KIRLOSKAR KPDS Programming manual

INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE - KPDS - KPDSQF
KIRLOSKAR BROTHERS LIMITED
REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002
GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 9 /(3-7), BANER, PUNE 411 045

KIRLOSKAR BROTHERS LIMITED
REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002
GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 9 /(3-7), BANER, PUNE 411 045
WARRANTY
We warrant that the um su lied from us is free from defective material
and faulty workmanshi . This warranty holds good for a eriod of 12
months from the date of commissioning the equi ment or 18 months from
the date of dis atch from our factory, whichever is earlier. Our liability in
res ect of any com laint is limited to re lacing art/ arts free of charge ex-
works or re airs of the defective art/ arts only to the extent that such
re lacement/re airs are attributable or arise solely from faulty workmanshi
or defective material.
This warranty holds good only for the roducts manufactured by us.
KIRLOSKAR BROTHERS LIMITED

CONTENTS:
PAGE NO.
1. INTRODUCTION 1
2. SAFETY INSTRUCTIONS 2
3. PRE-REQUISITES FOR SATISFACTORY OPERATION 6
4. PUMP HOUSE / TANK LAYOUT 6
5. PUMP HOUSE REQUIREMENTS 8
6. FOUNDATION 8
7. TOOLS AND EQUIPMENTS 9
8. EQUIPMENT SCHEDULE 10
9. EQUIPMENT OPERATION 10
10. ERECTION/ASSEMBLING PROCEDURE 11
11. OPERATION 17
12. MAINTENANCE 18
13. TECHNICAL DATA 22
14. CROSS SECTIONAL ASSEMBLY DRAWINGS & SPECIFICATIONS LIST 30
15. EXPLODED VIEW 38
Note: A copy of General instructions for maintenance, o eration &
maintenance of ‘Kirloskar pumps’ is attached at the end of this
manual.

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1. INTRODUCTION:
Pur ose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
• Read this manual carefully before installing and using the product. Improper
use of the product can cause personal injury and damage to property, and
may void the warranty.
NOTICE:
• Save this manual for future reference, and keep it readily available at the
location of the unit.
Product Descri tion: -
1.1 ‘KIRLOSKAR’ make KPDS - KPDSQF pumps are used for handling various types of
chemical liquids like acids, alkalis, hazardous liquids, hydrocarbons and water.
These pumps are manufactured to close tolerance and are of rigid construction,
However, proper installation, operation and maintenance are equally important to
ensure trouble free service. This booklet covers important guidelines and
instructions for installation, operation and maintenance. These instructions should
be followed carefully for satisfactory performance of the pumping unit. Only
mechanical aspects are dealt within this booklet.
1.2 This booklet covers instructions for following types of KPDS and KPDSQF series.
Unit 80C25 Unit 100C25 Unit 150C38 Unit 150C45
(1450RPM only)
20/13QF 25/16QF 25/26A# 65/32*
20/16QF 32/13* 32/26* 0/32*
20/20QF 32/16* 40/26* 0/40*/ 0/40N#
32/16A# 40/32* 100/26#
32/20* 50/26* 100/32*
32/20A# 50/32* 100/40*
40/13* 65/16* 125/26*
40/16* 65/20* 125/32*
40/20*,40/20A# 65/26* 125/40#,125/45#
50/13* 65/26N# 125/40N#
50/16* 0/16* 150/32*,150/32N#
50/16A# 0/20* 150/40#
50/20* 0/26* 65/43#
65/13* 100/20*
NOTES:
a) *Marked pumps are also supplied with semi-open (QF) type impeller as an
option.

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b) # Marked pumps are supplied with “Enclosed” type impeller only.
c) KPDS40/32QF & 50/32QF supplied in 1450 RPM only.
1.3 Description of KPDS pumps.
KPDS - KPDS pumps with enclosed impeller
KPDS-QF - KPDS pumps with semi open impeller.
KPDS - KIRLOSKAR PROCESS DEVELOPMENT SUMP
KPDS 32/13
32 INDICATES DELIVERY SIZE OF PUMP IN mm
13 INDICATES NOMINAL IMPELLER DIAMETER IN cm
Maximum column length & pump will be supplied in assembled condition up to 6.0
meters.
1.4 The complete range of ‘KPDS’ pump is covered by four driving units thereby reducing
inventory and achieving interchangeability.
1.5 Pumps when properly installed & given due care in operation & maintenance should
operate satisfactorily for a long period.
1.6 When the pump is received, sometime before the actual use of pump, it should be
inspected & located in dry place. The coupling should be rotated once in a month to
prevent pitting of bearing surfaces.
2. SAFETY INSTRUCTIONS:
2.1. General Information:
Before performing any actions detailed within this instruction, the Site Health and
Safety instructions shall be read and fully understood. The instructions in this
document shall also be read and fully understood.
Whenever the equipment is operated, maintained or used in any way, the procedures
detailed within the Health and Safety Dossier (DHS) and any procedures detailed
within these instructions shall be followed. The pump supplied by Kirloskar Brothers
Limited (KBL) has been designed with safety in mind, where hazards cannot be
eliminated; the risk has been minimized by the use of guards and other design
features. Some hazards cannot be guarded against and the instructions below MUST
BE COMPLIED WITH for safe operation. These instructions cannot cover all
circumstances. It is the responsibility of the user of the equipment for maintaining
safe working practices at all times.
2.1.1 KBL products are designed for installation in designated areas, which are to be kept
clean and free of obstructions that may restrict safe access to the controls and
maintenance access points.
Pump nameplate is fitted to each unit and must not be removed. Loss of this plate
could make identification impossible. This in turn could affect safety and cause
difficulty in obtaining spare parts.
2.1.2 Access to the equipment should be restricted to the personnel responsible for
installation, operation and maintenance and they must be trained, adequately
qualified and supplied with the appropriate tools for their respective tasks.
2.1.3 KBL firmly insists that all personnel responsible for installation, operation and
maintenance of the equipment must read the manual before any work is done.
2.1.4 Ear defenders should be worn where the specified equipment noise level exceeds
locally defined safe levels. Safety glasses or goggles should be worn where working

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with pressurized systems and hazardous substances. Other personal protection
equipment must be worn where local rules apply.
2.1.5 DO NOT wear loose or frayed clothing or jewelry, which could catch on the controls
or becomes trapped in the equipment.
2.1.6 Operation of the equipment for the application other than for which it is supplied
can increase the risk from hazards. Please consult KBL before making such change
in the application of the equipment.
2.1.7 Improper installation, operation and maintenance of the product supplied by KBL
could result in injury or death.
2.1. Within the manual, safety instructions are marked with safety symbols.
Hazard.
- This symbol refers to general mechanical aspects of safety.
Hazard.
- This symbol refers to electrical safety.
2.2 Environmental safety:
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations:
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
2.3 Trans ort handling and storage instructions:
2.3.1 Trans ort-
Pumps are dispatched in duly assembled condition. Pumps are protected against
corrosion and packed for transport by normal road, rail and sea carriers.

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2.3.2 Handling-
WARNING:
• Make sure that the pump cannot roll or fall over and injure people or damage
property.
• These pumps might use carbon or ceramic silicon carbide components. Do
not drop the pump or subject it to shock loads as this can damage the
internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the
pallet with the pump unit on top. Failure to do so can result in equipment
damage.
2.3.3 Lifting methods-
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and
support this equipment can result in serious physical injury and/or equipment
damage. Lift equipment only at the specifically identified lifting points. Lifting
devices such as eyebolts, slings, and spreaders must be rated, selected, and
used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting
methods and wear steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical
position and lower the unit into the sump. Then use the lifting lugs on the motor and a
suitable sling in order to hoist the motor into position. Use a tag line attached to the casing
end in order to prevent the pump from swinging. Refer Figure 1.
Pump set must be lifted from the lifting eye bolts provided on the support plate by using
suitable four chain lifting equipment.

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LIFTING ARRANGEMENT
A) With Rectangular Su ort late B) With Round Su ort late
Figure 1
NOTE: It is recommended to dismantle the motor from um along with electrical
connections and then lift the um assembly. This is recommended to avoid damage to the
motor, ro er alignment and levelling while commissioning the um .

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2.3.4 Storage.
2.3.4.1 Tem orary storage for u to six weeks-
If the pump unit is not to be used immediately it should be stored carefully in a
horizontal position, in a sheltered, dry location. Additional rust preventive should be applied
to all unpainted carbon steel or cast iron parts and should not be removed until final
installation.
2.3.4.2 Long storage instructions above 6 months & u to 2 Years-
If the pump is not to be installed and operated soon after arrival, store it in a clean,
dry place having slow, moderate changes in ambient temperature. Care should be taken to
protect the pump from moisture, dust, dirt and foreign bodies. It is recommended that
following has to be followed-
a) Ensure that the bearings are packed with the recommended grease, to
prevent moisture entry.
b) Ensure that suction and discharge branches of the pump and all other
openings are covered with cardboard, wood or masking tape to prevent
foreign objects entering the pump.
c) If the pump is to be stored where there is no protective covering, it is
advisable to cover the unit with a tarpaulin or other suitable covering.
d) The shaft should be manually rotated periodically preferably once in a
month to prevent pitting of the bearing surfaces by moisture.
For exposed storage or extreme variants in atmospheric or environmental conditions,
please refer to KBL for special storage instructions to suit the conditions acceptable.
3. PRE-REQUISITES FOR SATISFACTORY OPERATION:
For satisfactory working of the pump insure that the following preliminary conditions are
maintained.
a) Pump handles the liquid as specified in the order.
b) The liquid is free of solid particles since the P.T.F.E (Teflon) bearing life is
greatly affected by solids in the liquid.
c) Minimum submergence is kept as shown in the outline dimension drawing
supplied against the order.
d) Operation & maintenance instructions are followed as given in this
booklet.
e) Load of delivery pipe & other accessories such as sluice valve, reflux
valve, etc. is not coming directly on support plate.
Prior confirmation must be taken from the manufacturer/supplier, if the pump is to be used
for the conditions other than those specified in the order.
4. PUMP HOUSE / TANK LAYOUT:
The layout should be done after considering following-
4.1 Liquid inlet to the tank:
The liquid should enter in the tank such that turbulence, high velocity and air
entrainment are avoided at the suction of the pump.
4.2 Suction tank:
The tank should be designed to be so as to provide-

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4.2.1 Enough storage capacity to avoid sudden fluctuations in the liquid level,
kinematics disturbances at the suction of the pump such as turbulences,
eddies, vortices, air entrainment.
4.2.2 Low velocity:
Maximum liquid velocity of the liquid entering the tank should not exceed 1
m/sec.
4.2.3 Individual flow pattern:
Where one tank houses more than one pumping sets, care must be taken to
provide appropriate distances from walls, floor & adjacent pipes. It is advised
that such layouts should be referred to pump manufacturer. This is
necessary to ensure individual flow pattern of each pump undisturbed by
other pumps.
4.2.4 Pump Submergence:
The lowest liquid level should be as recommended in the outline drawing
supplied against the order. Highest liquid level also be below specified level
on the same drawing. The liquid level in the tank should be positively
controlled by liquid level controller/ float switch.
Below is the reference from HI pump intake design.
Dimension
Variable
Descri tion Recommended value
C Distance between the inlet bell & floor C = 0.3 D to 0.5 D
D Inlet bell design outside diameter Suction size of pump
H Minimum liquid depth H = S + C
S Minimum pump inlet bell submergence S = D(1.0+2.3F D )
w Constricted bay width near pump inlet bell w = 2D
Where, F D = Froude Number = V / √(gD)
V = Velocity at inlet face = Flow /Area

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5. PUMP HOUSE REQUIREMENTS:
These should cover mainly the following aspects.
5.1 The floor of tank should be sturdy enough to take total weight of the machine
including that of liquid column in the rising pipe/ column pipe, axial thrust of
impeller, etc.
5.2 Sufficient floor area for working & overhauling. In this following factors are to
be considered.
5.2.1 Proper spacing of the pump to avoid transmission of vibrations from
one machine to another.
5.2.2 Easy & safe accessibility to the electrical switch box.
5.2.3 Space for dismantled pump parts during overhauling.
5.3 Sufficient height of the room for erection. Provision for overhead traveling crane
or chain pulley block.
5.3.1 The pump house should provide adequate height of the room between the
foundation and upper most position of the crane hook. The minimum required
height is shown on outline drawing against order.
5.3.2 The pump house should provide sufficient cross travel of the trolley so that
the pump assembly can be moved without any hindrance or receiving any
undue stress during movement.
6. FOUNDATION:
6.1 The location of foundation bolts should be marked out as per the outline
drawing supplied in advance. The supporting frame should be strong enough to take
the load of complete unit, axial thrust, etc. and should be rigid enough not to
vibrate.
6.2 Leveling
For smooth working of the pumps, it is necessary that the motor stool keeps up its
horizontal level perfectly and the assembly keeps up its vertical position. The
rotating unit should be aligned with the vertical axis.
The whole foundation frame plane position on which the support plate is to be
mounted should be checked with straight edge and spirit level (0.05 mm accuracy)
for its horizontal level. The plane portion should be made horizontal by scraping
operation, if necessary. Use gasket in between support plate & foundation plane
portion so that the joints become leak tight for gases and air coming out of the

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tank. After tightening the foundation bolts, ensure that the top portion of the motor
stool is exactly horizontal.
6.3 Ensure that the holes on the delivery flange above support plate and that of
delivery pipe to be connected to it, exactly match, with proper uniform clearance in
between pipe flanges. That clearance will not give any rise to horizontal
displacement of the pumping unit. Due care should be taken to see that load of the
delivery pipes & accessories such as sluice valve, reflux valve, etc. should not come
on support plate. Separate firm supports should be given to the delivery pipe and its
accessories.
7. TOOLS AND EQUIPMENT’S:
Essential equipments required for errection are as follows.
7.1 The chain pulley block/crane should be of ample capacity to take the load of
the complete unit. The pulley block should have lift of three-meter minimum
and the hand chains provided should be long enough to operate it
conveniently from the floor. The chain pulley block of 3 tons capacity is
more suitable.
7.2 Chain and lifting hook.
7.3 Jute ropes, crow bars & small pipes for leverage.
7.4 Light but accurate straight edge.
7.5 Kerosene or thinner for cleaning of parts.
7.6 Spirit level having the accuracy of 0.02 mm per meter.
7.7 Small wire brush for cleaning threads at shaft.
7. Threading compounds for shaft and pipe threads.
7.9 ‘V’ blocks, dial gauge with magnetic stands to check run out of shafts.
7.10 Two sturdy wooden logs or mild steel girders to rest the clams during
errection process.
7.11 Besides following standard tools and equipments should be available for
smooth errection.
7.11.1 Files triangular, half round and flat of different cuts and sizes.
7.11.2 Triangular scraper, filler gauge.
7.11.3 Two sets of standard/ring spanners.
7.11.4 Set of wrenches and chain tang.
7.11.5 Adjustable spanners, screw drivers of 12“ & 6”.
7.11.6 Allen keys.
7.11.7 Steel rule and steel tape.
7.11. Set of taps and dies up to M16.
7.11.9 Chisel, hammer, hacksaw, vice, etc.
7.11.10 Emery paper, cloth.

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8. EQUIPMENT SCHEDULE:
8.1 Installation:
For location, preparing foundation, installation, alignment, piping, general
maintenance, trouble shooting, etc. the instructions given in our publication -
’GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION AND
MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed
along with this booklet must be followed very carefully. The external sealing
connection to the pump, if applicable, must be made after installing and before
commissioning the pump. Pump on hot service must have final coupling
alignment made with the unit at its operating temperature.
8.2 Mounting and alignment:
A flexible coupling is used to connect pump shaft to the driver. However other
types of coupling can be supplied against request.
8.2.1 Alignment-
ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL JOINT”.
Correct alignment is essential for the smooth operation of the pump. There are
two types of misalignment between the pump shaft and the drive shaft, which
are:
1) Angular misalignment – shaft with axis concentric, but not parallel.
2) Parallel misalignment – shaft with axis parallel, but not concentric.
This misalignment is checked by using a straight edge as shown in Fig. 1 given
above.
Following points should be checked before alignment.
i) Check the direction of rotation of prime mover before mounting.
ii) Fix the motor on motor stool.
iii) Check the float adjustment and start aligning the coupling.
iv)Check free rotation of shaft after alignment.
Before commissioning the pump set, please ensure:
A. The pipe connections are flushed and tightened properly.
B. Alignment is proper.
C. Auxiliary piping connections such as external lubrication connections,
cooling connections, etc. are made.
9. EQUIPMENT OPERATION:
9.1 Before starting the pump check the following:
1) The pump rotates freely by hand.
2) The cooling water connections are properly tightened and adjusted.
3) The direction of rotation of driver. It should correspond to the direction of
rotation of pump.
CORRECT
STEEL STRAIGHT STRAIGHT EDGE
INCORRECT PARALLEL
MISALIGNMENT
STEEL STRAIGHT STRAIGHT EDGE
STEEL STRAIGHT STRAIGHT EDGE
INCORRECT ANGULAR
MISALIGNMENT
Fig. 1

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4) Valve on delivery side is closed.
5) The cock for pressure gauge connection is closed.
9.2 Starting the pump
1) Start the pump.
2) Open the valve on delivery line gradually.
3) Regulate the required flow by adjusting the delivery valve.
4) Open the cock for pressure gauge connection.
9.3 During running the pump check the following things and regulate if needed -
1) The pump is running smooth.
2) The flow of cooling water is uninterrupted.
3) The bearings are not getting abnormally hot.
4) Head and capacity developed by the pump is as specified.
5) Power consumption is within limit.
6) Ensure that there is no mechanical friction in the pipe.
7) Stop the pump immediately, if any, defects are detected. Do not start the pump
unless the defects are rectified. Report immediately to the supplier, if it is not
possible to rectify the defects.
9.4 During stopping the pump
1) Close the valve on the delivery line.
2) Stop the motor.
3) Close the cooling water liquid connections.
4) It has always recommended that use of NRV (Non return valve) in delivery pipe
to avoid back flow during stopping the pump.
10. ERECTION/ASSEMBLING PROCEDURE:
Follow the procedure given below in case of pumps to be erected for the first time or
pumps to be assembled after dismantling for overhauling. Clean all the parts thoroughly in
Kerosene, Petrol or Benzene to remove dust, dirt, etc. Replace the parts with a new one if
found damaged. Use new gaskets and "O" rings at the time of reassembly of pump.
10.1 Insert shaft sleeve for pump side (31100) on pump shaft/impeller shaft
(1 000/1 600) with key for impeller (32000) in proper position. Mount impeller
(enclosed 15100 /semi open15300) on the shaft with gasket (51500) in position. Fit
the helicoil screw (47900) in the impeller nut (33000) by using special tool, tighten
the impeller nut (33000) with gasket (6 200) in between the impeller and Impeller
nut. For KPDS 20/13, 20/16 and 20/20QF impeller nut is inbuilt in impeller.

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10.1.1 Procedure for fitting bearing bush:
Applicable for 0C25 and 100C25 unit pumps-
Press the bearing bush (35300) in casing cover (22000) and drill and tap
(M6x10L), bush and casing cover together at the junction of bush and casing
cover (for 0C25 and 100C25 unit pumps). Fit a grub screw in the tapped hole
to avoid rotation of bush (this is necessary in case of replacement of bush only).
10.1.2 Applicable for 150C3 and 150C45 unit pumps-
Press the bearing bush (35300) in bearing shell (35600) and drill and tap
(M6x10L), bush and bearing shell together at the junction of bush and bearing
shell. Fit a grub screw in the tapped hole to avoid rotation of bush. Now fit the
bearing shell along with bush in casing cover and fix the hex. socketed cap
screws (66601). Mount the cover (27 01) on bearing shell and fix 4 nos. non
metallic screws.
10.2 Insert casing cover (22000) on to the pump shaft/impeller shaft (1 000/1 600) and
shaft sleeve (31100). Insert the assembly so far completed in to pump casing
(10700) with gasket (51100) in proper position. Tighten the hex. nuts on pump
casing studs diametrically opposite evenly.
Mount bottom column pipe (13301) on casing cover and tighten nuts on pump
casing studs. In short casing cover is sand-witched between pump casing and
bottom column pipe.
NOTE: For pumps with impeller diameters 32 & 40 cm (e.g. KPDS 40/32, 0/40, etc.) and
KPDS 20/16QF casing cover is double flanged, hence first nuts on casing cover to
be tightened and then bottom column pipe (13301) to be mounted on casing
cover (22000).
10.3 Mount bottom column pipe (13301) on casing cover (22000), tighten the nuts on
casing cover studs diametrically opposite evenly.

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10.4 Connect bend (2 000) to the pump casing (10700) with gaskets (51301) in
between the flanges. Also connect the first rising pipe (14201) (if the rising pipes
are in two pieces) to the bend with gasket (51302) in between the flanges and
tighten the nuts and bolts.
10.5 Apply thread compound liberally inside the screwed coupling (39500). Fit the
screwed coupling on impeller shaft (1 600) and then fit intermediate shaft
(1 400). While fitting screwed coupling, note that-
10.5.1 Use of thread compound is a must to prevent rust seizing.
10.5.2 Half of the screwed coupling length should come on each shaft.
10.5.3 Ends of shafts should rest on each other perfectly. Ensure this by taking
Colour seat.

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10.6 Fit adapter to casing cover and tee joint to bearing spider (if applicable). Connect
the transmission bearing flushing pipe to adapter with the help of nuts. (Applicable
if transmission bearing lubrication is external clear compatible liquid, otherwise fix
plug to the casing cover).
10.7 Fix the clamp to the bottom column pipe (13301).
10. Lift the unit vertically with the help of slings and chain pulley block. While lifting
take care that no part of the pump is being dragged against the floor.
10.9 Put two girders or strong wooden logs across the opening of the tank in which
pump is to be fitted. Rest the clamp while erecting the pump. Lower the unit till the
clamp rests on the girders.
10.10 Press the intermediate bearing bush (35100) in bearing spiders (24500) then drill
and tap (M6x10L) one hole at the junction of bush and bearing spider. Fit one grub
screw in the tapped hole to avoid the rotation of bush (This is required in case of
replacement of bush only). Mount cover (27 01) on bearing spider with the help of
screws. Fix non-metallic screw on bearing spider to avoid the rotation of bush.
10.11 Mount bearing spider (24500) on the bottom column pipe (13301).
10.12 Mount standard column pipe (13302) on bearing spider (24500). Fix it with the help
of screw and nuts. Tighten the diametrically opposite nuts one by one. Fix three
way pieces to the bearing spider (24500) and connect the flushing pipe coming
from casing cover (22000). Also fix one more flushing pipe to another end of three
way piece with the help of sealing nut.
10.13 Apply thread compound liberally inside the screwed coupling (39500) fitted on
the pump shaft and threaded portion of intermediated shaft (1 400). Fit the
successive screwed coupling in to intermediate shaft (1 400) and intermediate
shaft in to the screwed coupling already fitted on the pump shaft (1 600).
10.14 Lift the column pipe (13302) with the help of another clamp.
10.15 Lower the standard column pipe (13302) and fix to the lower column pipe (13301)
with the bearing spider in between. Tighten the diametrically opposite nuts one by
one.

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Fix another clamp to the standard column pipe (13302). Now fix the slings to the
upper clamp.
10.16 Fit a T joint on bearing spider and connect the end of first flushing pipe. Also
connect the successive bearing flushing pipe to the T joint with the help of nut.
Remove clamp fixed on bottom column pipe. Lower the unit till the clamp rests on
girder.
10.17 Lift the complete unit slightly and remove the clamp of bottom column pipe
(13301). Lower the complete unit till the clamp fixed to the standard column pipe
(13302) rest on girder.
10.1 Mount bearing spider along with intermediate bush on standard column pipe
(13302). Mount top column pipe (13200) and fix it with the help of screws and
nuts. Tighten the diametrically opposite screws one by one.
10.19 Repeat procedure given in 10.13, 10.14, 10.15, 10.16 and 10.17 till head shaft
(1 500), top column pipe (13200) and bearing flushing pipes are fitted. Let the
whole unit rest on the clamp fixed on the top column pipe.
10.20 While fitting the column pipes, rising pipes are also to be fitted if rising pipes are in
more than one piece.
10.21 Mount the shaft sleeve (31000) with O-Ring (52300) and key (32300). Mount
circlip (4 600) to locate the shaft sleeve.
10.22 Fit the pipe nut (33 01) with gasket (6 000) and washer (62500) on rising pipe
(14201).
10.23 Fit the adapter plate (46100) to the stuffing box housing (23 00) with gasket
(51200) in between.
10.24 Lift the support plate (46700) with the help of eye bolts (30000) and mount on
top column pipe (13200). Also mount the stuffing box housing (23 00) on the
support plate (46700) with gasket at the joint and clamp the stuffing box housing,
support plate and top column pipe together with the help of bolts. Tighten
diametrically opposite bolts evenly.
10.25 Adjust the pipe nut (33 01) till it touches the support plate. Tighten the pipe nut
(33 02) above support plate till it touches the support plate. Mount delivery flange
(49001) on rising pipe (14201) above support plate (46700).
Fix the flushing pipe to the support plate by using adapter and sealing nut.
10.26 Lift the unit slightly and remove the clamp fixed to the standard column pipe
(13302). Remove the girders used for erection and lower the unit till support plate
rests on the top of the tank.
: USE SUITABLE GASKET IN BETWEEN TANK FLANGE AND SUPPORT
PLATE (IF APPLICABLE)
10.27 With the hanging support to the support plate, adjust the holes of support plate
with that of the tank holes.

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10.2 Insert the gland packing (43000) and lantern ring (22700) into the stuffing box
housing (23 00) with 3+L+2 sequence.
10.29 Mount gland (22900) on stuffing box housing. Do not tight the nuts.
10.30 Replace the oil seal (50002) if it is damaged. Mount bearing holder (25400) on to
the stuffing box housing (23 00) (For 0C25 and 100C25 unit pumps).
Fit the oil seal (50001) in bearing cover (27001) and another oil seal (50002) in
bearing holder (25400).
10.31 Mount angular contact ball bearings (26300) with exact position on thrust bearing
carrier (24700). [Bearing should be fitted in such a way that axial thrust in
downward direction is taken by the bearing].
Mount the above assembly in bearing holder (25400) and mount the bearing holder
on stuffing box. Fix it with the help of screws. Insert the spacer for thrust bearing
carrier (19 00) with key (32400). This is for 150C3 and 150C45 unit pumps.
10.32 Insert the thrust bearing carrier (24700) in to the head shaft (1 500). Insert the
spacer for thrust bearing carrier (19 00) with key (32400). Insert the key (32400)
on the head shaft. This is for 0C25 and 100C25 unit pumps.
Fit the bearing cover after replacing oil seal if found damaged.
10.33 Insert the lock washer (41501) on head shaft (1 500) and then fit bearing nut
(33500) and lock nut (33600) on the head shaft (1 500). Do not tighten the lock nut
till the final stage of assembly.
10.34 Mount the motor stool (29000) on support plate (46700) and tighten the nuts.
10.35 Tighten the holding down bolts of the support plate (46700). Check the level on the
machined surface of the upper motor stool (29000). It should be levelled
accurately to the limit of 0.05 mm. Use gasket places underneath the support plate
to adjust the level.
10.35 Float adjustment –
10.35.1 For Semi-open type impeller pumps - Lift the rotating unit by 0.5-1.00 mm so
that impeller rotates freely. Tighten the lock nut (33600) to lock the bearing
nut. Fold one arm of lock washer (41500) in the bearing cover slot and fold
remaining arms on bearing nut (33500).
10.35.2 For enclosed impeller pumps - Mount the magnetic stand of dial indicator on
the motor stool (29000) and pop up the dial gauge on the top portion of the
head shaft (1 500). Adjust the zero of dial gauge. Loose the bearing nut
(33500) so that the impeller will touch casing ring. Note the reading on dial
gauge. Now tight the bearing nut so that impeller will touch the casing
cover. Note the reading on dial gauge. Calculate the difference between two
readings. Now adjust the bearing nut so that the difference is half of the
reading. Tighten the lock nut (33600) to lock the bearing nut. Fold one arm
of the lock washer (41501) in the bearing cover slot and fold remaining arms
on bearing nut (33500).

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ENSURE THAT THE SHAFT ROTATES ABSOLUTELY FREE.
10.36 Mount the pump half coupling (39000) and tighten the set screw. Put coupling star
(40300) in between (in case of coupling without spacer).
10.37 Make all the connections of valves and delivery pipe above support plate (46700).
10.3 Once again check the level on the machined surface of the motor stool (29000). If
level is disturbed once again it should be reset up in the range of 0.05 mm.
10.39 Make the motor electric connections. Mount the motor half coupling (39100) and
tighten the set screw of the coupling . Check the direction of rotation
before mounting the motor on the motor stool. The direction of
rotation of motor should be CLOCKWISE when viewed from top i.e. non-driving
end of the motor.
10.40 Mount the motor on the motor stool. Check the angular alignment with the help of
filler gauge and parallel alignment with the help of straight edge and filler gauge.
Alignment should be within 0.05 mm.
10.41 Grease the bearing (26300) with the help of grease gun.
10.42 Ensure that liquid level controller is fitted and is working properly.
10.43 Clearance between impeller vanes and wear plate should be 0.3 to 0.5 mm in case
of pumps with semi-open impeller.
10.44 Interchangeability:
Parts standardization is optimized utilizing interchangeable components to cover a
very wide performance. This unique feature enables the customer to have a very
low spare parts inventory even though he may have many sizes of these pumps.
11. OPERATION:
11.1 Prior to starting:
11.1.1 Rotate the coupling by hand. It should rotate freely.
11.1.2 Ensure that submergence is more than the recommended minimum on
outline drawing. Use of liquid level controller is recommended.
11.1.3 Ensure direction of rotation of Motor is CLOCKWISE (when viewed from
non-driving end) before connecting motor coupling to pump coupling.
Incorrect rotation even for small duration will quickly
damage the um .