THRUSTREAM EXTENDED

RANGE Horizontal Split Case

Centrifugal Pumps And Pump Sets

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 CONTENTS The pump sizes covered by this manual are:
Section Page
1. General Information and Safety Instructions ............................................ 3 Size Module
2. Transport Handling and Storage Instructions ........................................... 3
3. General Description................................................................................... 4 200/58
1E
4. Assembly and Installation ......................................................................... 5
300/34
5. Commissioning and Operation.................................................................. 8
6. Maintenance and Service .......................................................................... 9 250/42
6.2 Repacking the Stuffing Box.......................................................... 10
6.3 Maintenance of Mechanical Seals ................................................ 12 250/51
6.4 Bearing Lubrication ...................................................................... 12
250/68 2E
7. Faults and Remedial Action .................................................................... 20
8. Pump Details: .......................................................................................... 21 300/59
8.1 Cross Section Drawing - Single Stage Pump -
Clockwise Rotation:...................................................................... 21 350/39
8.2 Single Stage Pump Parts Identification List -
(Numbers as shown on cross section drawing) ............................ 22 300/48
8.3 Typical Pump Section Two Stage: Clockwise Rotation............... 23
8.4 Two Stage Pump Parts Identification List - (Numbers
300/77
as shown on cross section drawing).............................................. 24
9. Standard Metric Nut and Bolt Torque Recommendations...................... 25
350/44 3E

350/54

Introduction 350/66

This manual gives the safety, installation, operation and 150/48-2

maintenance instructions for pumps in the KBL Thrustream 2 Stage
Extended range of horizontal split case centrifugal pumps for 200/58-2
general water and industrial use.

Thrustream pumps are identified by their pump designation and by

their size code, the first number is the delivery branch diameter and This manual covers the Extended Range of Thrustream pumps that
the second number is the nominal diameter of the impeller in are built for use in the horizontal position. For information on
centimetres. pumps built for vertical applications, please refer to a separate
manual that can be obtained from KBL.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 1.6 Check and confirm that the manual is the relevant copy by
1. General Information and Safety comparing the serial number on the identification plate with
Instructions that on the manual.

1.7 Note any limits to the pump application specified in the

The products supplied by KBL, have been designed with
contract documentation. Operation of the equipment outside
safety in mind. Where hazards cannot be eliminated, the risk
these limits will increase the risk from hazards noted below
has been minimised by the use of guards and other design
and may lead to premature and hazardous pump failure.
features. Some hazards cannot be guarded against and the
instructions below MUST BE COMPLIED WITH for safe
1.8 Clear and easy access to all controls, gauges and dials etc.
operation. These instructions cannot cover all
MUST be maintained at all times. Hazardous or flammable
circumstances: YOU are responsible for using safe working
materials must NOT be stored in pump rooms unless safe
practices at all times.
areas or racking and suitable containers have been provided.
1.1 KBL products are designed for installation in designated
1.9 IMPROPER INSTALLATION, OPERATION OR
areas, which are to be kept clean and free of obstructions
MAINTENANCE OF THIS KBL PRODUCT COULD
that may restrict safe access to the controls and maintenance
RESULT IN INJURY OR DEATH.
access points.

1.10 Within the manual, safety instructions are marked with

A pump nameplate is fitted to each unit and must not be
safety symbols.
removed. Loss of this plate could make identification
impossible. This in turn could affect safety and cause
Hazard
difficulty in obtaining spare parts. Should accidental loss or
damage occur, contact KBL immediately. This symbol refers to general mechanical aspects of
safety.
1.2 Access to the equipment should be restricted to the
personnel responsible for installation, operation and Hazard
maintenance and they must be trained, adequately qualified This symbol refers to electrical safety.
and supplied with the appropriate tools for their respective
tasks.
This symbol gives warning of a hazard to the
ATTENTION pump itself, which in turn,could cause a risk to
1.3 KBL requires that all personnel that are responsible for
personal safety.
installation, operation or maintenance of the equipment,
have access to and study the product instruction manual
BEFORE any work is done and that they will comply with 2. Transport Handling and Storage
all local and industry based safety instructions and Instructions
regulations.
2.1 Transport
1.4 Ear defenders should be worn where the specified
equipment noise level exceeds locally defined safe levels. Horizontal Extended Thrustream pump sets are despatched
Safety glasses or goggles should be worn where working fully assembled except where stability or handling
with pressurised systems and hazardous substances. Other constraints require the motor to be packed and delivered
personal protection equipment must be worn where local separately.
rules apply.
Pumps are protected against corrosion and packed for
1.5 Do NOT wear loose or frayed clothing or jewellery that transport by normal road, rail and sea carriers.
could catch on the controls or become trapped in the
equipment.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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2.2 Handling If storage in the open cannot be avoided, cover the pump
Crushing Hazard with a tarpaulin sheet, but allow dry air to circulate around
the pump.
When lifting the pump unit, use lifting
equipment having a safe working load rating 2.3.3 Exposed or Extreme Conditions Storage
suitable for the weight specified. Use suitable slings for
lifting any pump not provided with lifting points. For exposed storage or extreme variants in atmospheric or
environmental conditions, please refer to KBL.
The use of suitable forklift truck and four-chain crane sling
equipment is recommended but locally approved equipment
of suitable rating maybe used. 3. General Description
Pump weight is shown on the general arrangement drawing
supplied with each pump or pumpset. KBL Thrustream Pumps are a range of centrifugal pumps
that are usually supplied as pump sets with electric motors
2.3 Storage but can be supplied separately for customers to fit to drivers
of their own preference.
Shearing Hazard
Do NOT place fingers or hands etc. into the 3.1 Pumps
suction or discharge pipe outlets and do NOT
touch the impeller. If rotated this may cause The mechanical assembly comprises a rigid shaft, supported
severe injury. To prevent ingress of any objects, by grease-lubricated ball bearings at each end of the pump
retain the protection covers or packaging in place until shaft. The pump casing is fitted with wear rings and houses
removal is necessary for installation. If the packaging or a double entry shrouded type impeller mounted on a stiff
suction and discharge covers are removed for inspection shaft. Some pumps in the range are fitted with a pair of
purposes, replace afterwards to protect the pump and single side entry impellers. The seal chamber is housed in
maintain safety. the casing inserts retained within the casing. Some
impellers may be fitted with wear rings if required. When
2.3.1 Temporary Storage for up to Six Weeks the upper half casing (1220001) is removed, the bearing
housings (2400001), inserts, shaft (1800001) and impeller
If the pump is not to be used immediately, it should be (1590001) assembly can be removed from the lower half
stored carefully in a horizontal position, in a sheltered, dry casing for maintenance without disconnection of pipework.
location. Additional rust preventive should be applied to all
unpainted carbon steel or cast iron parts. Fit or retain in The suction and discharge branch flanges are positioned
place the covers to the suction and discharge flanges and all horizontally at 90 degrees to and below the shaft centreline.
other pipe connections. Rust preventive and flange covers The pump casings allow for construction to suit different
should not be removed until final installation. rotations.
When pumps are not in use, the pump shaft (1800001)
should be rotated several turns, every six weeks. The standard pump is soft packed but the option to fit
internal component mechanical seals or selected external
2.3.2 Long Term Storage cartridge mechanical seals is provided to suit customer's
requirements. These pumps are normally supplied with a
It is recommended that the pump is stored in a clean dry cast iron casing and impeller but bronze may be supplied
place that is not subject to a wide temperature variation. where required. Other parts may be supplied in a variety of
Pack the bearings with the specified grease and periodically materials to suit the pump application.
inspect the bearing housings (2400001) to ensure that they
are free from damp and moisture. Leave the covers for the In standard form, these pumps are designed to pump liquids
suction and discharge flanges in place or replace with at temperatures up to 80oC. Where pumps are needed to suit
suitable covers to prevent ingress of dirt or moisture. Rotate higher temperatures, please refer to KBL.
the shaft (1800001) several turns monthly, to distribute the
grease and prevent pitting of bearing surfaces. Note: 1) Head specified is the Duty Head generated by the
pump only. 2) Suction pressure must be included when
assessing the Maximum Working Pressure.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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3.2 Electric Motor Driven Pump sets 4.3 Location of Pump

Pump sets supplied are mounted on a substantial fabricated The pump should be located as near the liquid source as
baseplate; the complete assembly is of a rigid construction, practical, with adequate accessibility for inspection and
being intended for mounting on suitable foundations. repair and sufficient headroom for lifting tackle if
necessary.
These pump sets are supplied fitted with a high efficiency
electric motor adequately sized for the duty specified. Where pumps are electric motor driven, power source
electrical characteristics should match those shown on
The proprietary flexible coupling has been selected to meet motor data plate. A qualified electrical contractor should be
the power transmission and other operating requirements used to make the electrical connection.
for the pump set
4.4 Foundations

4. Assembly and Installation The pump is to be mounted on a substantial floor or plinth

and secured with suitable foundation bolts to minimise
Shearing Hazard vibration. The foundation must have a flat level surface and
Do NOT place fingers or hands etc. into the be of sufficient depth to contain the foundation bolts. The
suction or discharge pipe outlets and do NOT pump unit should be installed with the flange faces set in a
touch the impeller (1590001), if rotated this vertical position. Packers may be placed under the baseplate
may cause severe injury. To prevent ingress near the bolt holes to level the unit if the floor is uneven.
of any objects, retain the protection covers or packaging in The foundation bolts should be tightened and the shaft
place until removal is necessary for installation. (1800001) alignment checked again before commissioning
and putting the pump into operation.
4.1 Initial Inspection for Damage
4.5 Pump Preparation
During transport and storage, accidental damage to the Abrasion & Entrapment Hazard
pump may have occurred. When the pump is to be installed, Do NOT touch any moving or rotating parts.
or in the event of a handling accident, carefully check that Guards are provided to prevent access to these
the pump is not damaged before installation and parts, where they have been removed for
commissioning. maintenance they MUST be replaced before
operating the equipment. For soft packed pumps the packing
4.2 Preparation for Mounting rings and related components are often supplied loose.
Ensure that the packing is installed as per instructions in
Before installation, check that the pump mounting location section 6.2 point 10 to 19.
is suitable for accepting the pump. Refer to the certified
General Assembly drawing, for details of pump installation
dimensions.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 Remove packaging but leave the flange covers in place, Bends in the suction pipeline should be as large as possible,
check that impeller (1590001) rotates freely by hand by the pipe made as short and as straight as possible and all
turning the shaft (1800001). joints must be fully airtight. A gradual rise in the suction
pipeline is recommended to prevent formation of air
If the pump has been in storage, remove any protective pockets. If fitting a foot valve, it should have a free area of
coatings. If the bearing housings (2400001) were filled with one and a half times the area of the suction pipe.
grease, flush and re-lubricate the bearings.
Where pumping water at temperatures above 70 °C, care
4.6 Suction Pipework must be taken to ensure that enough pressure is available at
the impeller (1590001) entry to prevent vaporisation.
The run of suction pipework must be such that air can NOT Expansion joints are recommended to prevent strain on the
become trapped where it would be drawn into the pump on pump casing.
starting. The bore of the suction pipe is recommended to be
one or two sizes larger than the pump suction branch and An appropriate fine strainer is recommended to prevent
reducers if used must be eccentric to eliminate the foreign matter from being drawn into the pump. A screen or
possibility of an air pocket being formed. basket strainer may also be required to hold back larger
items. These should be sized to maintain the flow through
CONCENTRIC REDUCER them to below 0.6 m/s.
WILL TRAP AIR IN THE
SUCTION PIPE
The suction pipe work must be flushed clean to ensure that
site debris is not drawn into the pump when it is
commissioned.

4.7 Discharge Pipework

The bore of the discharge pipe should ideally be sized to

X Foundation Plinth
ensure a flow velocity of 2.5 to 3 m/s is not exceeded. This
is usually one size larger than the discharge branch.
Pipework should be as short and straight as possible to
reduce friction head loss.

FLAT TOP REDUCER

WILL NOT TRAP AIR IN
A non-return valve is usually fitted to prevent the pump
THE SUCTION PIPE from excessive backpressure and reverse rotation and a
discharge valve is usually fitted for isolation purposes to
allow for inspection and maintenance on the pump.

Where adverse suction conditions may cause the pump to

lose its prime, the use of an external automatic priming
device, such as a vacuum pump, is recommended.

Foundation Plinth The suction and discharge pipe work must be independently
supported and positioned such that no excessive forces and
moments are exerted on the pump flanges.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 DISCHARGE
3. Confirm Lateral Alignment
CHECK DISCHARGE
VALVE PIPE
INCREASER VALVE
Mount the dial gauge on
the pump shaft or
coupling with gauge PUMP
running on the outer
machined surface of the
motor coupling. Turn the
pump shaft in the
Check direction of pump MOTOR
Valve rotation, and note the
Foundation Plinth
Support total indicator reading.

4. Adjustment
Failure to support suction and delivery pipework may result
in distortion of the pump casing, with the possibility of For horizontal lateral adjustment move the motor using the
early pump failure. motor jacking screws provided and for vertical and angular
adjustment fit shims between the motor feet and the
4.8 Guards baseplate.
If guards have been removed to install packing or to check
mechanical seal connections, they MUST be replaced to Note: Poor alignment is a major factor contributing to
maintain safe operation of the pump. shortening of pump bearing and seal life. It is
recommended that alignment is checked frequently and
4.9 Coupling Alignment maintained at below 10% of the manufacturer's specified
To minimise the bearing loading and to achieve full figure or 0.1mm.
coupling and bearing life, it is recommended that the shafts
(1800001) are aligned as accurately as possible i.e. well As the pump and motor feet are accurately machined, any
below the allowable misalignment of the coupling. discrepancy may be due to foreign matter between any of
the mating faces. These should be checked for cleanliness
Refer to the coupling manufacturer's instructions or proceed before assembly and before resorting to using shims under
generally thus: the motor feet.

ATTENTION Shaft alignment must be checked again after the final

positioning of the pump unit and connection to pipe work as
this may have disturbed the pump or motor mounting
1. Lateral Alignment positions.
PUMP

Mount a dial gauge on the

motor shaft or coupling 4.10 Grouting
with the gauge running on MOTOR A space of about 25mm should be left between the top
the outer-machined surface surface of the foundation plinth and the underside of the
of the pump coupling. Turn the motor shaft and note the baseplate to allow for grouting.
total indicator reading.
Recommended grouting should comprise one part of
2. Angular Alignment cement to two parts of sand, with sufficient water to
PUMP produce a heavy creamy consistency.
Mount a dial gauge on the
motor shaft or coupling to After the grout has dried, the alignment should be checked
run on a face of the pump before commissioning and putting the pump into operation.
coupling as near the outside MOTOR
edge as possible. Turn the
motor shaft and note the total indicator reading.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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5. Commissioning and Operation Check that the suction valve is open and that the pump is
primed.

5.1 Commissioning Checks

Open the discharge valve to one quarter open to prevent
These checks must be done after first installation and after hydraulic lock from occurring. Switch on the motor and
pump maintenance that required removal of the rotating allow it to build up to full operating speed. Slowly open
assembly. discharge valve until the pump reaches the required duty
condition.
Abrasion and Entrapment Hazard
Do NOT touch any moving or rotating parts.
Check that the motor is not overloading, unit is not
Guards are provided to prevent access to these
vibrating or excessively noisy, the motor is not overheating,
parts, where they have been removed for
and that the pump is developing the correct flow and head
maintenance they MUST be replaced before
requirements.
operating the equipment.

If the pump is operating at its normal speed, the pump

Check that the rotating assembly is free to rotate by hand
should be shut down at once if any of the following defects
before connecting the power supply. Also check that the
are found:
piping system has been properly connected with all joints
tightened and instrumentation is in position. a) No liquid delivered.
b) Not enough liquid delivered.
Check that the pump is primed. Pumps should never be run c) Not enough pressure.
dry as the pumped liquid acts as a lubricant for the close
d) Loss of liquid after starting.
running fits surrounding the impeller (1590001). Dry
e) Vibration.
running can cause serious damage to the pump and
seals. f) Motor runs hot.
g) Excessive noise from cavitation.
Prime the pump using an ejector, exhauster or vacuum
h) Pump overheating.
pump. If a foot valve is used in the suction line the pump
Recommended corrective action for these faults is given in Section
may be primed by venting and filling the casing with liquid.
Open the air release valve to bleed any air trapped in the 7 Faults and Remedial Action.
seal housing, as the seal must be lubricated and dry running
often results in premature seal failure. Disconnect the pump 5.3 During Operation
drive by removal of the spacer from the coupling. Connect
Hot Surfaces Hazard
the electrical supply to the pump unit. Momentarily switch
Do NOT touch surfaces that during normal
on motor and check direction of rotation. This should match
running will be sufficiently hot to cause injury.
the direction of rotation of the pump. For three phase
These are marked with the HOT warning symbol. Note that
electric motors, if the direction of rotation is incorrect,
these surfaces will remain hot after the pump has
disconnect the supply and change over two of the three
stopped: allow sufficient time for cooling before
supply phases. Replace the coupling spacer.
maintenance. Be cautious and note that other parts of the
pump may become hot if a fault is developing.
5.2 Starting Procedure

BEFORE A THRUSTREAM SERIES PUMP IS STARTED Cold Conditions Hazard

ALWAYS ENSURE THAT THE SUMP IS FILLED TO THE Do NOT operate water pumps in temperatures
CORRECT LEVEL WITH LIQUID, AND THAT ANY LEVEL below freezing point, without first checking that
CONTROLS ARE FUNCTIONING CORRECTLY. the pumped fluid is not frozen and the pump is
free to turn. Pumps in these environments should be drained
down during inactivity and reprimed before starting.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 Hazardous Noise
In addition to local or site regulations for noise
6. Maintenance and Service
protection, KBL recommends the use of General Introduction
Personal Ear Protection equipment in all
enclosed pump rooms and particularly those containing KBL Thrustream Series pumps will provide many years of
diesel engines. Care must be taken to ensure that any trouble free service when maintained in accordance with
audible alarm or warning signal can still be heard with ear these instructions. In the event of failure of the pump it is
defenders worn. recommended that KBL Service Department are called to
investigate and carry out repairs. The following instructions
Hazardous Gases, Mists, Sprays and Leaks are given to cover the main elements of strip and rebuild
Be aware of the hazards relating to the pumped but do NOT include instructions for work that MUST be
fluid, especially the danger from inhalation of done by KBL Engineer.
toxic gases, skin and eye contact or penetration.
The following hazards may arise during maintenance work:
Obtain and understand the hazardous
substance (COSHH) data sheets relating to the pumped fluid
Fluid Pressure Jet Hazards
and note the recommended emergency and first aid
Check and ensure that the pump operates at
procedures. Periodic Checks:
below the Maximum Working Pressure
specified in the manual or on the pump
a) Pump Bearings:
nameplate and before maintenance, ensure that
Check the bearing temperatures do not exceed 80 °C as an
the pump is drained down.
increase may indicate the early stages of bearing trouble.

Hazardous Materials
b) Noise:
Wear a suitable mask or respirator when
Listen for any unusual noise or an increase in normal sound
working with packing or gasket components that
level.
contain fibrous material, as these can be
hazardous when the fibrous dust is inhaled. Be
This may result from:
cautious if other supplier's components have been substituted
i) Loose fasteners for guards and other equipment.
for genuine KBL parts as these may then contain hazardous
ii) Air trapped in the pump i.e. the pump was not fully materials.
primed.
iii) Cavitation. Hazardous Gases, Mists, Sprays and Leaks
iv) Small solids in the liquid. Be aware of the hazards relating to the pumped
fluid, especially the danger from inhalation of
c) Suction Gauge Reading: toxic gases, skin and eye contact or penetration.
If this is lower than normal, investigate and check that Obtain and understand the hazardous substance (COSHH)
valves in the suction pipework are fully open or that the data sheets relating to the pumped fluid and note the
suction lift may have increased. recommended emergency and first aid procedures.

d) Discharge Gauge Reading:

If this is lower than normal, check for a leak in the
associated pipework or that a valve in the delivery line has
been opened when normally it is partially closed.

5.4 Stopping Procedure

Stop the motor then fully close the discharge valve.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 Recommended Maintenance Schedule 6.1 Preparation for Maintenance

Electric Shock & Accidental Starting Hazard

Visually check for leaks. Check for vibration.
Adjust gland as necessary to maintain slight
ISOLATE the equipment before any
EVERY leakage.
maintenance work is done. Switch off the
WEEK Hand test bearing housing for any sign of mains supply, remove fuses, apply lockouts
temperature. where applicable and affix suitable isolation warning signs
Voltage and current.
to prevent inadvertent re-connection.
EVERY Check bearing temperature with thermometer.
MONTH
During maintenance personnel should be aware of the risks
EVERY 3 Check grease lubricated bearings for of inhaling dangerous fumes or vapours.
MONTHS saponification.
No special tools are required for pump dismantling and
Check the packing and replace if necessary. re-assembly. However, it is important to ensure the suitable
Check shaft or shaft sleeve for scoring.
EVERY 6 lifting equipment is available and that the work is carried
Check alignment of pump and motor. Check
MONTHS out in a clean area.
holding down bolts for tightness.
Check coupling bush/rubber star.
6.2 Repacking the Stuffing Box

Check rotating element for wear. Where a soft packed gland seal is fitted, it will be necessary
Checks wear ring clearances. to replace the packing rings periodically when the gland can
EVERY
no longer be tightened to reduce leakage to the normal level,
YEAR Clean and regrease bearings.
or if the gland is overheating.
Measure total suction and discharge
Head as a test of pipe connection
Packing Removal Procedure

BEFORE ATTEMPTING ANY MAINTENANCE ON

1. Close the suction & discharge valves and release pressure
A PUMP, PARTICULARLY IF IT HAS BEEN
from the casing, remove the gland retaining nuts and pull the
HANDLING ANY FORM OF HAZARDOUS LIQUID,
split gland clear of the stuffing box.
ENSURE THAT THE UNIT IS SAFE TO WORK ON.
THE PUMP MUST BE FLUSHED THOROUGHLY
2. Remove the gland plate and separate and remove the two
WITH A SUITABLE CLEANSER TO PURGE AWAY
halves of the gland.
ANY OF THE PRODUCT LEFT IN THE PUMP
COMPONENTS. THIS SHOULD BE CARRIED OUT
3. Carefully withdraw the old packing rings and lantern ring,
BY THE PLANT OPERATOR AND A CERTIFICATE
using a pair of extractor tools of the correct size placed on
OF CLEANLINESS OBTAINED BEFORE
opposite sides of the pump shaft (1800001).
STARTING WORK. TO AVOID ANY RISK TO
HEALTH IT IS ALSO ADVISABLE TO WEAR 4. Clean the sleeve, the bore of stuffing box, the lantern ring and
PROTECTIVE CLOTHING AS RECOMMENDED the split gland with a clean oily cloth.
BY THE SITE SAFETY OFFICER, ESPECIALLY
WHEN REMOVING OLD SEALS OR GASKETS
THAT MAY BE CONTAMINATED.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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5. Check the sleeve for concentricity with the stuffing box bore 45°
and that the surface under the packing rings is free from
scores, pitting or grooves.

6. Examine the gland for general condition and replace if

damaged.

Packing Preparation 9. Cut each ring from the spiral at an angle of 45° diagonally
across the guidelines.
Champion Style (3116 or EQ.), Graphite cotton greasy packing
is used in the standard supply. However packing suitable for Repacking Procedure
liquid handled is also supplied against specific requirement.
If the packing is to be cut from a coil or long length the size, 10. Insert the first ring and tap it to the bottom of the stuffing box.
number of rings and length is thus: Each following ring should be installed in the same manner
and positioned in the stuffing box so that the 'split' is advanced
Gland packings are fitted with Impeller side 2 + L + 4 Gland 120°.
side (arrangement for 1E, 2E & 3E module pumps) & With
Impeller side 2+L+2+L+1 Gland side (Arrangement for 2-Stage 11. Install the lantern ring(s) in the proper position(s) to align with
module pumps) L = Lantern Ring. the seal lubrication connection(s), allowing for movement of
the ring deeper into the box as the packing is compressed.
Stuffing Box Data
PACKING SIZE NO. OF
SLEEVE SIZE of 12. When all the rings have been inserted, the last packing ring
PUMP SHAFT SQUARE LENGTH RINGS
DIA. RING ID/OD should not protrude from the stuffing box face.
MODULE SECTION of ONE PER
mm mm / mm
mm RING mm BOX
1E 100 12 355 100/125 6 13. Slide the gland into the stuffing box and ensure that it sits
2E 120 12 415 120/144 6
squarely against the last packing ring. Fit the gland plate and
3E 140 15 490 140/170 6
1 50/48-2 85 12 310 85/109 5 the gland retaining nuts on the studs and tighten evenly to
200/58-2 120 12 415 120/144 5 finger pressure.

14. Start the pump as per point 5.2, allow pressure to increase to
7. Wrap the packing around a dummy shaft, of the same normal level and ensure that air is not trapped in the pump
diameter as the sleeve casing.

15. A soft packed gland must have slight steady leakage, and this
should start soon after the pump reaches its normal operating
pressure.

16. If gland leakage stops, the pump will overheat leading to seal
damage or premature pump failure. If overheating is detected,
8. To assist in cutting rings, two guide lines parallel to the shaft the pump must be stopped and allowed to cool and when
axis and separated by a distance equal to the packing section restarted, gland leakage should start.
may be drawn on the spiral.
17. If the pump overheats again, stop the pump restart it again, do
not slacken the gland retaining nuts.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 Bearing Specifications
18. After the pump had been running for 10 minutes with steady Shaft Module Bearing Specification
leakage, tighten the gland nuts by one sixth of a full turn. 1E DE-6214, NDE-6214/7214
Continue to adjust at 10-minute intervals, each time evenly, by 2E DE-6218, NDE-6218/7218
one sixth of a full turn, until leakage is reduced to an acceptable 3E DE-6220, NDE-6220/7220
level (30 drops per minute minimum). SCT150/48-2 DE-6411, NDE-7411
SCT200/58-2 DE-6218, NDE-7218
19. Excessive gland pressure will cause damage by cutting off
lubrication to the packing, and the packing will burn and A suitable bearing puller is required for removal of the
damage the sleeve. bearings from the pump shaft (1800001). If a puller is not
available, a hammer and soft metal drift may be used to tap
6.3 Maintenance of Mechanical Seals evenly around the face of the inner ring.

Exerting force on the outer ring of a ball bearing can cause

Generally no maintenance is required on mechanical seals.
severe damage.

6.4 Bearing Lubrication

The work area and all tools used for bearing replacement
The ball bearings are supplied pre-loaded with appropriate must be clean and free of dust and grit to prevent
grease. A grease nipple and V ring seals are fitted to the contamination of a clean bearing and new grease.
bearing housing (2400001) to ensure that any surplus grease
is trapped inside the bearing housing. ATTENTION Ball bearings should not be dismantled.

It is important to know the weight of grease delivered by

each stroke your grease gun to ensure application of the For pumps fitted with cartridge mechanical seals:
correct amount of grease. Lock the seal before removing the retaining nuts and sliding
the seals back from the face of the insert.
It is recommended that the drive end bearings are topped up
as per the Recommended Maintenance Schedule in Section 6. When replacing all the bearings, complete the replacement of
the drive end bearings BEFORE commencing to replace the
Recommended Grease Lubricant: non-drive end bearings.
International DIN 51825:
Standard KP2 K-30 Drive End Bearing Replacement Procedure
As Supplied with a TEXACO MULTIFAK ALL
new pump. PURPOSE EP2
1. Remove the screws and slide the bearing covers (2700001 &
2710001) along the shaft (1800001) towards the water
deflector (2360001).

6.5 Bearing Replacement

2. Remove the screws to free the bearing housing (2400001) for
Ball bearings will provide satisfactory service for their removal.
designed working life if they are correctly lubricated and
inspected at the intervals shown in Section 6. -Recommended 3. Using a suitable puller, withdraw the bearing housing
Maintenance Schedule. (2400001) from the shaft (1800001).

4. Using a suitable bearing puller on the inner race, pull the

bearing (2600001) off the shaft (1800001).

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

12
5. Clean the bearing thoroughly with an approved cleaning fluid. 18. Fit the bearing cover (2710001) to the bearing housing
(2400001) using screws.
6. Dry the bearing with dry compressed air or with a clean soft
cloth by hand. 19. Check that the shaft (1800001) rotates freely by hand.

7. DO NOT SPIN A CLEAN DRY BEARING. 20. Secure bearing housing (2400001) to the upper half casing
(1220001) & lower half casing (1230001) & insert
8. Inspect the bearing for wear, fractures, cracks, corrosion or (9790001).
other damage, which may necessitate replacement.
21. Fit the new v-ring on the shaft (1800001) to abut against the
9. Lightly oil the bearing and wrap in greaseproof paper to bearing housing (2400001).
prevent contamination before reassembly.
22. Where applicable refit and set the mechanical seal.
10. Check that the shaft (1800001), bearing cover and housing are
clean and undamaged.
Non-Drive End Bearing Replacement Procedure
11. It is recommended that new v-rings are fitted when bearings are
replaced to ensure that contamination is prevented. 1. Proceed as per the drive end bearing replacement procedure,
paragraphs 1and 2.
12. Slide the v-ring onto the shaft (1800001) wipe the seal recess in
the bearing cover with grease and set in position on the shaft 2. Remove the bearing cover (2700001) from the non-drive end
(1800001) against the bearing cover (2710001). bearing housing (2400001) and using a suitable puller,
withdraw the bearing housing (2400001) from the shaft
13. Heat the bearing (2600001) to approximately 100 °C (230 °F) (1800001).
using bearing hotplate, induction heater or oven. NOTE - Do
not exceed 120 °C (248 °F). 3. Using a suitable punch, flatten the lock washer and remove
the bearing locknut (3360001) and the lock washer.
14. Slide the heated bearing onto the shaft (1800001) to abut the
shoulder. Ensure that the bearing sits fully and squarely against 4. Replace the non-drive end bearing and as per the drive end
the shoulder. bearing replacement procedure, paragraphs 4 to 16.

15. Cool the bearing to room temperature and pack both sides with 5. Place the locking washer onto the shaft (1800001) and screw
two/three ounces of recommended grease. on the bearing lock nut (3360001).

16. Coat the inside of the bearing housing (2400001) with grease 6. Fit and tighten the bearing locknut to 300 Nm and lift the tab
and slide into place over the bearings. of the lock washer.

17. If necessary use two screwed rods to pull the bearing housing 7. Fit the bearing housing (2400001) as per the drive end
(2400001) towards the bearing cover then fit four of the screws bearing replacement procedure, paragraphs 17 to 20.
& tighten evenly to pull the bearing housings (2400001) into
place, fit and tighten the remaining screws. 8. Refit the bearing cover (2700001).

6.6 Mechanical Seal Replacement

Mechanical seals will need replacement when failure has

occurred, they may not be replaced without removal of the
rotating assembly unless the motor is disconnected and the
coupling is removed from the pump shaft (1800001).

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

13
 It is recommended that new mechanical seals are fitted when 5 Press or tap out the dowels.
conducting a full pump strip-down for overhaul to give
maximum operating life. Lock the mechanical seal before 6 Remove the nuts and bolts joining the upper half casing and
removing the retaining nuts and sliding the seals back from lower half casing and remove the upper half casing, taking
the face of the insert (9790001). enough care not to damage the impeller (1590001) and casing
(wear) ring. While removing the upper half casing, first
Mechanical Seal Replacement Procedure slowly tighten the release bolts provided so that the upper half
and lower half casing will be separated conveniently. The
1 Isolate the pump and drain the casing using the air vent valve dowel pins inserted for location purpose should be removed
(4500001) and drain plugs provided. before taking out the upper half casing away from the lower
2 Disconnect the seal flush pipe, remove the four hexagon screws half casing.
that retain the mechanical seal, and slide the seal assembly off
the shaft (1800001). 7 If the lower half casing (1230001) is trapped between the
bearing housings (2400001), release the remaining screws
3 Proceed as per the bearing replacement instructions, paragraphs from the non-drive-end bearing housing and back it off by
1 to 10. about 1mm.
4 Remove the nuts from the studs and withdraw the mechanical
seal from the shaft (1800001). 8 Using the eyebolt and a suitable lifting device, lift the upper
half casing (1220001) clear of the impeller (1590001), place
5 Fit a new mechanical seal. to one side on a clean flat surface.
6 Reconnect the seal flush pipe.
9 At this stage, the impeller (1590001) may be inspected for
7 Proceed as per the bearing replacement instructions, point 11 to damage or blocking and cleaning if necessary.
21.
To check the pump shaft (1800001) and impeller (1590001)
6.7 Pump Overhaul and Repairs and to replace the wear rings or shaft sleeves, it is necessary to
Refer to a certified Pump Section drawing or the typical cross remove the rotating assembly from the lower half casing
section drawing. Note the hazards outlined in Section 6. (1230001).

Impeller Inspection Procedure

Preparation for Removal of the Rotating Assembly
1 Isolate the pump and drain the casing using the air vent valve
(4500001) and drain plug provided. Disconnect the motor coupling.

2 Remove the seal lubrication pipes from the inserts for soft For pumps fitted with mechanical seals, refer to the seal
packed pumps or from the mechanical seal. manufacturer's instructions and lock the seal before
removing the retaining screws and sliding the seals back
3 Remove the screws that retain the bearing housings (2400001) from the face of the insert (9790001).
to the lower half casing (1230001).
Provide a suitable lifting strap and support the weight of the
4 Remove the nuts from the casing studs securing the upper half rotating assembly thus:
casing (1220001) to the lower half casing (1230001).

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

14
 3. Using a suitable puller, withdraw the drive end bearing
housing from the shaft (1800001).

4. Remove the bearing cover from the non-drive end bearing

housing and using a suitable puller, withdraw the non-drive
end bearing housing from the shaft (1800001).

5. Using a suitable punch, flatten the lock washer and remove

the bearing locknut and the lock washer.

6. Using a suitable bearing puller on the inner race of each

Removal of the Rotating Assembly Procedure bearing, pull the bearings off the shaft (1800001).

1. Remove the remaining screws that retain the bearing housings 7. Release the screws and remove the liquid deflectors from
(2400001) to the lower half casing (1230001). the shaft (1800001).

2. Tap the inserts with a soft-faced hammer to break the seal 8. For pumps fitted with mechanical seals: Slide the
between the insert and the lower half casing (1230001). mechanical seal assemblies off the shaft (1800001), remove
the inserts and set aside for inspection.
3. Lift the rotating assembly clear of the lower half casing
(1230001) and support the shaft (1800001) on suitable V 9. For pumps fitted with soft packed glands: Remove the
blocks. glands from the shaft (1800001) and remove the inserts
complete with packing rings and lantern rings and set aside
4. If necessary, remove the casing wear ring dowels from the for inspection.
lower half casing (1230001).
10. If not already removed, remove the casing wear rings and
5. With feeler gauges, check the clearance between the casing set aside for inspection and measurement.
wear rings and the impeller (1590001). The Diametrical
clearances between Impeller (1590001) and casing rings For Clockwise pump construction:
(1900001) should be
11. Using a suitable 'C' spanner, unscrew and remove the
Minimum: 0.690 mm and maximum 0.939 mm (for special non-drive end sleeve and go to step 13.
material)
For Counter Clockwise pump construction:
Minimum: 0.440 mm and maximum 0.689 mm (for C.I/non
ferrous material) 12. Using a suitable 'C' spanner, unscrew and remove the drive
end sleeve.
Note: Increase in the wear ring clearance allows increased
internal leakage with resultant loss of pump performance, Note: Light tapping with a soft faced mallet may be needed to
head and efficiency. When the clearance is double the free the impeller (1590001) from the shaft (1800001), do not
original clearance, it is recommended that new wear rings are damage the impeller (1590001) if it is to be reused.
fitted. It is permissible to run the pump with increased
clearance due to wear but the loss of pump efficiency will
significantly increase the pump running costs.

Procedure to Dismantle the Rotating Assembly

1. Remove the screws and slide the bearing cover along the shaft
(1800001) towards the liquid deflector.

2. Remove the screws to free the bearing housing for removal.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

15
13. Using suitable pullers or levers, slide the impeller (1590001) of 10. Mount the shaft (1800001) between point centres or on
the shaft (1800001). rollers, and place the stem of a dial indicator in contact with
the shaft (1800001). Set the indicator dial at zero and turn
14. Scribe a line on the shaft (1800001) to mark the position of the the shaft (1800001) slowly by hand. Readings at any point
locked sleeve or nut for reassembly. A, B, C, D and E must not vary more than 0.05 mm
(0.002").
15. Withdraw the impeller key (3200001) and unscrew and remove
the remaining sleeve. A B C D E F

Cleaning and Inspection of Parts

11. For soft packed pumps: examine the shaft sleeves for wear,
1. Clean the bearings thoroughly with an approved cleaning fluid, replace the sleeve if it is scored or has any visible surface
kerosene or white spirit. damage.

2. Dry the bearings with dry compressed air or with a clean soft 12. If the shaft (1800001) runs true within tolerance, remount
cloth by hand and by spinning by hand. Confirm that the the shaft (1800001) as in step 10 but with the sleeve fitted
bearings rotate smoothly without slackness. in position, and check the sleeves run-out at the packing
contact positions. Indicator readings must not vary more
3. DO NOT OVERSPIN A CLEAN DRY BEARING.
than 0.07 mm (0.003").

4. Inspect the bearings for wear, fractures, cracks, corrosion or

13. The sleeve can be re-ground to provide a new packing
other damage to the running surfaces, which may necessitate
surface, to a maximum of 1.0 mm (0.04") below the initial
replacement.
diameter. Do not grind reduce sleeve diameter in the throat
bush area unless scored. The surface finish of the sleeve
5. Coat the bearings with rust preventive oil and wrap in
should be 20-30 C.L.A
greaseproof paper.
14. Scour any rust or scale from internal iron non-fitting
Note: It is recommended that all 'V' rings, 'O' rings and gaskets
surfaces and immediately repair or renew any previous
are replaced by new parts during an overhaul. If 'O' rings are
coating. Use WRC approved coating for pumps used for
to be reused they should be left in place in their grooves and
portable water.
protected from contamination by oil and dirt.
15. Clean all threads with kerosene followed by wire brushing,
6. Remove all O-rings from their grooves and discard where these
dry and wrap shaft (1800001) threads with protective
are to be replaced.
adhesive tape.

7. Remove all grease and other deposits from all other parts using
16. If the unit is not to be reassembled immediately, brush all
suitable cleaning fluid and a clean dry cloth.
bright iron and steel surfaces with Texaco Rust Proof
Compound L or Rust Proof Compound Spray or a suitable
8. Coat all unpainted carbon steel parts with a light smear of oil to
equivalent rust preventive fluid.
prevent rust.

17. Protect all parts (especially mechanical seal parts and faces)
9. Measure the inside diameter of the wear rings (1900001) and
against loss, weather or mechanical damage.
the outside diameter of the wear ring surfaces on the impeller
(1590001), calculate the clearance and compare these with
dimensions in Section 6.7.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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6.8 Before reassembly: 3 Place impeller key (3200001) into keyway and lock the
shaft sleeve.
1 Re-examine all old parts intended for refitting. Worn, damaged
or corroded parts should either be re-conditioned or, if beyond 4 Check the impeller (1590001) for correct direction of
this, be discarded and replaced by new. rotation and slide onto shaft (1800001).

2 Ensure that all parts to be refitted (especially new parts) are

free from burrs, with screw threads and abutting faces clean
and free from damage.

3 Examine 'O' and 'V' rings and renew if showing wear, damage
or deterioration.

Pump Reassembly

1 Lightly smear the shaft (1800001) with clean good quality

grease or light oil. 5. Screw opposite side shaft sleeve (Adjusting sleeve) onto
shaft (1800001) to retain the impeller (1590001) against the
For direction of rotation refer GA (General Arrangement) locked shaft sleeve.
drawing.
6. Slide the casing wear rings (1900001) onto the impeller
For clockwise rotation: (1590001).
IMPELLER KEY SHAFT SLEEVE (NDE)
(LOCKING SLEEVE) 7. Lightly grease and carefully fit new 'O' rings to the inserts.
(NDE) (DE)

8. Slide the inserts on to the shaft (1800001) with the guide

DIM. A
vane at top position.

For counter-clockwise rotation: 9. For soft packed pumps: Fit the packing, lantern rings and
SHAFT SLEEVE (NDE) IMPELLER KEY
glands as per instructions in section 6.2.
(LOCKING SLEEVE)
(NDE) (DE)
10. Fit the liquid deflectors on the shaft (1800001) and secure
with screws.
DIM. B

11. For mechanical seals: Slide mechanical seals into position

inside the inserts.
MODULE DIM. 'A' DIM. 'B'
1E 479 477
2E 579 577 12. Fit the mechanical seals to the shaft (1800001).
3E 654 652
150/48-2 574 572
200/58-2 699 697

Note: The position of the impeller key (3200001) and the shaft
sleeve (Locking Sleeve) is governed by the direction of rotation
of the pump. For clockwise pumps they are fitted at the drive
end of the shaft (1800001) slot and for counter-clockwise
pumps they are at the non-drive end.

Where the location was not marked, please refer to the pump
section drawing supplied or to KBL for dimensions A or B.

2 Screw the shaft sleeve onto the shaft (1800001) to the marked
position. Turn the sleeve to the nearest slot to align with the
keyway.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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13. Fit new v-rings, bearing covers and slide them on the shaft 26. Insert casing joint dowels and drive them home. Tighten the
(1800001), ready for assembly of the bearing housings joint nuts to the specified torques
(2400001).
Thread Size lb/ft Nm
M16 120 160
14. Heat the bearings to approximately 100 °C (212 °F) using M20 260 360
bearing hot-plate, induction heater or oven. NOTE: Do not M24 440 600
exceed 120 °C (248 °F).
27. Tighten the case screws in the following sequence:
15. Slide the heated bearings onto the shaft (1800001) to abut the
shoulder. Ensure that the bearings sit fully and squarely
against the shoulder.

16. Place the locking washer onto the shaft (1800001) and screw
on the bearing lock nut (3360001).

17. Fit and tighten the bearing locknut to 300 Nm and lift the tab
of the lock washer.

18. Cool the bearings to room temperature and pack both sides
with two/three ounces of recommended grease.

19. Coat the inside of the bearing housings (2400001) with grease
and slide into place over the bearings. If necessary use two
a) Tighten the four 'corner' screws marked 1, 2, 3 and 4.
screwed rods to pull the bearing housing towards the bearing
cover. b) Work outward along shaft (1800001) axis toward the
stuffing boxes in opposite quarters tightening screws in
20. Secure the bearing housings (2400001) to the insert
regions 5, 6, 7 and 8.
(9790001) with hex screws.
c) Work outward along the branch and in opposite quarters
21. Check and install the dowel pins in the lower half casing
tightening screws in regions 9, 10, 11 and 12.
(1230001) to locate the casing wear rings.
d) Repeat the whole sequence (a to d).
22. Place the rotating assembly into the pump casing lower half.
Correct any excessive 'O' ring twisting or buckling. Check 28. Check that the shaft (1800001) turns freely by hand.
that the impeller (1590001) is centralised in the casing and
that there are no rubs. 29. Top up the bearing lubrication by applying several strokes
with a grease gun.
23. Install casing gasket with a light coat of commercial cup
grease on both gasket surfaces. Carefully align the inner edge 30. The pump is now ready for re-coupling to the motor and
of the gasket with the insert 'O' rings. re-commissioning.

24. Lower the upper half casing into place and install casing joint
Procedure for Dismantling of rotating assembly of Two Stage
nuts. Pump

25. NOTE: When installing upper half casing, make sure that the
'O' rings are not cut or pinched and that the casing gasket is
hard against the 'O' rings.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

18
 Note: Two stage pumps are similar in construction to the single 3. Screw free impeller locking nut or sleeve onto shaft
stage pump and instructions relating to maintenance and (1800001) to retain the impellers against the locked
repair apply equally to both types. impeller nut or sleeve.

The difference relates to the disassembly of the two 4. Slide the casing wear rings onto the impeller.
impellers and the interstage plate. Proceed to disassemble
the rotating assembly as for single stage pumps to step 10 of 5. Check that the dowels that retain the interstage plate are
'Procedure to dismantle the rotating assembly'. correctly fitted.

For Clockwise pump construction: Continue with pump re-assembly from paragraph 7.

1. Using a suitable 'C' spanner, unscrew and remove the

non-drive end sleeve on a soft packed pump. For mechanical
seal pump first remove the seal & then follow the step 1.

For Counter Clockwise pump construction:

2. Using a suitable 'C' spanner, unscrew and remove the drive

end sleeve on a soft packed pump. For mechanical seal
pump first remove the seal & then follow the step 2.

Note: Light tapping with a soft faced mallet may be needed to

free the impeller from the shaft (1800001), do not damage
the impeller if it is to be reused.

3. Using suitable pullers or levers, slide the first impeller of the

shaft (1800001).

4. Withdraw the interstage ring (2040001) & bush (3130001)

from the impeller spacer (2010001) and check the condition
of the interstage bush (3130001) replace if worn.

5 Tap and pull the other impeller off the shaft (1800001) with
the impeller spacer (2010001).

6 Withdraw the impeller key and unscrew and remove the

locked shaft sleeve.

Procedure for Assembly of 'rotating unit' of Two

Stage Pump

Proceed with shaft assembly as for single stage pumps up to

step 3.

1. Select the first impeller for assembly, check the impeller for
correct direction of rotation and slide onto shaft (1800001)
to abut the locked shaft sleeve.

2. Fit new O rings to each side of the impeller spacer

(2010001), slide on to the shaft (1800001) and fit the
interstage bush (3130001) & ring with its O ring, ensuring
that it is the correct way round to fit in the pump casing.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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7. Faults and Remedial Action CAUSE REMEDIAL ACTION
Air leak in mechanical Check all joints, plugs and flushing lines, if fitted.
POTENTIAL FAULT OR DEFECT: seal. Note that prolonged running with air in the
No liquid delivered.
mechanical seal will result in damage and failure of
Insufficient liquid delivered.
Liquid delivered at low pressure. the seal.
Loss of liquid after starting. Air or gas in liquid. It may be possible to increase the pump
Excessive vibration.
Motor runs hotter than normal. performance to provide adequate pumping.
Excessive noise from pump cavitation. Discharge head too Check that valves are fully open and for pipe
PROBABLE CAUSES high (above rating). friction losses. An increase in pipe diameter may
Pump not primed. reduce the discharge pressure.
 Suction lift too high. Check for obstruction of pump inlet and for inlet
 Speed too low.
pipe friction losses. Measure the static lift, if above
  Speed too high.
rating, raise the liquid level or lower the pump.
   Air leak in suction pipework.
Air leak in mechanical seal. Not enough head Reduce the positive suction head by raising the
 
Air or gas in liquid. for hot liquid. liquid level.
 
  Discharge head too high (above rating). Inlet pipe not If the pump inlet cannot be lowered, provide a
 Suction lift too high. submerged enough. baffle to smother the inlet vortex and prevent air
 Not enough head for hot liquid. entering with the liquid.
   Inlet pipe not submerged enough. Liquid density Refer to KBL for guidance to increase the size or
  Viscosity of liquid greater than rating higher than rating. power of the motor or engine.
 Liquid density higher than rating. Insufficient net inlet Increase the positive suction head by lowering the
   Insufficient net inlet head. head. pump or raising the liquid level.
  Impeller plugged up or blocked. Impeller blocked. Dismantle pump and clean the impeller.
 Wrong direction of rotation.
Wrong direction of Check driver rotation with the direction arrow on
 Excessive wear ring clearance.
rotation. the pump casing.
  Damaged impeller.
Rotor binding.
Excessive wear ring Replace the wear rings when the clearance

Defects in motor. clearance. exceeds the maximum tolerances.

Damaged Replace if damaged or vanes are eroded.
 Voltage and/or frequency lower than rating.
 Foundation not rigid. impeller.
Misalignment of pump and driver. Rotor binding. Check for shaft run out, and replace if necessary.

 Rotor out of balance. Defects in Ensure that motor is adequately ventilated. Refer
 Shaft bent. motor. to manufacturers instructions.
 Impeller too small. Voltage and/or If voltage and frequency are lower than the motor
frequency lower than rating, arrange for provision of correct supply.
rating.
CAUSE REMEDIAL ACTION
Foundation not rigid. Ensure that the foundation bolts are tight; check that
Pump not Fill pump and suction pipe
foundations match KBL Recommendations.
primed. completely with fluid.
Speed too low. Misalignment of pump Check shaft run-out and replace if necessary.
Check that the motor is correctly connected and
and driver.
receiving the full supply voltage also confirm that
Rotor out of balance Check impeller for damage, replace as necessary.
the supply frequency is correct.
Speed too high. Check the motor voltage. Shaft bent. Check shaft run-out and replace if needed.
Air leak in suction Check each flange for suction draught, rectify as Impeller too small. Refer to KBL for options to fit a larger impeller.
pipework. necessary.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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8. Pump Details
8.1 Cross Section Drawing - Single Stage Pump - Clockwise Rotation:

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

21
8.2 Single Stage Pump Parts Identification List - (Numbers as shown on cross section drawing)

Note: Pump construction may vary slightly between the different pump sizes within each type, it is important to refer to the specific pump
section drawing and to quote the pump serial number when ordering parts to ensure that the correct part is supplied in the original
material of construction.

Item Description Qty 1800001 Pump Shaft 1

1220001 Casing Top Half 1 2360001 Deflector - Water 2
1230001 Casing Lower half 1 3360001 Bearing Lock Nut 1
5190001 Casing Gasket 1 4410001 Grease Nipple (Not Shown) 2
1590001 Impeller 1 3200001 Key - Impeller 1
1900001 Casing wear Ring 2 3210001 Key - Coupling 1
2270001 Lantern Ring 4 4500001 Air Vent Valve 1
3100001 Sleeve - Locked (Soft Packed) 1
3100101 Sleeve - Free (Soft Packed) 1
Parts for Pumps with Mechanical Seals:
5220201 O Ring - Shaft Sleeve 2
2230001 Mechanical Seal 2
2230001 Gland 2
3100001 Sleeve - Locked (M/C seal) 1
2700001 Bearing cover 2
3100101 Sleeve - Free (M/C seal) 1
4300001 Packing 10
9790101 Insert - Non Drive End 1
9790201 Insert- Drive End 1 Replacement parts should be obtained from KBL; use of parts from
5220101 O Ring Insert 2 unapproved suppliers will invalidate the pump warranty. When
2400101 Bearing Housing 2 ordering spare parts, please quote the pump serial number from the
2600101 Bearing Non-drive End 1 pump identification plate.
2600001 Bearing Drive End 2

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

22
8.3 Typical Pump Section Two Stage: Clockwise Rotation.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

23
8.4 Two Stage Pump Parts Identification List - (Numbers as shown on cross section drawing)

Note: Pump construction may vary slightly between the different pump sizes within each type, it is important to refer to the specific pump
section drawing and to quote the pump serial number when ordering parts to ensure that the correct part is supplied in the original
material of construction.

Item Description Qty

1220001 Casing Top Half 1
1230001 Casing Lower half 1
5190001 Casing Gasket 1
2010001 Impeller Spacer (Two Stage) 1
1570001 Impeller (Two Stage) 1
1580001 Impeller (Two Stage) 1
1900001 Casing wear Ring Parts for Pumps with Mechanical Seals:
2040001 Interstage ring 1 2230001 Mechanical Seal 2
3130001 Interstage Neck Bush 1 3100001 Sleeve - Locked (M/C seal) 1
1920001 Neck Ring 3100101 Sleeve - Free (M/C seal) 1
2270001 Lantern Ring 2/4
3100001 Sleeve - Locked 1
Replacement parts should be obtained from KBL; use of parts from
3100101 Sleeve - Free 1
5220201 O Ring - Shaft Sleeve 2 unapproved suppliers will invalidate the pump warranty. When
2230001 Gland 2 ordering spare parts please quote the pump serial number from the
4300001 Packing 5 pump identification plate.
9790101 Insert 1
9790201 Insert 1
5220101 O Ring Insert
2400101 Bearing Housing Non-drive End 1
2400101 Bearing Housing Drive End 1
2600101 Bearing Non-drive End 1
2600001 Bearing Drive End
1800001 Pump Shaft 1
3360001 Bearing Lock Nut 1
4410001 Grease Nipple
3200001 Key - Impeller 1
3210001 Key - Coupling 1
4500001 Air Vent Valve 1
St St Flexible pipe 2

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

24
9. Standard Metric Nut and Bolt Torque Recommendations
This information is for reference only. The user must check that the torque figures listed here are applicable to the fasteners used. Nuts and bolts should be
neither under nor over tightened.
Grade of Bolt Approximate Torque (Nm) for Bolt Diameters:
M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

4.6 2.7 4.5 11 22 38 95 185 320 633 1110

8.8 6.9 11.7 28 56 98 244 476 822 1634 2855
10.9 9.4 15.9 38 77 134 332 646 1120 2223 3885
12.9 11.2 19.1 46.4 92 160 397 775 1342 2666 4660

Note: These torque figures are approximate, and for un-plated fasteners only. No allowance has been made for special finishes or lubricants, washers or
mating surfaces.

Bolt and Nut Grade Combinations

Grade of BOLT 4.6 8.8 10.9 12.9 Note: It is permissible to fit higher grade nuts
Grade of NUT 4 8 12 12 than recommended.

Grade Identification

BOLTS & NUTS - Grade 4.6

BS4190 (ISO272, 885, 888 & 4759/1). Grade marking is optional. Normally there will be no
mark other than the 'M' thus:

BOLTS - Grade 8.8 NUTS - Grade 8

BS 3692 (ISO272, 4759/1). Grade marking is Indented marks as a clock face, dot at
mandatory, may also have trade marks 12.00, bar at 8.0, indicates grade 8 nut.

High Strength Friction Grip Bolts & Nuts

BOLT NUT
BOLT NUT Grade
12
Grade10.9

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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Installation & Maintenance Record
Date Summary of maintenance & repairs done - replacement parts fitted etc:

Initial Alignment TIR readings:

First Lateral Check: ...................................Angular Check: .............................. Confirmed Lateral Check:
Final Alignment TIR readings:
First Lateral Check: ...................................Angular Check: .............................. Confirmed Lateral Check:
Installed & Commissioned- Signed
Commissioning Engineer

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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 PUMP SPECIFICATION & OTHER DETAILS.

Pump type : SCT 200/58,300/34,250/42,250/51,250/68,300/59,350/39,

300/48,300/77,350/44,350/54,350/66,1 50/48-2,200/58-2
Qty :
Client :
Service :
Project :
KBL O/A No. :
Motor Rating :
Speed :
Make :
Frame :
Weight :
Pump Discharge :
Pump Head :
Pump Efficiency :
Pump Input :
Liquid Sp. Gravity :

*IMPORTANT: PUMP MUST BE OPERATED WITHIN THE WORKING RANGE AS SPECIFIED ON THE PERFORMANCE
CURVE.

This is a proprietary document of Kirloskar Brothers Limited, Kirloskarvadi-416308, Dist-Sangli (India)

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