Instructions on Installation,

Operation & Maintenance for

Kirloskar Pump Type – DB xe

KIRLOSKAR BROTHERS LIMITED

Established 1888
A Kirloskar Group Company
 Table of Contents

CONTENTS: Page No.

1. GENERAL 4
2. SAFETY INSTRUCTIONS 4
3. EQUIPMENT SCHEDULE 7
3.1 INSTALLATION 7
4. OPERATION 8
4.1 EQUIPMENT DESCRIPTION 8
4.2 EQUIPMENT OPERATION 8
5. MAINTENANCE 9
5.1 MAINTENANCE EHS INSTRUCTIONS 9
5.2 GENERAL MAINTENANCE DOCUMENTS 16
5.3 PREVENTIVE MAINTENANCE 16
5.4 CORRECTIVE MAINTENANCE 16
6. TECHNICAL DATA 17
7. SPARE PARTS LIST & CROSS-SECTIONAL DRAWINGS 22
8. CROSS SECTIONAL ASSEMBLY 23
9. OUTLINE DRAWING 25
10. CUT SECTION VIEW 26
11. MECHANICAL SEAL DETAILS 27
12. EXPLODED VIEW 28
1. GENERAL:

1.1 This booklet covers instructions for following models of pumps.

SHAFT UNIT – SHAFT UNIT – SHAFT UNIT – SHAFT UNIT –

25 25A 35 55
32/13 32/16 65/26 100/40
40/13 40/16 65/32 125/32
50/13 50/16 80/20 125/40
65/13 65/16 80/26 150/32
32/20 80/16 80/32 150/40
40/20 32/26 100/20
50/20 40/26 100/26
65/20 50/26 100/32

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125/26

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150/26

1.2 Kirloskar pumps are back -pull-out design which enables to remove the rotating unit of pump for

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inspection and repairs without disturbing the pipe connections and motor by using spacer type
coupling.
1.3 The complete range of pump is covered by four driving units thereby reducing inventory and

1.4
achieving interchangeability of parts. u
When the pump is received, sometime before the actual use of pump, it should be inspected and
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located in dry place. The coupling should be rotated once in a month to prevent pitting of bearing
surface.
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2. Safety Instructions:
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2.1 General Information

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Before performing any actions detailed within this instruction, the Site Health and Safety instructions
shall be read and fully understood. The instructions in this document shall also be read and fully
understood.
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Whenever the equipment is operated, maintained, or used in any way, the procedures detailed within
these instructions shall be followed. The pump supplied by Kirloskar Brothers Limited (KBL) has been
designed with safety in mind, where hazards cannot be eliminated; the risk has been minimized by use
of guards and other design features. Some hazards cannot be guarded against, and the instructions
below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover all circumstances.
It is the responsibility of the user of the equipment for maintaining safe working practices at all the
times. The pumps are supplied with stickers for hazard, caution, and safety wherever these are
applicable.
2.1.1 Within the manual, safety instructions are marked with safety symbols.

Hazard.

This symbol refers to general mechanical aspects of safety.

Hazard.

This symbol refers to electrical safety.

This symbol is used to introduce safety instructions whose non- observance may lead to
damage to the machine and its functions.

2.1.2 KBL products are designed for installation in designated areas, which are to be kept clean and free of

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obstructions that may restrict safe access to the controls and maintenance access points.
Pump nameplate is fitted to each unit and must not be removed. Loss of this plate could make

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identification impossible. This in turn could affect safety and cause difficulty in obtaining spare parts.
Should accidental loss or damage occur, contact KBL immediately.

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2.1.3 Access to the equipment should be restricted to the personnel responsible for installation, operation
and maintenance and they must be trained, adequately qualified and supplied with the appropriate
tools for their respective tasks.
2.1.4 KBL firmly insists that all personnel responsible for installation, operation and maintenance of the
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equipment must read the manual before any work is done.
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2.1.5 Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe
levels. Safety glasses or goggles should be worn where working with pressurized systems and
hazardous substances. Other personal protection equipment must be worn where local rules apply.
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2.2 DO NOT wear loose or frayed clothing or jewellery, which could catch on the controls or
become trapped in the equipment.
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2.3 Operation of the equipment for the application other than for which it is supplie d can increase the
risk from hazards. Please consult KBL before making such change in the application of the equipment.
2.4 Improper installation, operation and maintenance of the product supplied by KBL could result in
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injury or death.
2.5 Use safety equipment’s like hand gloves and safety shoes while operating DBxe pumps.
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2.6 Transport Handling and Storage Instructions:

2.6.1 Transport.
Pumps are dispatched in duly assembled condition. Lubricating oil in the bearing housing is drained prior to
dispatch of pump. Pumps are protected against corrosion and packed for transport by normal road, rail, and
sea carriers.

2.6.2 Handling

Crushing Hazard.
When lifting the pump or pump set, use lifting equipment having a safe working load rating suitable for the
weight specified. Use suitable slings for lifting any pump not provided with lifting points.
The use of suitable forklift truck and four chain crane sling equipment is recommended but locally approved
equipment rating may be used.

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Pump should be slung as shown.

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Pump set must be lifted from the lifting holes provided using suitable four chain lifting

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equipment.

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2.6.3 Storage.
2.6.3.1 Temporary Storage for up to six weeks.
If the pump unit is not to be used immediately it should be stored carefully in a horizontal position, in a
sheltered, dry location.

Additional rust preventive should be applied to all unpainted carbon steel or cast-iron parts
and should not be removed until final installation.
2.6.3.2 Long Term Storage.

Shearing Hazard.
DO NOT place fingers or hands, etc., into the suction or discharge pipe outlets and do NOT touch the impeller,
if rotated this may cause severe injury. To prevent ingress of any objects, retain the protection covers or
packaging in place until removal is necessary for installation. If the packaging or suction and discharge covers
are removed for inspection purposes, replace afterwards to protect the pump, and maintain the safety.
Fill the bearing housing with recommended oil to ensure that the shaft and bearings remain rust free.
2.6.3.3 Exposed or Extreme Conditions Storage.
For exposed storage or extreme variants in atmospheric or environmental conditions, please refer to KBL for
special storage instructions to suit the conditions acceptable.

2.7 Environmental safety

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Always keep the station clean to avoid and/or discover emissions.

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Waste and emissions regulations:
Observe these safety regulations regarding waste and emissions:

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Appropriately dispose of all waste.
Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
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Clean up all spills in accordance with safety and environmental procedures.
Report all environmental emissions to the appropriate authorities.
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Electrical installation
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For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
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Always follow local laws and regulations regarding recycling.

3. Equipment Schedule:
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3.1 Installation:
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3.1.1 For location, preparing foundation, installation, alignment, general maintenance, trouble shooting,
etc., the instructions given in our publication - ’GENERAL INSTRUCTIONS FOR INSTALLATION,
OPERATION AND MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along
this booklet must be followed very carefully. If the pump is drawing liquid from the vessel under
vacuum, then vacuum equalizing connection piping must be made as per instruction given in above
publication. The external sealing connection to the pump, if applicable, must be made after installing
and before commissioning the pump.

3.2 MOUNTING AND ALIGNMENT

A flexible coupling is used to connect pump shaft to the driver.

3.2.1 ALIGNMENT
ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL JOINT” .
Correct alignment is essential for the smooth operation of the pump. There are two types of
misalignment between the pump shaft and the drive shaft, which are:
1) Angular misalignment – Shaft with axis concentric, but not parallel.
 INCORRECT ANGULAR
STEEL STRAIGHT EDGE STEEL STRAIGHT EDGE MISALIGNMENT

CORRECT INCORRECT PARALLEL STEEL STRAIGHT EDGE

MISALIGNMENT

2) Parallel misalignment – Shaft with axis parallel, but not concentric.

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This misalignment is checked by using a straight edge as shown in figure given above.
Alternatively, it can be checked by any other suitable device like laser device.

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3.2.1.1 Before commissioning the pump set, please ensure:
A) The pipe connections are flushed and tightened properly.
B) Alignment is proper.

4. Operation:
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4.1 EQUIPMENT DESCRIPTION:
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All ‘DBxe’ type of pumps are constructed as standard water pumps in accordance EN733 with respect to main
dimensions and performance ratings. These are single stage, single suction, horizontal shaft, and volute type
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foot mounted pumps with the bearing bracket also having a support foot. These are centrifugal pumps with
enclosed type impeller and are fitted with standard accessories .
Either Gland packing or Mechanical seal is used to seal the leakage of pumped liquid across the shaft.
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4.2 EQUIPMENT OPERATION.

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4.2.1 Before starting the pump check the following:

1) The pump rotates freely by hand.

2) The sealing connections if any, is properly tightened and adjusted.
3) Fill in the oil for bearings in case of Oil lubricated bearings, if not done earlier.
4) The direction of rotation of driver. It should correspond to the direction of rotation of pump.
5) The pump casing and the suction pipeline is fully primed with the liquid.
6) Valve on delivery side is closed.
7) Stuffing box packing is properly tightened. If pump is kept for long time without use, then it calls
for replacement of gland packing, as gland packing may lose lubricity and become dry.
8) The cock for pressure gauge connection is closed.

4.2.2 Starting the pump

1) Start the pump. Let the prime mover pickup its full speed.
2) Open the valve on delivery line gradually.
3) Regulate the required flow by adjusting the delivery valve.
4) Open the wheel cock for pressure gauge connection.
4.2.3 During running the pump check the following things and regulate if needed -
1) The pump is running smooth.
2) The flow of sealing liquid (if external liquid is provided for sealing purpose) is uninterrupted.
3) Leakage through stuffing box is normal. There should be leakage of 60-80 drops per minute.
4) The bearings are not getting abnormally hot.
5) Head and capacity developed by the pump is as specified.
6) Power consumption is within limit.
7) Ensure that there is no mechanical friction in the pipe.

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8) Stop the pump immediately, if any, defects are detected. Do not start the pump unless the
defects are rectified. Report immediately to the supplier if it is not possible to rectify the defects.

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4.2.4 During stopping the pump
1) Close the valve on the delivery line.

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2) Stop the motor.
3) Close the cooling water and sealing liquid connections.
4) If the pump is not required to be operated for a long time, drain the casing completely. If the
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pump is required to be stored for a long time, the bearing housing should be dried internally with
hot air and should be flushed with moisture free protective such as light oil or kerosene.
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Failing to follow right shop practices during equipment operation will result into failure of product & in
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turn product warranty gets void.

5. MAINTENANCE:
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5.1 MAINTENANCE ENVIROMENT, HEALTH AND SAFETY (EHS) INSTRUCTIONS

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Following hazards may arise during maintenance work.

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Fluid Pressure Jet Hazards

Check and ensure that the pump operates at below the Maximum Working Pressure specified.

Hazardous Materials:

Wear a suitable mask or respirator when working with chemical material handling.

Hazardous Gases, Mists, Sprays and Leaks.

Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation from noxious
and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance
data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures.

Before attempting any maintenance on a pump, particularly if it has been handling any form of hazardous
liquid; ensure that the unit is safe to work on. The pump must be flushed thoroughly with suitable
cleanser to purge away any of the product left in the pump components. The plant operator should carry
this out and a certificate of cleanliness obtained before starting work. To avoid any risk to health it is also

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advisable to wear protective clothing as recommended by the site safety officer, especially when
removing old packing that may be contaminated.

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Electric Shock and Accidental Starting Hazard:

Isolate the equipment before any maintenance work is done. Switch off the mains supply, remove fuses,
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apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent re -
connection.
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In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapors, it is
recommended that maintenance work be carried out away from the pump location by removal of the
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rotating unit assembly to a suitable maintenance area.

5.2 GENERAL MAINTENANCE DOCUMENTS:

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1) Maintenance documents:
i) Pump Sectional assembly drawing with part list
ii) Pump Outline dimension drawing
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iii) Mechanical seal assembly drawing

iv) Foundation plan drawing
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2) Specific maintenance data:

5.2.1 Overhauling:
With normal daily operating spell, the pump will be due for overhaul after about 5000 working hours. This
work should be done by skilled personnel.
Procedure for dismantling and re-assembly
While dismantling and re-assembling, the cross-sectional assembly drawing and specification part list
should be referred.
5.2.1.1 Dismantling:
Follow the following simple steps to dismantle the pump.
5.2.1.1.1 Isolate power supply to motor.
5.2.1.1.2 Shut off valves controlling flow to and from the pump.
5.2.1.1.3 Remove the gland sealing connection and auxiliary piping, if any.
5.2.1.1.4 Remove the spacer of jaw type coupling in case of pumps fitted with spacer type coupling.
Remove the prime-mover in case of pumps fitted with standard type of jaw type coupling.
Remove the pump half of coupling from the pump shaft.
5.2.1.1.5 Drain the delivery casing by removing the drain plug (60100). Remove support foot (25100).
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5.2.1.1.6 Pumps covered under assembly ‘A’. (Refer exploded view on page 24).
Unscrew the nuts (58100) holding delivery casing (10500), stuffing box housing (22000) and
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bearing housing (24000). Take out the sub-assembly of bearing housing with stuffing box
and impeller, etc.
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5.2.1.1.7 Pumps covered under assembly ‘B’. (Refer exploded view on page 24).
5.2.1.1.8 Unscrew the nuts (58100) holding delivery casing (10500) and stuffing box housing. Take
out the sub-assembly of stuffing box housing, bearing housing, impeller, etc.
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5.2.1.1.9 Unscrew the impeller Hex Screw (66900) and remove gasket (68200).
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5.2.1.1.10 Remove the impeller (15100) from the pump shaft (18000).

5.2.1.1.11 Take ou t the impeller key (32000).

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5.2.1.1.12 In case of assembly ‘A’ just separate the stuffing box housing (22 000) from the bearing
housing.
5.2.1.1.13 In case of assembly ‘B’ separate the stuffing box housing (22000) from the bearing housing
by unscrewing the nuts (52802) holding them together.
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5.2.1.1.14 Unscrew the gland nuts (58201) and take out gland (22300).
5.2.1.1.15 Remove stuffing box packings (43000) along with lantern ring (22700) from the stuffing
box housing.
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5.2.1.1.16 Remove the shaft sleeve (31000) and remove gasket for shaft sleeve (51500).

5.2.1.1.17 Remove liquid deflector (23600). Remove the ‘V’ ring (93000) from shaft
5.2.1.1.18 Remove Stuffing Box guard (38800) by removing cap screw.

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5.2.1.1.19 Remove the Coupling key (32100) from pumps Shaft. Remove the ‘V’ ring (93000) from
shaft
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5.2.1.1.20 Remove the bolts (63100) holding bearing cover NDE and DE and remove bearing cover
(27000).
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5.2.1.1.21 Remove the DE side and NDE side Bearing cover gasket (51400).
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 5.2.1.1.22 Take out the shaft (180 00) from the bearing housing along with bearing (26000) by light
hammering from driving end.

5.2.1.1.23 Remove the bearings (26000) from shaft with the help of puller. Do not hammer the
bearings as hammering may spoil them.

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5.2.1.2 Reassembly
Before assembling, all the parts should be thoroughly cleaned in Kerosene, Petrol or Benzene to
remove the dirt, rust, etc. After cleaning, all the parts should be thoroughly checked for wear and
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replaced, if necessary. Replace all paper packings.

5.2.1.2.1 Mount the driving and non-driving end side bearings on the shaft. Use arbor press or
induction heater. Do not use hammer. Fill up the bearings with grease.
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5.2.1.2.2 Fit the NDE bearing cover and tighten the bolts to hold it on bearing housing.
5.2.1.2.3 Insert the shaft along with bearings in bearing housing from DE side.
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5.2.1.2.4 Fit the DE bearing cover and tighten the bolts to hold it on bearing housing.
5.2.1.2.5 Fit the ‘V’ ring on shaft adjacent with DE and NDE side bearing cover
5.2.1.2.6 Mount the liquid deflector on shaft on NDE side.
5.2.1.2.7 Fit the gasket for shaft sleeve on the shaft and fit the shaft sleeve.
5.2.1.2.8 Insert the gland over the shaft.
5.2.1.2.9 In case of pumps covered under assembly ‘A’ locate the stuffing box housing on bearing
housing.
5.2.1.2.10 In case of pumps covered under assembly ‘B’ locate the stuffing box housing on bearing
housing and tighten the nuts to hold them in position.
5.2.1.2.11 Insert the stuffing box packing rings along with lantern ring.
5.2.1.2.12 Tighten the gland nuts.
5.2.1.2.13 Fit the impeller key on shaft.
5.2.1.2.14 Fit the impeller on shaft.
5.2.1.2.15 Place the gasket between impeller and impeller Screw and tighten the impeller Screw.
5.2.1.2.16 Place the packing between delivery casing and stuffing box housing. In case of pumps
covered under assembly ‘A’ fit the sub-assembly of bearing housing, stuffing box housing
and impeller, etc., on the delivery casing and tighten the nuts holding delivery casing,
stuffing box housing and bearing housing.
 5.2.1.2.17 Place the packing between delivery casing and stuffing box housing. In case of pumps
covered under assembly ‘B’ fit the sub-assembly of bearing housing, stuffing box housing
and impeller, etc., on the delivery casing and tighten the nuts holding delivery casing and
stuffing box housing.
5.2.1.2.18 Fit the drain plug for delivery casing and other plugs, if any. Mount the foot support.
5.2.1.2.19 Fit the pump half of jaw type coupling on the pump shaft. For standard jaw type coupling,
fit the prime mover in position. For spacer type jaw type coupling fit the spacer in
position.
5.2.1.2.20 Fit the gland sealing and other auxiliary piping connections, if any.

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5.2.1.2.21 Fit the St. Box guard

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5.3 PREVENTVE MAINTENANCE:
Preventive maintenance schedule is the periodical checks and precautions by which possibilities of

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failures and breakdowns are minimized.

5.3.1 Daily checks:

5.3.1.1 Pressure gauge reading. u

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5.3.1.2 Bearing temperature.
5.3.1.3 Leakage through stuffing box.
5.3.1.4 Noise and vibration.
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5.3.1.5 Voltage and current.
5.3.1.6 Constant flow of external sealing liquid if provided.
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5.3.2 Periodical checks:

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5.3.2.1 Replenish the grease.

5.3.2.2 Change the stuffing box packing.
5.3.2.3 Check the alignment of the pump set.
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5.3.2.4 Calibrate the measuring instruments.

5.3.2.5 Check the sealing connections for leakage, etc.

In case failure to check above points and maintain proper records/precautions of checks by customer / user,
KBL warranty gets void.

5.4 CORRECTIVE MAINTENANCE

PUMP TROUBLE
When investigating trouble with Kirloskar pumps, always remember that pumps have been tested at
the factory and are mechanically correct when sent out. Discounting the possibility of damage during
transit, most of the trouble in the field is due to faulty installation. Investigation shows that most of
the troubles with centrifugal pumps result from faulty conditions on the suction side.

BREAK DOWN-CAUSE-CHECK POINTS

In case of break down we recommend the location of the fault by referring the table for ‘Break Down
Check Points’ given at the end of this manual.
 6. TECHNICAL DATA:

6.1 Models
‘DBxe ’ type of pumps are available in models as referr ed to in 1.1. Only three shaft units (driving units)
are used for complete range of ‘ ’ pumps. The models covered under individual shaft units are
given in interchangeability chart (Refer 6.2).
DBxe pumps are suitable for clean liquids having temperature –10 to +100° C.

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6.2 Interchangeability Chart

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INTERCHANGEABILITY CHART OF DBxe PUMP COMPONENTS
PART PUMP MODELS
QTY.PER UNIT

CODE DRIVING UNIT 25 DRIVING UNIT 25A DRIVING UNIT 35 DRIVING UNIT 55
NO.
PART DESCRIPTION

1 0 0 /2 0
1 0 0 /2 6
1 0 0 /3 2
1 2 5 /2 6
1 5 0 /2 6
1 0 0 /4 0
1 2 5 /3 2
1 2 5 /4 0
1 5 0 /3 2
1 5 0 /4 0
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3 2 /1 3
4 0 /1 3
5 0 /1 3
6 5 /1 3
3 2 /2 0
4 0 /2 0
5 0 /2 0
6 5 /2 0
3 2 /1 6
4 0 /1 6
5 0 /1 6
6 5 /1 6
8 0 /1 6
3 2 /2 6
4 0 /2 6
5 0 /2 6
6 5 /2 6
6 5 /3 2
8 0 /2 0
8 0 /2 6
8 0 /3 2
10500 PUMP CASING 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
15100 IMPELLER 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
18000 PUM P SHA FT 1 1 2 3
19000
19100
22000
WEARING RING (SUC.SIDE)
WEARING RING (DEL. SIDE)
CASING COVER
1
1
1
1
3
1
3
3
1
5
7
2
7
7
2
2 4 4 8
19 19 19 22
3 3 3 4
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3
5
3 6 8 10 2 4 6 9 10 11 12 13 14
3 21 21 25 20 20 8 23 24 26 23 24 25
5 6 6 6 7 7 7 8 9 10 8 9 10
14 14 15 16 14 15 15
26 25 26 27 28 29 28
11 9 11 12 13 14 13
17 16
29 30
14 13
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22300 GLAND 1 1 2 3
22700 LANTERN RING 1 1 2 3
23600 DEFLECTOR 1 1 2 3
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24000 BEARING HOUSING 1 1 2 3 4
25100 SUPPORT FOOT 1 1 1 1 2 2 2 2 3 1 1 2 4 3 3 3 3 3 5 2 3 6 3 5 6 6 7 8 8 9 8 9
26000 BEARING 2 1 2 3
27000 BEARING COVER (DE & NDE) 2 1 2 3
31000 SHA FT SLEEVE 1 1 2 3
32000 KEY FOR IMPELLER 1 1 2 3
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32100 KEY FOR COUPLING 1 1 2 3

33800 IMPELLER SCREW 1 1 2 3
43000 GLAND PACKING 4 1 2 3
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6.3 Direction of rotation

The direction of rotation is clockwise when viewed from driving end. Reverse rotation is not
possible.
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6.4 Rotation speed

All the models are suitable for speed of 1450 rpm.
Besides, following models are also suitable for nominal speed of 2900 rpm.
32/13, 40/13, 50/13, 65/13, 32/16, 40/16, 50/16, 65/16, 80/16, 32/20, 40/20, 50/20, 65/20, 80/20,
100/20, 32/26, 40/26, 50/26, 65/26, 80/26, 100/26.

Please contact the supplier or manufacturer, if the pump is to be used for other speeds than
specified above.
6.5 Bearings
The shaft is facilitated with antifriction sealed ball bearings at driving end and non- driving end. The
bearing specifications are given below. The designations of bearings are as per bearing
manufacturers catalogue. However, equivalent bearings in type, capacity and dimensions are also
used.
Sr. Shaft Unit Bearing nos. SKF or Equiv.
 No DE NDE
1 25 6305 2RS2 6305 2RS2
2 25A 6305 2RS2 6305 2RS2
3 35 6307 2RS2 6307 2RS2
4 55 6311 2RS2 6311 2RS2

6.6 Lubrication

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6.6.1 Bearings are factory sealed for life hence no periodical lubrication required.

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6.6.2 Pumps are also supplied with oil lubricated bearings against specific orders.

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6.6.3 Recommended oil grade for 10-50 C ambient temperature is ISO VG 46.

6.8 Stuffing box with gland packing arrangement.

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6.8.1 Stuffing box sealing arrangement –

Self liquid sealing is standard supply. External liquid sealing arrangement can be provided on
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request.

6.8.2 Stuffing box packing specification – Non-Asbestos Graphited cotton greasy packing is used in
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the pump as a standard supply. However, stuffing box packing suitable for liquid handled is
supplied against specific requirements.
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6.8.3 Stuffing box packing and Lantern ring – Please refer to the following chart for stuffing box
packing size and position of lantern ring.
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Shaft Size of packing Length of Packing arrangement and

Unit in mm (SQ) packing in mm Position of lantern
(L) from impeller side
25 &25A 8 510 1 + L + 3
35 10 650 1 + L + 3
45 10 840 1 + L + 3

6.9 Stuffing Box with Mechanical Seal arrangement.

The mechanical seal is optional feature and supply will be of DIN 24960, unbalanced type bare mechanical
seal only. The mechanical seal sizes are as below.

Unit Size Mech. Seal Size

Unit 25 & 25A 32 mm
Unit 35 38 mm
Unit 55 55 mm

6.9.1 Mechanical Seal chamber dimensions

These dimensions conform to requirements of DIN 24960 standard.
A) For Seal sizes 32, 38 & 55 mm

Sr. Pump Mechanical Seal Chamber Dimensions

No. Size Size D1 D2 D3 D4 D5 a b c f L
01 32/13
02 40/13
03 50/13
04 65/13

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05 32/20

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06 40/20
07 50/20
08 65/20

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32 48 42 55 38.5 2 5 43 4 42.5
09 32/16
10 40/16
11 50/16
12
13
65/16
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14 32/26
15 40/26
16 50/26
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17 65/26
18 65/32
19 80/20
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20 80/26
21 80/32
38 56 49 63 48 2 6 51 4 45
22 100/20
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23 100/26
24 100/32
25 125/26
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26 150/26
27 100/40
28 125/32
29 125/40 55 75 62 81 65 2.5 6 60 4 47.5
30 150/32
31 150/40
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6.9.2 Disassembly of pumps fitted with a Mechanical Seal:

Remove the impeller key and carefully withdraw the shaft sleeve complete with the rotating element of the
mechanical seal.
Note: If after examination of the rotating element, it is found ne cessary to remove the rubber bellows from
the shaft sleeve, the complete mechanical seal assembly will have to be replaced.

Removal of the mechanical seal depends on the pump construction:

For pumps with shaft sizes 25,25A 35 and 55 with a bolted casing cover construction only.

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a) Remove stud nuts from the bearing housing first, before proceeding with instruction

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For pumps with shaft size 25,25A or 35 and with clamped casing cover construction, commence with

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instruction b).

b) Using screw drivers or similar tools as levers in the recesses provided carefully rise apart and remove the
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casing cover complete with the stationary element of the mechanical seal, from the bearing housing. Care
must be taken to ensure that the stationary element of the seal and the shaft are not damaged when
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extracting the shaft.

c) The stationary element of the seal may be removed from the casing cover by pressing out by hand from the
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drive end. If the stationary element is damaged or shows signs of wear, it must be replaced. Pull off thrower
from shaft. Unscrew the hexagon screws and remove both bearing covers from the bearing housing. Using a
soft faced hammer or suitable drift, carefully drive the pump shaft out with its bearings in the direction of the
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drive end, i.e. away from the pump end, ensuring that the impeller nut thread is not damaged. Care must be
taken to ensure that the pump end bearing passes centrally through the bore of the drive end bearing
housing.
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6.9.3 Installation of Mechanical Seals

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Lubricate the outer surface of the stationary element of the mechanical seal (23000) with soapy water or
silicone grease (not oil), ensure that it is square to its housing in the casing cover (22000) and push home by
hand, taking care not to apply excessive force or to damage the sealing surface. Check that it has been seated
fully and that the sealing surface is clean and undamaged.
Refit the casing cover to the bearing housing; fit the bolts for the bolted casing cover, tightening them
uniformly and in diagonally opposed pairs sequence.
Position the rotating seal face over the shaft to butt against the static seal element, taking care not to
damage the sealing surfaces. Insert the gasket into the sleeve and ensure that it is properly seated.
Lubricate the inner and outer surfaces of the sleeve lightly with silicone grease, fit the spring assembly in
position and mount the sleeve over the shaft, compress the spring and insert the impeller key to retain the
sleeve in position. Ensure that the rotating seal face is floating against the spring before re-fitting the
impeller.
7. SPARE PARTS LIST & CROSS-SECTIONAL DRAWINGS
Part List for pumps
Part no. Description Quantity per Pump
10500 Pump Casing 1
15100* Impeller 1
18000 Pump Shaft 1
19000* Casing Wear ring, Suc. Side 1
19100 Casing Wear ring, Del. Side 1
22000 Casing Cover 1

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22300 Gland 1
22700* Lantern Ring 1

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23600* Liquid Deflector 1
24000 Bearing Housing 1
25100 Support Foot 1

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26000* Radial Ball Bearing SKF or eq. 2
27000 Bearing Cover 2
30300 Lifting Eye Bolt 1
31000* Shaft Sleeve 1
32000*
32100
Key for Impeller
Key for Coupling
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38000 St. Box Guard 2
41100 Lock Washer for Support Foot 1
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43000* Gland Packing 4
44500* Oil level Sight Glass (for oil lub. Pump) 1
44400 Oil Filter Plug (For Oil lub. Pump) 1
50000* Oil Seal (For Oil lub. Pump) 2
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51100* Gasket for Casing Cover 1

51400* Gasket for Bearing Cover 2
51500* Gasket for Shaft Sleeve 1
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63100 Hex Screw for Bearing Cover 6

63200 Hex Screw for Support Foot 1
58100 Hex Nut for Pump Casing Stud 8 or 12 (Based on pump size)
58201 Hex Nut for Gland Stud 2
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58202 Hex Nut for Casing Cover Stud to Bearing housing 6 or 8 (Based on pump size)
59000 Stud for Pump Casing and Casing Cover 8 or 12 (Based on pump size)
59101 Stud for Casing Cover and Gland 2
59102 Studs for Casing Cover to Bearing housing 6 or 8 (Based on pump size)
45700 Vent plug 1
60000 Gauge plug 2
60100 Drain plug for casing 1
60200 Sealing plug 1 or 2 (Based on pump size)
60500 Drain plug for bearing housing 1
51701 Gasket for collared plug 1
51702 Gasket for collared plug 1
51704 Gasket for st. Box sealing plug 1 or 2 (Based on pump size)
51703 Gasket for bearing housing drain plug 1
66900* Impeller Hex Screw 1
93000 “V” ring 2

‘*’ indicates recommended spares

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PART
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NO. PART DESCRIPTION

10500 Pump casing

15100* Impeller
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18000* Pump shaft

19000* Wearing ring (Suction side)
19100* Wearing ring (Delivery Side)
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22000 Casing cover

22300 Gland
22700* Lantern ring
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23600* Deflector
24000 Bearing housing
25100 Support foot
26000* Bearing
27000 Bearing cover (DE & NDE)
31000* Shaft sleeve for Gland packing
32000* Key for impeller
32100* Key for coupling
33800* Impeller screw
43000* Gland packing
51100* Gasket for casing cover
51400* Gasket for bearing cover
51500* Gasket for shaft sleeve

'*' indicates recommended spares

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PART
NO. PART DESCRIPTION
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10500 Pump casing

15100* Impeller
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18000* Pump shaft

19000* Wearing ring ((Suction side))
19100* Wearing ring (Delivery side)
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22000 Casing cover

22300 Gland
22700* Lantern ring
23600* Deflector
24000 Bearing housing
25100 Support foot
26000* Bearing
27000 Bearing cover (DE & NDE)
31000* Shaft sleeve for Gland packing
32000* Key for impeller
32100* Key for coupling
33800* Impeller screw
43000* Gland packing
51100* Gasket for casing cover
51400* Gasket for bearing cover
51500* Gasket for shaft sleeve

‘*’ indicates recommended spares

 9. OUTLINE DRAWING

UNIT PUMP DIMENSIONS FOOT DIMENSIONS SHAFT END d1

SIZE
NO. DEL. SUC. a f h1 h2 b c ml m2 n1 n2 Øs1 el Øs2 w Ød I y x
32/13 25 112 140 14 190 140 27 8
100
32/16 25A 80 132 160 50 14 100 70 27 8
32 50 240 190
32/20 25 160 180 14 27 8
360 110
32/26 25A 100 180 225 65 14 125 95 320 250 27 8
40/13 25 112 140 14 210 160 27 8
80 100
40/16 25A 132 160 50 14 100 70 240 190 27 8
40 65
40/20 25 160 180 14 265 212 27 8
100
40/26 25A 180 225 65 14 125 95 320 250 M12 260 24 50 27 8 100
50/13 25 132 160 14 240 190 27 8
50/16 25A 180 50 14 100 70 27 8
50 65 100 160 265 212
50/20 25 360 200 14 27 8
50/26 25A 180 225 14 320 250 27 8
65/13 25 180 14 27 8
160 65 125 95 280 212
65/16 25A 200 14 27 8
100
65/20 25 65 80 180 225 14 320 250 27 8
M12
65/26 200 250 16 360 280 25 10
35 470 80 160 120 M16 340 32 80 140
65/32 225 280 16 400 315 35 10
80/16 25A 360 225 14 320 250 260 24 50 27 8 100
180 65 125 95 M12 110
80/20 250 14 345 280 35 10
80 100 125
80/26 200 280 16 35 10
400 315
80/32 250 315 16 35 10
35 470 340 32 80
100/20 200 80 16 160 120 360 280 M16 35 10
280
100/26 225 16 35 10
100 125 400 315
100/32 250 315 16 35 10
140
100/40 55 530 280 100 18 200 150 500 400 M20 370 42 110 45 12
140
125/26 35 470 250 355 80 16 160 120 400 315 M16 342 32 80 35 10
125/32 125 150 280 18 45 12
500 400
125/40 315 18 45 12
55 530 400 100 200 150 M20 370 42 110
150/32 280 18 45 12
150 200 160 550 450
150/40 315 450 18 45 12
10. CUT SECTION VIEW

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11. For Pump section for shaft units 25,35 and 55 with Mechanical Seal Details.

1 ) With clamped casing cover.

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2) With bolted casing cover.

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12. EXPLODED VIEW

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GENERAL INSTRUCTIONS FOR INSTALLATION , OPERATION & MAINTENANCE
OF KIRLOSKAR CENTRIFUGAL PUMPS

INCORRECT CORRECT

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GENERAL INSTRUCTIONS
FOR INSTALLATION , OPERATION
& MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS
WARNING
The equipment supplied is designed for specific capacity, speed, pressure and temperature. Do not use the
equipment beyond the capacities for which it is manufactured. The equipment manufactured is also shop
tested for satisfactory performance and if it is operated in excess of the conditions for which it is
manufactured, the equipment is subjected to excessive stresses and strains.
LOCATION
The pump should be located as near the liquid source as possible. This will minimize suction lift and pump will
give better performance.

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Ample space should be provided on all the sides so that the pump can be inspected while in operation and
can be serviced whenever required.

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FOUNDATION
The foundation should be sufficiently substantial to sustain any vibrations and to form a permanent rigid

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support for the base plate. This is important in maintaining the alignment of a directly connected unit. A
concrete foundation on a solid base is advisable. Foundation bolts of the proper size should be embedded in
the concrete located by a drawing or template. A pipe sleeve of two and one half diameter larger than the
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bolt should be used to allow movement for the final position of the foundation bolts. Earthing is required to
be provided to the base plate.
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ALIGNMENT
Pumps and the drivers supplied by the manufacturers, mounted on a common base plate are accurately
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aligned before dispatch. However, as the alignments are likely to be disturbed during transit to some extent
and hence must not be relied upon to maintain the factory alignment. Re-alignment is necessary after the
complete unit has been leveled on the foundation and again after the grout has been set and foundation
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bolts have been tightened. The alignment must be checked after the unit is piped up and re-checked
periodically.
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FLEXIBLE COUPLING
A flexible coupling will not compensate for the misalignment of the pump and driver shafts. The purpose of
the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts
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without interference with each other while transmitting power from the driver to the pump. There are two
types of misalignments.
1) Angular misalignment – Shaft with axis concentric, but not parallel.
2) Parallel misalignment – Shaft with axis parallel, but not concentric.

LEVELING THE UNIT

When the unit is received with the pump and driver mounted on the base plate, it should be placed on the
foundation and the coupling halves disconnected. The coupling should not be reconnected until all
misalignment operations have been completed. The base plate must be supported evenly on wedge s inserted
under the four corners so that it will not be distorted or sprung by the uneven distribution of the weight.
Adjust the wedges until the shafts of the pump and the driver are in level. Check the coupling faces, suction
and discharge flanges for the horizontal and vertical position by means of spirit level.
FLEXIBLE COUPLING ALIGNMENT
The two halves of the coupling should be at least 3 mm apart so that they cannot touch each other when the
driver shaft is rotated. Necessary tools for approximately checking are straight edge or an outside caliper. A
check for parallel misalignment is made by placing a straight edge across both coupling periphery at the top,
bottom and both the sides. The unit will be in parallel alignment when the straight edge rest s evenly on the
coupling periphery at all the positions. Care must be taken that the straight edge must be parallel to the axis
of the shaft. May be other alternative method like laser can be used.

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GROUTING

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When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly. The unit
can then be grouted by working soft concrete under the edges. Foundation bolts should not be fully tightened

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until the grout is hardened, usually 48 hours after pouring.

FACTORS THAT MAY DISTURB ALIGNMENT

The unit should be periodically checked for alignment. If the unit does not stay in line after being properly
installed, the following are possible causes: u
1. Setting, seasoning of the foundation.
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2. Pipe strains distorting or shifting the machines.
3. Wear of the bearing.
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PIPING
Both suction and delivery pipes and accessories should be independently supported near the pump, so that
when the flanges, bolts are tightened no strains will be transmitted to the pump casing. It is usually advisable
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to increase the size of both the suction and delivery pipe at the pump nozzles in order to decrease the loss of
head due to friction and for the same reason piping should be arranged with minimum possible bends as
possible, or it should be made with long radius wherever possible. The pipe lines should be free from scales,
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welding residuals, etc., and have to be mounted in such a way that they can be connected to suction and
delivery flanges without any stress on the pump. It can be achieved by supporting the pipelines at appropriate
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locations.
SUCTION PIPE
The suction pipe should be as short as possible. This can be achieved by placing the pump near the liquid to
be pumped. The suction pipe must be kept free from air leakages. This is particularly important when the
suction lift is high. A horizontal suction line must have a gradual rise to the pump. Any high point in the pipe
will be filled with air and thus prevent proper operation of the pocket in the top of the reducer and the pipe.
Use an eccentric piece instead.
The end of the suction pipe must be well submerged to avoid whirlpools and ingress of air but must be kept
clear of any deposits of mud, silt, grit, etc. The pipe must be away from any side of the wall by 450 mm. the
end of the strainer must be provided with a strainer of sufficient open area.
DELIVERY PIPE
A check (non-return) valve and a gate or sluice valve (regulating valve) should be installed in the discharge
line. The check valve placed between the pump and the gate valve is to protect the pump from excessive
pressure and to prevent water running back through the pump in case of failure of the driving machine.
Discharge piping should be provided with a sluice valve adjacent to the delivery flange to control the
discharge if required.
VACUUM EQUALIZING LINE (AND LIQUID LINE)
If the pump draws from a system under vacuum an equalizing pipe must be carried from the highest point of
the suction line, however as close to the suction flange of the pump as possible, to the top of the feed tank to
keep gas bubbles that might have been entrapped in the flow from entering the pump. The line should be
fitted with an isolating valve which should be closed only for maintenance work on the pumpset.
Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air in the case of the pumps
with packed stuffing box. It is convenient to tap the sealing liquid from the delivery line above the non -return
valve.
FOOT-VALVE
It is advisable to install a foot-valve to facilitate priming. The foot-valve should have sufficient clear passage

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for water. Care must be taken to prevent foreign matter from being drawn in to the pump or choking the

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foot-valve and for this purpose an efficient strainer should be provided.

STUFFING BOXES AND PACKING (only for gland packed pump)

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Stuffing boxes should be carefully cleaned and packing placed in them. Be sure that sufficient packing is
placed at the back of the water seal cage. If the water to be pumped is dirty or gritty, sealing water should be
piped to the stuffing boxes from clean outside source of supply in order to prevent damage to the packing
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and shaft. In placing the packing, each packing ring should be cut to the proper length so that ends come
together but do not overlap. The succeeding rings of packing should not be pressed too tight, as it may result
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in burning the packing and cutting the shaft. If the stuffing box is not properly packed, friction in stuffing box
prevents turning the rotor by hand. On starting the pump, it is well to have the packing slightly loose without
causing an air leak, and if it seems to leak, instead of putting too much pressure on the gland, put some heavy
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oil in the stuffing box until the pump works properly and then gradually tighten up the gland. The packing
should be occasionally changed.
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BALL BEARINGS
Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as a guide to
re-lubrication periods under normal condition.
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Three monthly when on continuous duty.

Six monthly when on eight hour per day duty.
The bearings and housings should be completely cleaned and recharged with fresh grease after 2500 hours or
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the earliest pump overhaul time.

PRIMING
No pumping action occurs unless the pump casing is filled with the liquid. Pump casing and suction pipe must
therefore be completely filled with liquid and thus all air removed before the pump is started. Several
different priming methods can be used depending on the kind of installation and service involved.
1) Liquid level above pump level.
Pump is set below liquid level of source of supply, so that liquid always flows to pump under positive
head.
2) Priming with foot-valve.
a. When pump is installed on suction lift with foot valve at the end of suction line, fill pump with
water from some outside source till all air is expelled and water flows through the air vent.
b. When there is liquid under some pressure in the discharge pipe, priming can be effected by
bypassing the pressured liquid around the check and gate valve. Of course, the initial priming
must be effected from some outside source.
Note: In this case, the foot-valve must be capable of withstanding pump pressure and possible surge.
 3) Priming by ejector.
An ejector operated by steam, compressed air or water under pressure and connected to air vent a t
the top of casing can be used to remove air from pump and prime the pump on suction lift
installations.
4) Priming by dry vacuum pump.
A hand or power pump sucks in all the air from the casing and the suction pipe, and thus primes the
system.

STARTING

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The pump must not be started without being primed. Be sure that the driver rotates in the proper direction
as indicated by a direction arrow on the pump casing.

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RUNNING

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On account of its simple construction, the centrifugal pump requires practically no atte ntion while running.
Lubrication at the bearings and manipulation of the glands are the only things that need attention from the
operator.

STOPPING u
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Before stopping the pump; close the gate valve. This will prevent water hammer on the check valve.

STUFFING BOXES (only for gland packed pump)

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Do not tighten the glands excessively. A slight dripping of water from the stuffing boxes when pump is
running keeps packing in good condition.
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CASING RINGS
Casing rings are fitted in the casing to reduce the quantity of water leaking back from the high-pressure side
to the suction side. These casing rings are fitted to maintain a small clearance and depend on the water in the
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pump for lubrication. When the rings are worn out, the clearance becomes greater, and more water passes
back into the suction side. The rings must be replaced from time to time to restore the pump efficiency to its
normal value.
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SPARE PARTS
A set of ball bearings, a set of casing rings and a set of gland packing rings / mechanical seal must alway s be
kept at hand to ensure uninterrupted service from the pump. While ordering for spare parts, always give
type, size and serial number of the pump as stamped on the nameplate.

PUMP TROUBLE
When investigating trouble with Kirloskar pumps, always remember that pumps have been tested at the
factory and are mechanically correct when sent out. Discounting the possibility of damage during transit,
most of the trouble in the field is due to faulty installation. Investigation shows that the majority of troubles
with centrifugal pumps result from faulty conditions on the suction side.

BREAK DOWN-CAUSE-CHECK POINTS

In case of breakdown, we recommend the location of the fault by using the following table.
BREAKDOWN CHECK POINTS

Pump does not deliver 1 7 8 9 10 11 12 14 15 17 18 19 23 25 26 56 57 58

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 56
Pump delivers at reduced capacity
57 58
Delivery performance deteriorates 1 3 7 9 10 11 12 13 14 19 20 21 22 23 24 53 57 62
Pump delivers too much 16 56 57 58
1 3 6 7 8 9 10 11 12 13 14 15 16 19 22 23 25 26 56 57
Delivery is interrupted
58 62
After stopping pump runs in reverse

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direction

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Very noisy 1 2 5 6 7 8 11 12 13 15 19 20 22 54 55 56 57 62

19 20 22 31 32 33 35 36 37 38 39 40 43 44 47 48

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Unsteady running of pump
49 50 51 54 55 58
Stuffing box leaks excessively 24 27 28 29 30 31 47 48 49 53

Fumes from stuffing box u

22 23 24 25 26 27 28 29 30 41 42 43
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Pump rotor locked in standstill
22 45 46 50
position
23 24 25 26 27 28 29 30 40 41 42 45 47 48 49 50
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Pump is heating up and seizing
54
19 20 21 22 31 32 33 34 35 36 37 38 39 40 41 42
Bearing temperature increases
43 44 45 46 47 48 49 51 54 55 58
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Motor will not start 14 22 60

Motor gets hot or burns out 14 22 27 28 40 43 50 55 56 57 58 59 60 61
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Motor is difficult to start 14 22 27 28 45 46 50 58 59 60

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CHECK POINTS
1. Suction pipe, foot valve choked.
2. Nominal diameter of suction line too small.
3. Suction pipe not sufficiently submerged.
4. Too many bends in the suction line.
5. Clearance around suction inlet not sufficient.
6. Shut off valve in the suction line in unfavorable position.
7. Incorrect layout of suction line (formation of air pockets).
8. Valve in the suction line not fully open.
9. Joints in the suction line not leak-proof.
10. Air leaking through the suction line and stuffing box, etc.
11. Suction lift too high.
12. Suction head too low (difference between pressure at suction connection and vapor pressure too
low).
13. Delivery liquid contains too much gas and/or air.
14. Delivery liquid too viscous.
15. Insufficient venting.
16. Number of revolutions too high.
17. Number of revolutions too low.
18. Incorrect direction of rotation (electric motor incorrectly connected, leads of phases on the
terminal block interchanged).
19. Impeller clogged.
20. Impeller damaged.
21. Casing rings worn out.

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22. Separation of crystals from the flow of pumping liquid (falling below the temperature

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limit/equilibrium temp).
23. Sealing liquid line obstructed.
24. Sealing liquid contaminated.

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25. Lantern ring in the stuffing box is not positioned below the sealing liquid Inlet.
26. Sealing liquid omitted.
27. Packing incorrectly fitted.
28.
29.
Gland tightened too much/slanted. u
Packing not suitable for operating conditions.
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30. Shaft sleeve worn out in the region of the packing.
31. Bearing worn out.
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32. Specified oil level not maintained.
33. Insufficient lubrication of bearings.
34. Ball bearings over-lubricated.
35. Oil/Grease quality unsuitable.
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36. Ball bearing incorrectly fitted.

37. Axial stress on ball bearings (no axial clearance for rotor).
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38. Bearings dirty.

39. Bearings rusty (corroded).
40. Axial thrust too great because of worn out casing rings, relief holes obstructed.
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41. Insufficient cooling water supply to stuffing box cooling.

42. Sediment in the cooling water chamber of the stuffing box cooling.
43. Alignment of coupling faulty or coupling loose.
44. Elastic element of coupling worn out.
45. Pump casing under stress.
46. Pipeline under stress.
47. Shaft runs untrue.
48. Shaft bent.
49. Rotor parts insufficiently balanced.
50. Rotor parts touching the casing.
51. Vibration of pipe work.
52. Non-return valve gets caught.
53. Contaminated delivery liquid.
54. Obstruction in delivery line.
55. Delivery flow too great.
56. Pump unsuitable for parallel operation.
57. Type of pump unsuitable.
58. Incorrect choice of pump for existing operating conditions.
59. Voltage too low/power supply overloaded.
60. Short circuit in the motor.
61. Setting of starter of motor too high.
62. Temperature of delivery liquid too high.

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CUSTOMERS ARE ADVISED TO DISPOSE OF ALL UNUSABLE WASTE LIKE GASKETS, GLAND

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PACKING, OIL, BATTERIES, PACKING MATERIAL ETC THROUGH APPROPRIATE DISPOSAL
AGENCIES AND IN ACCORDANCE WITH LOCAL REGULATION TO AVOID HARMFUL IMPACT (IF

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ANY) ON ENVIRONMENT.

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 KIRLOSKAR BROTHERS LIMITED
Established 1888
A Kirloskar Group Company

Registered Office & Global Headquarters

"Yamuna", S. No. 98 (3-7), Plot No. 3, Baner, Pune - 411045, Maharashtra, India.

Phone: +91 (20) 67214444 l Fax No. 020 67211060

Email: marketing@kbl.co.in l Website : www.kirloskarpumps.com
CIN No. L29113PN1920PLC000670.