Kracht KFF 2.5-630 User manual

Gear pump KFF 2.5-630
English
09 • 26/07/2023
D.0027450002
Operating instructions (Translation)

Table of content Kracht GmbH
ii 88027450002-09
Table of content
1 General ........................................................................................................................................ 5
1.1 About the documentation............................................................................................................................ 5
1.2 Manufacturer address .................................................................................................................................... 5
1.3 Other applicable documents....................................................................................................................... 5
1.4 Symbols................................................................................................................................................................ 6
2 Safety........................................................................................................................................... 7
2.1 Intended use ...................................................................................................................................................... 7
2.2 Personal qualification..................................................................................................................................... 7
2.3 Basic safety instructions ................................................................................................................................ 8
2.4 Fundamental hazards ..................................................................................................................................... 9
3 Device description...................................................................................................................... 11
3.1 Functional principle......................................................................................................................................... 11
3.2 Variants ................................................................................................................................................................ 12
3.3 Type key............................................................................................................................................................... 13
3.4 Direction of rotation and discharge ......................................................................................................... 14
3.5 Types of seals .................................................................................................................................................... 15
3.6 Fluid seal.............................................................................................................................................................. 16
3.7 Special numbers ............................................................................................................................................... 17
3.8 Shaft ends ........................................................................................................................................................... 18
4 Technical data............................................................................................................................. 19
4.1 General................................................................................................................................................................. 19
4.2 Nominal sizes..................................................................................................................................................... 20
4.3 Assignment of viscosity - speed................................................................................................................. 21
4.4 Allowable pressures ........................................................................................................................................ 22
4.4.1 Operating pressure, suction and pressure side ................................................................ 22
4.4.2 Max. Betriebsdruck Saugseite für Dichtungsart 2 und 7............................................... 22
4.5 Assignment of differential pressure to viscosity.................................................................................. 23
4.6 Permissible temperature range .................................................................................................................. 23
4.7 Material data...................................................................................................................................................... 23
4.8 Weight.................................................................................................................................................................. 24
4.9 Dimensions......................................................................................................................................................... 24
5 Transport and storage ............................................................................................................... 25
5.1 General................................................................................................................................................................. 25
5.2 Transport............................................................................................................................................................. 25
5.3 Storage................................................................................................................................................................. 25
5.4 Storage conditions .......................................................................................................................................... 26

Kracht GmbH Table of content
88027450002-09 iii
6 Installation .................................................................................................................................. 27
6.1 Safety instructions for installation............................................................................................................. 27
6.2 Noise reduction ................................................................................................................................................ 28
6.3 Mechanical installation .................................................................................................................................. 29
6.3.1 Preparation...................................................................................................................................... 29
6.3.2 Gear pump with free shaft end ............................................................................................... 29
6.4 Connection lines............................................................................................................................................... 31
6.4.1 General.............................................................................................................................................. 31
6.4.2 Suction line...................................................................................................................................... 31
6.4.3 Pressure pipe.................................................................................................................................. 33
6.4.4 Connection line installation...................................................................................................... 33
6.5 Change of the direction of rotation.......................................................................................................... 33
7 Commissioning........................................................................................................................... 34
7.1 Safety instructions for start-up................................................................................................................... 34
7.2 Preparation......................................................................................................................................................... 34
7.3 Filling the quench chamber ......................................................................................................................... 35
7.4 Pressure valve setting..................................................................................................................................... 36
7.4.1 Pressure relief valve ..................................................................................................................... 36
7.5 Additional commissioning............................................................................................................................ 37
8 Removal....................................................................................................................................... 38
8.1 Safety instructions for disassembly........................................................................................................... 38
8.2 Dismantling ........................................................................................................................................................ 39
9 Maintenance ............................................................................................................................... 40
9.1 Safety instructions for maintenance......................................................................................................... 40
9.2 Maintenance work ........................................................................................................................................... 41
9.3 Maintenance instructions.............................................................................................................................. 41
9.4 Maintenance table........................................................................................................................................... 42
9.4.1 Maintenance table........................................................................................................................ 42
9.4.2 Check the rate of flow................................................................................................................. 43
9.4.3 Check the operating pressure.................................................................................................. 43
9.4.4 Check the media temperature................................................................................................. 43
9.4.5 Check the device temperature ................................................................................................ 43
9.4.6 Check the function of the add-on valve.............................................................................. 43
9.4.7 Check the equipotential bonding .......................................................................................... 43
9.4.8 Check the condition of the operating fluid........................................................................ 43
9.4.9 Auditory check Unusual noises ............................................................................................... 43
9.4.10 Cleaning ........................................................................................................................................... 43
9.4.11 Visual inspection for leakage................................................................................................... 44
9.4.12 Visual check of seal fluid level................................................................................................. 44
9.4.13 Visual check of the gearbox condition................................................................................. 44
9.4.14 Visual check of the condition of housing parts ................................................................ 44
9.4.15 Visual check of the condition of the plain bearings ....................................................... 44
9.4.16 Visual check of the condition shaft seal .............................................................................. 44
9.4.17 Visual check of the condition of the outboard bearing ................................................ 44
9.4.18 Replacing the outboard bearing ............................................................................................ 45
9.4.19 Replacing the plain bearings.................................................................................................... 45

Table of content Kracht GmbH
iv 88027450002-09
9.4.20 Replacing the shaft seal ............................................................................................................. 45
9.4.21 Replacing other seals.................................................................................................................. 45
10 Repair .......................................................................................................................................... 46
10.1 Safety instructions for repairs ..................................................................................................................... 46
10.2 General................................................................................................................................................................. 47
10.3 Fault table ........................................................................................................................................................... 48

Kracht GmbH General | 1
88027450002-09 5
1 General
1.1 About the documentation
These operating instructions describe the installation, operation and maintenance of the follow-
ing product:
Gear pump KFF 2.5-630
These operating instructions are an integral part of the product and must be kept in the imme-
diate vicinity of the
product and accessible to the personnel at all time.
Different versions of the product are produced. Which version is concerned
is stated on the device’s type plate.
If you have any questions about this operating manual, please contact the manufacturer.
1.2 Manufacturer address
KRACHT GmbH
Gewerbestraße 20
D-58791 Werdohl
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: www.kracht.eu
1.3 Other applicable documents
In addition to these instructions, also comply with the relevant instructions of plants or plant
parts available or planned on site.

1 | General Kracht GmbH
6 88027450002-09
1.4 Symbols
DANGER
Identification of an immediate hazard, which can lead to death or severe bodily injury if not
avoided.
WARNING
Identification of a potential medium risk hazard, which can lead to death or severe bodily injury
if not avoided.
CAUTION
Identification of a possible low-risk hazard that can result in minor or moderate physical injury if
not avoided.
ATTENTION
Identification of notes to prevent property damage.
NOTICE
Identification of basic safety instructions. Non-compliance can lead to hazards for people and
the product
TIP
Identification of special user tips and other particularly useful or important information

Kracht GmbH Safety | 2
88027450002-09 7
2 Safety
2.1 Intended use
1. The product has been designed for operation with fluids.
Dry operation is not permitted.
2. The product may only be operated when completely filled.
3. The fluid must be compatible with the materials used in the product. Chemical expertise is
required for that. Be careful with ethylene oxide or other catalytically or exothermically re-
acting or self-decomposing substances. Please consult the manufacturer in cases of doubt.
4. The product may only be used in normal industrial atmospheres. If there are any aggressive
substances in the air, always consult the manufacturer.
5. The product may only be operated in compliance with these operating instructions and the
applicable documents.
Deviating operating conditions require the express approval of the manufacturer.
6. Use of the product for purposes other than those for which it is intended invalidates any
warranty.
2.2 Personal qualification
The personnel charged with the assembly, operation and maintenance of the product must have
the necessary qualifications.
This can be achieved through training or appropriate instruction.
The personnel must be familiar with the contents of these operating instructions.
NOTICE
Read the operating instructions in full before using the product.

2 | Safety Kracht GmbH
8 88027450002-09
2.3 Basic safety instructions
NOTICE
Basic safety instructions
Non-compliance can lead to hazards for people and the unit.
a) Follow existing regulations for accident prevention and safety at work as well as the internal
regulations of the operating company.
b) Ensure the greatest possible cleanliness.
c) Wear suitable personal protective equipment.
d) Do not remove type plates or other information or make them illegible or unrecognisable.
e) Do not make any technical modifications.
f) Comply with maintenance intervals.
g) Only use spare parts approved by the manufacturer.

Kracht GmbH Safety | 2
88027450002-09 9
2.4 Fundamental hazards
DANGER
Hazardous fluids
Danger to life when handling hazardous fluids
a) Comply with the safety data sheets and regulations on handling the hazardous fluids.
b) Collect and dispose of hazardous fluids so that no hazard is created for persons or the en-
vironment.
DANGER
Hazardous fluids
Danger to life when handling hazardous fluids.
a) Defective components and connection lines must be replaced or fixed without delay.
b) Use only components and connection lines approved for the expected pressure range.
DANGER
Rotating parts
Risk to life due to entanglement or winding of parts of the body, hair or clothing items.
a) Before carrying out any work, disconnect any drives and actuators from the power supply
or depressurise them.
b) Safely prevent restarting during the work.
DANGER
Rotating parts
Risk to life due to entanglement or winding of parts of the body, hair or clothing items.
a) Take measures to prevent accidental touching of rotating parts.
WARNING
Rotating parts
Risk of injury caused by ejected parts
a) Enclose rotating parts so that in the event of fracture or malfunction, there is no risk caused
by ejected parts.

2 | Safety Kracht GmbH
10 88027450002-09
WARNING
Failure of pressure bearing parts due to overload
Risk of injury from flying parts.
Risk of injury due to splashing fluids.
a) Before carrying out any work, depressurise the product and all connection pipes.
b) Securely prevent the pressure from being restored during work.
WARNING
Failure of pressure bearing parts due to overload
Risk of injury from flying parts.
Risk of injury due to splashing fluids.
a) Use only connections and lines approved for the expected pressure range.
b) Securely prevent the permissible pressures from being exceeded, e.g. by using pressure re-
lief valves or bursting discs.
c) Pipelines must be designed in such a way that no tension e.g. caused by changes in length
due to fluctuations in temperature can be transferred to the product.
WARNING
Failure of pressure bearing parts due to overload
Risk of injury caused by flying parts.
Risk of injury caused by splashing fluids.
a) Do not operate the product with shut-off devices closed.
b) Do not operate the production in the wrong rotational direction.

Kracht GmbH Device description | 3
88027450002-09 11
3 Device description
3.1 Functional principle
The pumps of this series are external gear pumps, which operate according to the displacement
principle.
S Suction connection
P Pressure connection
During rotation, two interlocking gears cause a volume increase by opening the tooth spaces on
the suction side (S), so that the medium can flow in and at the same time, on the discharge side
(pressure side, P), a corresponding volume is displaced by the meshing of the teeth in the filled
tooth gaps. Fluid transport takes place through entrainment in the tooth spaces along the wall
of the wheel chamber.
With each gear rotation, the so-called geometric displacement volume Vg is displaced.
A value that is named the rated volume Vgn in technical documents to specify the pump size.
The displacement process described takes place initially without a noticeable pressure build-up.
Only after external loads are applied, e.g. by head, flow resistances, pipe elements, etc., does the
required working pressure set in to overcome these resistances.
The pressure applied to the shaft seal equals the pressure at the suction connection of the
product. The permissible pressure is determined by the type of seal.
This series were developed specifically for use with fuels, especially for marine fuels. Especially
diesel fuels (MGO/DMA) exhibit low lubricity, which cannot be determined through the viscosity.
The HFRR test acc ISO 12156 is a recognised method for measuring the lubricity of diesel fuels.
The characteristic value determined in this manner is referred to as the Wear Scar Diameter
(WSD) and increases with decreasing lubricity. This characteristic value is stated by fuel manu-
facturers and used when assessing the stability of components.

3 | Device description Kracht GmbH
12 88027450002-09
3.2 Variants
Gear pump
1 End cover 2 O-ring
3 Housing 4 Driven shaft
5 Driving shaft 6 Plain bearings
7 Shaft seal
(Types of seals [}15])
8 Roller bearings
(Fixing type: G; X)
9 Valve
(only Direction of rotation: B)
Gear pump with pressure relief valve
1 Pressure relief valve 2 Gear pump
3 Adjustment screw 4 Hexagonal nut
5 Retaining screw

Kracht GmbH Device description | 3
88027450002-09 13
Gear pump with pressure relief valve (T-valve)
1 Pressure relief valve with Tank connection 2 Gear pump
3 Adjustment screw 4 Hexagonal nut
5 Retaining screw
3.3 Type key
Ordering example
KFF 40 R F 2 /158 - D15
1. 2. 3. 4. 5. 6. 7.
Explanation of type key
1. Product name
2. Nominal
Vgn
Size 1: 2.5; 4; 5; 6; 8; 10; 12; 16; 20; 25
Size 2: 32; 40; 50; 63; 80
Size 3: 100; 112; 125; 150; 180; 200
Size 4: 250; 315; 400; 500; 630
3. Direction of rotation
RClockwise BClockwise/counterclockwise
with changing direction of delivery
LCounterclockwise
4. Fixing type
FDIN flange without roller bearings WMounting angle without roller
bearings
GDIN flange with roller bearings XMounting angle with roller bear-
ings

3 | Device description Kracht GmbH
14 88027450002-09
Explanation of type key
5. Seal type
2Rotary shaft seal FKM (BABSL) 7Double rotary shaft seal FKM
(BABSL)
5
Mechanical seal with FKM sec-
ondary seals (AX30)
C2S2V1G3G1 (KF 2.5-200)
B10SV1G3G1 (KF 250-630)
40
Mechanical seal with FKM second-
ary seals (L4)
AQ2VFF
6. Special number
Special numbers [}17]
7. Valve option
Pressure relief valve
D15 Pressure setting ranges 0-15 bar D25 Pressure setting ranges 15-25 bar
D30 Pressure setting ranges 15-30 bar
Pressure relief valve with Tank connection
T15 Pressure setting ranges 0-15 bar T25 Pressure setting ranges 15-25 bar
Viscosity range Pressure relief valve with Tank connection
No spe-
cification 12-300 B1000-5000
A300-1000
3.4 Direction of rotation and discharge
The direction of rotation is indicated by the curved arrow, when looking towards the end of the
drive shaft. The pump connections are below the drive shaft.
The flow direction is indicated by the straight arrow.
S = Suction connection
P = Pressure connection

Kracht GmbH Device description | 3
88027450002-09 15
3.5 Types of seals
Rotary shaft seal
Seal type: 2
Rotary shaft seal with roller bearings
Seal type: 2
Double rotary shaft seal
Connection borehole G 1/8
(for fluid buffer)
Seal type: 7
Double rotary shaft seal
(for vacuum operation)
Connection borehole G 1/8
(for fluid buffer)
Seal type: 7
Special number: 74

3 | Device description Kracht GmbH
16 88027450002-09
Mechanical seal
Seal type: 5; 40
Mechanical seal with fluid buffer
KF 32-80: Connection borehole G 1/4
(for fluid buffer)
Seal type: 5; 40
Special number: 182; 198
3.6 Fluid seal
Versions with a fluid seal are used if absolute leak tightness is required at the shaft seal, e.g.
when pumping media
– which harden on contact with air.
– which crystallise on contact with the moisture in air.
– which must not be allowed to leak into the environment.
– which are under vacuum and whose seal should be gas tight.
Select the installation so that the connection for the fluid seal is at the top.

Kracht GmbH Device description | 3
88027450002-09 17
3.7 Special numbers
Special number Description
74 Double rotary shaft seal for vacuum operation
158
Housing connection
KF 2.5-12: Flange connection SAE 3/4"
KF 16-25: Flange connection SAE 1“
182 Mechanical seal and front-mounted rotary shaft seal
198
Special number 182
KF 100-150 mechanical seal : AX 15 S-015 Q2Q2V1G3G1 (5)
KF 100-150 mechanical seal : L4BD015DINA10Q20VFF-B4CC (40)
KF 100-112 mechanical seal : AX 15 SL025 Q2Q2V1G3G1 (5)
232
Housing connection
KF 50-80 Flange connection SAE 2“
KF 100-112 Flange connection SAE 2 1/2“
KF 125-150 Flange connection SAE 3“
KF 180-200 Flange connection SAE 3 1/2“
KF 250-315 Flange connection SAE 3 1/2“
KF 400-630 Flange connection SAE 5“
402 Combination of Special number 74 + 158 or 232
506 With SAE A 4-hole flange
Shaft end with splined shaft profile

3 | Device description Kracht GmbH
18 88027450002-09
3.8 Shaft ends
Nominal L Sh8 M dj6 l m n t u
KFF 2.5-25 33 63 714 25 16 416 5
KFF 32-80 44 80 24 36 28 27 8
KFF 100-200 60 110 828 50 40 5 31 8
KFF 250-630 90 160 38 80 63 8 41 10
Nominal Special number L Sh8 M Profile Diametral
pitch (DP)
Num-
ber of
teeth
dh11 l
KFF 32-80 506 31.75 82.17 7 SAE A 16/32 9 15.26 16

Kracht GmbH Technical data | 4
88027450002-09 19
4 Technical data
4.1 General
General information
Housing connection (1)
KFF 2.5-12 Whitworth pipe thread G 3/4
KFF 2.5-12 …/158 Flange connection SAE 3/4"
KFF 16-25 Whitworth pipe thread G 1
KFF 16-25 …/158 Flange connection SAE 1“
KFF 32-80 SAE 1 1/2"
KFF 50-80…/232 Flange connection SAE 2“
KFF 100-112
KFF 100-112 …/232
Flange connection
SAE 2 1/2"
KFF 125-150
KFF 125-150 …/232 SAE 3“
KFF 180-200
KFF 180-200 …/232 SAE 3 1/2"
KFF 250-315 SAE 3“
KFF 400-630 SAE 4“
Mounting position
KFF without fluid buffer Any
KFF with fluid buffer Shaft end horizontal , fluid buffer
connection top
External loads on shaft
end
Faxial Axial forces are not permissible
Fradial
Radial forces are only permissible in combination with an roller
bearings
Nominal sizes
Speed n Nominal sizes+ Assignment of viscosity - speed [}21]
Operating pressure peAllowable pressures [}22]
pb
Viscosity νmin Assignment of differential pressure to viscosity [}23]
νmax 20000 mm²/s
Fluid temperature ϑmPermissible temperature range [}23]
Ambient temperature ϑuPermissible temperature range [}23]
Filtering β ≤ 60 μm
Materials Material data [}23]
Permissible media
Lubricating fluids without abrasive components
(Petrols, solvents, etc. are not permissible)
Fuels (WSD ≤ 520 μm) (2)
(1)Pipe thread : DIN EN ISO 228-1; Flange connection : DIN ISO 6162-1 (SAE J518)
(2) Limit value applicable for marine fuels compliant with ISO 8217 (WSD = Wear Scar Diameter)

4 | Technical data Kracht GmbH
20 88027450002-09
TIP
A reduced shaft seal life is possible in the vertical installation position (shaft end at the top).
4.2 Nominal sizes
Nominal Geom. dis-
placement
Speed Perm. radial
force
Sound pres-
sure level
Mass inertia
Vgn Vgnmin nmax
(2)
Fradial [N] LpA (1) x10-6
[cm³/U] [1/min] (n= 1500 1/
min)
[dBA] J [kg m²]
2.5 2.55
200
3600
700 ≤ 67
14.0
44.03 15.9
55.05 17.8
66.38 20.5
88.05 24.0
10 10.11 28.4
12 12.58 33.7
16 16.09 42.3
20 20.1 50.8
25 25.1 61.7
32 32.12
1500
≤ 68
217
40 40.21 254
50 50.2 299
63 63.18 368
80 80.5
3000
443
100 101.5 ≤ 69 741
112 113.5 806
125 129.4
≤ 65
1418
150 155.6 1637
180 186.6 1911
200 206.2 2500 2072
250 245.1
2000 2500
≤ 75 4133
315 312.9 5011
400 399.5 ≤ 77 6618
500 496.5 7830
630 622.5 ≤ 80 9591
(1) n= 1500 1/min; ν= 34 mm²/s; p= 5-25 bar
(2) Pay attention to the viscosity