfact ry, rem unt the shaft as
in 2 ab ve, but with the sleeve fitted and check f r true with dial indicat r.
Indicat r readings must n t vary m re than 0.08mm.
5.3.2 Re-assembly:
This pr cedure c vers re-assembly f pump after c mplete dismantling f the
pump. Bef re re-assembly, all the parts sh uld be th r ughly cleaned in
ker sene, petr l r benzene t rem ve the dust, rust, etc. After cleaning, the
necessary parts sh uld be replaced.
5.3.2.1 The assembly f the pump unit is carried ut in the reverse rder f
dismantling .
Use arb ur press while fitting the bearings. H wever, it is rec mmended
that bearings sh uld be heated in il bath at temperature 70 t 80
0
C and
then fitted. (If h t il bath is n t available then ARBOUR PRESS must be
used).
Use gloves w ile fitting bearings from ot oil bat .
a) Slide inb ard ball bearing n shaft by hand, make sure that it is square with
shaft. Press evenly the inner race f the bearing until bearing is seated firmly
against the shaft sh ulder.
b) D n t use hammer t fit the bearings. D n t damage the shaft surface
especially where it is in c ntact with il seal.
5.3.2.2 If the shaft is t be fitted with new bearing, it is necessary t heat t a
temperature f 80 ° C. The bearings must l cate against the sh ulders f the
shaft.
5.3.2.3 Pri r t assembly f bearings, they sh uld be packed with clean, g d quality
lubricating grease. DE and NDE bearing c vers (27000/27100) sh uld als be
CAUTION
CAUTIONCAUTION
CAUTION

19 IOM/GK/SEP19/00
lightly packed with grease, bef re sliding ver shaft end, l cating and
securing t bearing h using (24000).
5.4 Maintenance Tools required:
N special t ls are required f r dismantling and reassembling. T lb x
c ntaining a general set f t ls such as different size ring spanners, t rque
wrenches, pen ended spanners, light ball peen hammer, w den mallet,
vari us sizes Allen keys, etc., serves the purp se. It is imp rtant t ensure
that the suitable lifting equipment is available and that the w rk is carried ut
in clean area.
5.5 PREVENTIVE MAINTENANCE :
Preventive maintenance schedule is the peri dical checks and precauti ns by
which p ssibilities f failures and breakd wns are minimized.
5.5.1 Daily C ecks:
5.5.1.1 H urly rec rd f sucti n and delivery pressure, discharge quantity, input t
the pump driver sh uld be maintained.
5.5.1.2 Bearing temperature, stuffing b x leakage / stuffing b x temperature, this
gives an idea f mechanical perf rmance f the pump.
5.5.1.3 N ise and vibrati ns are the first signs f impending tr ubles like cavitati n,
air l ck, bearing failure, ch king f impeller r casing and such ther
perating tr ubles. The pump perf rmance sh uld theref re be checked f r
n ise and vibrati ns.
5.5.2 Periodical C ecks :
5.5.2.1 The temperature f the bearing sh uld be measured by therm meter. Safe
maximum w rking temperature f the bearing is 80° C.
5.5.2.2 The lubricants f the bearing sh uld be checked. The lubricant might get
c ntaminated with f reign material r get blackened due t verheating. In
such cases, bearings sh uld be flushed and charged with fresh lubricants.
5.5.2.3 Check f r the stuffing b x leakage.
5.5.2.4 The alignment f the pump unit sh uld be checked. Due t perati nal
vibrati ns, atm spheric temperature r stress induced by the weight f the
piping, the alignment may get disturbed.
5.5.2.5 Sufficient quantity f suitable type f lubricant sh uld be ready f r daily and
emergency use.

20 IOM/GK/SEP19/00
5.5.2.6 Calibrate the measuring instrument.
5.5.3 Annual C ecks:
5.5.3.1 The pump sh uld be verhauled c mpletely t check the clearance and t
replace w rn- ut parts. Clearance between impeller and casing rings, shaft
sleeves and thr at bush, lantern ring and shaft sleeve, etc., are very
imp rtant. The bearings sh uld be cleaned th r ughly and lubricated.
5.5.3.2 The effects f liquid handled n pump c mp nents sh uld be checked. If
abn rmal c rr si n, er si n is bserved, the c mp nent sh uld be replaced
with that f suitable material .
5.5.3.3 The auxiliary pipelines and functi ning f the auxiliary system sh uld be
checked. The main pipe als sh uld be checked f r scaling, leakage etc.
5.5.3.4 The measuring instruments, gauges, etc., sh uld be recalibrated.
5.5.3.5 Full running test may be carried ut t check whether there is any fault in
the perf rmance, in c mparis n with riginal perf rmance.
5.5.3.6 Piping supp rts sh uld be checked s that the pipes d n t induce unwanted
stresses n the pump.
In case failure to check above points & maintain proper records/precautions of checks by
customer/user, KBL warranty gets void.
5.5.4 Mec anical Seal in Pumps :
The mechanical seal is a precisi n pr duct having been subjected t quality
c ntr l thr ugh ut all stages f manufacture. The seals are designed t
acc mm date reas nable t lerances in the equipment, h wever in rder t btain
the maximum life with tr uble free perf rmance, the equipment sh uld be
adequately maintained.
When mechanical seal is functi ning satisfact rily with ut any leakage, the
preventive maintenance is n t adv cated. If leakage ccurs, a th r ugh check up
is needed. While fitting the mechanical seals in the pump initially by KBL, due
care is taken f r its pr per fitment.
Like ther parts in the equipment the mechanical seals are subject t wear at the
mating faces f the r tating and stati nary ring. The rate f wear will differ with
the perating c nditi ns and vari us ther fact rs such as lubricating pr perty f
the liquid pumped, the presence f impurities in liquid and ther perating
c nditi ns. In view f this n firm rec mmendati ns can be given f r renewal f
seal rings / c mplete seals.
The mechanical seal is pti nal feature and supply will be f unbalanced type
mechanical seal nly and n further perating length adjustments are required.