SPX FLOW Johnson pump User manual

KGE/EN (1711) 6.5
KGE
Orginal instructions
Read and understand this manual prior to operating or servicing this product.
INSTRUCTION MANUAL
Self-priming centrifugal pump

EC/EN (1609) 5.9 1
EC Declaration of conformity
(Directive 2006/42/EC, appendix II-A)
Manufacturer
SPX Flow Technology Assen B.V.
Dr. A.F. Philipsweg 51
9403 AD Assen
The Netherlands
hereby declares that all pumps member of productfamilies CombiBloc, CombiBlocHorti,
CombiChem, CombiDirt, CombiFlex(U)(B), CombiPrime H, CombiLine, CombiLineBloc,
CombiMag, CombiMagBloc, CombiNorm, CombiPro(L)(M)(V), CombiPrime V, CombiSump,
CombiTherm, CombiWell, FRE, FRES, FREF, FREM, KGE(L), KGEF, HCR, MCH(W)(S),
MCHZ(W)(S), MCV(S), PHA, MDR whether delivered without drive (last position of serial
number = B), or delivered as an assembly with drive (last position of serial number = A),
are in conformity with the provisions of Directive 2006/42/EC (as altered most recently)
and where applicable the following directives and standards:
• EC directive 2014/35/EU, "Electric equipment for use within certain voltage limits"
• standards EN-ISO 12100 part 1 & 2, EN 809
The pumps to which this declaration refers may only be put into operation after they have
been installed in the way prescribed by the manufacturer, and, as the case may be, after
the complete system of which these pumps form part, has been made to fulfil the
requirements of Directive 2006/42/EC (as altered most recently).
Declaration of incorporation
(Directive 2006/42/EC, appendix II-B)
Manufacturer
SPX Flow Technology Assen B.V.
Dr. A.F. Philipsweg 51
9403 AD Assen
The Netherlands
hereby declares that the partly completed pump (Back-Pull-Out unit), member of
productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiDirt, CombiFlex(U)(B),
CombiPrime H, CombiLine, CombiLineBloc, CombiMag, CombiMagBloc, CombiNorm,
CombiPro(L)(M)(V), CombiTherm, CombiPrime V, FRE, FRES, FREF, FREM, KGE(L), KGEF,
HCR, PHA, MDR is in conformity with the following standards:
• EN-ISO 12100 parts 1 & 2, EN 809
and that this partly completed pump is meant to be incorporated into the specified pump
unit and may only be put into use after the complete machine of which the pump under
consideration forms part has been made and declared to comply with that directive.
Assen, September 1st 2016
R. van Tilborg,
Managing Director

2EC/EN (1609) 5.9

INT/EN (1512) 1.2 3
Instruction manual
All technical and technological information in this manual as well as possible drawings
made available by us remain our property and shall not be used (otherwise than for the
operation of this pump), copied, duplicated, made available to or brought to the notice of
third parties without our prior written consent.
SPXFLOW is a global multi-industry manufacturing leader. The company's highly-
specialized, engineered products and innovative technologies are helping to meet rising
global demand for electricity and processed foods and beverages, particularly in
emerging markets.
SPX Flow Technology Assen B.V.
P.O. B ox 9
9400 AA Assen
The Netherlands
Tel. [phone]
Fax. [phone]
Copyright © 2015 SPXFLOW Corporation

4INT/EN (1512) 1.2

KGE/EN (1711) 6.5 5
KGE
Table of Contents
1 Introduction 9
1.1 Preface 9
1.2 Safety (general) 9
1.2.1 Signs on the pump 9
1.2.2 This instruction manual is meant for: 9
1.2.3 Safety instructions relevant for operation 10
1.2.4 Safety instructions relevant for maintenance, inspection and assembly work 10
1.3 Guarantee 10
1.3.1 Copyright 10
1.4 SPXFLOW service 11
1.5 Symbols used 11
1.6 Check delivery 11
1.7 Instructions for transport and handling 12
2 General information 13
2.1 Field of application 13
2.2 Inadvisable use 13
2.3 Type designation 14
2.4 Materials 14
2.5 Selfpriming action 14
3 Installation and preparation start-up 17
3.1 General 17
3.2 Location 17
3.3 Main piping (suction / discharge) 18
3.3.1 Forces and torques on the flanges 18
3.4 Piping accessories 19
3.5 Foundation / base plate 19
3.5.1 Pump units assembled on base plate 19
3.5.2 Alignment pump unit 19
3.6 Preparations start-up 20
3.7 Drive 21
3.7.1 Connection of electric motors 21
3.7.2 Types 22
3.8 Combustion engines 23
3.9 Direction of rotation 24
4Start-up 25
4.1 Temperature 25
4.2 Noise emission 25

6KGE/EN (1711) 6.5
4.3 System pressure 25
4.4 Shut-down 26
4.5 Re-use 26
4.6 Scrapping of the pump 26
5 Trouble shooting 27
6 Maintenance 29
6.1 Precautionary measures 29
6.2 Daily 29
6.3 Periodic inspection 29
6.4 Flushing 30
6.5 Ball Bearings 30
6.6 Electrical installation 30
6.7 The oil chamber 30
6.8 Mechanical seal 31
6.9 Oil seal 31
6.10 Impeller 31
7 Disassembly and assembly 33
7.1 General 33
7.2 Replacing the impeller 33
7.2.1 Disassembly impeller 34
7.2.2 Impeller assembly 34
7.3 Replacement of mechanical seal 35
7.3.1 Disassembly of mechanical seal 35
7.3.2 Assembly of single mechanical seal 35
7.4 Replacement of the bearings 35
7.4.1 Disassembly of the ball bearings 35
7.4.2 Assembly of the ball bearings 36
7.5 Motor replacement (KGEF) 36
7.5.1 Motor disassembly 36
7.5.2 Motor assembly 36
7.6 Waste handling/material recycling 36
8 Technical specifications 37
8.1 Technical data 37
8.2 Survey curve (n = 2900 min-1) 38
9Dimensions 39
9.1 KGE Pump with bare shaft end 39
9.2 Dimensions KGEF Pump with flanged motor 41
9.3 Dimensions KGE pump with motor (assembly A6) 42
10 Parts 43
10.1 Ordering parts 43
10.1.1 Order form 43
10.1.2 Recommended spare parts 43
10.2 Parts list and sectional drawing KGE, Bearing bracket 00, KGE11-3 /
KGE11-4 44
10.3 Parts list and sectional drawing KGE, Bearing bracket 0, KGE12(b)-5 / KGE12-645
10.4 Parts list and sectional drawing KGE+, Bearing bracket 0+, KGE14-8 46
10.5 Parts list and sectional drawing KGE, Bearing bracket 0, KGE16-3 47
10.6 Parts list and sectional drawing KGE+, Bearing bracket 0+, KGE15-6 / KGE16-648
10.7 Parts list and sectional drawing KGE, Bearing bracket 1, KGE18-4 /
KGE20b-5 49

KGE/EN (1711) 6.5 7
KGE
10.8 Parts list and sectional drawing KGE, Bearing bracket 2, KGE22-6 50
10.9 Parts list and sectional drawing KGEF, Bearing bracket 00, 0 and 0+ (+) 51
10.10 Parts list and sectional drawing KGEF, Bearing bracket 1 and 2, KGEF18-4 /
KGEF20b-5 52
Order form for spare parts 53

8KGE/EN (1711) 6.5

KGE/EN (1711) 6.5 Introduction 9
KGE
1 Introduction
1.1 Preface
• The data published in these operating instructions have been based on the most
recent information. They are provided subject to alterations.
• We reserve the right to change the design and/or construction of our products at any
time without being obliged to adapt earlier supplies accordingly.
• These operating instructions (and annex if any) contain useful and important
information allowing your pump to be properly operated and maintained. They also
contain important instructions for preventing possible accidents and serious damage
prior to commissioning and during operation of the installation, thus ensuring as safe
and trouble free an operation of your installation as possible. Carefully read the
instructions prior to putting the pump into operation, familiarize yourself with the
functioning and operation of your pump and strictly adhere to the instructions given. In
this respect we would emphasize the importance of training in the correct handling of
the installation. It is essential that these operating instructions are kept in a fixed place
in the vicinity of the installation.
! Should you have any further questions or wish to receive additional
explanation regarding specific matters concerning your pump (adjusting,
assembly/disassembly ...) which are not included in this instruction manual,
please do not hesitate to contact our technical or service departments from
SPXFLOW.
1.2 Safety (general)
1.2.1 Signs on the pump
It is imperative that signs affixed to the pump, e.g. arrow indicating the direction of
rotation or symbols indicating fluid connections be observed and kept legible.
1.2.2 This instruction manual is meant for:
• Personnel that should read and understand this instruction manual completely: The
personnel responsible for operation, maintenance, inspection and assembly. These
people must be adequately qualified. Scope of responsibility and supervision of the
personnel must be exactly defined by the plant operator. Moreover, the plant operator
is to make sure that the contents of the operating manual are fully understood by the
personnel. If the staff does not have the necessary knowledge, they must be
trained and instructed, which may be performed by the machine
manufacturer or supplier on behalf of the plant operator.
• Your technical and servicing personnel which is provided with the required information
in chapter 10 "Parts". Sectional drawings with part lists are intended for those who are
responsible for spare parts ordering.

10 Introduction KGE/EN (1711) 6.5
1.2.3 Safety instructions relevant for operation
• The limit values specified in the data sheet must under no circumstances be
exceeded.
• If hot or cold machine components involve hazards, they must be guarded against
accidental contact.
• Guards for moving parts (e.g. coupling) must not be removed from the machine while
in operation.
• Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal)
must be drained away so as to prevent any risk to persons or the environment.
Statutory regulations are to be complied with.
• Hazards resulting from electricity are to be prevented (see for example, the VDE
Specifications and the bye-laws of the local power supply utilities).
1.2.4 Safety instructions relevant for maintenance, inspection and assembly work
• Any work on the machine shall only be performed when it is at a standstill, it being
imperative that the procedure for shutting down the machine described in this manual
be followed.
• Pumps and pump units which convey hazardous media must be decontaminated.
• Using spare parts and accessories authorised by the manufacturer is in the interest of
safety. Use of other parts may exempt the manufacturer from any liability.
• Any modification may be made to the machine only after consultation with the
manufacturer.
• The reliability of the machine delivered will only be guaranteed if it is used in the
manner intended, in accordance with instructions in this manual.
• On completion of work all safety and protective facilities must be reinstalled and made
operative again.
• Prior to restarting the machine, the instructions listed under “Initial Commissioning”
are to be observed.
1.3 Guarantee
We point out that any guarantee issued for your installation will become null and void and
that you shall indemnify us against any product liability claims filed by third parties if:
• The servicing and maintenance jobs have not been performed strictly in accordance
with the instructions, repairs have not been carried out by our personnel or carried out
without our prior written consent;
• The installation has been changed without our prior written consent;
• Non-original SPXFLOW parts or lubricants other than those specified have been
used;
• The installation has been used inexpertly, incorrectly, carelessly or not in line with its
nature and/or destination.
All parts subject to wear are excluded from any guarantee claim.
The General Terms of Delivery already in your possession are also applicable.
1.3.1 Copyright
Any technical and technological information contained in these operating instructions, as
well as any drawings and technical specifications made available by us remain our
property and shall not to be used (other than for the operation of this installation), copied,
multiplied, handed over or communicated to third parties without our prior written
consent.

KGE/EN (1711) 6.5 Introduction 11
KGE
1.4 SPXFLOW service
Should you have any further questions or wish to receive additional explanation regarding
specific matters concerning your pump (adjusting, assembly/disassembly etc.), please
do not hesitate to contact us.
1.5 Symbols used
While following instructions you may notice some of them are only applicable for certain
constructions. That is why following division is maintained:
! Construction 0 and 0+ have different bearings
1.6 Check delivery
Check immediately upon receipt for any damage, and that the goods are conform to the
delivery note. Have the carrier report (in writing) any damage, or missing items. Each
pump has a serial number. Please state this number on all documents and letters.
In case the pump is not immediately put into service, take the necessary measures to
prevent it from seizing up (e.g. periodically rotate the pump shaft several times).
pump size construction symbol
11-3 00 
11-4
16-3
0
12b-5
12-5
12-6
15-6
0+ +16-6
14-8
18-4 1
20b-5
22-6 2 
Figure 1: Name plate with serial number.
Ø
No.
SPX Flow Technology Assen B.V. - www.johnson-pump.com
Dr.A.F. Philipsweg 51, NL-9403 AD Assen CR Nr.04029567
eff.
MEI
≥

12 Introduction KGE/EN (1711) 6.5
1.7 Instructions for transport and handling
Pumps or pump units are often too heavy for manual repositioning.
• Consult chapter 8 "Technical specifications" of your pump and do use the proper
transport and lift tools.
• Leave movement of pumps to authorised personnel. Do not operate or walk under
heavy loads.

KGE/EN (1711) 6.5 General information 13
KGE
2 General information
2.1 Field of application
KGE pumps are selfpriming centrifugal pumps with volute and radial (semi-open or
closed) impeller, mounted overhung on the bearing pedestal. If a spacer type coupling is
used, the pump can easily be dismantled without it being necessary to disturb the
pipings or to move the motor.
The KGE pumps can be used for:
• Clean, contaminated and low viscosity liquids.
• The maximum particle size of the impurities depends on the pump size (see chapter 8
"Technical specifications").
• Capacities up to 80 m3/h
• Delivery heads up to 60 m
• Max. suction head 8 m
• Viscosities up to 150 mPa.s
• In pumping viscous liquids, you should allow for a decrease in hydraulic performance
and an increase in power. Please ask our advice.
• Max. system pressures = max. working pressure (consult chapter 8 "Technical
specifications")
Applications :
• Draining building excavations.
• Emptying ponds, ditches and swimming-pools.
• Water extraction for irrigation and watering.
• Aboard ships as bilge, deck wash and general service pumps. Emptying pits and
throughs containing waste water.
• Handling fuels.
• Condensate extraction pumps.
2.2 Inadvisable use
It is inadvisable to use the pump for a purpose other than that for which it was originally
installed. Whenever a pump is applied in a system or under system conditions
for which it is not designed (type of liquid, system pressure, temperature, etc.)
dangers to the user can arise.

14 General information KGE/EN (1711) 6.5
2.3 Type designation
There are a large number of different KGE configurations, which are defined by the pump
type designation.
Example: KGE F 11 3 A6
2.4 Materials
2.5 Selfpriming action
KGE pumps are of the selfpriming type. The selfpriming action relies on the principle of
injection. The pump has to be filled with liquid once. When it has been switched on, the
air (or gas) is evacuated from the suction line. The aspirated air is mixed with the liquid
contained in the impeller.
Through the centrifugal force, the liquid / air mixture from the volute flows to the upper
half of the pump casing. In the generously sized pump casing the liquid can be de-
aerated. The air escapes to the discharge line. The de-aerated liquid has a higher
specific gravity than the liquid with air contained the volute. This causes the liquid to
return to the volute (with some pumps the liquid flows back through the impeller inlet),
where it is aerated and then de-aerated again in the upper part of the pump casing. The
air is evacuated from the suction line and the liquid level in this piping rises.
Pump family
KGE
Pump construction
KGE pump with bare shaft end
KGEF pump with flanged motor
KGEL countreclockwise rotation when viewing the shaft end
with bearing pedestal
Pump size
11 Impeller diameter [cm]
3Suction and discharge connections [cm]
Drive specifications
Awithout motor, with bare shaft end
A5 with assembly parts, without motor
A6 with three phase motor
A7 with single phase motor
Part Material
Pump casing cast iron
Impeller cast iron, bronze or polypropylene
Mechanical seal cover cast iron
Pump shaft 17% chrome steel
Mechanical seal material carbon / ceramic
Elastomers Buna for bearing bracket assembly 00,0,0+
Viton for mechanical seal with bearing bracket assemblies 1-2

KGE/EN (1711) 6.5 General information 15
KGE
Once all air has been evacuated, the pump starts working as a normal centrifugal pump.
A precondition for good functioning is that it should be possible for the aspirated air to
escape without back pressure in the discharge line (open valves !). The pump has a non-
return valve, so the suction and discharge lines can not be siphoned empty, when the
pump has been stopped. The remaining liquid in the pump is always sufficient for the next
suction phase.
.
Figure 2: Selfpriming action
AWater /air separation
BPump casing
CVolute
DImpeller
EBack flow opening

16 General information KGE/EN (1711) 6.5

KGE/EN (1711) 6.5 Installation and preparation start-up 17
KGE
3 Installation and preparation
start-up
The instructions for installation contain important and helpful information for the proper
functioning and maintenance of your equipment. It is absolutely vital that you go through
this publication attentively, to acquaint yourself with the operation and to follow the
recommendations. The instructions for installation contain also hints to avoid accidents
and severe damage before commissioning and during operation, and to assure safe and
trouble free performance of the pump. (See also general information)
3.1 General
• Leave installation and start-up to authorised personnel.
• Make sure rotating parts are well covered and that the pump is isolated, and cannot
be started whilst jobs are carried out on the pump.
• Make sure that a guard offers protection against rotating parts when running the
pump.
• Mount any parts that may have been supplied separately.
• In case the pump is provided with an isolation, special attention has to be paid To
temperature limits of shaft seal and bearing.
3.2 Location
• Locate the pump / pumpunit close to the liquid source. The better the suction
conditions, the better the performance of the pump.
• Sufficient room should be left around the pump / pump unit to allow proper inspection,
pump isolation and maintenance. (refer to dimensions in chapter 9 "Dimensions").
• It is imperative that the operating device of pump and/or pump unit is always (also
during operation) accessible.
• The area in which the pump unit is to be placed should be adequately ventilated. A too
high ambient temperature and air humidity, as well as a dusty environment may have a
negative effect on the functioning of the pump.
• If there is any risk of freezing, switch off the pump, drain it and preferably flush or fill it
with oil, if permitted.

18 Installation and preparation start-up KGE/EN (1711) 6.5
3.3 Main piping (suction / discharge)
• Select the suction line diameter as a function of its length. It must not be smaller than
the pump suction connection.
• The suction and discharge lines should have a snug fit and remain stress free, also
during operation.
3.3.1 Forces and torques on the flanges
The working forces and torques on the flanges cause deformation of the pump unit.
Excessive forces and torques can cause mechanical damage to the pump. These forces
and torques manifest themselves in a displacement of the ends of the pump and motor
shafts. As a point of departure for determining the permitted forces and torques on the
flanges, the following maximum values for the radial displacement of the end of the pump
shaft can be applied :
For the determination of the forces, the weight of the pipes and the liquid must be taken
into account. A distinction must be made between a pump unit which has its base plate
set in concrete and one that does not.
bearing bracket mm
00 0,15
0 / 0+ 0,20
1 0,20
2 0,20
Figure 3: Forces and torques on the flanges
Index v: in the vertical direction (the y-axis)
Index h: in the horizontal direction (x- and z-axes)
M: torque in the surface (plane) of the flange
Fv: force in the vertical direction
Fh: force in the horizontal direction