BFP Manual

OPERATION
INSTRUCTION
AND
MAINTENANCE
MANUAL
Client : M/s. Thyssenkrupp Industries India P.Ltd.
Project : Bajaj Infra Development Co.
P.O.No. :
BOHT-DGV-2M0020;2M0021 & 2M0022
Date : 24.02.2010
Pump Type : HGC 4 - 11
S.O.No. : 51110 40711; 40712; 40713
_______________________________________________________________________________________________
CONTENTS
DESCRIPTION
PAGE REFERENCE
Chapter : General
OIMPG General 1
1. General Information
2. Disposal
3. Conformity with EU Regulations (if applicable)
OIMPG General 2
OIMPG General 3
OIMPG General 3
Chapter : Safety
Marking of Instructions in the Instruction Manual
Personnel Qualification and Training
Non-compliance with Safety Instructions
Safety Awareness
Safety Instructions for the Operator/User
Safety Instructions for Work on the Pump Set
Unauthorized Modification and Manufacture of Spare Parts
Unauthorized Modes of Operation
OIMPG Safety 1
OIMPG Safety 1
OIMPG Safety 1
OIMPG Safety 1
OIMPG Safety 1
OIMPG Safety 2
OIMPG Safety 2
OIMPG Safety 2
Chapter : Transport / Interim Storage

1.1 Hoisting Tackle (e.g. ropes, gear)
1.2 Signals during Transport
1.3 Transport Symbols
2. Transport of the Packaged Components of the Pump Set
3. Transport of the Partly-packaged or Unpackaged Components
of the Pump Set
3.1 Transport of Pump Set
3.2 Transport of the Pump
3.3 Transport of the Other Pump Set Components
3.4 Transport of Pump Rotor
3.5 Transport of Pump Set Accessories
4 Interim Storage
4.1 Prerequisites
4.2 Place of Storage
4.3 Period of Storage up to 12 Months
4.4 Period of Storage over 12 Months
Contents OIM Pages 3
OIMPG TRANSPORT 1
OIMPG TRANSPORT 1
OIMPG TRANSPORT 1
OIMPG TRANSPORT 2
OIMPG TRANSPORT 2
OIMPG TRANSPORT 2
OIMPG TRANSPORT 3
OIMPG TRANSPORT 4
OIMPG TRANSPORT 5
OIMPG TRANSPORT 5
OIMPG TRANSPORT 6
OIMPG TRANSPORT 7
OIMPG TRANSPORT 7
OIMPG TRANSPORT 7
OIMPG TRANSPORT 7
OIMPG TRANSPORT 7
1/7
DESCRIPTION
Chapter : Installation on Site
Conditions
Foundation
Site management
Place of Installation
Drive way to the Place of Installation
Adequate means of Transport
Preparations
Checking the Foundation
Correct deviating foundation dimensions
Transporting the Pump set Components to the Place of Installation
Removal of Packaging
Protecting the Pump Set Components
Procedure for levelling and grouting of Base Frame at Site
Making the Piping
Cleaning the Piping
Connecting the Coupling
Information about Readiness for connecting of the Piping
Checking the Alignment
Mounting the Instruments
Detailed description of Mounting/dismounting the connecting Coupling
General Information
Mounting
Dismantling
Detailed description of Connecting Coupling Alignment
1. Conditions
2. Preparations
3. Runout Check of the Coupling Hubs
4. Alignment of Coupling
5. Alignment Corrections
6. Pinning the Feet
Cladding (touch guard) for the Shaft Seal

Rev. 17.07.2007
PAGE REFERENCE
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 1
Installation 2
Installation 2
GEN 02.01 I
Installation 3
Installation 3
Installation 4
Installation 4
Installation 4
Installation 4
Installation 4
Installation 5
Installation 5
Installation 6
Installation 7
Installation 8
Installation 8
Installation 8
Installation 8
Installation 9
Installation 10
Installation 11
Installation 12
Installation 13
2/7
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DESCRIPTION
PAGE REFERENCE
Chapter : Commissioning, Start-up/Shutdown

1. Work to be carried out prior to Commissioning, Start-up
OIMPG COMM 31
1.2 General Information
OIMPG COMM 31
1.3 Removal of Preservation
OIMPG COMM 31
1.4 Additional Work to be carried out Prior to returning to Service after OIMPG COMM 31
Standstill > 12 Months
1.5 Topping up the Bearings with Lubricating Oil
OIMPG COMM 31
1.5.1 General Information
OIMPG COMM 31
1.5.2 Bearing with Oil Sight Gauge
OIMPG COMM 31
1.5.3 Lift-off Device (if applicable)
OIMPG COMM 32
1.5.4 Bearing wit Constant Level Oiler
OIMPG COMM 32
1.5.5 Other Accessories
OIMPG COMM 32
1.6 Checking the Direction of Rotation
OIMPG COMM 32
1.6.1 Prerequisites
OIMPG COMM 33
1.6.2 Direction of Rotation
OIMPG COMM 33
1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator OIMPG COMM 33
1.6.4 Checking the Direction of Rotation without a Phase-sequence Indicator OIMPG COMM 33
1.7 Rotatability of the pump Rotor
OIMPG COMM 34
1.8 Mounting the Connecting Coupling
OIMPG COMM 34
1.9 Mounting Guards Preventing Accidental Contact
OIMPG COMM 34
1.10 Functional Test and Adjustment of the Instruments
OIMPG COMM 34
2. Commissioning, Start-up
OIMPG COMM 35
2.1 Prerequisites
OIMPG COMM 35
2.2 Priming
OIMPG COMM 35
2.3 Checks Prior to Starting
OIMPG COMM 36
2.4 Starting and Trial Run
OIMPG COMM 36
3. Shutdown
OIMPG COMM 37
3.1 Pump Set remains Ready for Operation
OIMPG COMM 37
3.2 For Maintenance of the Pump Set or Prolonged Standstill
OIMPG COMM 37
4. Work after Shutdown
OIMPG COMM 38
4.1 During Readiness for Instant Start-up
OIMPG COMM 38
4.2 For Maintenance of the Pump Set
OIMPG COMM 38
4.3 Standstill, Pump not ready for Operation
OIMPG COMM 39
5. Detailed description of Preservation for Standstill
OIMPG COMM 39
Chapter : Pump Supervision Plan

Supervision of Rotor Position (only for the pumps with Balancing Disc)
Log Sheet
OIMPG SUPERVISION 06
3/7
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DESCRIPTION
PAGE REFERENCE
Chapter : Servicing
OIMPG SERVICING 01
1.2 Requirement of Documentation
1.3 Prerequisites
1.4 Service Intervals
2. Dismantling the Guards Preventing Accidental Contact
3. Pump Servicing Plan
4. Servicing Work
4.1 Oil Changes
4.2 Re-lubrication
OIMPG SERVICING 01
OIMPG SERVICING 01
OIMPG SERVICING 01
OIMPG SERVICING 01
OIMPG SERVICING 01
OIMPG SERVICING 02
OIMPG SERVICING 03
OIMPG SERVICING 03
OIMPG SERVICING 04
Chapter : Maintenance
OIMPG MAINTENANCE 01
1.2 Required Documentation
1.3 Prerequisites
2.1 Sound Insulation Hood
2.2 Coupling Guard/Cover
2.3 Guard Preventing Accidental Contact for Shaft Seal
3. Dismantling the Connecting Coupling
3.2 Removing the Coupling Hubs
3.3 Run-out Check of the Shaft Ends
4. Removing the Pump from the Installation
4.1 Dismantling the Piping and Instruments
4.2 Removing the Pump from Baseframe
4.3 Transporting the Pump to the Place of Dismantling
5. Dismantling the Bearings

5.1 Preparations
5.2 Dismantling the Add-on Parts
5.3 Dismantling the Lift-off Device, with Antifriction Bearings
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing
5.5 Dismantling the Thrust Bearing
5.6 Dismantling the Radial Bearings
5.6.1 HG Pump Sizes 1 and 2
5.6.2 HG Pump Sizes 3 to 6
5.7 Dismantling the Bearing Housings
5.7.2 HG Pump size 3
6. Dismantling the Shaft Seal

6.1 Preparations
6.2 Dismantling the Mechanical Seal
6.2.1 Make : Eagle Poonawalla
6.2.2 Make : Flowserve Sanmar
6.2.3 Make : Burgmann
6.3 Dismantling the Casing Parts
4/7
_______________________________________________________________________________________________
DESCRIPTION
PAGE REFERENCE
7. Dismantling the Balancing Device

7.1 HG Pump Sizes 1 and 2
7.2 HG Pump Size 3
7.3 HG Pump Size 4
7.4 Measuring the Approximate Radial Clearance
8. General Information on Reassembly
9. Checking the Balancing Device with Contact Fluid

9.2 HG Pump Size 3

9.3 HG Pump Sizes 4
10. Mounting the Balancing Device

10.2 HG Pump Size 3
10.3 HG Pump Size 4
11. Mounting the Shaft Seal

11.1 Mounting the Housing Components
11.2 Assembling the Shaft Seal
11.2.1 Make Eagle Poonawalla
12. Mounting the Bearings

12.1 Mounting the Bearing Housings and Lifting the Pump Rotor
12.2 Mounting the Radial Bearings
12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings
12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing
12.5 Mounting the Thrust Bearing (if applicable)
13. Mounting the Piping and Instruments
14. Mounting the Connecting Coupling

14.1 Fitting the Coupling Hubs
14.2 Aligning the Connecting Coupling

14.3 Mounting the Coupling Connections
5/7
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DESCRIPTION
PAGE REFERENCE
15. Mounting the Guards Preventing Accidental Contact

15.1 Coupling Guard
15.2 Coupling Cover
15.3 Guard Preventing Accidental Contact for Shaft seal
15.4 Sound Insulating Hood
16. Maintenance of the Other Pump Set Components

16.1 Maintenance of Connecting coupling
16.2 Maintenance of Drive
16.3 Maintenance of Minimum Flow System
16.4 Maintenance of Instruments and Valves
16.5 Maintenance of Oil Supply Unit, etc. (if applicable)
16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable)
17. Spare Parts

17.1 Ordering Spare Parts
17.2 Spare Parts Stock
17.3 Storage
Chapter : Trouble Shooting
OIMPG TROUBLE-SHOOTING 1
1.2 Requisite Documentation
1.3 Prerequisites
Problem / Possible causes / Measures
Chapter : Tables of Clearances

Antifriction Bearings
Diametrical Clearance : Balancing Device
Theoretical Axial Clearance
Plane Bearings
Bearing Clearance
Plane Bearings, Heavy
Bearing Clearance
OIMPG CLEAR AF 1
OIMPG CLEAR AF 2
OIMPG CLEAR AF 1
OIMPG CLEAR AF 2
OIMPG CLEAR PLANE 1
OIMPG CLEAR AF 2
OIMPG CLEAR PLANE H1
OIMPG CLEAR PLANE H1
6/7
_______________________________________________________________________________________________
DESCRIPTION
PAGE REFERENCE
Chapter : Table of Tightening Torque

1. Prerequisites
2. Pump
3. Fastening of Pump Feet
4. Flange Connections
Bolts for Flange Connection, Discharge Nozzle and Tapping
Nozzle; Flanges as per DIN
Bolts for Flange Connection, Discharge Nozzle and Tapping
Nozzle; Flanges as per ANSI
Bolts for Flange Connection, Suction Nozzle
OIMPG TIGHT TRQ 1

OIMPG TIGHT TRQ 1
OIMPG TIGHT TRQ 1
OIMPG TIGHT TRQ 1
OIMPG TIGHT TRQ 2
OIMPG TIGHT TRQ 3
OIMPG TIGHT TRQ 4
Chapter : Table of Weights

HG Pump Size 1
HG Pump Size 2
HG Pump Size 3
HG Pump Size 3
HG Pump Size 4
HG Pump Size 5
OIMPG WEIGHT 1
OIMPG WEIGHT 2
OIMPG WEIGHT 3
OIMPG WEIGHT 4
OIMPG WEIGHT 5
OIMPG WEIGHT 6
Technical Data
Technical Appendix
7/7
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General
Non-compliance with the regulations laid down in the instruction manual

leads to forfeiture of any and all rights to claim for damages.
All work on the pump set must only be performed by properly trained
personnel who are familiar with the dismantling/reasembly work required.
This instruction manual must always be kept close to the location of

operation of the pump set for easy access.
We recommend to call in KSBs experienced personnel for installation,

commissioning/start-up, maintenance, and in case of problems.
OIMPG General 1
_____________________________________________________________________
This instruction manual contains fundamental information which must be complied with during work on the
pump set.
Therefore this instruction manual must be read both by the service engineers and responsible trained
personnel, prior to commencement of work.
All users must not only comply with the general safety instructions laid down in the chapter on Safety, but also
the specific safety instructions included elsewhere in the instruction manual.
KSB pumps are developed in accordance with state-of-the-art technology, are manufactured with utmost care
and are subjected to continuous quality control. If they are properly installed, serviced and maintained, the
pumps will give reliable and trouble-free operation.
We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will only
assume responsibility for faultless execution of the work and for the safety of the personnel involved if
dismantling/reassembly and maintenance have been performed by KSBs specialist personnel.
This pump set must not be operated beyond the limit values specified in the data sheets. Make sure that the
operation in accordance with the instructions laid down in this manual. The operator must take into account the
information given in Technical Appendix, or in other parts of the instruction manual or in the contract
documentation.
It is of vital importance to observe the specified electrical connection values as well as the
dismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measures
are taken and the regulations in accordance with the relevant legislation are complied with.
________________________________________________________________________________________
Caution
The temperature of the medium handled must not exceed the values
indicated on the pump name plate.
________________________________________________________________________________________
________________________________________________________________________________________
Operation of the pump set outside the conditions mentioned above

may lead to overloads which, in turn, may result in personal injury and
damage to property.
_______________________________________________________________
The descriptions and instructions set forth in this instruction manual refer to KSBs scope of supply (e.g. pump
or pump set). This instruction manual does not cover all possible eventualities or events which might occur
during installation, maintenance, servicing and operation of the machine.
Neither does the instruction manual take into account any safety regulations applicable at the place of
installation; the Operator must ensure that such regulations are strictly observed by all, including the personnel
called in for execution of the work.
Instructions on labels, tags and stickers attached to the pump set must be observed.
The pump name plate indicates the main data; please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
If you need any additional information or instructions exceeding the scope of this instruction manual, please
contact KSBs nearest customer service centre.
In case of problems please contact your nearest customer service centre or the manufacturing works.
OIMPG General 2
_____________________________________________________________________
__________________________________________________________________________________________
Prior to returning any pump set components, carefully follow the

!
instructions given in the Disposal section and in the chapter on
Commissioning, Start-up/Shut-down to avoid any risks (e.g. those
posed by residues of the medium handled in the pump).
____________________________________________________________________________
____________________________________________________________________________
Caution
All measuring instruments supplied with the pump should be

calibrated before commissioning of the pump set.
____________________________________________________________________________
Set points of the instruments, wherever conveyed through operating instruction manual, are only as guideline, and
final values are to be set on the site as per observations and requirements.
___________________________________________________________________________________________
Caution
The pump should never be run below the speed of 1000 rpm (higher
limit in case of mechanical seals with pumping ring), even during the
starting process. The acceleration time from switch on (zero rpm) to
1000 rpm should be less than 10 seconds. Specific care is necessary
for the pumps with variable frequency drive & pumps with hydraulic
coupling.
____________________________________________________________________________
2.
Disposal
According to the local anti-pollution regulations
- packaging components must be disposed of by the consignee
- lubricants no longer used, cleaning material, media handled, electric equipment, etc. must be disposed
of by the Operator at their own expense.
3.
Conformity with EU Regulations (if applicable)

The relevant declaration as defined in EU Directive Machinery (89/292/EEC) is enclosed separately.
OIMPG General 3
_____________________________________________________________________
Safety
Marking of Instructions in the Instruction Manual
The safety instructions contained in this instruction manual which must be observed without fail to avoid
hazards to persons are specially marked with the general hazard sign, namely
The electrical danger warning sign is
The word
Caution
is used to introduce safety instructions which must be observed to avoid damage to the pump set and its
functions.
Instructions attached directly to the pump set, e.g.
- the arrow indicating the direction of rotation
- markings for fluid connections and safety instructions
must always be complied with and be kept in perfectly legible condition at all times.
Personnel Qualification and Training

All personnel involved in the work to be performed on the pump set must be fully qualified to carry out the
work involved. Personnel responsibilities, competence and supervision must be clearly defined by the
Operator. If the personnel in question is not already in possession of the requisite know-how, appropriate
training and instruction must be provided. If required, the Operator may commission the manufacturer
/supplier to take care of such training. In addition the Operator is responsible for ensuring that the contents
of the instruction manual are fully understood by his personnel.
Non-compliance with Safety Instructions

Non-compliance with safety instructions can jeopardize the safety of the personnel, the environment and
the pump set itself. Moreover non-compliance with these safety instructions may lead to forfeiture of any
and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
- failure of important pump set functions
- hazard to persons by electrical, mechanical, chemical and thermal effects
- hazard to the environment caused by leakage of hazardous substances.
Safety Awareness
It is imperative to comply with safety instructions contained in this manual, the relevant national health and
safety regulations, and the Operators own internal work, operation and safety regulations, if any.
Safety Instructions for the Operator/User

Any hot or cold components of the pump set that could pose a hazard must be equipped with a guard
preventing accidental contact by the Operator.
Guards which are fitted to prevent accidental contact with moving parts must not be removed whilst the
pump set is operating.
Leakages (e.g. at the shaft seal) of hazardous media handled must be contained so as to avoid any hazard to persons
and the environment caused by hot, toxic or explosive media. Pertinent legal provisions must be
OIMPG Safety 1
_____________________________________________________
adhered to.
Any electrical hazard must be eliminated. For details, please refer to the relevant safety regulations of the
individual countries or the local energy supply companies.
The Operator must ensure that the pumps can be cooled down to a temperature below 50 0C and
depressurized prior to any work on the pump set. The drives must have been disconnected from their
energy supply (e.g. electrical power system, steam or fuel supply system) and secured so as to prevent
unintentional starting.
Safety Instructions for Work on the Pump Set

The operator is responsible for ensuring that all work on the pump set performed by authorized, qualified
personnel who are thoroughly familiar with the contents of the instruction manual.
Work on the pump set must be carried out only during standstill and after the pump or pump set has cooled
down to a temperature below 50 0C. The shut down procedure described in the instruction manual for
taking the pump set out of service must be adhered to without fail. Pump set components in contact with
media injurious to health or harmful to the environment must be decontaminated by the Operator in
accordance with the applicable local regulations. Immediately following completion of the work, all safetyrelevant and protective devices must be re-installed or re-activated.
Please observe all instructions set out in chapter on Commissioning, Start-up/Shutdown before returning
the pump set to service.
Unauthorized Modification and Manufacture of Spare Parts

Any modifications or alterations of the pump set are permitted only after consultation with and approval by
the manufacturer. Original spare parts and accessories authorized by the manufacturer ensure safety. The
use of other parts invalidates any liability of the manufacturer for damage resulting thereof.
Unauthorized Modes of Operation

The warranty relating to the operating reliability and safety of the supplied pump set is only valid if it is used
in accordance with its designated use and if all operating instructions described in chapter General of the
instruction manual have been followed.
The limits stated in data sheets must neither be exceeded nor underrun under any circumstances.
Deviations require prior consultation with KSB.
Markings
Lifting links
All lifting links are marked with the chain symbol.
Temperature > 80 C/176 F

It is imperative to observe the information plate on the pump.
OIMPG Safety 2
Transport / Interim Storage

1.
General Information
Caution
Check the load carrying capacity of the floor (consult the building drawing) before
starting with the transport and hoisting work. Above all give due attention to the
position of the centre of gravity.
Observe the applicable local safety regulations.

Loose parts must be fastened so as to prevent them from falling down.
If a crane is used, check the brake of the hoisting gear by trial braking
under load.
After fastening the ropes, align the crane hook in such a manner that
the crane hoisting ropes are suspended vertically.
Loads must be lifted at a right angle to the drum axis of the rope
winch. Loads must not be lifted at an angle.
Keep the period of tome for which the load is in free suspension to a
minimum.
Use a guide rope in addition if long objects are handled.
Transport of persons together with load is not permitted.
Keep out of the danger area. Work under suspended loads is not
permitted.
The permissible lifting capacity of the lifting equipment must not be
exceeded.
Lower the loads at the lowest lowering speed of the hoist.
1.1
Hoisting Tackle (e.g. ropes, gear)
1.1.1
To determine the lifting capacity, give due consideration to the position of the center of
gravity, the angle of spread and bending radii of the lifting links attached to the load to be
lifted.
Do not use chains, if possible.
1.1.2
Hoisting tackle, and any transport device that might be required, must
only be attached in accordance with section 2 and 3 in this chapter.
Damaged or untested hoisting tackle must not be used
1.1.3
For selection and attachment, only follow the instructions given by the person responsible
for this.
1.2
Signals during Transport

Only follow the instructions given by responsible for giving signals during transporting.
_____________________________________________________________________
3.1
Transport of the Pump Set

For transporting the pump set components mounted on the base plate, shackles
must be attached to the lifting lugs of the pump/baseplate.
__________________________________________________________________
Caution
Do not damage any built-on accessories and pipes.
__________________________________________________________________
Transport of pump sets mounted on baseplates ( examples )
OIMPG TRANSPORT 3
_____________________________________________________________________
3.2
Transport of the Pump

Attach the hoisting tackle as shown in the figure or to the marked lifting links.
_________________________________________________________________
Caution
Do not attach the ropes to the shaft ends or bearing housings.

Secure the pump against overturning.
_________________________________________________________________
OIMPG TRANSPORT 4
_____________________________________________________________________
3.3
Transport of the Other Pump Set Components
3.3.1 Transport the other pump set components in accordance with the relevant manufacturers
documentation.
3.3.2 If these components are included in KSBs scope of supply, the relevant documents
mentioned elsewhere in the manual.
3.4
Transport of the Pump Rotor
3.4.1 Attach hemp or plastic ropes as required by the length of the pump rotor and transport the
pump rotor horizontally; see figure.
_______________________________________________________________________
Caution
Do not use wire ropes or chains in order not to damage the pump
rotor.
_______________________________________________________________________
3.4.2 When setting the pump rotor down, it must be supported so that it is not damaged and is
secured against overturning/rolling.
OIMPG TRANSPORT 5
_____________________________________________________________________
3.5
Transport of Pump Set Accessories

Attach the hoisting tackle as shown in the figure.
______________________________________________________________________
Caution
Do not exert pressure on the strainer element and strainer meshes or

damage them.
We recommend transport by hand.
______________________________________________________________________
<120
<120
OIMPG TRANSPORT 6
<120
_____________________________________________________________________
4.
Interim Storage
4.1
Prerequisites
______________________________________________________________________
Caution
The load carrying capacity of the floor of the storage area must be
adequately designed.
______________________________________________________________________
4.1.1 Weights with packaging : see packing list.
4.1.2 Weights without packaging : See table of weights given in Technical Appendix.
4.1.3 Check each package for damage before it is stored. In case of transport damage, asses
the exact damage, document it and notify KSB about the damage, in writing, immediately.
______________________________________________________________________
Caution
4.2
All openings of the mounted pump set components are closed and
must not be opened before they are needed during installation.
_______________________________________________________________________
Place of Storage
_______________________________________________________________________
Caution
Protect the stored components from humidity, dirt, vermin and

unauthorized access.
_______________________________________________________________________
4.2.1 All components supplied should be stored in a dry room where the atmospheric humidity
is as constant as possible.
4.2.2 In case of outdoor storage it is absolutely necessary to cover the pump set and crates to
form watertight barrier and to protect them against condensation of water so that any
contact with humidity is avoided.
______________________________________________________________________
Elastomeric parts must not be stored together with chemicals,
solvents, fuels, acids, etc. In addition, they should be kept away from
Caution
light, in particular sunlight, strong artificial light high in ultraviolet
rays.
_______________________________________________________________________
4.3
4.4
Period of Storage up to 12 Months

The pimp is supplied duly preserved for storage up to 12 months (standard preservation).
Period of Storage over 12 Months
If the pump is to be stored more than 12 months, it must be preserved appropriately. If the
requisite preservation measures have not been performed by KSB (special preservation),
they must be discussed with and approved by KSB prior to putting the pump into storage.
_______________________________________________________________________
Caution
In case of storage periods of more than 5 years, the pump must be

dismantled before it is installed, and the O-rings must be replaced.
_______________________________________________________________________
OIMPG TRANSPORT 7
_____________________________________________________________________
Installation on Site
Conditions
Foundation
-
has been prepared

the concrete has set
the surface is truly horizontal and even (check with a spirit level, accuracy < 0.3 mm/m in longitudinal
and cross directions.
The area surrounding the foundation holes is truly horizontal and even.
Site management
-
has checked the dimensional accuracy of the foundation and its correct position as per the reference
points given in the foundation and building drawing.
Has marked the center line of the foundation
Has released the foundation
Place of installation
-
is cleared
its condition is such that the installation can be performed without interruptions
adequate devices for aligning are available
Drive way to the place of installation

-
is cleared
is suitable for transport
Adequate means of transport

-
including personnel are available until completion of the installation work
Preparations
Checking the foundation
-
for dimensional accuracy in accordance with GA drawing.

Whether the foundation is truly horizontal and even
Whether the area surrounding the foundation holes is truly horizontal and even.
Correct deviating foundation dimensions

-
by adequate measures after consultation with site management
Transporting the pump set components to the place of installation

- using adequate means of transport
- For weights, please refer to GA drawing
_____________________________________________________________________________________
Caution
For transport, the guidelines of the chapters on Safety, and

Transport/Interim Storage must be complied with.
_______________________________________________________________________
Installation 1
_____________________________________________________________________
Removal of packaging
-
not until the installation work actually starts

Avoid damaging the pump set
All connection points must be closed
The packaging must be disposed off by the consignee (responsible contractor)
_____________________________________________________________________________________
If parts have to be lifted to remove the packaging, proceed as described in

the chapter on Transport / Interim Storage.
______________________________________________________________________________________________
Protecting the pump set components

_____________________________________________________________________________________
Caution
Components remaining on site have to be protected against dirt,

humidity and damage. If components of the pump set are received
damaged, wet or dirty, inform KSB.
_______________________________________________________________________
Completely cover the pump set components to protect them for the full duration of the installation work
on site against construction site dirt, spark discharge, grinding dust and other harmful ambient
influences.
Take special care to adequately protect instruments, electrical cables and wiring ducts.
- Spare parts and parts which are not immediately needed must be stored in such a way that they are
protected from dirt accumulation, humidity and damage.
_____________________________________________________________________________________
-
Caution
Do not store elastomeric parts together with chemicals, solvents,

fuels, acids etc. In addition, they should be kept away from the
light, particular direct sunlight and strong artificial light high in ultraviolet
light.
_______________________________________________________________________
Installation 2
PROCEDURE FOR LEVELLING & GROUTING OF BASE FRAME AT SITE

( FOR HDA / HDB / HG / CHT PUMPS ONLY )
PURPOSE :
High speed rotory equipment needs to be installed with maximum contact area between base frame
and the foundation. To achieve this conventionally, blue matching procedure is adopted between packer
plates and foundation. This calls for skilled millwright fitters to work on and consumes lot of time.
Despite this, the contact area achieved is nowhere near 100%.
Therefore, the following procedure is recommended which ensures :
1. Nearly 100% contact area between the foundation, the packer plates and the base frame.
2. Considerable saving in time and manpower.
PREPARATION :
The following preparation is followed, in case the base frame and the packer plates ( equal to the
number of foundation bolts ) are in scope of KSB. Otherwise, the user is requested to follow the
preparation as under :
l
l
The base frame is provided with the pads, which are welded at the bottom, machined in one setting
and drilled to 15 mm. Dia. ( Ref. Fig. 1).
Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to the
welded pads at the bottom of the base frame, are required with tapping of M 10. These packer plates
are to be bolted with pads at the bottom of the base frame, using M10 bolts ( Ref. Fig. 2 & 3 ).
PROCEDURE :
01.Bolt the pump on the base frame.
02.Bolt the packer plates on the bottom pads of the base frame.
03.Place the unit on the foundation.
04.Suspend foundation bolts into the pockets provided on the foundation blocks.
05.Level the pump on the delivery flange or feet, within 0.04 mm. per meter, using jacking bolts pro
vided at the corners of the base frame.
06.Grout the foundation bolts and the packer plates by using quick setting non-shrink cement, ACC
make Shrinkkomp or Forsoc make Cobextra-GP2 or equivalent ( Ref. Fig. 4 ).
07.Allow curing time of 24 to 72 hours depending upon the grout used.
08.Remove M 10 bolts, which are holding packer plates with the base frame.
09.Carry out final levelling by inserting shims (SS shims preferred) between packer plates and the base
frame.
10.Tighten the foundation bolts and recheck the levelling. Correct it, if necessary.
11. Grout the complete base frame, including the hollow portion, if any, using conventional grouting mix, i.e.,
portland cement, sand and aggregate in proportion 1 : 2 : 2 and gravel size not to exceed 20 mm.
12.Plaster the foundation and apply suitable oil resistant paint.
GEN 02.01 I
Base frame
Base frame for bottom pads

machined with 15 plain holes
Weld
Fig. 1 : Base frame bottom pad
Found
bolt
M10
M10
Packer plate
Found
bolt
Packer plate
View from W
Fig. 2 : Packer plates in pairs, machined for

for base frame with channel
View from Z
Fig. 2A : Packer plates in pairs, machined for

base frame with double channel / I beam
M20 through
for leveling
M10 bolts
Base frame
15
Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts
20
Base frame
Non shrink cement grout
Levelling bolts
15
30
Found block
80 min.
1.5xd
Fig. 4 : Grouting of packer plate

Note :
GEN 02.01I
The foundation to be made of concrete on solid ground. Foundation bolts and packer plates to be
grouted with non shrink grout only. Balance hollow portion of base frame to be grouted with
portland cement sand and aggreegate in preparation 1:2.2 Gravel size should be < 20 mm. After
final grouting all surface should be finished with fine plaster and apply oil resistent paint.
6a
_____________________________________________________________________
Making the piping
General information
- The pipes are already mounted within the dimensions of base frame.
- Straight length pipes are supplied for further connection of piping, if within the scope of KSB supply. Bends and
flanges are supplied loose.
- Offset at flanges and pipe connections is not allowed.
Cleaning the piping

General information
- Pipes delivered by KSB are cleaned and closed.
- The pipes delivered shall be checked for subsequent impurities in the interior and cleaned, if required.
___________________________________________________________________________________________
Caution
Pipes made on the site must be cleaned prior to final mounting.
____________________________________________________________________________
Connecting the piping
General information
- Run the pipes as indicated in the G. A. Drawing.
- Do not remove the covers on the pump nozzles and the desiccants till the pipes are to be actually connected.
Disposal by the consignee / Operator.
- The nominal diameters of the pipes shall be at least equal to the pump connections.
- It is recommended to fit check valves and isolating valves.
- The thermal expansions of the pipes must be compensated by suitable measures in order not to transfer them
on the pump.
- The suction piping must be slanting towards the pump.
- The weight of the suction piping must not transfer on the pump.
- Under no circumstances the pump should be used as an anchorage point for the piping.
___________________________________________________________________________________________
Caution
Connect all the pipes in cold condition and without transmitting any stresses or
strains.
The unbalance of the forces and moments created by the suction / discharge
piping must not exceed the permissible values. (Refer G. A. Drawing)
____________________________________________________________________________
Suction piping
- Not the part of KSB scope of supply.
- Clean the tank and pipe prior to fitting.
Balancing liquid piping
- The balancing liquid piping is connected back to the suction nozzle.
- If the balancing liquid piping is connected back to the suction vessel (deaerator) the flow velocity in the
balancing liquid piping should on no account exceed 5 m/s. The pressure of the balancing liquid must at least
0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressure
must not exceed 2.5 % of the maximum discharge pressure.
Discharge piping
- Not the part of KSB scope of supply.
Flushing piping
- The piping is already installed.
Minimum flow system
- On the discharge side of the pump, a minimum flow control valve is required. G. A. Drawing indicates whether it
is in KSBs scope of supply.
- Refer separate operating instructions for Minimum flow control valve.
Installation 3
_____________________________________________________________________
Minimum flow piping
- Not the part of KSBs scope of supply.
Return piping
- For drain and leakage liquids, the Operator must fit a return piping. Connections and dimensions are specified
in the G. A. drawing.
Information about readiness for connection of the piping
- Inform the responsible site management that the piping is ready for connection.
- Do not continue the piping unless the required piping by the Operator is completed.
Checking the alignment
- Repeat the alignment of the coupling, after the completion of piping by the Operator.
- Enter the final measuring results in the coordinate system of the alignment / acceptance record sheet of each
connecting coupling.
- Record the shaft displacements due to vertical and lateral misalignment of the pump set components under
remarks.
- Have the alignment/acceptance record sheet confirmed by the responsible site management and distribute it to
the authorized persons.
- Have the table of tightening torques for all fastening screws and foundation bolts checked and confirmed by
responsible site management.
Mounting the instruments
General information
- Measuring lines with isolation valves have been installed.
- Do not remove the plugs of the connection points till the actual mounting.
- Just before commissioning / start up perform the functional test.
- Laying of electrical cables varies according to the constructional conditions. Cables must be layed in the
conduits up to the points just near the actual measuring point.
- Electrical cable connections must be done by authorized personnel.
Mounting the pressure gauges
- Insert the sealing disc.
- Select the pressure gauge with sufficient measuring range.
Mounting the oil sight gauge
- Remove the plug and screw in the oil sight gauge with seal.
- Attach required extension piece.
Detailed description of preservation for standstill

Close the suction, discharge and minimum flow pipe and secure against opening.
Close all openings and inlet pipes.
Introduce and fasten desiccants in the pump or the strainer casing.
For quality, identification and monitoring of the desiccants please refer to DIN 55473 and DIN 55474.
In case of water ingress, open the pump drain, flush the pump interior, close the pump drain and re-preserve
the pump interior.
- Remove visible foreign matter which falls in the pump through the pump nozzle. In case of problem in removing
the foreign matter, inform KSB.
Additional measures after standstill of 6 months.
- Dismantle the spacer sleeve of the coupling, preserve it and the bolts using an appropriate preservative, pack
into foil and store properly.
-
Installation 4
_____________________________________________________________________
Detailed description of mounting/dismantling the connecting coupling
General Information
____________________________________________________________________________
Caution Check the shaft ends for runout, prior to mounting the coupling hubs. Permissible
tolerance < 0.04 mm (see figure Runout check of the shaft ends). If the tolerance
is exceeded, please inform KSB.
Observe the manufacturers mounting/dismantling instructions. The pump shafts
check values shall be read after a 900 turn.
____________________________________________________________________________
Runout check of Shaft ends
z Mounting
Fitting the coupling hubs
Thoroughly clean shaft ends and bores of the coupling hubs and check them for dimensional accuracy.
Slightly deburr the hub grooves and insert the key.
Check the protrudent dimension of the key. Tolerance in accordance with the figure Clearance between groove
and key.
0.2-0.3mm
Clearance between groove and key
In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseize
agent.
0
- To facilitate fitting, the coupling hub may be heated evenly to a temperature of 80 C max.
Elastomeric parts must be removed before heating!
___________________________________________________________________________________________
-
Caution
Do not use elastomers which have already been heated up once. Use new parts!
______________________________________________________________________________________________________
Installation 5
_____________________________________________________________________
Use safety gloves.
Risk of fire in case of open fire.
Remove inflammable material
____________________________________________________________________________
-
Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft end and the hub face
match.
___________________________________________________________________________________________
Caution
Fit the coupling hubs only using the appropriate device to prevent the shaft
bearings from damages by the axial friction force. Impacts on the coupling hubs
are not allowed.
____________________________________________________________________________
X = thread size, refer Technical Appendix.
Securely tighten the grub screws, wherever provided.
Connecting the coupling hubs

- Assemble the connecting coupling as described in manufacturers documentation.
Dismantling
Preparations
- Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid
subsequent confusions.
Installation 6
_____________________________________________________________________
Detailed description of connecting coupling alignment
1. Conditions
-
Shaft distances as indicated in the G. A. drawing.

Pump set components are set in place on the base frame.
Coupling hubs are mounted in accordance with the description under Detailed description of
mounting/dismantling the connecting coupling.
2. Preparations
-
Dismantle the coupling guards mounted to the pump set as described under Detailed description of
mounting/dismantling the connecting coupling guards, and store them appropriately.
Separate the couplings mounted to the pump set as described under Detailed description of
mounting/dismantling the connecting coupling.
Comply with the coupling hub distance shown in the G. A. drawing.
3. Runout check of the coupling hubs

-
Check the coupling halves using a dial micrometer.

Use spacer plates.
Arrangement of spacer plates ( examples )
Secure the drive against unintentional starting.

____________________________________________________________________________
-
True running tolerance 0.04 mm.

If true running tolerance > 0.04 mm : inform KSB
Runout check ( example )
Installation 8
_____________________________________________________________________
4. Alignment of coupling
General information
- Align the coupling when the pump is cold (< 500 C/ 1220 F).
- In case of motors with axial tolerance, their rotors must be set in the magnetic center. For this purpose,
either set the rotor to the center marking made by the manufacturer (if any) or to the center position
between right and left side.
- Move the pump shaft towards the suction casing until the rotor abuts.
Order of alignment :pump drive.

Alignment using dial micrometer
___________________________________________________________________________________________
Caution
The coupling must not be turned at the alignment device.

Do not damage the shaft and hubs.
___________________________________________________________________________
Device for connecting coupling with spacer sleeve ( example )
Installation 9
_____________________________________________________________________
Radial misalignment of the coupling hubs
- Permissible value : kr 0.04 mm, measured at 4 points at a distance of 900.
___________________________________________________________________________________________
Caution
kr < 0.04 mm/0.016 inch + vertical/lateral misalignment. (For dimensions,

please refer to the section Alignment corrections)
Kr
___________________________________________________________________________________________
Angular misalignment of the coupling hubs in horizontal direction

- Permissible value : kh 0.04 mm
kh =
Smax Smin
_________________
2
Angular misalignment of the coupling hubs in vertical direction

- Permissible value : kv 0.04 mm
kv =
Smax Smin
_________________
2
Smax.
Smin.
5. Alignment corrections
Vertical correction
Pump :
Installation 10
_____________________________________________________________________
6. Pinning the feet
Pump
C
Pinning the pump feet
A = nozzle orientation in accordance with the G. A. drawing.

C = drill and mount after final adjustment of the pump at the place installation. ( Drill 10mm diameter x 20mm deep )
D = tighten the bolts and lock the nuts with locknuts.
Drive :
- In accordance with the manufacturers documentation.
Detailed description of mounting/dismantling the guards

Coupling guard
_______________________________________________________________________
Caution
The pump must not be operated without coupling guard.
_______________________________________________________________________
Mounting the coupling guard :
- Align the coupling guard over the connecting coupling.
- Make sure there is an adequate distance from both shaft ends and the coupling halves.
- Fasten the coupling guard adequately with bolts.
Coupling guard ( example )
Installation 12
_____________________________________________________________________
Dismantling the coupling guard :
- Remove the guard and store it appropriately.
Cladding (touch guard) for the shaft seal

_____________________________________________________________________________________
Caution
The pump must not be operated without cladding (touch guard)
_____________________________________________________________________________________
Mounting the cladding (touch guard) :
- Fasten the cladding (touch guard) adequately with bolts at the bearing housing.
Dismantling cladding (touch guard) :
- Remove the guard and store it appropriately.
Installation 13
_____________________________________________________________________
Commissioning, Start-up/Shutdown
1. Work to be carried out prior to Commissioning, Start-up
_________________________________________________________________________
Caution
Improper handling of preservatives, oil and grease causes hazardous

environmental impact.
Handling and disposal only by qualified personnel!
_________________________________________________________________________
1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc.,
please refer P & I Diagram.
1.2 General Information

1.2.1 In addition to this instruction manual of pump portion, the technical documents (instruction manuals)
of other accessories & instrumentation etc. are also needed for commissioning/start-up and shutdown. If
these are part of scope of supply of KSB, the relevant instruction manuals are separately enclosed.
1.2.2 Perform all dismantling and reassembly work in accordance with chapter Maintenance.
1.3 Removal of Preservation

1.3.1 If the pump has been filled with a glycol/water mixture for preservation, this fill must be drained before
further work is started.
1.3.1.1 Open the pump drain (6B), collect fill in an appropriate container and dispose of according to the local
anti-pollution regulations.
1.3.1.2 Close the pump drain.
1.3.2 Flush sufficiently to remove any residues of the preservative.
1.3.3 Remove the grease on the out sides of all pump set components.
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.5
Additional Work to Be Carried out Prior to Returning to Service after Standstill

> 12 Months
Dismantle the pump-end coupling hub.
Dismantle the bearing.
Dismantle the mechanical seal and check it in accordance with the manufacturers documentation.
If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be
fitted.
Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor.
Re-mount the pump-end coupling hub.
Topping up the Bearings with Lubricating Oil

1.5.1.1 Oil quality, refer Technical Appendix.
1.5.1.2 After standstill > 12 months, check the oil quality. Clean or replace the oil, if required.
1.5.1.3 Filter the oil prior to topping up; filter mesh size 30 m.
_______________________________________________________________________
Caution
During operation, the oil level in the bearing housing falls!

Check the oil level only during standstill of pump!
_______________________________________________________________________
1.5.2
Bearing with Oil Sight Gauge
OIMPG COMM 31
________________________________________________________________________
1.5.2.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the
minimum and maximum markings of the oil sight gauge (639).
1.5.2.2 Fit the vent plug (913.01 or 672) again.
1.5.3 Lift-off Device (if applicable)
1.5.3.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the
minimum and maximum markings of the oil sight glass (642.01).
1.5.3.2 Fit the vent plug (913.01 or 672) again.
1.5.4
1.5.4.1
1.5.4.2
1.5.4.3
Bearing with Constant Level Oiler (if applicable)

Remove the vent plug (913.01 or 672).
Hinge down the constant level oiler (638).
Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant
level oiler until oil appears in the vertical portion of the connecting elbow of the constant level oiler, see
figure Constant level oiler.
1.5.4.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.
1.5.4.5 Fit the vent plug (913.01 or 913.02 or 672) again.
1.5.4.6 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one
third of the reservoir filled at all times. If the oil level is underrun, top up with oil.
_____________________________________________________________________________________
Caution
The oil level always be below the level of the vent opening arranged at the
top edge of the connecting elbow. Make sure the opening is always
perfectly dry.
Position of
reservoir for
topping up oil
Oil level
Constant level oiler

1.5.5 Other accessories
Fill with oil in accordance with the manufacturers documentation.
1.6 Checking the Direction of Rotation

If the pump set is driven by an electric motor, the direction of rotation of the motor must be checked prior to
Commissioning/start-up.
_____________________________________________________________________________________
!
_______________________________________________________________________
OIMPG COMM 32
_____________________________________________________________________
1.6.1 Prerequisites
1.6.1.1
1.6.1.2
1.6.1.3
Check the direction of rotation prior to the final assembly of the connecting coupling.
Comply with the manufacturers documentation.
The electric motor is provided with a lubricant.
1.6.2 Direction of Rotation

1.6.2.1
1.6.2.2
The pumps direction of rotation is indicated by an arrow on the driven-end bearing housing. In order to
ensure the correct direction of rotation, the direction of rotation of the drive must correspond to the
direction indicated in the G. A. drawing.
The direction of rotation of the drive is indicated in the G. A. drawing.
1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator

The direction of rotation of the electric motor can be checked by means of an electromagnetic phasesequence indicator.
1.6.4 Checking the Direction of Rotation without Phase-sequence Indicator

1.6.4.1 In the case of curve tooth coupling, fix the drive-end coupling sleeve on the hub using spacer plate (if
applicable supplied loose), see figure Arrangement of spacer plates.
Arrangement of spacer plates (example)

1.6.4.2 The electric motor shall be switched on by authorized personnel for a short period of time.
1.6.4.3 Switch off the electric motor again immediately before the operating speed is reached.
1.6.4.4 Check the direction of rotation. If wrong, have the terminal connections reversed by authorized personnel
and check the direction of rotation once again.
_____________________________________________________________________________________
Caution
Mark the connections in the terminal box.
_______________________________________________________________________
_______________________________________________________________________
!
____________________________________________________________
OIMPG COMM 33
_____________________________________________________________________
1.6.4.5 In case of electric motors with axial float, if applicable, the coupling hub of motor shaft must be realigned as
required by the actual magnetic center. If coupling has a spacer, it must be possible to mount and remove
it.
1.7
Rotatibility of the Pump Rotor
1.7.1
In the case of curved tooth coupling, fix the pump-end coupling sleeve on the hub using spacer plate (if
applicable supplied loose), see figure Arrangement of spacer plates.
Prior to start of the work, check the oil level in the bearing housings.
It must be easy to rotate the pump rotor by hand, and it may be only rotated in the direction of rotation of
the pump. If necessary, attach an appropriate tool at the coupling hub, see figure Rotatability of the pump
rotor.
In case the pump with balancing disc without lift off device, move the pump rotor towards the driven end by
approx. 1 mm before you turn it by hand, see figure Rotatability of the pump rotor.
1.7.2
1.7.3
1.7.4
Rotatability of the pump rotor ( example )
1.8 Mounting the Connecting Coupling

Mount the spacer of the connecting coupling as described in the manufacturers documentation.
1.9 Mounting Guards Preventing Accidental Contacts

Mount all guards preventing accidental contact.
1.10 Functional Test and Adjustment of The Instruments

1.10.1 Check all the instruments in accordance with the individual manufacturers documentation for correct
measuring data and adjust the instruments, if required.
OIMPG COMM 34
_____________________________________________________________________
_____________________________________________________________________________________
Caution
All measuring instruments supplied with the pump should be calibrated

before commissioning of the pump set.
_______________________________________________________________________
1.10.2 Set the Alarm & Trip values in accordance with the Logic Diagram, in cooperation with control engineering
specialists.
_____________________________________________________________________________________
Caution
The pump should never be run below the speed of 1000 rpm, even during
the starting process. The acceleration time from switch on (zero rpm) to
1000 rpm should be less than 10 seconds. Specific care is necessary for
the pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
2. Commissioning, Start-up
2.1 Prerequisites
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
Installation and alignment have been performed in accordance with good engineering practice, recorded
and accepted by the Operator.
The pump rotors rotatability by hand has been checked.
All pump set components have been checked in accordance with the relevant manufacturers
documentation.
The direction of rotation of the drive has been checked.
All guards preventing accidental contact have been mounted.
All pipes have been cleaned and connected.
All instruments have been fitted and checked for correct functioning.
2.2 Priming
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Close all drains and drain pipes.

Fully open the cooling water main valve and all cooling water throttle valves.
Vent the complete cooling water circuit.
Vent the complete mechanical seal cooling circuit.
Monitor the cooling water flow at the sight glasses or flow indicators.
_____________________________________________________________________________________
Caution
Do not cool the cooling chamber and heat exchangers with aggressive
untreated water.
_______________________________________________________________________
2.2.6
2.2.7
2.2.8
If applicable, check the filter in the mechanical seals cooling circuit and clean, if required.
Open the valves in the minimum flow line.
Check the oil levels and top up with oil, if required.
_____________________________________________________________________________________
During operation, the oil level in the bearing housing falls!

Check the oil levels only during standstill of the pump!
______________________________________________________________________
Caution
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
If there is no bypass, open the gate valve in the suction piping by 10 to 20 %.

Prime the suction piping, pump and discharge piping up to the closed discharge gate valve.
Vent all pressure gauge lines until there is no more air to escape.
Fully open the valve in the suction piping.
Check whether suction pressure is available.
OIMPG COMM 35
_____________________________________________________________________
2.3 Checks Prior to Starting
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
2.3.11
The suction tank, suction piping, pump and discharge piping have been primed and vented.
The valve in the suction piping is fully open.
The valve in the discharge piping is fully closed.
The connection for tapping, if applicable, is closed.
The shut-off valves in the stand-by heating system, if applicable, are closed.
The shut-off valves in the minimum flow line are open.
The cooling water system is in operation.
The cooling liquid pressure at the inlet must not exceed 6 bar.
The cooling liquid temperature at the outlet must not exceed 550 C.
All temperatures indicated are below the limit values.
In the case of a pump set with variable speed coupling, check the scoop tube position for compliance with
the manufacturers documentation and readjust, if required.
2.3.12 Check all pipes, flanges, screw/bolt connections and pipe unions for leakage.
2.4 Starting and Trial Run

_______________________________________________________________________
Caution
Should alarm signals or problems occur during starting or trial run,

proceed as described in chapter Trouble shooting!
_______________________________________________________________________
_______________________________________________________________________
The minimum discharge head of 150 m must not be underrun, except the
start-up and shutdown phases.
the pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
Caution
2.4.1 Switch on the drive as described in the manufacturers documentation.

2.4.2 For pump set with variable speed coupling :
2.4.2.1 The drive is operating at maximum speed. Due to the scoop tube position, however, the pump is operating
at a minimum speed of 1000 rpm or a minimum head of Hmin = 150 m.
2.4.2.2 Adjust the pump to minimum flow by changing the scoop tube position.
2.4.3 Monitor the temperature and smooth running of the bearings.
2.4.4 Monitor the pump pressures and differential pressures.
2.4.5 Make sure the minimum flow control valve works (hydrodynamic noise).
_____________________________________________________________________________________
!
The minimum flow pipe gets hot.
____________________________________________________________
2.4.6 Check the mechanical seals. Mechanical seal must not drip.
2.4.7 For pump set with variable speed coupling:
2.4.7.1 For minimum speed or minimum head (pump) set the limiting cams of the scoop tube positioning device to
approx. 80% (can be read on the scale).
2.4.7.2 Increase the pump speed until the operating speed is reached.
2.4.8 Slowly open the valve of the discharge pipe until it is completely open.
OIMPG COMM 36
_____________________________________________________________________
2.4.9 Permanently monitor the pump sets operating behaviour.
2.4.10 Open the shut-off valves upstream and downstream of the orifice plate in the stand-by heating system, if
applicable.
_____________________________________________________________________________________
Caution
Close the shut-off valves of the standby heating system only for
maintenance work of the pump.
_______________________________________________________________________
2.4.11 For mechanical seals with circulating cooling :
If there is a magnetic separator, check after its commissioning/start-up whether the temperature of the
circulation liquid remains constant.
3. Shutdown
3.1 Pump set remains ready for Operation
3.1.1
3.1.2
Close the valve in the discharge pipe.

Make sure the minimum flow control vale works.
_____________________________________________________________________________________

_______________________________________________________________________
_______________________________________________________________________
Caution
The minimum discharge head of 150 m must not be underrun, except in

the start-up and shutdown phases.
pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
3.1.3
3.1.4
3.1.5
3.1.6
In the case of a pump set with variable speed coupling reduce the speed until the minimum head or
minimum speed is reached.
Switch off the drive, making sure it runs smoothly down to a standstill.
Note the run down time.
The cooling water remains on!
3.2 For Maintenance of the Pump Set or Prolonged Standstill

3.2.1
3.2.2
Close the valve in the discharge pipe.

Make sure the minimum flow control valve works.
_____________________________________________________________________________________
!
____________________________________________________________
OIMPG COMM 37
_____________________________________________________________________
_______________________________________________________________________
Caution
The minimum discharge head of 150 m must not be underrun, except in

the start-up and shutdown phases.
pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
3.2.3
In the case of a pump set with variable speed coupling reduce the speed until the minimum head or
minimum speed is reached.
Switch off the drive, making sure it runs smoothly down to a standstill.
Note the run down time.
_____________________________________________________________________________________
3.2.4
3.2.5
!
_______________________________________________________________________
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
Close the shut-off valve in the tapping pipe, if applicable.

Close the shut-off valves of the standby heating system, if applicable.
Close the shut-off valves in the minimum flow line.
Close the shut-off valves in inlet pipe.
Turn off the cooling water when the casing temperature, measured the pump nozzles, is lower than 500 C.
Close the other pipes.
4. Work after shutdown

4.1 During Readiness for Instant Start-up
4.1.1
General Information
If the period of standstill during readiness for start-up is longer than 2 weeks, the pump set components
such as gear or variable speed coupling must be protected against water ingress and humidity as
described in the manufacturers preservation instructions.
4.1.2 Every 4 to 6 weeks

4.1.2.1
Put the pump into operation as described in Commissioning, Start-up section of this chapter.
4.1.2.2
Switch off the pump after approx. 10 minutes as described in Shutdown section of this chapter.
4.1.2.3
Check at the connecting coupling whether pump rotor runs down smoothly to a standstill.
4.1.3
Every two months (in the case of pump set with variable speed coupling)
If the scoop tube actuator was used during stand-by operation, re-lubricate the guide bush; see the
manufacturers documentation.
4.2 For Maintenance of the Pump set

_________________________________________________________________________
The pump has been depressurized and the casing temperature is < 500 C,
measured at the pump nozzles!
______________________________________________________________
4.2.1
4.2.2
4.2.3
Secure all valves against opening.

Open all drains and/or drain pipes.
Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.
OIMPG COMM 38
_____________________________________________________________________
_____________________________________________________________________________________
If the medium handled is toxic, inflammable, explosive or hazardous in a

different way, the pump must be flushed thoroughly to avoid that any residues
remain in the pump.
____________________________________________________________
4.2.4
If the period of standstill is longer than 2 weeks, the pump set components such as gear or variable speed
coupling must be protected against water ingress and humidity as described in the manufacturers
preservation instructions.
4.3 Standstill, Pump not Ready for Operation.

4.3.1
General information
_____________________________________________________________________________________
Caution
In the case of dander of frost, the pump must be drained and preserved as
described under Detailed Description of Preservation for Standstill in this
chapter.
_______________________________________________________________________
4.3.1.1 Secure all valves against opening.
4.3.1.2 Close all openings and supply pipes.
4.3.2 Standstill > 2 Weeks
4.3.2.1 Preserve the pump as described under Detailed Description of Preservation for Standstill in this chapter.
4.3.2.2 Protect the pump set components such as gear or variable speed coupling against water ingress and
humidity as described in the manufacturers preservation instructions.
5. Detailed Description of Preservation for Standstill

________________________________________________________________________
The pump has been depressurized and the casing temperature is < 500 C,
measured at the pump nozzles!
_________________________________________________________________________
5.1 Secure all valves against opening.

5.2 Open all drain and/or drain pipes.
5.3 Collect the fill in an appropriate container and dispose of according to anti-pollution regulations.
________________________________________________________________________________________
If the medium handled is toxic, inflammable, explosive or hazardous in a

different way, the pump must be flushed thoroughly to avoid that any
residues remain in the pump.
_________________________________________________________________________
5.4 Close all drains and/or drain pipes.
5.5 Fill the pump with glycol/water mixture at a proportion of 1 : 2.
0
Important : This mixture ensures protection against frost up to approx. 20 C.
A mixture at a proportion of 1 : 1 increases the protection up to 420C.
5.6 Dismantle and store the coupling guards mounted on the pump set.
5.7 Dismantle and store the connecting coupling spacer in accordance with the manufacturers documentation.
5.8 If necessary, fill the bearing housing with oil.
5.9 Rotate the pump rotor once or twice a month to prevent a separation of the preservation fill, check the fill level
and top up, if required.
OIMPG COMM 39
_____________________________________________________________________
The Rotor Position Indicator is mounted on the discharge side of the pump. There are two types of Rotor Position
Indicators.
The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearing
end cover, which is the stationary part, and the rotating indicator (624) is screwed in the shaft threading.
The bush has two scriber marks, at right angles to shaft axis, which are 1.5 mm apart.
1. If the balancing device is new, the position of the indicator (624) must be as shown in the figure Pump running
normally.
2. In the case of maximum wear of the balancing device the position of the indicator (624) is as shown in the
figure Time to shut down the pump.
Pump running normally
623
624
Time to shut down the pump

623
624
0
Rotor position indicator
Rotor position indicator
_____________________________________________________________________
Pump Supervision Plan
For exact description of pump as well as scope of supply of accessories & instrumentation etc.,
Point to be supervised
Pump Bearings : Plain
Thrust Bearing Tilting pads
(if applicable)
Lift-off device with antifriction bearings
(if applicable)
Lift-off device with Tilting pads bearings
(if applicable)
Indicator
(only for pumps with balancing disc)
Mechanical seal (433)
Differential pressure gauge
Strainer I suction pipe (if applicable)
Differential pressure gauge
Duplex filter
(if applicable)
Measuring instrument, suction side ps
(gauge holder )
(if applicable)
Measuring instrument, discharge side pd
(gauge holder )
(if applicable)
Measuring instrument, tapping
(gauge holder )
(if applicable)
Measuring instrument, balancing water pE
(gauge holder )
(if applicable)
Thermometer
(Suction nozzle/discharge nozzle)
(if applicable)
Thermometer
(cooling water inlet)
(if applicable )
Cooling water pipe
(supply and return flow)
(if applicable)
Sight glass
(cooling water inlet pipe) (if applicable)
Oil pressure gauge
(gauge holder)
(if applicable)
Level indicator
(Oil supply system)
(if applicable)
Connecting coupling
(only for coupling with pressure oil lubr.)
Supervisory action
Value to be met
0
Checking the temperature once a week

Checking the oil level once a week
(only for pumps with ring oil lubrication)
Checking for smooth operation
Once a week
Once a week
< 90 C
Middle between minimum and
maximum marks
The pump set shall run smooth
and free from vibrations.
0
< 90 C

Once a week
Once a week
Checking the rotor position once a week
< 90 C
Middle of oil level sight glass
0
< 90 C
See section Rotor Position in
this chapter
0
80 C
15 drops per minute
< 0.3 bar

Checking the leakage once a week
Checking the differential pressure
Once a week
Checking the differential pressure
Once a week
Checking the pressure once a week

PE ps + 0.5 bar
45 C
t 10 C
Checking the cooling water flow once a

week
Water is flowing
- 20 mm
Checking for leakage once a week
No leakage permitted
In case of deviations, proceed in accordance with the Cause Remedy specified under
the chapter Trouble shooting.
We recommend recording the information tabulated above in a logbook, in the form of enclosed
LOG SHEET.
LOG SHEET
PUMP TYPE
CUSTOMER ITEM NO.
NO.
1
2
3
4
5
DESCRIPTION
PRESSURE AT
Suction nozzle
Differential across suction strainer
Discharge nozzle
Balancing line
Oil inlet to bearing (forced oil lubrication)
5.1 Suction side bearing
5.2 Discharge side bearing
5.3 Lift off / Thrust bearing
6
7
8
9
9.1
9.2
9.3
10
10.1
10.2
10.3
11
11.1
11.2
11.3
11.4
11.4
12
TEMPERATURE AT
Suction nozzle
Discharge nozzle
Balancing line
Bearings
Suction side
Discharge side
Lift off / Thrust
Oil inlet to bearing (forced oil lubrication)
Suction side
Discharge side
Lift off / Thrust
Flushing liquid
Shaft seal - Suction
Shaft seal - Discharge
Cooling Water Inlet / outlet
Suction
Discharge
Lift off / Thrust
SERIAL NO.
UNIT
READING
kg/cm2
kg/cm2
kg/cm2
kg/cm2
kg/cm2
kg/cm2
kg/cm2
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
Deg C
ROTOR POSITION
13
VIBRATIONS AT
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
Amplitude
microns (peak to peak)
H
V
A
RMS Velocity
mm / s
H
V
A
Suction side bearing housing

Discharge side bearing housing
Lift off / Thrust bearing housing
Suction flange
Discharge flange
Suction side support foot
Discharge side support foot
Base Frame
H = Horizontal ;
DATE / TIME
V = Vertical ;
A = Axial.
SIGNATURE OF OPERATOR
LOG SHEET
B1
_____________________________________________________________________
Servicing
We recommend that KSBs specialist personnel be present during the servicing of the
pump!
________________________________________________________________________________________
Caution
Improper handling of preservatives, oil and grease causes hazardous

environmental impact.
Handling and disposal only by qualified personnel!
_________________________________________________________________________
1.2 Required documentation
1.2.1 The following documents are necessary for servicing of pump set.
Sectional Drawing, Pump
List of Components, Pump
Documentation of the Mechanical Seal (if applicable)
1.2.2 Documentation of Connecting Coupling
1.2.3 Documentation of Drive
1.2.4 Documentation of the Minimum Flow System (if applicable)
1.2.5 Documentation of Valves and Equipment (if applicable)
1.2.6 Documentation of the Instrumentation (if applicable)
1.3 Prerequisites
1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown
sections of chapter Commissioning, Start-up/Shutdown) and has been prepared for the servicing work.
_____________________________________________________________________________________
!
Secure the drive against unintentional starting
____________________________________________________________
1.4 Service Intervals
________________________________________________________________________________________
Caution Perform a visual inspection of the pump set as far as accessible about
500 operating hours after commissioning/start-up.
_________________________________________________________________________
1.4.1
1.4.2
The periods of the time indicated are recommendations for normal operating conditions at trouble-free
operation, which have to be adapted to the actual operating conditions, for example the dirt accumulation,
switching frequency, load, etc.
In the case of problems and unusual operating conditions that represent electric or mechanical overloads,
off-schedule servicing must be performed.

Dismantle / remove the guards preventing accidental contact mounted to the pump set as described in the
Dismantling the Guards Preventing Accidental Contact section in chapter Maintenance.
OIMPG SERVICING 01
_____________________________________________________________________
3. Pump Servicing Plan
after Commissioning/Start-up and Stand-by
Location to be
serviced
Bearing
(Ring oil lubricated)
(if applicable)
Bearing
(Forced oil lubricated)
(if applicable)
Connecting Coupling
(if applicable)
Drive
(if applicable)
Instruments
(if applicable)
Pressure gauge
(if applicable)
Differential pressure
gauge
(if applicable)
Temperature measuring
instruments
(if applicable)
Vibration measurement
(if applicable)
Shaft positioning
monitoring (if applicable)
Inspection
(axial thrust measurement)
(if applicable)
Checks
Oil level, oil quality
Oil level, oil quality
Grease fill
(if applicable)
Checking the axial
movability
See manufacturers
documentation
Perfect condition and
functioning
functioning
functioning
Opening and closing
points
functioning
Switching points
functioning
functioning
functioning
Servicing Intervals
Servicing Work
First oil change after 300

operating hours
Subsequent oil changes
after 8000 operating hours,
at least after 1 year
First oil change after 300
operating hours
Subsequent oil changes
after 8000 operating hours,
at least after 2 years
See manufacturers
documentation
After approx. 8000
operating hours
See manufacturers
documentation
See manufacturers
documentation
See the Servicing Work

section in this chapter
Every 3 months;
See the manufacturers
documentation
Replace defective equipment;

see manufacturers
documentation
After approx. 8000

operating hours, at least
after 2 years

see manufacturers
documentation
See manufacturers
documentation
See manufacturers
documentation
See manufacturers
documentation
see manufacturers
documentation
In case of deviations, proceed in accordance with the (Cause Remedy specified under
the chapter (Trouble shooting.
OIMPG SERVICING 02
_____________________________________________________________________
4. Servicing Work
4.1 Oil Change
4.1.1.1 Oil quantity and quality, refer Technical Appendix.
4.1.1.2 Filter the oil prior to topping up; filter mesh size 30 m.
4.1.2 Bearing with Oil Sight Gauge (639)
4.1.2.1 Remove the screwed plug (13 B.1 and/or 13 B.2), completely drain off the oil fill and dispose of in
accordance with the local anti-pollution regulations.
4.1.2.2 Screw the screwed plug (including sealing element) back again.
4.1.2.3 Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the
4.1.2.4 Fit the vent plug (913.01 or 672) back again.
4.1.3 Bearing with Constant Level Oiler (638) (if applicable)
4.1.3.1 Remove the screwed plug (13 B.1), completely drain off the oil fill and dispose of in accordance with the
local anti-pollution regulations.
4.1.3.2 Screw the screwed plug (including sealing element) back again.
4.1.3.3 Remove the vent plug (913.01 or 913.02 or 672).
4.1.3.4 Hinge down the constant level oiler (638).
4.1.3.5 Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant
level oiler until oil appears ii the vertical portion of the connecting elbow of the constant level oiler, see
figure Constant level oiler.
4.1.3.6 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.
4.1.3.7 Fit the vent plug (913.01 or 913.02 or 672) back again.
4.1.3.8 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one
third of the reservoir filled at all times. If the oil level is underrun, top up with oil.
_____________________________________________________________________________________
Caution
The oil level must always be below the level of the vent opening arranged
at the top edge of the connecting elbow. Make sure the opening is always
dry.
_______________________________________________________________________
Position of
reservoir for
topping up oil
Oil level

4.1.4
Other Pump set Components

Fill the oil in accordance with the manufacturers documentation.
OIMPG SERVICING 03
_____________________________________________________________________
4.2 Re-lubrication
4.2.1.1 Oil quantity and quality, see Technical Appendix.
4.2.1.2 Filter the oil prior to topping up; filter mesh size 30m.
_____________________________________________________________________________________
Caution
During operation, the oil level in the bearing housing drops! Check the oil
level only during standstill of the pump!
In case of extraordinary loss of oil, find and eliminate the cause.
_______________________________________________________________________
4.2.2 Bearing with Oil Sight Gauge (639)
_____________________________________________________________________________________
Caution
4.2.1.1
4.2.1.2
4.2.2
4.2.3.1
4.2.3.2
4.2.3.3
4.2.3.4
4.2.3.5
4.2.3.6
The oil level may drop during start-up of the pump. If the minimum mark is
underrun, top up with oil.
_____________________________________________________________________________________
Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the
Fit the vent plug (913.01 or 672) back again.
Bearing with Constant Level Oiler
Remove the vent plug (913.01 or 913.02 or 672).
Hinge down the constant level oiler (638).
Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant
level oiler until oil appears in the vertical portion of connecting elbow of the constant level oiler, see figure
Constant level oiler.
Fill the reservoir of the constant level oiler with oil and snap it back into operating position.
Fit the vent plug (913.01 or 913.02 or 672) back again.
After a short time check whether the oil level in the reservoir has dropped. It is important to keep at
least one third of reservoir filled at all times. If the oil level is underrun, top up with oil.
_____________________________________________________________________________________
Caution
The oil level must always be below the level of the vent opening arranged
at the top of the connection elbow. Make sure the opening is always perfectly dry.
_______________________________________________________________________
Position of
reservoir for
topping up oil
Oil level

4.2.4
4.3
4.3.1
4.3.2
Other Pump Set Components

Top up with oil in accordance with the manufacturers documentation.
Connecting Coupling (if applicable)
Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting
Coupling and Mounting the Connecting Coupling in chapter Maintenance.
Perform all servicing work in accordance with the manufacturers documentation.
OIMPG SERVICING 04
_____________________________________________________________________
Maintenance
________________________________________________________________________________________
Caution
During the warranty period, pumps should be dismantled only by KSB

personnel!
_________________________________________________________________________
1.2 Required documentation
1.2.1 The following documents are necessary for servicing of pump set.
Sectional Drawing, Pump
List of Components, Pump
Documentation of the Mechanical Seal (if applicable)
1.2.2 Documentation of Connecting Coupling
1.2.3 Documentation of Drive
1.2.4 Documentation of the Minimum Flow System (if applicable)
1.2.5 Documentation of Valves and Equipment (if applicable)
1.2.6 Documentation of the Instrumentation (if applicable)
1.3 Prerequisites
1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown
sections of chapter Commissioning, Start-up/Shutdown) and has been prepared for the servicing work.
1.3.2 All spare parts required are available.
1.3.3 Proper hoisting tackle and means of transport are available and ready for use.
1.3.4 Sufficient room space and appropriate tools are available.
1.3.5 The drive has been secured against unintentional starting.

2.1 Sound Insulating Hood (If applicable)
Dismantle the sound insulating hood as far as necessary as described in manufacturers documentation.
2.2 Coupling Guard/Coupling Cover
Dismantle and store the coupling guards and/or coupling covers mounted on the pump set.
Coupling cover ( example )
Dismantling the coupling cover.

________________________________________________________________________________________
Caution
Do not damage the seal elements and sealing surfaces!
_________________________________________________________________________
_____________________________________________________________________
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
Remove all pipes on the cover.

Remove the taper pins and screw of the cover split joint.
Use the eye bolt as transport aid as shown in the figure Coupling cover.
Unscrew the screws in the upper part of the flange.
Remove the upper half of the coupling cover.
Remove the internal injection lines.
Disconnect the lower half of the coupling cover from the flange and store it.
2.3 Guard Preventing Accidental Contact for Shaft Seal.

Dismantle the guard preventing accidental contact as far as necessary and store it.
3. Dismantling the Connecting Coupling

3.1 Dismantling the Coupling Connection
3.1.1
Give due attention to markings on the coupling, if any, or mark the coupling to rule out later mix-ups.
3.1.2
Dismantle the connecting coupling spacer as described in the manufacturers documentation.

____________________________________________________________________________________
!
Secure the spacer against falling down.
____________________________________________________________
3.1.3
Store the parts appropriately.
3.2 Removing the Coupling Hubs

3.2.1
3.2.2
3.2.3
Dismantle the retaining ring, if applicable, from the coupling hub.

Remove the grub screws (if provided).
0
To facilitate removing, the coupling hub may be heated uniformly to a temperature of 80 C max.
_____________________________________________________________________________________
Use protective gloves!

!
Risk of fire in case of open flames.
Remove flammable substances from the danger area.
_______________________________________________________________________
3.2.4
Elastomeric parts must be removed before heating!

_____________________________________________________________________________________
Caution
Elastomeric parts which have been heated must not be used any more.
Use new parts for reassembly.
_______________________________________________________________________
3.2.5 Remove the coupling hubs as shown in the figure Removing the coupling hubs.
_____________________________________________________________________
_____________________________________________________________________________________
Secure the coupling against falling down.
_____________________________________________________________________________________
_____________________________________________________________________________________
Caution
Remove the coupling hubs using only the appropriate device to prevent
the shaft bearings form damage by axial frictional force. Impacts on the
coupling are not permitted.
_______________________________________________________________________
3.2.6
3.2.7
Mark the keys prior to removing them.

Store the coupling hubs and keys appropriately.
3.3 Run-out Check of the Shaft Ends

3.3.1
3.3.2
After removing the coupling hubs check the shaft ends for run-out, see figure Run-out check of shaft ends.
Permissible tolerance 0.03 mm; if this value is exceeded, inform KSB.
Run-out check of the shaft ends (example)
4. Removing the Pump from the Installation

The work described in sections 4.1 to 4.3 is required only if the pump is to be
removed from the installation for maintenance.
4.1 Dismantling the Piping and Instruments
_____________________________________________________________________
_____________________________________________________________________________________
!
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.2
4.2.1
Operating fluids can run out when unscrewing the pipes and instruments.
These are to be collected and properly disposed of by the Operator.
_____________________________________________________________________________________
Undo the connections between discharge nozzle and discharge pipe & between suction nozzle and suction
pipe.
Fasten the suction and discharge pipes to temporary holders.
Dismantle the minimum flow control valve, if necessary.
Disconnect the tapping pipe, if applicable.
Detach and dismantle any auxiliary lines such as circulation, cooling liquid and oil pipes as well as
measuring lines as far as necessary.
Dismantle the measuring devices and instruments as far as necessary, and store them appropriately.
If required, dismantle the cooler of the shaft seal including support.
Removing the Pump from Baseframe

Unscrew the fastening studs at the pump feet; see the figure Fastening of the pump feet.
1-Pump foot, 2-Nut, 3-Disc, 4-Shims, 5-Stud, 6-Base plate

4.2.2
Loosen nuts and adjusting screws at the guide block; see figure Adjusting screw at the guide casing.
Adjusting screws at the guide casing ( example )
_____________________________________________________________________
4.3 Transporting the Pump to the Place of Dismantling
_______________________________________________________________________________________
Caution
The pumps have to be lifted and transported in accordance with the

guidelines laid down in the chapter Transport / Interim Storage.
Do not fasten the ropes to the shaft ends or the bearing housings.
_______________________________________________________________________________________
4.3.1
Lift the pump from the baseframe, transport it to the place of dismantling and set it down on assembly
supports.
_____________________________________________________________________________________
Secure the pump against overturning.
_____________________________________________________________________________________
_____________________________________________________________________________________
Mark the matching shims between the pump feet and baseframe so that
they can be inserted in the same place on subsequent reassembly, and
store them appropriately.
_______________________________________________________________________
Caution
_____________________________________________________________________
5. Dismantling the Bearings
5.1 Preparations
5.1.1
5.1.2
5.1.3
5.1.4
Prior to dismantling, drain the oil fill of the bearing housings and the thrust bearing housing and dispose of
in accordance with the local anti-pollution regulations.
If applicable, dismantle the cooling liquid pipes and oil supply pipes as far as necessary.
If applicable, dismantle the oil sight gauge (639) and/or constant level oiler (638) as well as the
thermometer (692.01 or 692.02) and/or RTDs.
If applicable, remove the splash ring (507.01 and/or 507.02) on the driven end from the shaft (210) after
loosening the grub screws (904.05, if applicable).
5.2 Dismantling the Add-on Parts (for example flanged-on oil pump, shaft position
indicator, etc.) (if applicable)
5.2.1
For applicable add-on parts, refer Sectional Drawing and P&I Diagram.
5.3 Dismantling the Lift-off Device, with Antifriction Bearings (if applicable)
5.3.1
5.3.2
5.3.3
Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11).
Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).
Pull the bearing cartridge (381) including the two angular contact ball bearings (320) out of the thrust
bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01.
Dismantle further, if required.
_____________________________________________________________________________________
In case of slight discolourations (incl. rust stain) or any damage, the bearings
Caution must be replaced.
Clean used bearings with cleaning oil! After cleaning immediately spray the
bearings with oil!
5.3.4
5.3.5
5.3.6
5.3.7
_____________________________________________________________________________________
Take the springs out of the thrust bearing housing (354).
Take away the thrust bearing housing (354) including O-ring (412.10).
If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).
Remove the spacer ring (504.01) from the shaft (210).
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing (if applicable)\
5.4.1
5.4.2
5.4.3
Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11).
Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).
Pull the bearing cartridge (381) including the thrust bearing, thrust bearing plate (384) and counter thrust
bearing plate (388) out of the thrust bearing housing (354) using the appropriate device as described in the
work instruction UA3 13473 01. Dismantle further, if required.
_____________________________________________________________________________________
Caution
In case of slight discolourations (incl. rust stain) or any damage, the

bearing segments must be replaced!
_______________________________________________________________________
5.4.4
5.4.5
5.4.6
5.4.7
Take the springs out of the thrust bearing housing (354).

Take away the thrust bearing housing (354) including O-ring (412.10).
If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).
Take away the key out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).
5.5 Dismantling the Thrust Bearing (if applicable)

5.5.1
5.5.2
5.5.3
Unscrew the hex nuts (920.11) and remove the bearing end cover (361) including thrust bearing (314), Oring (412.11), circlip (932.03) and shaft seal (420.01, 562.02).
Screw nut (920.09) from the shaft (210).
Remove the spacer sleeve (525.05) from the shaft (210).
_____________________________________________________________________
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in the
work instruction UA3 13475 01 or UA3 14758 01.
Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).
Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and
remove them together with the adjoining segments.
Pull the thrust bearing (314) out of the thrust bearing housing (354) using the appropriate device as
described in the work instruction UA3 13475 01 or UA3 14758 01.
Unscrew the hex socket head cap screws (614.04) and take the thrust bearing housing (354) including
parallel pin (562.02), shaft seal ring (420.01) circlip (932.03) and O-ring (412.10) out of the bearing housing
(350.01).
_____________________________________________________________________________________
Caution
In the case of slight discolourations (incl. rust stain) or any damage, the
______________________________________________________________________
5.6 Dismantling the Radial Bearings
______________________________________________________________________________________
Caution
When the bearing shells are dismantled, the shaft must not rest on the
bearing housing or labyrinth rings!
________________________________________________________________________
_____________________________________________________________________________________
Caution
Mark the bearing shells to ensure their correct assignment to the bearing
housings! Protect the bearing shells against damage!
_____________________________________________________________________________________
_____________________________________________________________________________________
Caution
In the case of slight discolourations (incl. rust stain) or any damage, the
_______________________________________________________________________
5.6.1.1 Unscrew the hex head bolts (901.01 and 901.03) and remove the bearing cover (360) and bearing end
cover (361) including O-ring (412.09).
5.6.1.2 Remove the pins (560.01) including washers (550.07) and nuts (920.07) as well as hex socket head cap
screw (914.05) including circlips (932.05) and take away the upper part of the bearing housing (350.01)
including the upper half of labyrinth ring (423.01).
5.6.1.3 Remove the upper bearing shell (370) and lubricating ring (644, if applicable).
5.6.1.4 Remove the lower half of labyrinth ring (423.01) and lower bearing shell (370); for that purpose lift the shaft
(210) using a wooden rod.
5.6.2 HG pump sizes 3 to 6
5.6.2.1 Unscrew the hex head bolts (901.01 and 901.06) and remove the bearing cover (360) and bearing end
cover (361) including O-ring (412.09).
5.6.2.2 Remove the hex head bolt (901.13) including washers (550.12) and gasket (411.03).
5.6.2.3 If applicable, undo the grub screw (904.06) and dismantle the lubricating ring (644).
5.6.2.4 Remove the bearing shell (370) and glued-in labyrinth ring (423.01) and O-ring (412.18) from the shaft,
using the appropriate device as described in the work instruction UA7 23062 01.
_____________________________________________________________________
5.7 Dismantling the Bearing Housings
5.7.1.1
Remove the hex head bolts (901.05) and nuts (920.14).
5.7.1.2
Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing
housing (350.01).
5.7.1.3
Remove the splash ring (507.01 or 507.02) from the shaft (210).
5.7.2 HG Pump Size 3
5.7.2.1
Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts
(921.14).
5.7.2.2
Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing
housing (350.01).
5.7.2.3
Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws
(904.05, if applicable).
5.7.3 HG Pump Sizes 4 to 6.
5.7.3.1
Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts
(921.14).
5.7.3.2
Unscrew the nuts (920.04) at the studs (902.01) and take away the bearing housing (350.01).
5.7.3.3
Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws
(904.05, if applicable).
_____________________________________________________________________
6 Dismantling the Shaft Seal
6.1 Preparations
Dismantle any cooling, flushing, quenching pipes, wherever applicable. All the openings should be plugged.
6.2 Dismantling the Mechanical Seal.

(Part numbers, specified in the following description are only representative)
_______________________________________________________________________________________
Caution
Refer order specific sectional drawing of mechanical seal for correct part
numbers as well as description!
Refer Manufacturers documentation!
_______________________________________________________________________________________
6.2.1.1
Shaft Seal
6.2.1.1.1 Loosen the hex bolt (14) and locate the sliding washer (13) into the groove provided on the sleeve (6)
and tighten the hex bolt (14).
6.2.1.1.2 Loosen socket screws (12) and dog point screws (17).
6.2.1.1.3 Unscrew and remove fixing screws of gland plate (4).
6.2.1.1.4 With the help of jacking bolts, provision made on gland plate (4), remove cartridge off the shaft (210).
Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.1.2
Dismantling of Cartridge (if required).
6.2.1.2.1 Remove hex bolt (14) and sliding washer (13). For removing sliding washers, slightly compress the
springs (e) of the mechanical seal.
6.2.1.2.2 Remove socket screws (12) and dog point screw (17) from the drive collar (11).
6.2.1.2.3 Remove drive collar (11) from the sleeve (6).
6.2.1.2.4 Remove the mechanical seal rotary head assembly consisting of components a,b,c,d,e,f.
_____________________________________________________________________________________
Caution
Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical
seal components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution
In the event of slight scoring marks on the rubbing faces of seal ring (b)
and mating ring (2), they can be sent back to the manufacturer for
touching up.
_____________________________________________________________________________________
6.2.2.1
Shaft Seal
6.2.2.1.1 Loosen the cap screw (K) and locate retaining plate (15) into the groove provided on the sleeve (10)
and tighten the cap screw (K).
6.2.2.1.2 Loosen set screws (13) of sleeve collar (9).
6.2.2.1.3 Unscrew and remove fixing screws of gland ring (1).
6.2.2.1.4 With the help of jacking bolts, provision made on gland ring (1), remove cartridge off the shaft (210).
Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.2.2
Dismantling of Cartridge (if required).
6.2.2.2.1 Remove cap screw (K) and retaining plate (15). For removing retaining plate, slightly compress the
springs (c) of the mechanical seal.
6.2.2.2.2 Remove socket screws (13) and dog point screw (12) from the sleeve collar (9).
6.2.2.2.3 Remove sleeve collar (9) from the sleeve (10).
6.2.2.2.4 Remove the mechanical seal rotary head assembly consisting of components 3,4,45,5,c,d,e,p.
_____________________________________________________________________
_____________________________________________________________________________________
Caution
Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical
seal components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution
In the event of slight scoring marks on the rubbing faces of seal ring (b)
and mating ring (2), they can be sent back to the manufacturer for
touching up.
____________________________________________________________________________________________
6.2.3.1
Shaft Seal
6.2.3.1.1 Loosen the hex bolt (15) and locate the assembly fixture (14) into the groove provided on the sleeve (6)
and tighten the hex bolt (15).
6.2.3.1.2 Loosen set screws (13) of clamping ring (11).
6.2.3.1.3 Unscrew and remove fixing screws of gland (4).
6.2.3.1.4 With the help of jacking bolts, provision made on gland (4), remove cartridge off the shaft (210). Follow
the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.3.2 Dismantling of Cartridge (if required).
6.2.3.2.1 Remove hex bolt (15) and assembly fixture (14). For removing assembly fixture, slightly compress the
springs (1.4) of the mechanical seal.
6.2.3.2.2 Remove set screws (12) and (13) from the clamping ring (11).
6.2.3.2.3 Remove clamping ring (11) from the sleeve (6).
6.2.3.2.4 Remove the mechanical seal rotary head assembly consisting of components 1.1,1.2,1.3,1.4,1.5,1.6.
_____________________________________________________________________________________
Caution
Damaged sleeve (6), seal face (1.1), seat (2) and other mechanical seal
components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution
In the event of slight scoring marks on the rubbing faces of seal face (1.1)
and seat (2), they can be sent back to the manufacturer for touching up.
______________________________________________________________________________________________
6.3 Dismantling the Casing Parts

6.3.1.1 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part
(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).
6.3.2.1 If applicable, loosen and remove the hex socket head cap screws (914.08, non-driven end).
6.3.2.2 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part
(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).
6.3.2.3 If applicable, loosen and remove the hex nuts (920.04 or 920.05) on the studs (902.01, on either end or
902.05, on the driven end).
6.3.2.4 Fasten the seal casing (441 or 441.01 or 441.02 as per the execution) to the crane by means of eyebolt
and rope, force off with screws and remove it. Unscrew the hex socket head cap screws (914.09, if
applicable).
6.3.2.5 On the driven end, loosen and remove hex nuts (920.05) on the studs (902.05) or the hex socket head cap
screws (914.15, if applicable), fasten the casing part (130) to the crane by means of eyebolt and rope,
force off with screws and remove it.
_____________________________________________________________________
7. Dismantling the Balancing Device
7.1.1
7.1.2
7.1.3
7.1.4
Remove the spacer ring (504.02) and if applicable spacer sleeve (525.02) from the shaft (210).
Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the
work instruction UA2 13474 01
Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as
described in the work instruction UA2 13474 01
Check the balancing disc (601.01) and counter balancing disc (602.01) for signs of damage.
7.2 HG Pump Size 3

7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
Pull the retainer ring (505.01) from the shaft (210) and remove key (940.07) and split ring (501.01).
Remove the spacer ring (504.02) or spacer sleeve (525.02) from the shaft (210).
Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the
work instruction UA2 14761 01.
Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as
described in the work instruction UA2 14761 01.
If applicable, take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from
the shaft (210).
Check the balancing disc (601.01), the counter balancing disc (602.02) and throttle sleeve (522.01), if
applicable, for signs of damage.
7.3 HG Pump Size 4

7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
7.3.7
Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.07) out of the shaft keyway.
Unscrew the hex socket head cap screws (914.10) and pull off the retainer ring (505.01).
Take the split ring (501.01) out of the shaft groove and pull the spacer ring (504.02) from the shaft (210).
Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the
work instruction UA2 14765 01.
Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the
discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 01.
Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft.
Check the balancing disc (603.02), counter balancing disc (602.01) and throttle sleeve (522.01) for signs of
damage.

7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.06) out of the shaft keyway.
Unscrew the hex socket head cap screws (914.10) and remove the retainer ring (505.01).
Take the split ring (501.01) out of the shaft groove and remove the spacer ring (504.02) from the shaft
(210).
Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the
work instruction UA2 14765 02
Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the
discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 02.
Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft (210).
Pull the throttle bush (542.01) out of the discharge casing (107) using the appropriate device as described
in the work instruction UA2 14765 02.
Check the balancing disc (603.02), counter balancing disc (602.01), throttle bush (542.01) and throttle
sleeve (522.01) for signs of damage.
7.5 Measuring the Approximate Radial Clearance

_______________________________________________________________________________________
Caution
Measure the approximate radial clearance if the pump body is not to be

dismantled.
Exact checking of the rotor clearance is possible only with the pump
dismantled.
_________________________________________________________________________________________________
_____________________________________________________________________
7.5.1
7.5.2
7.5.3
Place the dial gauge holder on a firm base (for example flange or discharge nozzle) and position the dial
gauge on the seat of the balancing piston as shown in the figure Measuring the approximate radial
clearance.
Carefully lift the shaft until it abuts on the top. Shaft deflection must not be increased (incorrect
measurement).
The diametrical clearance determined this way must not exceed 0.8 mm; if it does, the pump must be
dismantled and overhauled.
HG Pump Sizes 1 - 3
HG Pump Sizes 4 - 6
Measuring the approximate radial clearance
8. General Information on Reassembly

8.1 Meticulously clean all dismantled components, in particular the fit and sealing surface areas.
________________________________________________________________________________________
Caution
8.2
8.3
8.4
8.5
Do not damage the locating and sealing surfaces!
________________________________________________________________________________________
If required, remove any lime and incrustation from the cooling chambers.
Check all dismantled components for signs of damage.
If required, use new parts.
As a general rule, always use new O-rings and gaskets for reassembly.
________________________________________________________________________________________
Caution
Do not take the O-rings out of their original packing until those are actually
required to be fitted and protect them from mineral oil and grease!
_________________________________________________________________________
_________________________________________________________________________
Do not fit the O-rings in dry condition but wet them with silicone grease! In
Caution
exceptional cases, soapy water may be used.
________________________________________________________________________
8.6 Prior to reassembly coat the screw/bolt connections and pipe unions as well as the fits of the individual
components using respective specified lubricating agent as described in the work instruction UA4 28699 01.
8.7 Reassembly must be performed in accordance with the rules of good engineering practice.
9. Checking the Balancing Device with the Contact Fluid Engineers Blue.
The steps 9.1 to 9.3 are required only if balancing piston (603.02) or counter
balancing disc (602.02) were remachined or replaced.
9.1.1
9.1.2
Meticulously clean the axial running face of the counter balancing disc (602.02).
Insert the grooved pin (561.03) in the discharge casing (107).
_____________________________________________________________________
9.1.3
9.1.4
Fit the counter balancing disc (602.02) without O-rings (412.04 and/or 412.05). The grooved pin (561.03)
must engage in the groove of the counter balancing disc (602.02).
Adjust the pump rotor position; see figure Adjusting pump rotor position.
5 0 2 .0 2
2 3 0 .0 2
1 7 1 .0 2
S a 1
S a 2
A d ju s tin g t h e p u m p r o t o r p o s itio n
9.1.4.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end.
_____________________________________________________________________________________
Caution
This rotor position must not be changed when measuring the balancing
device!
_____________________________________________________________________________________
9.1.5 Adjust the balancing disc (601.01); see figure Adapting the balancing piston.
b1
Sl2
a1
Machine here
602.01
504.02
601.01
Adapting the Balancing disc
9.1.5.1 Measure the distance a1 from the running face of the counter balancing disc (602.01) to the impeller of
the last stage.
9.1.5.2 Shorten the balancing disc (601.01) to the dimension b1 as sown in the figure Adapting the balancing
disc: b1 = a1 SL2 (SL2, see table of clearances).
9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.
_____________________________________________________________________
x
a
504.02
601.01 602.01
Varient without spacer sleeve
504.02 525.02
601.01 602.01
Varient with spacer sleeve (525.02)
Adjusting the spacer ring

9.1.6.1 Measure the distance x from the running face of the counter balancing disc (602.01) to the shaft collar.
9.1.6.2 Determine the dimension b between the running face and face of balancing disc (601.01) as well as the
length y of the spacer sleeve (525.02, if applicable).
9.1.6.3 Shorten the spacer ring (504.02) to the dimension a : a = x b or a = x - b-y. The maximum permissible
deviation from plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
As a general rule, always use a new spacer ring (504.02)!
_______________________________________________________________________
9.1.7
9.1.8
9.1.9
9.1.10
9.1.11
9.1.12
9.1.13
9.1.14
9.1.15
9.1.16
Insert the key (940.04).

Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the
balancing piston (601.01) without O-ring (412.02) on the shaft (210).
Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210)
Mount the casing part (130, if applicable) and seal casing (441) without O-rings.
Mount the shaft sleeve (524.01, pump with gland packings).
Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section so far
as to make the free rotation of the pump rotor possible.
For the check with the contact fluid engineers blue, move the rotor towards the driven end and turn it
slowly.
Move the pump rotor to the non-driven end and dismantle all pump components including the counter
balancing disc (602.01) in reverse order.
At least of the axial running face of the counter balancing disc (602.01) must have a uniform print of the
contact fluid in the upper zone. If this is not the case, remachining the counter balancing disc (602.01) on a
lathe and repeat the contact fluid checks.
After completion of the contact fluid check, clean the axial running faces of the balancing piston (601.01)
and counter balancing disc (602.01).
9.2
HG Pump Size 3
9.2.1
9.2.2
9.2.3
Insert the grooved pin (561.03) in the discharge casing (107).
Fit the counter balancing disc (602.01) without O-rings (412.04 or 412.05). The grooved pin (561.03) must
engage in the groove of the counter balancing disc (602.01).
If applicable, slide throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and hey (940.03)
until abutting against the impeller (230.02).
Adjust the pump rotor position; see figure Adjusting the pump rotor position.
9.2.4
9.2.5
_____________________________________________________________________
5 0 2 .0 2
2 3 0 .0 2
1 7 1 .0 2
S a 1
S a 2
A d ju s tin g t h e p u m p r o t o r p o s itio n
9.2.5.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end.
_____________________________________________________________________________________
Caution
The rotor position must not be changed when the measuring the balancing
device!
_______________________________________________________________________
9.2.6 Adapt the throttle sleeve (522.01) and/or balancing disc (601.01); see figure Adapting the throttle sleeve or
figure Adjusting the balancing disc.
Machine
here
602.01
504.02
601.01
522.01
Adapting the throttle sleeve
Machine
here
602.01
504.02
Adapting the balance disc
601.01
_____________________________________________________________________
the last stage and, if required, the dimension c1 of the balancing disc (601.01).
9.2.6.2 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the
throttle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc
: b1 = a1 c1 Sl2 or b1 = a1 Sl 2 (Sl2 see tables of clearances).
9.2.7 Adapt the spacer ring (504.2) or spacer sleeve (525.02); see figure Adapting the spacer ring or see figure
Adapting the spacer sleeve.
504.02
601.01 602.01 522.01
Adapting the spacer ring
525.02
601.01 602.01 522.01
Adapting the spacer sleeve
9.2.7.1 Measure the distance x from the running face of the counter balancing disc (602.01) to the split ring
(501.01).
9.2.7.2 Determine the dimension b between the running face and face of the balancing disc (601.01).
9.2.7.3 Shorten the spacer ring (504.02) or spacer sleeve (525.02) to the dimension a : a = x b. The maximum
permissible deviation form plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
As a general rule, always use a new spacer ring (504.02)or spacer sleeve
(525.02)!
_______________________________________________________________________
9.2.8
9.2.9
9.2.10
9.2.11
9.2.12
9.2.13
9.2.14
9.2.15
9.2.16
9.2.17
9.3
9.3.1

Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the
balancing disc (601.01) without O-ring (412.02) on the shaft (210).
Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210).
Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over
them.
Mount the casing part (130, if applicable) and seal casing (441) without O-rings.
Fit the driven-end and non-driven end bearings in accordance with the Mounting the Bearings section, so
far as to make possible the free rotation of the pump rotor.
For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly.
Move the pump rotor to the non-driven end and dismantle all components including the counter balancing
disc (602.01) in reverse order.
contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.02) on a
lathe and repeat the contact fluid check.
After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and
counter balancing disc (602.01).
HG Pump Size 4
Meticulously clean the axial running face of counter balancing disc (602.01).
_____________________________________________________________________
9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the throttle
sleeve : b1 = a1 c1 - Sl2 (Sl2 see table of clearances).
x
b
504.02
601.01 602.01
522.01
(501.01).
9.3.7.3 Shorten the spacer ring (504.02) to the dimension a : a = x b. The maximum permissible deviation from
plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
_______________________________________________________________________
9.3.8
9.3.9
9.3.10
9.3.11
9.3.12
9.3.13
9.3.14
9.3.15
9.3.16
9.3.17

Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing
disc (601.01) without O-ring (412.02) on the shaft (210).
Slide the spacer ring (504.02) over the shaft (210).
Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the
balancing disc (601.01), using hex socket head cap screws (914.10).
Mount the casing part (130) and seal casing (441) without O-rings.
Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so
For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly.
Move the pump rotor to the non-driven end and dismantle all components including the counter balancing
After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and

9.4.1
9.4.2
9.4.3
9.4.4
Fit the throttle bush (542.01) without O-ring (412.05).
Insert the parallel pin (562.03) in the discharge casing (107).
Insert the key (940.03) and slide the throttle sleeve (522.01) without O-ring (412.02) over the shaft (210)
and key (940.03) until abutting against the impeller (230.02).
_____________________________________________________________________
9.4.5
9.4.6
Fit the counter balancing disc (602.01) without O-ring (412.16) and fasten with the hex socket cap screws
(914.06). The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01).
Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pump
rotor position.
502.02
230.02
171.02
Sa1
Sa2
Adjusting the pump rotor position
_____________________________________________________________________________________
Caution
This rotor position must not be changed when measuring the balancing
device!
_______________________________________________________________________
9.4.7
Adapt the throttle sleeve (522.01); see figure Adapting the throttle sleeve.
c1
b1
Sl2
a1
Machine
here
602.01
542.01
504.02
601.01
Adapting the throttle sleeve
522.01
_____________________________________________________________________
last stage and the dimension c1 of the balancing disc (601.01).
9.4.7.2 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the throttle
sleeve : b1 = a1 c1 - Sl2 (Sl2 see table of clearances).
x
b
504.02
601.01 602.01
522.01 542.01

(501.01).
9.4.8.3 Shorten the spacer ring (504.02) to the dimension a : a = x b. The maximum permissible deviation from
plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
_______________________________________________________________________
9.4.9 Insert the key (940.04).
9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing
disc (601.01) without O-ring (412.02) on the shaft (210).
9.4.11 Slide the spacer ring (504.02) over the shaft (210).
9.4.12 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the
balancing disc (601.01), using hex socket head cap screws (914.10).
9.4.13 Mount the casing part (130) and seal casing (441) without O-rings.
9.4.14 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so
9.4.15 For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly.
9.4.16 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing
9.4.17 At least of the axial running face of the counter balancing disc (602.02) must have a uniform print of the
9.4.18 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and
_____________________________________________________________________
10. Mounting the Balancing Device
______________________________________________________________________________________
Caution
If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing

disc (602.01) were remachined or replaced, the check with the contact
fluid engineers blue as outlined in sections 9.1 to 9.4 must be performed!
_____________________________________________________________________________________

10.1.1 Insert the grooved pin (561.03) in the discharge casing (107).
10.1.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)
10.1.3 Adjust the pump rotor position; see figure Adjusting the pump rotor position.
502.02
230.02
171.02
3mm

10.1.3.1
Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to the
non-driven end.
10.1.4 Insert the key (940.04).
10.1.5 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc
(601.01) over the shaft (210) until abutting against the counter balancing disc (602.01).
10.2 HG Pump Size 3

10.2.1 Insert the grooved pin (561.03) in the discharge casing (107).
10.2.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)
10.2.3 If applicable, slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key
(940.03) until abutting against the impeller (230.02).
10.2.4 Adjust the pump rotor position; see figure Adjusting the pump rotor position.
_____________________________________________________________________
502.02
230.02
171.02
3mm

10.2.4.1 Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to the
non-driven end.
10.2.5 Insert the key (940.04).
10.2.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc
(601.01) over the shaft until abutting against the counter balancing disc (602.01).
10.2.7 Slide the spacer ring (504.02) or spacer sleeve (525.02) over the shaft (210).
10.2.8 Insert the key (940.07) and split ring (501.01) in the shaft keyway and slide the retainer ring (505.01) over
them.
10.3
HG Pump Size 4
10.3.1 Insert the parallel pin (562.03) in the discharge casing (107).
10.3.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex
socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin
(562.03) must engage in the groove of the counter balancing disc (602.01).
10.3.3 Insert the key (940.04) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210)
and key (940.04) until it abuts against the impeller (230.02).
10.3.4 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump
rotor position.
10.3.5 Insert the key (940.04).
_____________________________________________________________________
230.02
502.02
171.02
Sa1
Sa2
10.3.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01)
over the shaft (210) until it abuts against the counter balancing disc (602.01).
balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant
work instruction.
10.3.9 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

10.4.1 Fit the throttle bush (542.1) including O-ring (412.05).
10.4.2 Insert the parallel pin (562.03) in the discharge casing (107).
10.4.3 Insert the key (940.03) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210)
and key (940.03) until it abuts against the impeller (230.02).
10.4.4 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex
socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin
(562.03) must engage in the groove of the counter balancing disc (602.01).
10.4.5 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump
rotor position.
10.4.6 Insert the key (940.04).
_____________________________________________________________________
230.02
502.02
171.02
Sa1
Sa2
10.4.7 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01)
over the shaft (210) until it abuts against the counter balancing disc (602.01).
balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant
work instruction.
10.4.10 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.
_____________________________________________________________________
11. Mounting the Shaft Seal
11.1 Mounting the Housing Components
11.1.1 HG Pump Size 1 to 3
11.1.1.1
In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in
position.
11.1.1.2
If applicable, mount on the driven end casing part (130) including O-rings (412.06 or 412.13, if
applicable) and parallel pin (562.11, if applicable). The parallel pin (562.11) must engage in the groove
of the counter balancing disc (602.02).
11.1.1.3
Mount the seal casing (441 or 441.01 and 441.02, depending upon the execution). Fit hex socket head
cap screws (914.09, if applicable).
11.1.2.1
In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in
position.
11.1.2.2
Insert O-ring (412.19) in the groove of the casing part (130, non driven end) and fit the casing part to
the discharge casing (107).
11.1.2.3
Depending upon the execution, fit the washers (550.05 or 550.09) and hex nuts (920.05 or 920.04), or
hex socket head cap screws (914.09) and tighten them; tightening torque, see the relevant work
instruction.
11.1.2.4
Depending upon the execution, fit again the studs (902.01 or 602.05) on the non driven end, if they
have been removed.
11.1.2.5
Fit the seal casing (441 or 441.01 and 441.02, depending upon the execution) including O-rings
(412.07 and 412.08) to the suction casing (106) and/or casing part (13.0). Fit the hex socket head cap
screws (914.09, if applicable).
11.2 Assembling the Shaft Seal

(Part no.s specified in the following description are only representative)
Caution
Refer order specific sectional drawing of mechanical seal for correct part
numbers as well as description.
Refer manufacturers documentation.
_______________________________________________________________________________________
11.2.1.1
Slide mechanical seal cartridge [attached to gland plate (4)] on the shaft until the gland plate (4) gets
located on seal casing (441).
11.2.1.2
Tighten the nuts of gland plate.
11.2.1.3
Tighten set screws (12 and 17) of drive collar (11).
11.2.1.4
Loosen the bolt (14) and take aside the sliding washer (13) from the groove of the sleeve (6).
11.2.1.5
Slip splash ring (507) onto the shaft.
11.2.2.1
Slide mechanical seal cartridge [attached to gland ring (1)] on the shaft until the gland ring (1) gets
located on seal casing (441).
11.2.2.2
Tighten the nuts of gland plate.
11.2.2.3
Tighten set screws (13) of sleeve collar (9).
11.2.2.4
Loosen the cap screw (K) and take aside the retaining plate (15) from the groove of the sleeve (10).
11.2.2.5
11.2.3.1
Slide mechanical seal cartridge [attached to gland (4)] on the shaft until the gland (4) gets located on
seal casing (441).
11.2.3.2
Tighten the nuts of gland.
11.2.3.3
Tighten set screws (13) of clamping ring (11).
11.2.3.4
Loosen the hex bolt (15) and take aside the assembly fixture (14) from the groove of the sleeve (6).
11.2.3.5
_____________________________________________________________________
12. Mounting the Bearings
12.1 Mounting the Bearing Housing and Lifting the Pump Rotor
12.1.1.1
Slide the splash ring (507.01 and/or 507.02) over the shaft (210).
12.1.1.2
Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten
the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.
12.1.1.3
On the driven end, slide the bearing cover (360) including O-ring (412.09) and if applicable the splash
ring (507.01 and/or 507.02) over the shaft (210). Do not yet fasten the bearing cover to the bearing
housing.
12.1.1.4
Fit the pump coupling hub as described under Mounting the connecting coupling.
12.1.1.5
Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work
instruction UA7 28679 01.
12.1.1.6
The lifting values (only approximate values) are stamped on the bearing housings and marked with Lift
up. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor
has increased within the permissible limits, half the clearance increase must be added to the lifting
values.
_____________________________________________________________________________________
Caution
When the bearing shells and labyrinth rings are dismantled the shaft must
not rest on the bearing housing!
_______________________________________________________________________
12.1.1.7
On the driven and non driven ends insert the lower bearing shells (370) and read the vertical pump
rotor displacement at the dial gauges. To facilitate inserting the bearing shells (370), lift the shaft (210)
using a wooden rod.
12.1.1.8
Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head
bolts (901.05).
_____________________________________________________________________________________
Caution
This adjustment may only be effected by trained specialist personnel!
_______________________________________________________________________
12.1.1.9
In order to check the measured values, remove the bearing shells (370) and insert them again. The
measured values must be reached again. Enter the lifting values in the check data sheet.
12.1.1.10 The bearing housings (350.01) are aligned laterally by means of the horizontally fitted hex head bolts
(901.05). The exact lateral alignment has been achieved when the lower bearing shells (370) can be
placed easily from either side in their fits between shaft (210) and bearing housing (350.01).
____________________________________________________________________________________
Caution
_______________________________________________________________________________
12.1.1.11
After having completed rotor lifting, lock the hex head bolts (901.05) with nuts (920.14) and tighten the
hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.

12.1.2.1
Slide the splash ring (507.01 and/or 507.02) over the shaft (210).
12.1.2.2
Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten
the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.
12.1.2.3
Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work
instruction UA7 23062 01.
12.1.2.4
The lifting values (only approximate values) are stamped on the bearing housings and marked with Lift up.
They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased
within the permissible limits, half the clearance increase must be added to the lifting values.
_____________________________________________________________________
_____________________________________________________________________________________
Caution
When the bearing shells and labyrinth rings are dismantled the shaft must
not rest on the bearing housing!
_______________________________________________________________________
12.1.2.5 On the driven and non driven ends insert the half ring (tool 969.85) in accordance with the work instruction
UA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting of
the half rings (tool 969.85), lift the shaft (210) using wooden rod.
12.1.2.6 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head
bolts (901.05).
_____________________________________________________________________________________
Caution
_______________________________________________________________________
12.1.2.7 In order to check the measured values, remove half rings (969.85) and insert them again. The measured
values must be reached again. Enter the lifting values in the check data sheet.
12.1.2.8 Check the position of the shaft in relation to the bearing housing by means of the instrument holder
(699.71) and fitted measuring instrument (690) and adjust the position, if required, by means of the hex
bolts (901.05); see work instruction UA7 23062 01.
____________________________________________________________________________________
Caution
_______________________________________________________________________________
12.1.2.9 After having completed rotor lifting, tighten hex nuts (920.04 and/or 920.05) uniformly; tightening torque,
see the relevant work instruction; and fix the bearing housing (350.01) with the taper pins (560.02); if
necessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten the
grub screws (904.05, if applicable).
12.2
Mounting the Radial Bearings

_____________________________________________________________________________________
Caution
When mounting the bearings, the holes for thermometers in the bearing
shells and the associated thermometer connections in the bearing
housings must be aligned!
_____________________________________________________________________________________
12.2.1.1 Turn the lower bearing shells (370) and lower labyrinth ring half (423.01) in the bearing housing bottom
part (350.01); for that purpose lift the shaft (210) using a wooden rod.
12.2.1.2 Fit the lubricating ring (644, if applicable) and the upper bearing shell (370) including parallel pin (562.01).
12.2.1.3 Place the upper labyrinth ring half (423.01) including the parallel pin (562.10) in the bearing housing top
part (350.01).
12.2.1.4 Mount the bearing housing top part (350.01) including the upper labyrinth ring half (423.01) and fix with
the taper pins (560.01). The parallel pin (560.01) must engage in the groove of the bearing housing top
part (350.01).
12.2.1.5 Fit the hex socket head cap screws (914.05) including circlips (932.05) and tighten them uniformly;
tightening torque, see the relevant work instruction.
12.2.1.6 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten
the hex head bolts (901.01 or 901.03) uniformly; tightening torque, see the relevant work instruction.
_____________________________________________________________________
Additional Work for Pumps with Balancing Disc :
12.2.1.7 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.2.1.8 For rotor position indicator the description under Supervision of Rotor Position in the section Pump
Supervision Plan.
12.2.2.1 Place the bearing shell (370) with glued-in labyrinth ring (423.01) and O-ring (412.18) in the bearing
housing (350.01).
_____________________________________________________________________________________
Caution
The labyrinth ring has been glued in the bearing shell with Loctite 75/AVV
or equivalent!
12.2.2.2 Fit and tighten the hex head bolts (901.13) including washer (550.012) and gasket (411.03); the bolt must
engage in the bearing shell groove.
12.2.2.3 If applicable, fit the lubricating ring (644).
12.2.2.4 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten
the hex head bolts (901.01 or 901.06) uniformly; tightening torque, see relevant work instruction.
Additional Work for Pumps with Balancing Disc :
12.2.2.5 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.2.2.6 For rotor position indicator the description under Supervision of Rotor Position in the section Pump
Supervision Plan.
12.3
Mounting the Lift-off Device (if applicable) with Antifriction Bearings.
12.3.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).
12.3.2 Fit the thrust bearing housing (354) including O-ring (412.10) and springs (950).
12.3.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against
12.3.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with rolling element bearing.
a
c
b
y
z
Adjusting the lift-off device
12.3.4.1.1 Measure the dimension a from the face of the thrust bearing housing (354) to the bottom faces of the
springs (950), dimension b between the contact face of the angular contact ball bearing and the
springs contact face of the bearing cartridge (381) as well as the distance c from the face of the
thrust bearing housing (354) to the shaft collar.
_____________________________________________________________________
12.3.4.2 Calculate the auxiliary dimension x : x = a b 30 mm. (30 mm = installation length of the prestressed
springs).
12.3.4.3 Shorten the spacer ring (504.01) to the dimension y y = c x. The maximum permissible deviation from
parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
_____________________________________________________________________________________
12.3.5
12.3.6
Slide the spacer ring (504.01) over the shaft (210).

Mount the bearing cartridge (381) including two angular contact ball bearings (320) and the circlip
(932.04).
12.3.7 Screw in the hex socket head cap screw (914.03), fit and tighten the shaft nit (920.09).
12.3.8 Check the lift-off limitation z : when the balancing disc (601.01) abuts against the counter balancing disc
(602.01), the specified value is 10.1 mm. If required, remachine the bearing end cover (361); see figure
Adjusting the lift-off device with rolling element bearing.
12.3.9 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).
12.3.10 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with tightening torque given in the
relevant work instruction.
12.4
Mounting the Lift-off Device (if applicable) with Tilting-pad Thrust Bearing
12.4.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).
12.4.2 Fit the thrust bearing housing (354) including O-ring (4121.10) and springs (950).
12.4.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.4.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with tilting-pad thrust bearing.
a
c
e
b
Slg1
d
z
y
x
Adjusting
the lift-off
device
tilting-pad
thrusthousing
bearing (354) to the bottom faces of
12.4.1.1 Measure the dimension
a from
the face
of with
the thrust
bearing
springs (950), dimension b from the thrust bearing plate (384) to the springs contact faces on the
bearing cartridge (381), distance c from the face of the thrust bearing housing (354) to shaft collar as
well as the dimension d of the thrust bearing plate.
12.4.1.2 Calculate the auxiliary dimension x : x = a b + d 30 mm. (30 mm = installation length of the prestressed springs.
12.4.4.2 Shorten the spacer ring (504.01) to the dimension y y = c x. The maximum permissible deviation from
parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
_____________________________________________________________________________________
_____________________________________________________________________
12.4.6 If parts of the lift-off device have been reworked or replaces, adjust the thrust bearing clearance Slg1
as shown in the figure Adjusting the lift-off device with tilting-pad bearing.
12.4.6.1
Measure the distance e from the contact face of the bearing cartridge (381) to the circlip (932.04).
12.4.6.2
Determine the total length f of the thrust bearing (314) and thrust bearing plate (384).
12.4.6.3
Shorten the counter thrust bearing plate (388) to the dimension x : x = e f Slg1 (Slg1, see
table of clearances). The maximum permissible deviation from plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
As a general rule, always use a new counter thrust bearing plate (388)!
_______________________________________________________________________
12.4.7 Mounting the bearing cartridge (381) :
12.4.7.1
Fit the parallel pin (562.02) and shaft seal (420.01) in the bearing cartridge (381) and fasten them
with the circlip (932.03).
12.4.7.2
Fit the thrust bearing (314) including parallel pin; the parallel pin must engage in the groove of the
bearing cartridge (381).
12.4.7.3
Insert the thrust bearing plate (384).
12.4.7.4
Fit the parallel pin (562.02) and shaft seal (420.01) to the counter thrust bearing plate (388) and
fasten with the circlip (932.03).
12.4.7.5
Mount the counter thrust bearing plate (388) so that the groove in the counter thrust bearing plate
is in alignment with the hole in the bearing cartridge (381) and insert the circlip (932.03).
12.4.8 Insert the key (940.05) and slide the completely assembled bearing cartridge (381) on the shaft (210).
12.4.9 Screw in the hex socket head cap screw (914.03), and fit and tighten the shaft nut (920.09).
12.4.10 Check the lift-off dimension z : when the balancing disc (601.01) abuts against the counter balancing
disc (602.01), the specified value is 10.1 mm. If required, remachine the bearing end cover (361); see
figure Adjusting the lift-off device with tilting-pad thrust bearing.
12.4.11 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).
12.4.12 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with the tightening torque given in
the relevant work instruction.
12.5 Mounting the Thrust Bearing (if applicable)

_____________________________________________________________________________________
Caution
When mounting the bearings, the holes for thermometers in the bearing
shells and the associated thermometer connections in the bearing
housings and/or bearing end cover must be aligned!
_______________________________________________________________________
12.5.1 Fit the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01), circlip (932.03)
and O-ring (412.10) in the bearing housing (350.01).
12.5.2 Fit the hex socket head cap screws (914.04) including the gaskets (411.02) and tighten the screws with the
tightening torque given in the relevant work instruction.
12.5.3 Mount the thrust bearing (314) including all segments and fit it in the thrust bearing housing (354).
12.5.4 Move the pump rotor in the direction of the driven end until the balancing piston (603.02) abuts against the
12.5.5 Adjust the axial clearance Sl3 at the balancing piston and Slg2 at thrust bearing as shown in the figure
Adjusting the thrust bearing.
_____________________________________________________________________
d
c
b
Slg2
e
Adjusting the thrust bearing
12.5.5.1 Measure the distance a from the bearing face of the thrust bearing (314) to the shaft collar.
12.5.5.2 Shorten the spacer ring (504.01) to the dimension b : b = a Sl3 (Sl3 see table of clearances). The
maximum permissible deviation from the plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution
______________________________________________________________________
12.5.5.3 Measure the distance c from bearing face of the thrust bearing (314, in bearing end cover) to the contact
face of the bearing end cover (361), distance d from the bearing face of the thrust bearing (314, in the
thrust bearing housing) to the contact face of the thrust bearing housing (354), and width e of the thrust
bearing plate (384).
12.5.5.4 Calculate the bearing clearance : Slg2 = c + d e.
12.5.5.5 If the bearing clearance is within the permissible limits given in the table of clearances, the thrust bearing
may be mounted. If the clearance is too large, the contact face of the bearing end cover (361) must be
remachined. If the clearance is too small, the contact face of the thrust bearing (314) in the bearing end
cover (361) must be remachined.
12.5.6 Slide the spacer ring (504.01) over the shaft (210) and insert the key (940.05) into the shaft keyway.
12.5.7 Slide the thrust bearing plate (384) and spacer sleeve (525.05) on the shaft (210).
12.5.8 Screw the nut (920.09) on the shaft (210) and tighten it.
12.5.9 Fit the studs (902.11) to the bearing end cover (361).
12.5.10 Fit the bearing end cover (361) including thrust bearing (314), O-rings (412.11 and 412.12), parallel pin
(562.02), shaft seal ring (420.01) and circlip (932.03) and tighten the hex nuts (920.11) uniformly;
tightening torque, see the relevant work instruction.
_____________________________________________________________________
13. Mounting the Piping and Instruments
All pipes and instruments, which have been dismantled in connection with maintenance work, must be reinstalled as described in the chapter Installation on Site.
14. Mounting the Connecting Coupling

14.1 Fitting the Coupling Hubs
14.1.1 Thoroughly clean the shaft ends and bores of the coupling hubs and check them for dimensional accuracy.
_____________________________________________________________________________________
Caution
Check the shaft ends for run-out prior to mounting the coupling hubs.
Permissible tolerance < 0.03 mm (see figure Run-out check of the shaft
ends). If the tolerance is exceeded, please inform KSB.
Observe the manufacturers mounting/dismantling instructions.
The pump shafts check values shall be read after each 900 turn.
_____________________________________________________________________________________
Run-out check of the shaft ends (example)
0.2-0.3mm
14.1.2 Slightly deburr the hub keyway and insert the keys.
14.1.3 Check the protrudent dimension of the keys. Tolerance in accordance with figure Clearance between
keyway and key.
Clearance between keyway and key
_____________________________________________________________________
14.1.4 To facilitate fitting, the coupling hub may be heated uniformly to a temperature of 800 C max.
_____________________________________________________________________________________
Use protective gloves.

!
Risk of fire in case of open flames.
Remove flammable substances from the danger area.
______________________________________________________________________
14.1.5 Elastomeric parts must be removed before heating!
_____________________________________________________________________________________
Caution
Elastomeric parts which have been heated must not be used anymore.
Use new parts for reassembly.
_____________________________________________________________________________________
14.1.6 Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft ends and the hub faces
are in alignment.
_____________________________________________________________________________________
Caution
Fit the coupling hubs using only the appropriate device to prevent the
shaft bearings from damage by axial friction force. Impacts on the coupling
hubs are not permitted.
14.1.7 Securely tighten the grub screws (wherever applicable).
14.1.8 Fit the retaining ring, if applicable, to the coupling hub.
_____________________________________________________________________
14.2 Aligning the Connecting Coupling
Align the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapter
Installation on Site.
14.3 Mounting the Coupling Connection

Mount the connecting coupling spacer as described in the manufacturers documentation.
15. Mounting the Guards Preventing Accidental Contact

15.1 Coupling Guard
______________________________________________________________________________________
Caution
The pump must not be operated without a coupling guard.
________________________________________________________________________

15.1.1 Align the coupling guard over the connecting coupling.
15.1.2 Make sure the distance between the shaft ends and the coupling components is sufficient.
15.2 Coupling Cover

______________________________________________________________________________________
Caution
The pump must not be operated without a coupling cover!
________________________________________________________________________
Couplin cover (example )
_____________________________________________________________________
15.2.1 Meticulously clean the locating and sealing surfaces.
_____________________________________________________________________________________
Caution
Do not damage the seal elements and sealing surfaces!
_____________________________________________________________________________________
15.2.2 Insert the gasket and O-ring.
15.2.3 Mount the lower cover half and fasten it to the backing ring.
15.2.4 Adjust the injection nozzles (if applicable) as shown in the figure Installation of the injection nozzles.
15.2.5 Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature resistant sealing agent (up
0
to 120 C).
15.2.6 Use eyebolt as a transport aid as shown in the figure Coupling cover.
15.2.7 Fix the cover halves with two taper pins.
15.2.8 Fasten the upper and lower halves with screws.
15.2.9 Connect the pipes to the cover.
15.3 Guard Preventing Accidental Contact for Shaft Seal

_____________________________________________________________________________________
Caution
The pump must not be operated without a guard preventing accidental

contact!
_____________________________________________________________________________________
Fasten the guard preventing accidental contact to bearing housing using screws.
15.4 Sound Insulating Hood (if applicable)

Mount the sound insulating hood as described in the manufacturers documentation.
16. Maintenance of the Other Pump Set Components

16.1 Maintenance of the Connecting Coupling
See the manufacturers documentation.
16.2 Maintenance of Drive

_____________________________________________________________________
16.3 Maintenance of the Minimum Flow System
16.4 Maintenance of the Instruments and Valves

Maintenance actions are not required; in the case of malfunctioning they are replaced.
16.5 Maintenance of Oil Supply Unit, etc. (if applicable)

16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable)

17. Spare Parts

17.1 Ordering Spare Parts
Please direct your orders to the nearest KSB Customer Service Center or Sales Office.
When ordering spare parts, please quote
17.1.1 The KSB work orders number as indicated on the title page of this instruction manual or the pump name
plate.
17.1.2 The required pump set component, part no., designation and quantity required in accordance with the
list of components and sectional drawing.
17.2 Spare Parts Stock

For quick elimination of possibly occurring problems, we recommend to keep a stock of spare parts.
17.3 Storage
The parts should be stored as described under Interim Storage in the chapter Transport/Interim Storage.
_____________________________________________________________________
Trouble Shooting
________________________________________________________________________________________
Caution
During the warranty period, pumps must be attended only by KSB

personnel!
________________________________________________________________________________________
1.1 For exact description of the pump design as well as the pump set components and
accessories supplied by KSB, please refer to P & I Diagram.
1.2 Requisite Documentation

For the elimination of problems described in the tables on the subsequent pages, the technical documentation
of the order pump set components is required in addition to this instruction manual. If these components are
included in kSBs scope of supply, the relevant documents are appended to this instruction manual.
-
Technical Data
Operating Data
General Arrangement Drawing
P & I Diagram
Table of Clearances
Table of Tightening Torques
Cross Sectional Drawing, Pump
List of components, Pump
Cross Sectional Drawing, Mechanical seal (if applicable)
Documentation of Mechanical seal (if applicable)
Work Instructions
Documentation of the Connecting Coupling
Documentation of the Drive
Documentation of the Minimum Flow System (if applicable)
Documentation of the Valves and Equipment (if applicable)
Documentation of the Sound Insulating Hood, i.e. Acoustic Enclosure (if applicable)
Documentation of Oil Supply Unit, i.e. Lube Oil Plant (if applicable)
Documentation of Gear/Variable Speed Coupling (if applicable)
1.3 Prerequisites
1.3.1
1.3.2
1.3.3
All spare parts required are available.

Proper hoisting tackle and means of transport are available and ready for use.
Sufficient room space and appropriate tools are available.
1.3.4 For the work required as per the tables on the subsequent pages, the pump set has been taken out of
service in accordance with the Shutdown and Work after Shutdown sections in chapter Commissioning,
Start-up/Shutdown.
1.3.5
The drive has been secured against unintentional starting.

_____________________________________________________________________________________
Caution
Before rectifying any faults, check all measuring instruments for proper
functioning!
_____________________________________________________________________________________
_____________________________________________________________________
In case of problems not described in the following table, consultation with
KSBs Customer service is required.
Problem (what)
Possible causes
Measures
Flow rate of pump > specified

value
Pump delivers against an excessive high
Open the valve in the discharge pipe further until the

Duty point is adjusted
Mount larger impeller(s)
Excessive back pressure
Contact KSBs Service Center
Pump or piping are not completely vented or

primed
Inlet pipe or impeller(s) clogged
Formation of air pockets in the piping
NPSHavailable too low (inlet)
Suction head is too high
Air intake at the gland packing
Wrong direction of rotation

Speed is too low
Increase the speed of the turbine or internal combustion

engine
Check plant for impurities
Vent and/or prime
Remove deposits in the pump and/or piping
Alter the piping layout
Fit a new valve
Correct the liquid level
Fully open the valve in the inlet pipe
Change the inlet pipe, if the resistances in the inlet pipe
are too high
Inlet pipe is too big
Check the strainers installed
Observe the permissible speed of pressure fall
Clean the strainer element and inlet pipe
Change the inlet pipe
Replace the gland packing
See chapter Commissioning Startup/Shutdown &
Maintenance
Interchange 2 phases of the power supply
Increase the speed
Increase the voltage
Alter the impeller diameter

Wear of internal pump parts (check in
accordance with the Tables of clearances)
Replace defective parts

Motor is running on 2 phases only
Pump discharge pressure >
specified value
Speed is too high
OIMPG TROUBLESHOOTING 2
Replace defective fuses

Check the power cable connections
_____________________________________________________________________
Problem (what)
Possible causes
Measures
Pressure ps > specified value
Damaged measuring instrument

Differential pressure in the strainer element is
too high
Valve in the inlet pipe is not fully open
Pressure in the inlet vessel is too low
Damaged measuring instrument
Speed is too low
Inlet pressure is too low
In case of tapping, quantity tapped is too high
Temperature of the medium pumped is too low
or too high
Defective minimum flow system
Defective shaft seal
Score marks or roughness on shaft protection
sleeve (524) and/or sleeve of mechanical seal
Gland (gland plate / gland ring) have been
tightened incorrectly
Wrong packing material
Replace the measuring instrument

Dismantle and clean the strainer element
Pressure p d > specified value
Shaft seal leakage
Pump runs rough
Pump set alignment

Pump is warped
Insufficient quantity of cooling liquid
Dirty cooling liquid chamber or cooler
Fault in the circulation liquid pipe
Surface pressure on the sealing clearance is
too high, lack of lubricant or circulation liquid
Open the valve

Check the inlet vessel and/or increase the pressure
Replace the measuring instrument
Check the drive
Check the inlet pressure and inlet vessel
Throttle the tapping quantity
Increase or reduce the temperature
Check the minimum flow system
Check; replace, if required
Replace the shaft protection sleeve (524) or sleeve of
mechanical seal
Check
Replace
See chapter Commissioning/Startup/Shutdown &
Maintenance
Correct the suction conditions
Re-align the pump
Re-balance the pump rotor
Increase pressure at the suction nozzle
Check the coupling; re-align, if required
Check the piping connections and the fastening of the
pump
Increase the cooling liquid quantity
Clean the cooling liquid chamber and/or cooler
Check the cooling liquid; purify/clean, if required
Increase the effective cross section
Check the pipes
Check the installation dimensions
_____________________________________________________________________
Problem (what)
Possible causes
Measures
Increased bearing temperature
Defective bearing
Check; replace, if required

See chapter Maintenance
Check the oil quantity; top up or replace, if required
See chapter Servicing and Technical Appendix
Check
See chapter Servicing and Technical Appendix
Replace the casing wearing rings
Replace the defective parts
Oil quantity
Oil quality
Increased axial thrust
Wear of internal pump parts (check in

Unbalance of the pump rotor
Pump set not correctly aligned
Pump is warped
Coupling hub distance
Temperature of pump >
specified value
Pump leakage

primed
Clean the pump rotor

Balance the pump rotor
Check the coupling and re-align, if required
pump
Check the coupling hub distance for compliance with the
GA Drawing; correct, if required
Vent and/or prime
Flow rate < specified value

Defective O-rings and/or metallic sealing
surfaces
Change in the inlet pipe, if resistances in the inlet pipe

are too high
Inlet pipe is too long
Increase the minimum flow
Replace O-rings and/or remachine the metallic sealing
surfaces
Tie rods have loosened

Tighten
In accordance with the relevant work instruction
_____________________________________________________________________
Problem (what)
Possible causes
Measures
Pump runs rough

primed
Vent and/or prime
Wear of internal pump parts ( check in

Backpressure of pump is lower than specified

in the purchase order
Pump set alignment

Pump is warped
Oil quantity
Oil quality
Unbalance of the pump rotor
Cavitation noise in the pump

and/or piping
Defective bearing
Flow rate < specified value
Damaged inlet pipe
Valve in the inlet pipe is not fully open
Pressure in the inlet vessel is too low
NPSHavailable / NPSHrequired too low
Air intake at the seal elements/valves/shaft seal

primed

Change the inlet pipe, if the resistances in the inlet pipe
are too high
Replace defective parts

Adjust the duty point accurately by means of the valve in
the discharge pipe
In the case of permanently overload, turn down the
impeller(s), if necessary
Check the coupling and re-align, if required
pump
Check the oil quantity; top or replace, if required
Check
See Technical Appendix
Clean the pump rotor
Balance the pump rotor
Replace
Increase the minimum flow
Check the inlet pipe
Open the valve
Check the inlet vessel and/or increase the pressure
Check the inlet pipe
Change the inlet pipe
Excessive speed of pressure fall
Check the piping; check shaft seal for leakage
Vent and/or prime
_____________________________________________________________________
Problem (what)
Possible causes
Measures
Pressure and/or quantity of

balancing liquid fluctuates

primed
Vent and/or prime

Increased axial thrust
Drive is overloaded
Change in cross section of balancing liquid pipe

Excessive resistances
Joining of several pipes near the pump
Balance flow leakage counter balancing disc /
final stage diffuser
Wear on the balancing device
Back pressure of pump is lower than specified

in the purchase order

Change the inlet pipe, if resistances in the inlet pipe are
too high

Replace the casing wearing ring
Check the mode of operation
Check the return pipe
Check the pump pressures
Check the rotor clearances and balancing device

Adjust the duty point accurately by means of the valve in
the discharge pipe
In the case of permanently overload, turn down the
impeller(s), if necessary
Higher density or viscosity of the medium

pumped than specified in the purchase order
Gland tightened excessively or askew
Speed is too high
Pump is warped
Operating voltage is low
Motor is running on 2 phases only

Alter
Reduce the speed of the turbine or internal combustion
engine
pump
Replace defective fuses
_____________________________________________________________________
Tables of Clearances
Diametrical Clearances :
Pump size
Hydraulics
1; 2
3;4
5
6
4
7;8
5
9 ; 10
6
11;12;13
Max. permissible diametrical clearance (mm)
Sl2
Sl3
0.50 1.0
0.25 0.40
0.80 1.2
S7
2
S6
2
S8
2
1
2
3
Nominal diametrical clearances [mm]

S6
S7
S8
S9
0.25 0.34 0.35 0.50 0.27 0.36 0.90 1.40
0.90 1.50
0.30 0.36 0.40 0.51 0.35 0.45
1.0 1.5
0.30 0.37
0.35 0.41 0.45 0.51 0.32 0.39
1.0 1.6
0.35 0.47
0.40 0.50 0.45 0.51 0.40 0.48
1.0
1.0
1.0
2.0
Sl3
Sl2
Clearance between double balance

drum and balance disc seat
S9
2
Clearance between balance disc seat

and throttle sleeve or balance disc
Clearance between suction

casing or inlet ring and shaft
OIMPG CLEAR AF 1
Sl2
_____________________________________________________________________
Theoretical Total Axial Clearance
Pump size
1
2
3
4
5
6
Sa1 + Sa2 [mm]

Impeller material
Hydraulic
1
2
3
4
5
6
7
8
9
10
11
12
502.02
CI
Cr Steel
8.5 8.0
7.5 7.0
9.0 8.5
7.0 6.5
9.0 8.5
7.0 6.5
-------------
8.5 8.0
7.5 7.0
8.5 8.0
6.5 6.0
8.5 8.0
6.0 5.5
230.02
171.02
Sa1
Sa2
Total axial clearance of pump rotor
OIMPG CLEAR AF 2
6.5 8.0
8.5 10.0
10.0
_____________________________________________________________________
Bearing Clearances
Bearing design :
Tilting-pad Thrust Bearing
Pump size
Bearing Clearance Slg2 [mm]

(Diametrical clearance)
0.33 0.58
0.34 0.60
0.40 0.75
1,2
3, 4
5, 6
Slg2
Bearing design :
Lift-off Device with Tilting-pad Thrust Bearing
Pump size
1-6
Bearing clearance Slg1 [mm]

0.30 - 0.50
Slg1
Lift-off Device with Tilting-pad Thrust Bearing
OIMPG CLEAR PLANE 1
_____________________________________________________________________
Bearing Clearances
Bearing design :
Pump size
3, 4
5, 6
Bearing clearance Slg2 [mm]

(Diametrical clearance)
0.34 - 0.60
0.40 - 0.75
Diametrical Clearances :
Pump size
Hydraulics
1
2
3
1; 2
3;4
5
6
7;8
9 ; 10
11;12;13
4
5
6
Max. permissible
diamet-
Nominal diametrical clearances [mm]

S6
S7
S8
S9
0.25 0.34 0.35 0.50 0.27 0.36 0.90 1.40
0.90 1.50
0.30 0.36 0.40 0.51 0.35 0.45
1.0 1.5
0.30 0.37
0.35 0.41 0.45 0.51 0.32 0.39
1.0 1.6
0.35 0.47
0.40 0.50 0.45 0.51 0.40 0.48
1.0
1.0
1.0
2.0
rical clearance (mm)
OIMPG CLEAR PLANE H 1
Sl2
Sl3
0.50 1.0
0.25 0.40
0.80 1.2
_____________________________________________________________________
Table of Tightening Torques

Tightening Torques [Nm]
HG Pump Sizes 1 6
1.
1.1
1.2
1.3
1.4
Prerequisites
The threads of the screws/bolts and nuts are not damaged.
The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred and cleaned thoroughly.
The threads move smoothly.
The washers are plane, deburred and cleaned thoroughly.
2. Pump
Observe the tightening torques for the screwed/bolted connections as per relevant work instruction.
3. Fastening of Pump Feet
Thread
Tightening torque MA [Nm]
M 20
190
M 24
330
M 30
660
M 36
1160
4. Flange Connection
If the bolting for the flanged connections are in the KSBs scope of Supply, the tightening torques will be as
specified in the table on the following pages.
OIMPG TIGHT TRQ 1
_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle
The tightening torques apply only if the bolts and screws are part of KSBs scope of supply.
Flanges as per DIN

Nominal diameter DN [mm]
25
40
50
65
80
100
125
150
200
250
OIMPG TIGHT TRQ 2
Nominal pressure PN [bar]

160
250
64
160
250
64
160
250
64
160
250
64
160
250
64
160
250
320
400
500
160
250
320
400
500
160
250
320
400
500
160
250
320
400
500
160
250
320
400

90
140
140
160
240
160
270
240
140
240
270
250
370
350
530
500
490
490
650
660
1150
1260
_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle
Flanges as per ANSI

Nominal diameter DN [inch]
1
1
2
2
3
8
10
OIMPG TIGHT TRQ 3
Nominal pressure PN [class]

600
1500
600
1500
600
1500
600
1500
600
900
1500
600
900
1500
2500
900
1500
2500
900
1500
2500
900
1500
2500
900
1500
2500
Tightening torque MA
[Nm]
80
240
140
350
90
240
140
270
240
490
490
650
650
1100
490
830
830
1350
840
_____________________________________________________________________
Bolts for Flange Connection, Suction Nozzle
Flanges as per DIN

Nominal diameter DN [mm]
65
80
125
150
200
250
300
Nominal pressure PN [bar]

16
40
16
40
16
40
16
40
16
25
40
16
25
40
16
25
40

50
70
50
70
70
150
130
200
130
190
240
210
290
380
210
240
320
Flanges as per ANSI

Nominal diameter DN [inch]
2
3
5
6
8
10
12
OIMPG TIGHT TRQ 4
Nominal pressure PN [class]

300
300
300
300
300
300
300

90
90
210
120
210
260
320
_____________________________________________________________________
Table of Weights
HG Pump Size 1
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
107
210
350.01
Designation
Suction Casing
Discharge Casing
Shaft for 3 stages
each additional stage
Bearing Housing
Rotor 3 stages
Each additional stage
Weights (reference values in kg)

35.0
58.0
17.9
1.2
25.0
31.0
4.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
OIMPG WEIGHT 1

Without water fill
Water fill
234
8.0
250
809
266
9.7
282
10.6
298
11.5
314
12.4
330
13.3
346
14.2
362
15.1
378
16.0
394
16.9
410
17.8
426
18.7
442
19.6
458
20.5
474
21.4
490
22.3
506
23.2
_____________________________________________________________________
Table of Weights
HG Pump Size 2
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
107
108
210
350.01
Designation
Suction Casing
Discharge Casing
Stage Casing
Shaft for 3 stages
Bearing Housing
Rotor 3 stages

54.1
140.0
25.0
21.1
1.6
25.0
52.0
6.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
OIMPG WEIGHT 2

Without water fill
Water fill
410
19.0
440
21.6
470
24.2
500
26.8
530
29.4
560
32.0
590
34.6
620
37.2
650
39.8
680
42.4
710
45.0
740
47.6
770
50.2
800
52.8
830
55.4
860
58.0
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
107
108.01
108.02
130
210
350.01
354
361
441
Designation
Suction Casing
Discharge Casing
Stage Casing
Stage Casing
Casing Part, for double piston
For mechanical seal
Shaft for 3 stages
Bearing Housing
Thrust Bearing Housing, thrust bearing/plain bearing
Bearing End Cover, thrust bearing/plain bearing
Seal Casing
Rotor 3 stages

161.0
225.0
38.00
28.0
25.0
30.5
51.4
3.0
57.0
25.0
29.0
39.0
83.0
9.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OIMPG WEIGHT 3

Without water fill
Water fill
736
27.0
774
30.0
812
33.0
850
36.0
888
39.0
926
42.0
964
45.0
1002
48.0
1040
51.0
1078
54.0
1116
57.0
1154
60.0
1192
63.0
1230
66.0
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
107
108.01
108.02
130
131
210
350.01
350.02
354
361
441
Designation
Suction Casing < 320 bar
420 bar
Discharge Casing < 320 bar DN 80
< 250 bar DN 100
>320 bar DN 100
420 bar DN 100
DN 125
Stage Casing
Stage Casing
Casing Part, for double piston
For mechanical seal
Inlet Ring
Shaft for 3 stages
Bearing Housing, suction side
Heavy bearing housing
Bearing Housing, discharge side
Seal Casing
Rotor 3 stages

210.0
250.0
255.0
285.0
315.0
530.0
550.0
31.0
38.0
25.0
30.5
80.0
51.4
3.0
57.0
61.0
150.0
25.0
29.0
35.0
39.0
83.0
9.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OIMPG WEIGHT 4

Without water fill
Water fill
736
27.0
774
30.0
812
33.0
850
36.0
888
39.0
926
42.0
964
45.0
1002
48.0
1040
51.0
1078
54.0
1116
57.0
1154
60.0
1192
63.0
1230
66.0
_____________________________________________________________________
Table of Weights
HG Pump Size 4
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
107
Designation
Suction Casing
Discharge Casing
108.01
108.02
130
131
210
Stage Casing
Stage Casing
Casing Part
Inlet Ring
Shaft for 3 stages
Bearing Housing, suction side
Bearing Housing, discharge side
Seal Casing
Balancing Piston
Tie Rods for 3 Stages
M 45
Rotor 3 stages
350.01
350.02
354
361
441
603.02
905

290.0
395.0
60.0
68.0
33.0
110.0
74.7
4.8
57.0
61.0
150.0
25.0
29.0
35.0
39.0
28.0
10.3
1.3
130.0
16.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OIMPG WEIGHT 5

Without water fill
Water fill
1380
41.8
1477
47.4
1574
53.0
1671
58.6
1768
64.2
1865
69.8
1962
75.4
2059
81.0
2156
86.6
2253
92.2
2350
97.8
2447
103.4
2544
109.0
2641
114.6
_____________________________________________________________________
Table of Weights
HG Pump Size 5
_____________________________________________________________________________________
Caution
Weights 25 kg
_____________________________________________________________________________________
Pump Components
Part No.
106
Designation
Suction Casing
420 bar
107
Discharge Casing
420 bar
420 bar
108.02
DN 200
DN 200
DN 250
DN 150
DN 200
Stage Casing, Hydraulic 9

Hydraulic 10
Stage Casing, Hydraulic 9
Casing Insert
Casing Part
Inlet Ring
Diffuser
Diffuser
Shaft for 3 stages
Bearing Housing
Bearing Housing
Bearing Cover
Bearing End Cover
Seal Casing
Balancing Disc
Balancing Piston
Balancing Piston
M 45
M 52
Rotor 3 stages
108.03
13-6
130
131
171.01
171.02
210
350.01
350.02
354
360.01
361
441
601
603.01
603.02
905

622.0
819.0
635.0
821.0
1020.0
1170.0
93.0
84.0
100.0
96.0
59.0
180.0
25.0
25.0
109.0
7.0
124.0
165.0
32.0
36.0
44.0
29.0
25.0
43.0
57.0
12.9
1.6
17.5
2.1
243.0
25.0
Pump
Number of stages
3
4
5
6
7
8
9
10
11
12
13
OIMPG WEIGHT 6

Without water fill
Water fill
2775
80
2930
90
3085
100
3240
110
3395
120
3550
130
3705
140
3860
150
4015
160
4170
170
4325
180
RATHI TRANSPOWER PVT. LTD. PUNE - INDIA
INSTALLATION INSTRUCTIONS
GEAR-FLEX COUPLING
L-II-G-01/01-07/09
Page 1
GEAR-FLEX COUPLING
INSTALLATION INSTRUCTIONS FOR STD. LFG / LHG COUPLINGS
(A)
BEFORE INSTALLATION
1. Remove the coupling from packing & thoroughly inspect for signs of damage.
2. Disassemble the coupling by removing nuts & bolts. Clean all the parts carefully.
3. Remove protective coatings / lubricants from bores & keyways.
(B)
MOUNTING PROCEDURE
1. Slide the sleeves with internal teeth with rubber O ring on shafts before mounting
the hubs.
2. Mount the hubs with external teeth on their respective shafts flushed with the
faces of hubs as shown in Fig. 1.
Fig. 1
L-II-G-01/01-07/09
Page 2
GEAR-FLEX COUPLING
3. With one machine firmly bolted down, set the equipments at a distance G (refer
table A & B) between shaft ends by using a spacer bar equal in thickness to the
required gap G as shown in Fig. 2.
Fig. 2
Deviation in standard DBSE is defined as axial misalignment (end float). For normal
applications the shaft end should be flushed with inner face of the adapter. In some
special cases the shaft ends may protrude beyond the inner face of the adapter or
may remain inside, if required. The distance between two faces of adapter flanges is
to be maintained as specified. The variation in this distance should not exceed the
permissible initial axial misalignment given in table A.
(C)
ALIGNMENT PROCEDURE
Alignment procedure is given separately for each type of alignment, for simplicity.
However all 3 types of misalignments may be present at the same time.
IMPORTANT : The misalignment capabilities shown in drawings or in product
literature are for dynamic conditions and variations.
For optimum service from the coupling the installation misalignment (Initial
misalignment) should not be more than 25% of the maximum allowable
misalignments limits. Allowance should be made for any anticipated movements
which will occur during operation (e.g. Thermal movements).
For Permissible INITIAL misalignments refer table A
For Permissible MAXIMUM misalignments refer table B
L-II-G-01/01-07/09
Page 3
GEAR-FLEX COUPLING
(I)
CHECKING PARALLEL /RADIAL ALIGNMENT
Check the parallel/Radial alignment with the help of

straight edge resting squarely on both the hubs at 4 places
apart. The deviation in the readings should not exceed the
permissible initial parallel misalignment mentioned in table
(Refer Fig. 3)
Fig. 3
(II)
90
A.
CHECKING ANGULAR ALIGNMENT
Fig. 4
Check the angular misalignment with

the help of slip gauges by inserting in
the gap at 4 places 90 apart. The
deviation in the values of standard gap
G is Total Indicated Reading (TIR). The
angular misalignment X in mm is half
the Total Indicated Reading. The values
of angular misalignment should not
exceed permissible initial misalignments
mentioned in table A. (Refer Fig. 4).
(D). ASSEMBLY PROCEDURE

IMPORTANT: If the coupling is dynamically balanced, ensure that the match marks
are in straight line & unidirectional before bolting the assembly.
1. Insert the gasket between the flanges. Position the
flanged sleeves with lubrication plugs.
2. Insert the bolts & tighten the nuts.
Remember: Assemble only with the help of the
fasteners furnished with the coupling.
Fig. 5
3. Fill with recommended grease/oil (RSG/RSL with reqd. qty.) for lubrication. For
grease quantity for respective coupling size, refer table No. C.
4. Change the grease after the interval of 6 months & the oil after the interval of 1
year or after 8000 working hours.
Use Loctite to prevent the loosening of threads, if required.
IMPORTANT: The necessity for shields & guards varies with individual installations.
The owner or user must provide the required safety guards. Safety guards or shields
are not furnished by us with this equipments.
L-II-G-01/01-07/09
Page 4
GEAR FLEX COUPLING

TABLE A
PERMISSIBLE INITIAL MISALIGNMENTS FOR GEAR COUPLINGS
TYPE LFG
COUPLING
SIZE
ANGULAR
degrees
per gear
mesh
TYPE LHG
PARALLEL/
RADIAL
AXIAL
(mm)
(mm)
(mm)
ANGULAR
degree
s per
gear
mesh
GAP
G
AXIAL
Std
(mm)
(mm)
(mm)
101
0.5
0.2
0.5
102
0.6
0.2
0.6
103
0.7
0.3
104
0.8
0.3
105
0.9
0.3
106
1.0
107
0.12
0.7
0.06
0.8
0.9
10
0.4
1.0
10
1.1
0.4
1.1
10
108
1.2
0.5
109
1.4
0.5
1.4
10
1.6
0.6
1.6
10
111
1.8
0.8
10
112
1.9
0.9
10
113
2.2
1.6
114
2.4
1.8
NOT
15
115
2.5
2.0
AVAILABLE
15
116
2.9
2.1
117
3.2
2.3
118
3.6
2.4
20
119
4.0
2.5
20
110
0.37
0.37
0.25
1.2
0.5
0.12
10
15
20
0.75
20
Half Flexible Gear Couplings Type LHG cannot accommodate parallel

misalignment.
Gap G in the above table is given when angular & axial misalignments are zero.
L-II-G-01/01-07/09
Page 5
GEAR FLEX COUPLING

TABLE B
PERMISSIBLE MAXIMUM MISALIGNMENTS FOR GEAR COUPLINGS
TYPE LFG
COUPLING
AXIAL
(mm)
(mm)
(mm)
101
2.2
0.8
2.2
102
2.4
0.95
2.4
103
2.9
1.1
104
3.2
1.3
105
3.7
1.45
106
4.2
107
degrees
per gear
mesh
ANGULAR
GAP
G
PARALLEL/
RADIAL
SIZE
ANGULAR
TYPE LHG
degrees
per gear
mesh
0.5
AXIAL
Std
(mm)
(mm)
(mm)
2.9
0.25
3.2
3.7
10
1.55
4.2
10
4.6
1.8
4.6
10
108
5.0
1.9
109
5.6
2.2
5.6
10
6.4
2.6
6.4
10
111
7.1
3.3
10
112
7.7
3.5
10
113
8.9
6.6
114
9.5
7.3
NOT
15
115
10.2
8.1
AVAILABLE
15
116
11.8
8.5
117
13.1
9.1
118
14.4
9.6
20
119
16.3
10.2
20
110
1.5
1.5
1.0
5.0
2.0
0.5
10
15
20
3.0
20
Half flexible Gear Couplings type LHG cannot accommodate parallel misalignment.
GapG in the above table is given when angular & axial misalignments are zero.
L-II-G-01/01-07/09
Page 6
GEAR FLEX COUPLING

TABLE C
GREASE FOR GEAR COUPLING (LFG/ LHG)
Sr. No.
COUPLING SIZE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
GREASE QTY. (Kg)

LFG
LHG
0.035
0.018
0.047
0.024
0.09
0.045
0.216
0.108
0.375
0.188
0.46
0.23
0.715
0.358
1
0.5
1.3
0.65
2.2
1.1
3
1.5
4.5
6.6
8.8
11.3
14.8
22.5
32
44.5
53
-
RECOMMANDED GREASE LOVEJOY SPECIAL GREASE (RSG)

(g = 910 Kg/m3)
L-II-G-01/01-07/09
Page 7
GEAR-FLEX COUPLING
INSTALLATION INSTRUCTIONS FOR R- LFG/ R-LHG COUPLINGS
(A)
BEFORE INSTALLATION
1. Remove the coupling from packing & thoroughly inspect for signs of damage.
2. Disassemble the coupling by removing nuts & bolts. Clean all the parts carefully.
3. Remove protective coatings / lubricants from bores & keyways.
(B)
MOUNTING PROCEDURE
1. Slide the sleeves with internal teeth with rubber O ring on shafts before mounting
the hubs.
2. Mount the hubs with external teeth on their respective shafts flushed with the
faces of hubs as shown in Fig. 1.
Fig. 1
3. With one machine firmly bolted down, set the equipments at a distance G (refer
table A & B) between shaft ends by using a spacer bar equal in thickness to the
required gap G as shown in Fig. 2.
Fig. 2
L-II-G-01/01-07/09
Page 8
GEAR-FLEX COUPLING
Deviation in standard DBSE is defined as axial misalignment (end float). For normal
applications the shaft end should be flushed with inner face of the adapter. In some
special cases the shaft ends may protrude beyond the inner face of the adapter or
may remain inside, if required. The distance between two faces of adapter flanges is
to be maintained as specified. The variation in this distance should not exceed the
permissible initial axial misalignment given in table A.
(C)
ALIGNMENT PROCEDURE
Alignment procedure is given separately for each type of alignment, for simplicity.
However all 3 types of misalignments may be present at the same time.
Refer the alignment procedure mentioned for LFG / LHG gear couplings.
IMPORTANT: The misalignment capabilities shown in drawings or in product
literature are for dynamic conditions and variations.
For optimum service from the coupling the installation misalignment (Initial
misalignment) should not be more than 25% of the maximum allowable
misalignments limits. Allowance should be made for any anticipated movements
which will occur during operation (e.g. Thermal movements).
For Permissible INITIAL misalignments refer table A
For Permissible MAXIMUM misalignments refer table B
(D).
ASSEMBLY PROCEDURE
IMPORTANT: If the coupling is dynamically balanced, ensure that the match marks
are in straight line & unidirectional before bolting the assembly.
1. Insert the end float limiters in its position. (See
fig. below)
2. Insert the gasket between the flanges.
3. Position the flanged sleeves with lubrication
plugs.
4. Insert the bolts & tighten the nuts.
Remember: Assemble only with the help of the
fasteners furnished with the coupling.
Fig. 5
L-II-G-01/01-07/09
Page 9
GEAR-FLEX COUPLING
3. Fill with recommended grease/oil (RSG/RSL with reqd. qty.) for lubrication. For
grease quantity for respective coupling size, refer table No. C.
4. Change the grease after the interval of 6 months & the oil after the interval of 1
year or after 8000 working hours.
Use Loctite to prevent the loosening of threads, if required.
IMPORTANT: The necessity for shields & guards varies with individual installations.
The owner or user must provide the required safety guards. Safety guards or shields
are not furnished by us with this equipments.
L-II-G-01/01-07/09
Page 10
API Piping
Plan 23
REV 2.0
Definition:
A closed loop primary product seal flush plan, where the product is circulated to and from the
primary seal flange through a heat exchanger via an integral pumping ring in the primary seal
chamber.
Objective:
To reduce the temperature of the pumped product lubricating and dissipating the heat generated
by the mechanical seal. A reduction in heat is usually required when the conditions in the stuffing
box are at or near the vapor pressure of the liquid being pumped. Recirculation of the product to
and from the heat exchanger reduces the temperature of the seal flush loop to 150-200 F. This
reduction is accomplished by re-cooling the same product over and over. The heat load on the heat
exchanger is also reduced which slows fouling and hard water deposits in the case side of the
exchanger.
Line Up Procedure:
The following steps outline the checks required before, during and after start-up of the equipment.
1) Check to make sure any valves in the seal flush line are open. These lines should be free of
valves, if possible. Otherwise, any valves in this line must remain open until the pump is
pulled for repair. (With the exception of the vent valve.)
2) Check to make sure the cooling water lines to the heat exchanger are open.
3) Open the case drain on the heat exchanger to clear debris from the cooling water system and
check for flow.
4) Proceed with opening the suction and discharge valves for service.
5) Open the vent valve in the seal flush loop. A full product stream to grade should be obtained
before the vent valve is closed. This will insure the seal is immersed in liquid prior to pump
start-up.
6) Check for leaks around valves in the seal flush line.
6) Start pump per normal procedures.
7) Once running, check to make sure product is flowing to and from the heat exchanger. This
can be confirmed by checking for a temperature drop across the heat exchanger ( i.e.. the
product line entering is hotter than the product line exiting). [Caution: Use caution when
pumping temperature is above 150 F.]
8) Once running, check to make sure the cooling water is flowing through the case side of the
heat exchanger. This can be confirmed by checking for a temperature rise across the heat
exchanger (i.e.. the cooling water line entering will be cooler than the cooling water line
exiting). [Caution: Use caution if the pumping temperature is above 150F.]
Preventive Maintenance and Troubleshooting:

This seal flush plan should be checked on normal operator rounds. Both the inlet and exit lines of
both the process side and cooling water side of the heat exchanger can be checked using a
temperature indicator. During normal operation, the product line exiting the heat exchanger will be
noticeably cooler than the product line entering the heat exchanger. During normal operation, the
cooling water line entering the heat exchanger will be cold all the way to the heat exchanger and the
cooling water line leaving will be noticeably warmer. The body of the heat exchanger will be warm
at all times. The case side of the exchanger should be purged through the case drain line once a
shift. This will insure debris in the cooling water system does not clog the heat exchanger.
[Caution: Use caution if the pumping temperature is above 150F.]
The typical modes of failure in this flush plan are an unvented system, a closed valve in the seal
flush line or the lack of cooling water flow to the heat exchanger. During these modes, you will
note the following on the seal flush system on a particular piece of equipment.
Unvented or Closed Valve in the Seal Flush Line

When the seal flush lines are not vented or a valve is closed, you will find the seal flush lines and
the heat exchanger cold. The seal flush lines may be hot at their origin, but they will become cold
as you move away from the connections towards the heat exchanger. You will also find the body
of the heat exchanger cold.
Solution
Upon finding the above situation, you should check for closed valves in the seal flush line, with
the exception of the vent valve. If no valves are present or they are open, vent the process side of
the cooler through the vent line. In the event the heat exchanger is vapor locked on the process
side, this should promote circulation. In the event you cannot find a problem, contact your
maintenance or BW/IP personnel for further assistance.
Clogged or Closed Cooling Water System

When the cooling water system is clogged or closed, you will find the process lines entering and
exiting the heat exchanger at the same temperature. The body of the heat exchanger will also be
very hot to the touch. The cooling water lines entering and exiting the heat exchanger will be very
hot at the cover and both lines will cool as you move away from the heat exchanger.
Solution
Check the cooling water lines to make sure all valves are open. If open, open the case drain on
the heat exchanger to check for clogging of the heat exchanger case. [Caution: The water will be
hot as it exits the heat exchanger.] Let the water flow to grade until you are confident the case is
clean. Close the case drain. If the above attempts are unsuccessful, begin procedures to shut the
equipment down in an orderly manner.
Shutdown Procedure
Once the equipment has been prepared for maintenance, remove the cooling water lines and check
for clogging. Once cleared, check both the supply and return header pressure. The differential
pressure should be 50 psi minimum. Check the heat exchanger for clogging and repair or replace if
needed.
In the event you cannot find a problem, contact your maintenance or BW/IP personnel for further
assistance.

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OPERATION

BOHT-DGV-2M0020;2M0021 & 2M0022

Chapter : Transport / Interim Storage

Contents OIM Pages 3

Chapter : Installation on Site

Contents OIM Pages 3

Chapter : Commissioning, Start-up/Shutdown

Chapter : Pump Supervision Plan

Contents OIM Pages 3

5. Dismantling the Bearings

6. Dismantling the Shaft Seal

Contents OIM Pages 3

7. Dismantling the Balancing Device

8. General Information on Reassembly

9. Checking the Balancing Device with Contact Fluid

9.2 HG Pump Size 3

10. Mounting the Balancing Device

11. Mounting the Shaft Seal

12. Mounting the Bearings

13. Mounting the Piping and Instruments

14. Mounting the Connecting Coupling

14.2 Aligning the Connecting Coupling

Contents OIM Pages 3

15. Mounting the Guards Preventing Accidental Contact

16. Maintenance of the Other Pump Set Components

17. Spare Parts

Chapter : Trouble Shooting

Chapter : Tables of Clearances

Contents OIM Pages 3

Chapter : Table of Tightening Torque

OIMPG TIGHT TRQ 1

Chapter : Table of Weights

Contents OIM Pages 3

Non-compliance with the regulations laid down in the instruction manual

This instruction manual must always be kept close to the location of

We recommend to call in KSBs experienced personnel for installation,

Operation of the pump set outside the conditions mentioned above

Prior to returning any pump set components, carefully follow the

All measuring instruments supplied with the pump should be

Conformity with EU Regulations (if applicable)

The electrical danger warning sign is

Personnel Qualification and Training

Non-compliance with Safety Instructions

Safety Instructions for the Operator/User

Safety Instructions for Work on the Pump Set

Unauthorized Modification and Manufacture of Spare Parts

Unauthorized Modes of Operation

Temperature > 80 C/176 F

Transport / Interim Storage

Observe the applicable local safety regulations.

Hoisting Tackle (e.g. ropes, gear)

Signals during Transport

Transport of the Pump Set

Transport of pump sets mounted on baseplates ( examples )

Transport of the Pump

Do not attach the ropes to the shaft ends or bearing housings.

Transport of Pump Set Accessories