EXTERNAL OIL PUMPS

Grasso KF 3/63, KF 3/80 AND KF 3/112

Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

Specified Use
It must be ascertained that the medium to be
delivered is compatible with the materials used in
construction of pump (see “Technical data”).
The maximum permissible operating data given in the
“Technical Data” section must be stictly adhered to.

DESCRIPTION OF EQUIPMENT

General
Pumps in the KF Series are external gear wheel
pumps, which operate according to the displacement
principle. Two gear wheels which are rotating in mesh
with each other cause an increase in volume to occur
SAFETY
as the spaces between the gear wheels are exposed at
If these warnings are not heeded, the consequence the pump inlet (suction side), so that the medium can
can be dangerous to life and damage the equipment. flow into the pump. Simultaneously, a corresponding
volume is displaced at the pump outlet (pressure side)
through rotation of the gear teeth into the filled area
General Safety Instructions vacated by the preceding teeth. The transport of fluid
is achieved through the entrainment along the cavities
Operating safety of supplied pump is only guaranteed
between the gear teeth and the walls of the gear
if the pump is used as specified (see “Description of
chambers. The so-called geometric delivery volume Vg
equipment”). The stated limiting values (see
is displaced per revolution of the gearwheels. A value
“Technical data”) must not be exceeded under any
Vgn, referred to as the nominal volume, is used in
circumstances.
technical documentation to identify the pump size.
Personnel having the responsibility for installing,
Gear wheel pumps are self-priming over a wide range.
operating or repairing the pump must possess
The described displacement process is initially achieved
appropriate qualifications; these may have been
without noticeable pressure rise. It is only after the
obtained through training or appropriate instructions.
burden of external loading is applied, for example if a
Such personnel must be familiar with contents of
delivery head is imposed, there is resistance at the
these operating instructions.
pump outlet, pipeline components, etc., that a
During the execution of all work, the prevailing working pressure must be generated to overcome
national regulation relating to accident prevention these resistances.
and safety at work place and where appropriate,
internal regulations of the operator must be observed,
even if the latter is not named in these operating ) Displacement pumps must never be operated
instructions. Leakage of dangerous substances against “closed valves”, since the uncontroll-
handled by the pump must be contained and disposed able pressure heads which occur in this case
of in such a way that there is no danger to personnel lead to damage to the pump and to the
or to environment. associated plant elements.
As is usual in the case of so-called rigid pumps, i.e.,
Leakages of dangerous substances handled by the pumps without compensation for axial play, the
pump must be contained and disposed of in such a
way that there is no danger to personnel or to the
environment. In so doing, the relevant statutory
regulations must be observed.
During all work on the pump and prior to installation,
the connecting pipework must be depressurised and
the motor isolated!
The operator must ensure that these operating
instructions are accessible at all times to personnel
concerned with the operation of the equipment.
lateral play between the gear wheel contact surfaces
is set such that the permissible operating pressure is
safely controlled.

4.11.03/ 2 637820gbr.doc - 1/10

 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

The directions of rotation and supply of outside gear Structure

wheel pumps, when viewed on the end of the drive
shaft, are given as in the following drawings:
clockwise, when the shaft is rotating in a clockwise
direction,
anti-clockwise, when the shaft is rotating in an
anti-clockwise direction.
The drawing below gives both the dirction of rotation
and flow of the pump.
The following scheme shows the structure of a
lubrication pump for Grasso screw compressor units.
The pumps are regular equipped with shaft seal and
can work with inlet pressure on suction side. If a
leakage occurs at the shaft seal it will be transferred
outside by an observable tube (see “Technical Data”).
Leakages must be contained and disposed of
according to the relevant regulations.

Clockwise direction of rotation:

) The pumps are supplied by Grasso
exclusively with clockwise rotation!

1 Housing 5 Gear
2 Flange cover 6 Plain bearing bush
3 End cover 7 Shaft seal
4 Shaft seal holder 8 Tube (leakage control)

637820gbr.doc - 2/10 4.11.03/ 2

 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

TECHNICAL DATA
General

Type of Construction External gear pump

Connection Flange connection
Installation vertical
horizontal possible (leakage tube down)
Rotation clockwise KF3/. F1..
Operating pressure operation
suction side pe min - 0,4 bar
pe max 25 bar
standstill
pe min -1 bar
pe max 35 bar
Operating pressure ∆pmax 10 bar
discharge side pn max 35 bar
Speed nmin 200 1/min
nmax 2000 1/min
Viscosity νmin 12 mm²/s
νmax 20000 mm²/s

Temperature of delivered ϑmin - 10 °C

medium ϑmax 100 °C

Ambient temperature ϑu min - 20 °C

ϑu max 60 °C

Leakage perm. 1 drop /min

1000 hrs/year approx. 0,2 l/year
max. 0,3 cm³/hrs
(shaft seal has to be observed and to be changed if
necessary)
Admitted medium Refrigerating machine oil (synthetic)
Refrigerating machine oil (mineral)
Sealing materials KF 3 .../153 CR
KF 3 .../172 HNBR
Filtering
of medium upstream of pump Filter mesh ≤ 60 µm
Grasso oil pump unit
(oil pump + motor preassembled) Specification cf. pages 8 and 9

4.11.03/ 2 637820gbr.doc - 3/10


Grasso
Refrigeration Division
PUMP INSTALLATION
Mechanical Installation
) Only pipe lines and connections for the
expected pressure range are permitted.
Please pay attention to the manufacturers
instructions!
• Pumps are displacement pumps (see “Equipment
description” section). This means that the use of a
pressure limiting valve in the system is essential!
• Prior to installation, the pump has to be
inspected for possible damage and fouling during
transportation.
• The respective coupling hubs must be mounted
on the motor and pump shaft. When installing
the coupling, the hub should be heated up and
slid onto the shaft in the heated condition.
• The shaft must not be struck during the
mounting operation!
• Each coupling hub must be secured on the
respective shaft against axial displacement by
means of the threaded pin, which presses on the
adjusting spring!
Alignment of the Coupling
• When installing the coupling, care should be
taken that the dimension E is precisely main-
tained, so that during operation the coupling is
free to move axially.
Shaft separation „E“ Shaft with adjuster spring
sith in toothed rim (dw)
• If the shaft clearance dimension is less than the
coupling dimension “E”, then one of the shaft
ends can extend into the toothed rim section.
The dimension “dW” corresponds to the
maximum shaft diameter which, with the
adjuster spring, is allowed to penetrate into the
toothed rim, dimension “dH”. If it is possible to
remove the adjuster spring, i.e., only the shaft
penetrates into the toothed rim section, then the
shaft dimension can be increased to up to 2 mm
less than the given dimension “dH”, so that the
axial freedom of movement of the toothed rim is
not restricted. The couplings can either take up a
radial or an angular misalignment.
637820gbr.doc - 4/10
EXTERNAL OIL PUMPS
KF 3/63, KF 3/80 AND KF 3/112
OPERATING AND MAINTENANCE INSTRUCTIONS
Coupling E s dH dw
type (mm) (mm) (mm) (mm)
19 (19/24)
28 (28/38)
16 ± 1,2
20 ± 1,5
2
2,5
18
30
12
22
The buyer must protect rotating parts from being
accidentally touched!
• Mount the pump on the pump supports.
• Before installing the pump, clean the pipework,
remove dirt, sand, swarf etc. Welded pipes, in
particular, must be scoured or scavenged. Do not
use cotton waste/rags for cleaning purposes.
• Remove the protective stoppers in the pump
suction and pressure connections.
• Connect the pipelines on suction and pressure
side of the pump. In doing so, the instructions of
the relevant manufacturer should be followed.
Neither the suction or the pressure side pipelines
should transfer loads to the pump!
The pipelines must connect with the pump supports
in an absolutely stress-free condition. The pipelines
are to be constructed in such a way, that even during
operation, no stresses can be transferred through the
pipelines, for example through changes in length due
to temperature fluctuations.
Damaged pipelines and hoses have to be replaced
immediately!
• On installation must be ensured that no sealing
material can enter the pipeline.
Electrical Installation
All technical data mentioned on the motor type plate
have to be compared to the required working data.
The overload protection has to be adjusted to the
right value. The direction of rotation has to be
checked before connecting the pump.
4.11.03/ 2

Grasso
Refrigeration Division
COMMISSIONING
) Commissioning is only to be carried out by
instructed and qualified personnel. Prior to
starting up plant, it must be ascertained that
an adequate quantity of the operating
medium is available in order to avoid dry
running.
• Check the permissible operating values against
the anticipated operating conditions.
• Check all fixing bolts on the pump.
• Check the direction of rotation.
) The pumps must only run in direction of
rotation indicated by the arrow / in direction
of rotation indicated by the symbol on the
type plate. Pump operation in the opposite
direction of rotation to indicated will
damage the shaft seal.
• Before operating, the pump and the sealing area
have to be filled with the fluid medium.
• The pumps should be started up at either very low
or zero pressure loading. The existing shut-off
devices should be fully opened.
• The satisfactory operation being detectable either
from manometer readings or from the noise
generated by the pump should be achieved over a
period of no longer than 30 seconds.
• On attaining the required operating values, the
temperature of medium and pump should be
checked. The control points on the pump are the
shaft bearing positions and the shaft seals. The
temperatures reached on the surface of the pump
housing may be approx. 10°C greater than the
temperature of the medium.
• Check the pumps static sealing at suction and
pressure connection and separation joints for
leakages.
• Check the screwing for leakage. Leaking can easy
be removed by tighten the screwing.
• Please also check all fixing screws at motor and
pump after some working hours.
4.11.03/ 2
EXTERNAL OIL PUMPS
KF 3/63, KF 3/80 AND KF 3/112
OPERATING AND MAINTENANCE INSTRUCTIONS
MAINTENANCE
Assuming correct installation in accordance with the
conditions of use and correct operating, gear pumps
are of such construction that a long and fault-free
operational life will be obtained. They require a
minimum of maintenance which, however, is
necessary for reliable operation, since experience has
shown that a high percentage of the faults and
damage which occur are attributable to the ingress of
dirt and inadequate maintenance. The extent of
servicing required and the service and inspection
intervals are, in general, laid down by the
manufacturer in an appropriate plan.
) The regular examination of all operating data,
such as pressure, temperature, current con-
sumption, degree of filter fouling, etc., contri-
butes to the early detection of potential failure.
Mechanical disassembly
) Prior to carrying out any work on the pump and
its disassembly, relieve pressure from the
connecting lines and deenergize the motor!
Prevent also in any case restarting of the motor
when work is being carried out on the pump.
Extreme cleanliness should be ensured during all
work. Before loosing screwed connection, the
surrounding areas are to be cleaned.
Remove depressurized lines from the pump.
) At operating temperatures exceeding 60°C , let
the pump chill out first. There is the danger of
scalding!
) Leakages of dangerous media must be collected
and disposed of in such a way that no danger
results to personnel or to the environment. In
so doing, the statutory regulations must be
observed.
Seals
• Regularly check the static seals at the points of
separation of the suction and pressure connections.
• The shaft seal is extremely exposed to wear and has
to be controlled carefully. Too high pressure, wrong
direction of rotation, fouling or high gas portion
cause higher wear and leakage (admissible data see
section “technical data”). Small leakage is necessary
to the shaft seal function. A leakage up to 1
drop/min is necessary for lubricating the seals
(leakage is according to 0,2 l and 1000 working hours
annually). When a leakage of 0,3 cm³/h occurs it has
to be observed, if it is raising or constant at 0,3 cm³/h
the shaft seal has to be replaced. Pay attention to the
mounting instructions.
637820gbr.doc - 5/10

Grasso
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS
MOUNTING AND DISASSEMBLING INSTRUCTIONS
FOR SHAFT SEAL AX30
The shaft seal has a functional relation to the
direction of rotation
) Repairs must only be carried by trained
specialist personnel.
Disassembling
The retaining ring item 240 (use a mounting tool) has to
be disassembled from the shaft. Unscrew three screws
item130 and the shaft seal holder item 30 (pay attention
to the fitting position!). Dismount the retaining ring item Detection and Elimination of Faults
140 (use a mounting tool), remove the protection ring
item 70 and push out the counter ring item 300.2 and the
O-ring item 300.4. Disassemble the seal ring, the O-ring
and the spring item 300.1, 300.3 and 300.5.
Preparations for Mounting:
A frequent source of failure is the wrong mounting
of the seal. Pay attention to a clean work place and
avoid to damage the sealing. Lubricate the 0-rings
with a suitable fluid to reduce the frictional force
when mounting the seal. The sliding surfaces have to
be mounted clean, dry and dust-free.
Check the rotation direction before assembling the
shaft seal (see drawing).
Mounting:
The O-ring item 300.4 has to be fit on the counter
ring item 300.2 and both parts have to be pushed
into the shaft seal holder item 30. Insert the
protection ring item 70 acc. to the drawing and
install the retaining ring item 140.
637820gbr.doc - 6/10
EXTERNAL OIL PUMPS
KF 3/63, KF 3/80 AND KF 3/112
The rotation unit ( seal ring, O-ring and spring item
300.1, 300.3 and 300.5) can be pulled on to the shaft
without difficulty by applying a screw motion in the
winding direction of the spring (spring “open”) as
well as a thin oil film on the shaft. Install the
mounted shaft seal holder (replace the 0-ring item
330). The shaft seal holder’s leakage oil bore has to
correspond to the flange mounting cover. Screws
item 130 (with spring washer item 200) has to be
tightened with 25 +5 Nm. The shaft seal will be
prestressed to laid length.
REPAIRS
A repair comprises:
• Diagnosing examination, i.e. isolation of the
fault. Determining and localising the cause of the
fault.
• Elimination of fault, i.e. replacement or repair of
defective components and elimination of the
primary cause.
• In most of the cases the faults will be elemimated
by exchange the defective components. The repair
of components is generally undertaken by the
manufacturer.
• Given the appropriate know-how and adequate
equipment, the repair may also be carried out by the end
user or the initial supplier. Assistance is available in form
of spare parts lists and repair instructions.
Diagnosing examination
Lack of adequate sealing is a frequent source of
failure. If this occurs at the pipeline connections, it
may be eliminated by simply tightening the screwed
fittings.
In case of a lack of sealing on the pump, the respec-
tive seals must be replaced (see spare parts lists).
Detection and Elimination of Faults
) Repairs must only be carried by trained
specialist personnel.
) To order Spare parts
Grasso GmbH Refrigeration Technology
- Spare Parts Department -
Holzhauser Straße 165
GERMANY
13509 Berlin
Phone: +49 (0)30 — 435 92 750
Fax: +49 (0)30 — 435 92 758
The following list gives the causes of faults which are
most frequently encountered during operational
failures together with an indication of problem areas
to be rectified.
4.11.03/ 2
 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

In the event of occurrence of a fault which cannot be identified, please request assistance from Grasso.

FAULT POSSIBLE CAUSE

Increased noise Mechanical vibrations − Faulty aligned or loose coupling
− Coupling is worn out
− Faulty or inadequate pipeline fixing
− Pressure relief valve is flapping
− Installation not optimised for noise (lack of damping
elements)
− Pump installed in unfavourable position
− Pump is worn out, tooth flank wear
Insufficient supply − Throttled shut-off element in suction line
flow − Fluid level too low
− Viscosity too low
− Pressure too high
− Pressure relief valve set too low
− Pump is worn out
Insufficient pressure Supply flow too low − Viscosity too low
− Pressure relief valve set too low or does not close
− Rpm too low
Working resistances in − Drive power too low
pressure line too low
− Pump is worn out
Power consumption − Pressure too high
too high − Viscosity too high
− Drive power too low
− Motor winding dedective
Operating − Cooling and heat dissipation inadequate
temperature − Fluid supply too low
too high
− Fluid conveyed under load into the reservoir via pressure
relief valve
Pump heat-up − Pressure too high
above permissible − Viscosity too low
level
− Pump is worn out
Leakage at the − Inlet pressure above permissible value
shaft sealing − Incorrect direction of rotation
− Gas portion in oil too high
− Seal wear
− Seal temperature too high
− Mechanical vibrations
− Incorrect seal material
Coupling wear − Incorrectly aligned or loose coupling
− Inadequate axial play in coupling
− Coupling overloaded
− Temperature too high

4.11.03/ 2 637820gbr.doc - 7/10

 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

SPECIFICATION
OIL PUMP UNIT KF 3/63 F10B N0A 7GP43 /153 IDENT-NO.: 456098030 1)
/172 IDENT-NO.: 456098030N 1)
1)
consisting of - oil pump KF 3/63 Housing material: (GG25)-EN-GJL-250
- three-phase motor
- pump support Z3/200/125
- coupling RS 19/24 - Z25/19 — Z25/24
- rectangular flange 260x260x6
- welding flange NW 32

Weight and motor data

Motor make Birkenbeul
(other motor makes on request,
e.g. with explosion protection)

Weight oil pump unit 35,4 kg

Weight oil pump 12 kg

Oil pump motor — Technical Data

Nominal capacity: 1,5 kW Model Type 90 Design type IM B35
Protection type: IP 55 Voltage 220 - 240 V ∆ / Current three-phase a.c.
Nominal speed: 1410 rpm, 50 Hz 380 — 420 V Y, 50 Hz; Current 3,4 A - 400 V, 50 Hz
1692 rpm, 60 Hz 440 — 480 V Y, 60 Hz consumption

SPARE PARTS

KF3/63.../153 KF3/63.../172
Item Qty. Description
Ident-No.: XXXXXXXXX Ident-No.: XXXXXXXXX
70 1 Ring rack-out protection E.0184280001
140 1 Retaining ring L.0024000114
230 1 Retaining ring N.0004710027
240 1 Retaining ring N.0004710024
300 1 Shaft seal L.0038000035
330 1 O-ring L.0017100033 L.0017240003

637820gbr.doc - 8/10 4.11.03/ 2

 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

SPECIFICATION
OIL PUMP UNIT KF 3/80 F10B N0A 7GP43 /153 IDENT-NO.: 456098065 1)
/172 IDENT-NO.: 456098065N 1)
1)
consisting of - oil pump KF 3/80 Housing material: (GG25)-EN-GJL-250
- three-phase motor
- pump support Z3/250/135
- coupling RS 28 — Z35/19 — Z35/28
- rectangular flange 280x280x10
- welding flange NW 40

Oil pump motor — Technical Data

Nominal capacity: 2,2 kW Model Type 100L Design type IM V1
Protection type: IP 55 Voltage 220 - 240 V ∆ / Current three-phase a.c.
Nominal speed: 1420 rpm, 50 Hz 380 — 420 V Y, 50 Hz; Current 5A - 400 V, 50 Hz
1704 rpm, 60 Hz 440 — 480 V Y, 60 Hz consumption - 460 V, 60 Hz

SPARE PARTS

KF3/80.../153 KF3/80.../172
Item Qty. Description
Ident-No.: XXXXXXXXX Ident-No.: XXXXXXXXX
70 1 Ring rack-out protection E.0184280001
140 1 Retaining ring L.0024000114
230 1 Retaining ring N.0004710027
240 1 Retaining ring N.0004710024
300 1 Shaft seal L.0038000035
330 1 O-ring L.0017100033 L.0017240003

4.11.03/ 2 637820gbr.doc - 9/10

 EXTERNAL OIL PUMPS
Grasso KF 3/63, KF 3/80 AND KF 3/112
Refrigeration Division OPERATING AND MAINTENANCE INSTRUCTIONS

SPECIFICATION
OIL PUMP UNIT KF 3/112 F10B N0A 7GP43 /153IDENT-NO.: 456098031 1)
/172 IDENT-NO.: 456098031N 1)
1)
consisting of - oil pump KF 3/112 Housing material: (GG25)-EN-GJL-250
- three-phase motor
- pump support Z3/250/135-k
- coupling RS 28 — Z35/19 — Z35/28
- rectangular flange 280x280x10
- welding flange NW 40

Weight and motor data

Motor make Birkenbeul
(other motor makes on request,
e.g. with explosion protection)

Weight oil pump unit 35,4 kg

Weight oil pump 12 kg

Oil pump motor — Technical Data

Nominal capacity: 3 kW Model Type 100 Design type IM B35
Protection type: IP 55 Voltage 220 - 240 V ∆ / Current three-phase a.c.
Nominal speed: 1430 rpm, 50 Hz 380 — 420 V Y, 50 Hz; Current 6,5 A - 400 V, 50 Hz
1716 rpm, 60 Hz 440 — 480 V Y, 60 Hz consumption
SPARE PARTS

KF3/112.../153 KF3/112.../172
Item Qty. Description
Ident-No.: XXXXXXXXX Ident-No.: XXXXXXXXX
70 1 Ring rack-out protection E.0184280001
140 1 Retaining ring L.0024000114
230 1 Retaining ring N.0004710027
240 1 Retaining ring N.0004710024
300 1 Shaft seal L.0038000035
330 1 O-ring L.0017100033 L.0017240003

637820gbr.doc - 10/10 4.11.03/ 2