A. - Pump OIM - 3

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CONTENTS
DESCRIPTION PAGE REFERENCE
Chapter : General OIMPG General 1

1. General Information OIMPG General 2
2. Disposal OIMPG General 3
3. Conformity with EU Regulations (if applicable) OIMPG General 3
Chapter : Safety
Marking of Instructions in the Instruction Manual OIMPG Safety 1
Personnel Qualification and Training OIMPG Safety 1
Non-compliance with Safety Instructions OIMPG Safety 1
Safety Awareness OIMPG Safety 1
Safety Instructions for the Operator/User OIMPG Safety 1
Safety Instructions for Work on the Pump Set OIMPG Safety 2
Unauthorized Modification and Manufacture of Spare Parts OIMPG Safety 2
Unauthorized Modes of Operation OIMPG Safety 2
Chapter : Transport / Interim Storage

1. General Information OIMPG TRANSPORT 1
1.1 Hoisting Tackle (e.g. ropes, gear) OIMPG TRANSPORT 1
1.2 Signals during Transport OIMPG TRANSPORT 1
1.3 Transport Symbols OIMPG TRANSPORT 2
2. Transport of the Packaged Components of the Pump Set OIMPG TRANSPORT 2
3. Transport of the Partly-packaged or Unpackaged Components OIMPG TRANSPORT 2
of the Pump Set
3.1 Transport of Pump Set OIMPG TRANSPORT 3
3.2 Transport of the Pump OIMPG TRANSPORT 4
3.3 Transport of the Other Pump Set Components OIMPG TRANSPORT 5
3.4 Transport of Pump Rotor OIMPG TRANSPORT 5
3.5 Transport of Pump Set Accessories OIMPG TRANSPORT 6
4 Interim Storage OIMPG TRANSPORT 7
4.1 Prerequisites OIMPG TRANSPORT 7
4.2 Place of Storage OIMPG TRANSPORT 7
4.3 Period of Storage up to 12 Months OIMPG TRANSPORT 7
4.4 Period of Storage over 12 Months OIMPG TRANSPORT 7
Contents OIM Pages 3 1/7

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Chapter : Installation on Site

Conditions Installation 1
Foundation Installation 1
Site management Installation 1
Place of Installation Installation 1
Drive way to the Place of Installation Installation 1
Adequate means of Transport Installation 1
Preparations Installation 1
Checking the Foundation Installation 1
Correct deviating foundation dimensions Installation 1
Transporting the Pump Set Components to the Place of Installation Installation 1
Removal of Packaging Installation 2
Protecting the Pump Set Components Installation 2
Procedure for leveling and grouting of Base Frame at Site GEN 02.01 I
Making the Piping Installation 3
Cleaning the Piping Installation 3
Connecting the Piping Installation 4
Information about Readiness for connecting of the Piping Installation 4
Checking the Alignment Installation 4
Mounting the Instruments Installation 4
Detailed description of Preservation for Standstill Installation 4
Detailed description of Mounting/dismounting the Connecting Coupling Installation 5
General Information Installation 5
Mounting Installation 5
Dismantling Installation 6
Detailed Description of Connecting Coupling Alignment Installation 8
1. Conditions Installation 8
2. Preparations Installation 8
3. Runout Check of the Coupling Hubs Installation 8
4. Alignment of Coupling Installation 9
5. Alignment Corrections Installation 10
6. Pinning the Feet Installation 12
Cladding (touch guard) for the Shaft Seal Installation 13

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Chapter : Commissioning, Start-up/Shutdown

1. Work to be carried out prior to Commissioning, Start-up OIMPG COMM 31
1.2 General Information OIMPG COMM 31
1.3 Removal of Preservation OIMPG COMM 31
1.4 Additional Work to be carried out Prior to returning to Service after OIMPG COMM 31
Standstill > 12 Months
1.5 Topping up the Bearings with Lubricating Oil OIMPG COMM 31
1.5.1 General Information OIMPG COMM 31
1.5.2 Bearing with Oil Sight Gauge OIMPG COMM 31
1.5.3 Lift-off Device (if applicable) OIMPG COMM 32
1.5.4 Bearing wit Constant Level Oiler OIMPG COMM 32
1.5.5 Other Accessories OIMPG COMM 32
1.6 Checking the Direction of Rotation OIMPG COMM 32
1.6.1 Prerequisites OIMPG COMM 33
1.6.2 Direction of Rotation OIMPG COMM 33
1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator OIMPG COMM 33
1.6.4 Checking the Direction of Rotation without a Phase-sequence Indicator OIMPG COMM 33
1.7 Rotatability of the pump Rotor OIMPG COMM 34
1.8 Mounting the Connecting Coupling OIMPG COMM 34
1.9 Mounting Guards Preventing Accidental Contact OIMPG COMM 34
1.10 Functional Test and Adjustment of the Instruments OIMPG COMM 34
2. Commissioning, Start-up OIMPG COMM 35
2.1 Prerequisites OIMPG COMM 35
2.2 Priming OIMPG COMM 35
2.3 Checks Prior to Starting OIMPG COMM 36
2.4 Starting and Trial Run OIMPG COMM 36
3. Shutdown OIMPG COMM 37
3.1 Pump Set remains Ready for Operation OIMPG COMM 37
3.2 For Maintenance of the Pump Set or Prolonged Standstill OIMPG COMM 37
4. Work after Shutdown OIMPG COMM 38
4.1 During Readiness for Instant Start-up OIMPG COMM 38
4.2 For Maintenance of the Pump Set OIMPG COMM 38
4.3 Standstill, Pump not ready for Operation OIMPG COMM 39
5. Detailed description of Preservation for Standstill OIMPG COMM 39
Chapter : Pump Supervision Plan OIMPG SUPERVISION 06

Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 02
Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 03
Log Sheet

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Chapter : Servicing OIMPG SERVICING 01

1. General Information OIMPG SERVICING 01
1.2 Requirement of Documentation OIMPG SERVICING 01
1.3 Prerequisites OIMPG SERVICING 01
1.4 Service Intervals OIMPG SERVICING 01
2. Dismantling the Guards Preventing Accidental Contact OIMPG SERVICING 01
3. Pump Servicing Plan OIMPG SERVICING 02
4. Servicing Work OIMPG SERVICING 03
4.1 Oil Changes OIMPG SERVICING 03
4.2 Re-lubrication OIMPG SERVICING 04
Chapter : Maintenance OIMPG MAINTENANCE 01

1. General Information OIMPG MAINTENANCE 01
1.2 Required Documentation OIMPG MAINTENANCE 01
1.3 Prerequisites OIMPG MAINTENANCE 01
2. Dismantling the Guards Preventing Accidental Contact OIMPG MAINTENANCE 01
2.1 Sound Insulation Hood OIMPG MAINTENANCE 01
2.2 Coupling Guard/Cover OIMPG MAINTENANCE 01
2.3 Guard Preventing Accidental Contact for Shaft Seal OIMPG MAINTENANCE 02
3. Dismantling the Connecting Coupling OIMPG MAINTENANCE 02
3.2 Removing the Coupling Hubs OIMPG MAINTENANCE 02
3.3 Run-out Check of the Shaft Ends OIMPG MAINTENANCE 03
4. Removing the Pump from the Installation OIMPG MAINTENANCE 03
4.1 Dismantling the Piping and Instruments OIMPG MAINTENANCE 03
4.2 Removing the Pump from Baseframe OIMPG MAINTENANCE 04
4.3 Transporting the Pump to the Place of Dismantling OIMPG MAINTENANCE 05
5. Dismantling the Bearings OIMPG MAINTENANCE 06

5.1 Preparations OIMPG MAINTENANCE 06
5.2 Dismantling the Add-on Parts OIMPG MAINTENANCE 06
5.3 Dismantling the Lift-off Device, with Antifriction Bearings OIMPG MAINTENANCE 06
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing OIMPG MAINTENANCE 06
5.5 Dismantling the Thrust Bearing OIMPG MAINTENANCE 06
5.6 Dismantling the Radial Bearings OIMPG MAINTENANCE 07
5.6.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 07
5.6.2 HG Pump Sizes 3 to 6 OIMPG MAINTENANCE 07
5.7 Dismantling the Bearing Housings OIMPG MAINTENANCE 08
5.7.2 HG Pump size 3 OIMPG MAINTENANCE 08
6. Dismantling the Shaft Seal OIMPG MAINTENANCE 13

6.1 Preparations OIMPG MAINTENANCE 13
6.2 Dismantling the Mechanical Seal OIMPG MAINTENANCE 13
6.2.1 Make : Eagle Poonawalla OIMPG MAINTENANCE 13
6.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 13
6.2.3 Make : Burgmann OIMPG MAINTENANCE 14
6.3 Dismantling the Casing Parts OIMPG MAINTENANCE 14

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7. Dismantling the Balancing Device OIMPG MAINTENANCE 26
7.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 26
7.2 HG Pump Size 3 OIMPG MAINTENANCE 26
7.4 Measuring the Approximate Radial Clearance OIMPG MAINTENANCE 26
8. General Information on Reassembly OIMPG MAINTENANCE 27
9. Checking the Balancing Device with Contact Fluid OIMPG MAINTENANCE 27

OIMPG MAINTENANCE 28
9.3 HG Pump Sizes 4 OIMPG MAINTENANCE 31
10. Mounting the Balancing Device OIMPG MAINTENANCE 36

11. Mounting the Shaft Seal OIMPG MAINTENANCE 40

11.1 Mounting the Housing Components OIMPG MAINTENANCE 40
11.2 Assembling the Shaft Seal OIMPG MAINTENANCE 40
11.2.1 Make Eagle Poonawalla OIMPG MAINTENANCE 40
11.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 40
11.2.3 Make : Burgmann OIMPG MAINTENANCE 40
12. Mounting the Bearings OIMPG MAINTENANCE 43

12.1 Mounting the Bearing Housings and Lifting the Pump Rotor OIMPG MAINTENANCE 43
12.2 Mounting the Radial Bearings OIMPG MAINTENANCE 44
12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings OIMPG MAINTENANCE 45
12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing OIMPG MAINTENANCE 46
12.5 Mounting the Thrust Bearing (if applicable) OIMPG MAINTENANCE 47
13. Mounting the Piping and Instruments OIMPG MAINTENANCE 49
14. Mounting the Connecting Coupling OIMPG MAINTENANCE 49

14.1 Fitting the Coupling Hubs OIMPG MAINTENANCE 49
14.2 Aligning the Connecting Coupling OIMPG MAINTENANCE 51
14.3 Mounting the Coupling Connections OIMPG MAINTENANCE 51

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15. Mounting the Guards Preventing Accidental Contact OIMPG MAINTENANCE 51
15.1 Coupling Guard OIMPG MAINTENANCE 51
15.2 Coupling Cover OIMPG MAINTENANCE 51
15.3 Guard Preventing Accidental Contact for Shaft seal OIMPG MAINTENANCE 52
15.4 Sound Insulating Hood OIMPG MAINTENANCE 52
16. Maintenance of the Other Pump Set Components OIMPG MAINTENANCE 52

16.1 Maintenance of Connecting coupling OIMPG MAINTENANCE 52
16.2 Maintenance of Drive OIMPG MAINTENANCE 52
16.3 Maintenance of Minimum Flow System OIMPG MAINTENANCE 53
16.4 Maintenance of Instruments and Valves OIMPG MAINTENANCE 53
16.5 Maintenance of Oil Supply Unit, etc. (if applicable) OIMPG MAINTENANCE 53
16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable) OIMPG MAINTENANCE 53
17. Spare Parts OIMPG MAINTENANCE 53

17.1 Ordering Spare Parts OIMPG MAINTENANCE 53
17.2 Spare Parts Stock OIMPG MAINTENANCE 53
17.3 Storage OIMPG MAINTENANCE 53
Chapter : Trouble Shooting OIMPG TROUBLE-SHOOTING 1

1. General Information OIMPG TROUBLE-SHOOTING 1
1.2 Requisite Documentation OIMPG TROUBLE-SHOOTING 1
1.3 Prerequisites OIMPG TROUBLE-SHOOTING 1
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 2
Chapter : Tables of Clearances

Antifriction Bearings
Diametrical Clearance : Balancing Device OIMPG CLEAR AF 1
Theoretical Axial Clearance OIMPG CLEAR AF 2
Plane Bearings
Diametrical Clearance : Balancing Device OIMPG CLEAR AF 1
Bearing Clearance OIMPG CLEAR PLANE 1
Plane Bearings, Heavy
Bearing Clearance OIMPG CLEAR PLANE H1
Diametrical Clearance : Balancing Device OIMPG CLEAR PLANE H1

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Chapter : Table of Tightening Torque

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

HG Pump Size 1 OIMPG WEIGHT 1
Technical Data
Technical Appendix

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

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

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

commissioning/start-up, maintenance, and in case of problems.
OIMPG General 1
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1. General Information
This instruction manual contains fundamental information which must be complied with during work on the
pump set.
Therefore this instruction manual must be read both by the service engineers and responsible trained
personnel, prior to commencement of work.
All users must not only comply with the general safety instructions laid down in the chapter on “Safety”, but also
the specific safety instructions included elsewhere in the instruction manual.
KSB pumps are developed in accordance with state-of-the-art technology, are manufactured with utmost care
and are subjected to continuous quality control. If they are properly installed, serviced and maintained, the
pumps will give reliable and trouble-free operation.
We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will only
assume responsibility for faultless execution of the work and for the safety of the personnel involved if
dismantling/reassembly and maintenance have been performed by KSB’s specialist personnel.
This pump set must not be operated beyond the limit values specified in the data sheets. Make sure that the
operation in accordance with the instructions laid down in this manual. The operator must take into account the
information given in Technical Appendix, or in other parts of the instruction manual or in the contract
documentation.
It is of vital importance to observe the specified electrical connection values as well as the
dismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measures
are taken and the regulations in accordance with the relevant legislation are complied with.
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Caution The temperature of the medium handled must not exceed the values
indicated on the pump name plate.
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Operation of the pump set outside the conditions mentioned above
! may lead to overloads which, in turn, may result in personal injury and
damage to property.
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The descriptions and instructions set forth in this instruction manual refer to KSB’s scope of supply (e.g. pump
or pump set). This instruction manual does not cover all possible eventualities or events which might occur
during installation, maintenance, servicing and operation of the machine.
Neither does the instruction manual take into account any safety regulations applicable at the place of
installation; the Operator must ensure that such regulations are strictly observed by all, including the personnel
called in for execution of the work.
Instructions on labels, tags and stickers attached to the pump set must be observed.
The pump name plate indicates the main data; please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
If you need any additional information or instructions exceeding the scope of this instruction manual, please
contact KSB’s nearest customer service centre.
In case of problems please contact your nearest customer service centre or the manufacturing works.
OIMPG General 2
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Prior to returning any pump set components, carefully follow the

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

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

The relevant declaration as defined in EU Directive “Machinery” (89/292/EEC) is enclosed separately.
OIMPG General 3
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Safety
Marking of Instructions in the Instruction Manual

The safety instructions contained in this instruction manual which must be observed without fail to avoid
hazards to persons are specially marked with the general hazard sign, namely
The electrical danger warning sign is
The word
Caution
is used to introduce safety instructions which must be observed to avoid damage to the pump set and its
functions.
Instructions attached directly to the pump set, e.g.
- the arrow indicating the direction of rotation
- markings for fluid connections and safety instructions
must always be complied with and be kept in perfectly legible condition at all times.
Personnel Qualification and Training

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

Non-compliance with safety instructions can jeopardize the safety of the personnel, the environment and
the pump set itself. Moreover non-compliance with these safety instructions may lead to forfeiture of any
and all rights to claims for damages.
In particular, non-compliance can, for example, result in:

- failure of important pump set functions
- hazard to persons by electrical, mechanical, chemical and thermal effects
- hazard to the environment caused by leakage of hazardous substances.
Safety Awareness
It is imperative to comply with safety instructions contained in this manual, the relevant national health and
safety regulations, and the Operator’s own internal work, operation and safety regulations, if any.
Safety Instructions for the Operator/User

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

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

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

The warranty relating to the operating reliability and safety of the supplied pump set is only valid if it is used
in accordance with its designated use and if all operating instructions described in chapter ‘General’ of the
instruction manual have been followed.
The limits stated in data sheets must neither be exceeded nor underrun under any circumstances.
Deviations require prior consultation with KSB.
Markings
Lifting links
All lifting links are marked with the chain symbol.
0 0
Temperature > 80 C/176 F
It is imperative to observe the information plate on the pump.
OIMPG Safety 2
Transport / Interim Storage
Check the load carrying capacity of the floor (consult the building drawing) before
Caution starting with the transport and hoisting work. Above all give due attention to the
position of the centre of gravity.
Observe the applicable local safety regulations.

Loose parts must be fastened so as to prevent them from falling down.
If a crane is used, check the brake of the hoisting gear by trial braking
under load.
After fastening the ropes, align the crane hook in such a manner that
the crane hoisting ropes are suspended vertically.
Loads must be lifted at a right angle to the drum axis of the rope
winch. Loads must not be lifted at an angle.
Keep the period of tome for which the load is in free suspension to a
minimum.
Use a guide rope in addition if long objects are handled.
Transport of persons together with load is not permitted.
Keep out of the danger area. Work under suspended loads is not
permitted.
The permissible lifting capacity of the lifting equipment must not be
exceeded.
Lower the loads at the lowest lowering speed of the hoist.
1.1 Hoisting Tackle (e.g. ropes, gear)

1.1.1 To determine the lifting capacity, give due consideration to the position of the center of
gravity, the angle of spread and bending radii of the lifting links attached to the load to be
lifted.
1.1.2 Do not use chains, if possible.
Hoisting tackle, and any transport device that might be required, must
only be attached in accordance with section 2 and 3 in this chapter.
Damaged or untested hoisting tackle must not be used
1.1.3 For selection and attachment, only follow the instructions given by the person responsible
for this.
1.2 Signals during Transport
Only follow the instructions given by responsible for giving signals during transporting.
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3.1 Transport of the Pump Set
For transporting the pump set components mounted on the base plate, shackles
must be attached to the lifting lugs of the pump/baseplate.
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Caution Do not damage any built-on accessories and pipes.

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Transport of pump sets mounted on baseplates ( examples )
OIMPG TRANSPORT 3
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3.2 Transport of the Pump

Attach the hoisting tackle as shown in the figure or to the marked lifting links.
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Caution Do not attach the ropes to the shaft ends or bearing housings.
Secure the pump against overturning.
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OIMPG TRANSPORT 4
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3.3 Transport of the Other Pump Set Components

3.3.1 Transport the other pump set components in accordance with the relevant manufacturer’s
documentation.
3.3.2 If these components are included in KSB’s scope of supply, the relevant documents
mentioned elsewhere in the manual.
3.4 Transport of the Pump Rotor

3.4.1 Attach hemp or plastic ropes as required by the length of the pump rotor and transport the
pump rotor horizontally; see figure.
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Caution Do not use wire ropes or chains in order not to damage the pump
rotor.
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3.4.2 When setting the pump rotor down, it must be supported so that it is not damaged and is
secured against overturning/rolling.
OIMPG TRANSPORT 5
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3.5 Transport of Pump Set Accessories

Attach the hoisting tackle as shown in the figure.
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Caution Do not exert pressure on the strainer element and strainer meshes or
damage them.
We recommend transport by hand.
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<120°
<120°
<120°
OIMPG TRANSPORT 6
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4. Interim Storage
4.1 Prerequisites
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Caution The load carrying capacity of the floor of the storage area must be
adequately designed.
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4.1.1 Weights with packaging : see packing list.

4.1.2 Weights without packaging : See table of weights given in Technical Appendix.
4.1.3 Check each package for damage before it is stored. In case of transport damage, asses
the exact damage, document it and notify KSB about the damage, in writing, immediately.
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Caution All openings of the mounted pump set components are closed and
must not be opened before they are needed during installation.
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4.2 Place of Storage
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Caution Protect the stored components from humidity, dirt, vermin and
unauthorized access.
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4.2.1 All components supplied should be stored in a dry room where the atmospheric humidity
is as constant as possible.
4.2.2 In case of outdoor storage it is absolutely necessary to cover the pump set and crates to
form watertight barrier and to protect them against condensation of water so that any
contact with humidity is avoided.
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Elastomeric parts must not be stored together with chemicals,
Caution solvents, fuels, acids, etc. In addition, they should be kept away from
light, in particular sunlight, strong artificial light high in ultraviolet
rays.
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4.3 Period of Storage up to 12 Months

The pimp is supplied duly preserved for storage up to 12 months (standard preservation).
4.4 Period of Storage over 12 Months
If the pump is to be stored more than 12 months, it must be preserved appropriately. If the
requisite preservation measures have not been performed by KSB (special preservation),
they must be discussed with and approved by KSB prior to putting the pump into storage.
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Caution In case of storage periods of more than 5 years, the pump must be
dismantled before it is installed, and the O-rings must be replaced.
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OIMPG TRANSPORT 7
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Installation on Site
Conditions
Foundation
- has been prepared
- the concrete has set
- the surface is truly horizontal and even (check with a spirit level, accuracy < 0.3 mm/m in longitudinal
and cross directions.
- The area surrounding the foundation holes is truly horizontal and even.
Site management
- has checked the dimensional accuracy of the foundation and its correct position as per the reference
points given in the foundation and building drawing.
- Has marked the center line of the foundation
- Has released the foundation
Place of installation
- is cleared
- its condition is such that the installation can be performed without interruptions
- adequate devices for aligning are available
Drive way to the place of installation

- is cleared
- is suitable for transport
Adequate means of transport

- including personnel are available until completion of the installation work
Preparations
Checking the foundation
- for dimensional accuracy in accordance with GA drawing.
- Whether the foundation is truly horizontal and even
- Whether the area surrounding the foundation holes is truly horizontal and even.
Correct deviating foundation dimensions

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

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

Transport/Interim Storage must be complied with.
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Installation 1
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Removal of packaging
- not until the installation work actually starts
- Avoid damaging the pump set
- All connection points must be closed
- The packaging must be disposed off by the consignee (responsible contractor)
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! If parts have to be lifted to remove the packaging, proceed as described in

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

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

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

fuels, acids etc. In addition, they should be kept away from the
light, particular direct sunlight and strong artificial light high in ultraviolet
light.
_______________________________________________________________________
Installation 2
PROCEDURE FOR LEVELLING & GROUTING OF BASE FRAME AT SITE
( FOR HDA / HDB / HG / CHT PUMPS ONLY )
PURPOSE :
High speed rotory equipment needs to be installed with maximum contact area between base frame
and the foundation. To achieve this conventionally, blue matching procedure is adopted between packer
plates and foundation. This calls for skilled millwright fitters to work on and consumes lot of time.
Despite this, the contact area achieved is nowhere near 100%.
Therefore, the following procedure is recommended which ensures :
1. Nearly 100% contact area between the foundation, the packer plates and the base frame.
2. Considerable saving in time and manpower.
PREPARATION :
The following preparation is followed, in case the base frame and the packer plates ( equal to the
number of foundation bolts ) are in scope of KSB. Otherwise, the user is requested to follow the
preparation as under :
l The base frame is provided with the pads, which are welded at the bottom, machined in one setting
and drilled to 15 mm. Dia. ( Ref. Fig. 1).
l Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to the
welded pads at the bottom of the base frame, are required with tapping of M 10. These packer plates
are to be bolted with pads at the bottom of the base frame, using M10 bolts ( Ref. Fig. 2 & 3 ).
PROCEDURE :
01.Bolt the pump on the base frame.

02.Bolt the packer plates on the bottom pads of the base frame.
03.Place the unit on the foundation.
04.Suspend foundation bolts into the pockets provided on the foundation blocks.
05.Level the pump on the delivery flange or feet, within 0.04 mm. per meter, using jacking bolts pro
vided at the corners of the base frame.
06.Grout the foundation bolts and the packer plates by using quick setting non-shrink cement, ACC
make ‘Shrinkkomp’ or Forsoc make ‘Cobextra-GP2’ or equivalent ( Ref. Fig. 4 ).
07.Allow curing time of 24 to 72 hours depending upon the grout used.
08.Remove M 10 bolts, which are holding packer plates with the base frame.
09.Carry out final levelling by inserting shims (SS shims preferred) between packer plates and the base
frame.
10.Tighten the foundation bolts and recheck the levelling. Correct it, if necessary.
11. Grout the complete base frame, including the hollow portion, if any, using conventional grouting mix, i.e.,
portland cement, sand and aggregate in proportion 1 : 2 : 2 and gravel size not to exceed 20 mm.
12.Plaster the foundation and apply suitable oil resistant paint.
GEN 02.01 I 6
Fig. 1 : Base frame bottom pad
➮ W
➮
View from W Z View from Z
Fig. 2 : Packer plates in pairs, machined for Fig. 2A : Packer plates in pairs, machined for
for base frame with channel base frame with double channel / I beam
Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts
Fig. 4 : Grouting of packer plate

Note : The foundation to be made of concrete on solid ground. Foundation bolts and packer plates to be
grouted with non shrink grout only. Balance hollow portion of base frame to be grouted with
portland cement sand and aggreegate in preparation 1:2.2 Gravel size should be < 20 mm. After
final grouting all surface should be finished with fine plaster and apply oil resistent paint.
GEN 02.01I 6a
_____________________________________________________________________
Making the piping

General information
- The pipes are already mounted within the dimensions of base frame.
- Straight length pipes are supplied for further connection of piping, if within the scope of KSB supply. Bends and
flanges are supplied loose.
- Offset at flanges and pipe connections is not allowed.
Cleaning the piping

General information
- Pipes delivered by KSB are cleaned and closed.
- The pipes delivered shall be checked for subsequent impurities in the interior and cleaned, if required.
___________________________________________________________________________________________
Caution Pipes made on the site must be cleaned prior to final mounting.
____________________________________________________________________________
Connecting the piping

General information
- Run the pipes as indicated in the G. A. Drawing.
- Do not remove the covers on the pump nozzles and the desiccants till the pipes are to be actually connected.
Disposal by the consignee / Operator.
- The nominal diameters of the pipes shall be at least equal to the pump connections.
- It is recommended to fit check valves and isolating valves.
- The thermal expansions of the pipes must be compensated by suitable measures in order not to transfer them
on the pump.
- The suction piping must be slanting towards the pump.
- The weight of the suction piping must not transfer on the pump.
- Under no circumstances the pump should be used as an anchorage point for the piping.
___________________________________________________________________________________________
Caution Connect all the pipes in cold condition and without transmitting any stresses or
strains.
The unbalance of the forces and moments created by the suction / discharge
piping must not exceed the permissible values. (Refer G. A. Drawing)
____________________________________________________________________________
Suction piping
- Not the part of KSB scope of supply.
- Clean the tank and pipe prior to fitting.
Balancing liquid piping
- The balancing liquid piping is connected back to the suction nozzle.
- If the balancing liquid piping is connected back to the suction vessel (deaerator) the flow velocity in the
balancing liquid piping should on no account exceed 5 m/s. The pressure of the balancing liquid must at least
0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressure
must not exceed 2.5 % of the maximum discharge pressure.
Discharge piping
- Not the part of KSB scope of supply.
Flushing piping
- The piping is already installed.
Minimum flow system
- On the discharge side of the pump, a minimum flow control valve is required. G. A. Drawing indicates whether it
is in KSB’s scope of supply.
- Refer separate operating instructions for Minimum flow control valve.
Installation 3
_____________________________________________________________________
Minimum flow piping
- Not the part of KSB’s scope of supply.
Return piping
- For drain and leakage liquids, the Operator must fit a return piping. Connections and dimensions are specified
in the G. A. drawing.
Information about readiness for connection of the piping

- Inform the responsible site management that the piping is ready for connection.
- Do not continue the piping unless the required piping by the Operator is completed.
Checking the alignment

- Repeat the alignment of the coupling, after the completion of piping by the Operator.
- Enter the final measuring results in the coordinate system of the alignment / acceptance record sheet of each
connecting coupling.
- Record the shaft displacements due to vertical and lateral misalignment of the pump set components under
“remarks”.
- Have the alignment/acceptance record sheet confirmed by the responsible site management and distribute it to
the authorized persons.
- Have the table of tightening torques for all fastening screws and foundation bolts checked and confirmed by
responsible site management.
Mounting the instruments

General information
- Measuring lines with isolation valves have been installed.
- Do not remove the plugs of the connection points till the actual mounting.
- Just before commissioning / start up perform the functional test.
- Laying of electrical cables varies according to the constructional conditions. Cables must be layed in the
conduits up to the points just near the actual measuring point.
- Electrical cable connections must be done by authorized personnel.
Mounting the pressure gauges
- Insert the sealing disc.
- Select the pressure gauge with sufficient measuring range.
Mounting the oil sight gauge
- Remove the plug and screw in the oil sight gauge with seal.
- Attach required extension piece.
Detailed description of preservation for standstill

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

Risk of fire in case of open fire.
Remove inflammable material
____________________________________________________________________________
- Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft end and the hub face
match.
___________________________________________________________________________________________
CautionFit the coupling hubs only using the appropriate device to prevent the shaft
bearings from damages by the axial friction force. Impacts on the coupling hubs
are not allowed.
____________________________________________________________________________
X = thread size, refer Technical Appendix.
- Securely tighten the grub screws, wherever provided.
Connecting the coupling hubs

- Assemble the connecting coupling as described in manufacturer’s documentation.
Dismantling
Preparations
- Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid
subsequent confusions.
Installation 6
_____________________________________________________________________
Detailed description of connecting coupling alignment

1. Conditions
- Shaft distances as indicated in the G. A. drawing.
- Pump set components are set in place on the base frame.
- Coupling hubs are mounted in accordance with the description under Detailed description of
mounting/dismantling the connecting coupling.
2. Preparations
- Dismantle the coupling guards mounted to the pump set as described under Detailed description of
mounting/dismantling the connecting coupling guards, and store them appropriately.
- Separate the couplings mounted to the pump set as described under Detailed description of
mounting/dismantling the connecting coupling.
- Comply with the coupling hub distance shown in the G. A. drawing.
3. Runout check of the coupling hubs
- Check the coupling halves using a dial micrometer.
- Use spacer plates.
Arrangement of spacer plates ( examples )
! Secure the drive against unintentional starting.

____________________________________________________________________________
- True running tolerance ≤ 0.04 mm.

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

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

Do not damage the shaft and hubs.
___________________________________________________________________________
Device for connecting coupling with spacer sleeve ( example )
Installation 9
_____________________________________________________________________
Radial misalignment of the coupling hubs
- Permissible value : ∆kr ≤ 0.04 mm, measured at 4 points at a distance of 900.
___________________________________________________________________________________________
Caution ∆kr < 0.04 mm/0.016 inch + vertical/lateral misalignment. (For dimensions,
please refer to the section Alignment corrections)
___________________________________________________________________________________________
Kr
Angular misalignment of the coupling hubs in horizontal direction

- Permissible value : ∆kh ≤ 0.04 mm
Smax – Smin
∆ kh = _________________
2
Angular misalignment of the coupling hubs in vertical direction
- Permissible value : ∆kv ≤ 0.04 mm
Smax – Smin
∆ kv = _________________
Smax.
Smin.
5. Alignment corrections
Vertical correction
Pump :
Installation 10
_____________________________________________________________________
6. Pinning the feet

Pump
D C
Pinning the pump feet
A = nozzle orientation in accordance with the G. A. drawing.

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

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

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

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

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

1.3.1 If the pump has been filled with a glycol/water mixture for preservation, this fill must be drained before
further work is started.
1.3.1.1 Open the pump drain (6B), collect fill in an appropriate container and dispose of according to the local
anti-pollution regulations.
1.3.1.2 Close the pump drain.
1.3.2 Flush sufficiently to remove any residues of the preservative.
1.3.3 Remove the grease on the out sides of all pump set components.
1.4 Additional Work to Be Carried out Prior to Returning to Service after Standstill
> 12 Months
1.4.1 Dismantle the pump-end coupling hub.
1.4.2 Dismantle the bearing.
1.4.3 Dismantle the mechanical seal and check it in accordance with the manufacturer’s documentation.
1.4.4 If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be
fitted.
1.4.5 Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor.
1.4.6 Re-mount the pump-end coupling hub.
1.5 Topping up the Bearings with Lubricating Oil

1.5.1 General Information
1.5.1.1 Oil quality, refer Technical Appendix.
1.5.1.2 After standstill > 12 months, check the oil quality. Clean or replace the oil, if required.
1.5.1.3 Filter the oil prior to topping up; filter mesh size 30 µm.
_______________________________________________________________________
Caution During operation, the oil level in the bearing housing falls!
Check the oil level only during standstill of pump!
_______________________________________________________________________
1.5.2 Bearing with Oil Sight Gauge
OIMPG COMM 31
________________________________________________________________________
1.5.2.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the
minimum and maximum markings of the oil sight gauge (639).
1.5.2.2 Fit the vent plug (913.01 or 672) again.
1.5.3 Lift-off Device (if applicable)

1.5.3.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the
minimum and maximum markings of the oil sight glass (642.01).
1.5.3.2 Fit the vent plug (913.01 or 672) again.
1.5.4 Bearing with Constant Level Oiler (if applicable)

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

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

If the pump set is driven by an electric motor, the direction of rotation of the motor must be checked prior to
Commissioning/start-up.
_____________________________________________________________________________________

_______________________________________________________________________
OIMPG COMM 32
_____________________________________________________________________
1.6.1 Prerequisites
1.6.1.1 Check the direction of rotation prior to the final assembly of the connecting coupling.
1.6.1.2 Comply with the manufacturer’s documentation.
1.6.1.3 The electric motor is provided with a lubricant.
1.6.2 Direction of Rotation

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

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

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

1.6.4.2 The electric motor shall be switched on by authorized personnel for a short period of time.
1.6.4.3 Switch off the electric motor again immediately before the operating speed is reached.
1.6.4.4 Check the direction of rotation. If wrong, have the terminal connections reversed by authorized personnel
and check the direction of rotation once again.
_____________________________________________________________________________________
Caution Mark the connections in the terminal box.

_______________________________________________________________________
_______________________________________________________________________

____________________________________________________________
OIMPG COMM 33
_____________________________________________________________________
1.6.4.5 In case of electric motors with axial float, if applicable, the coupling hub of motor shaft must be realigned as
required by the actual magnetic center. If coupling has a spacer, it must be possible to mount and remove
it.
1.7 Rotatibility of the Pump Rotor

1.7.1 In the case of curved tooth coupling, fix the pump-end coupling sleeve on the hub using spacer plate (if
applicable – supplied loose), see figure Arrangement of spacer plates.
1.7.2 Prior to start of the work, check the oil level in the bearing housings.
1.7.3 It must be easy to rotate the pump rotor by hand, and it may be only rotated in the direction of rotation of
the pump. If necessary, attach an appropriate tool at the coupling hub, see figure Rotatability of the pump
rotor.
1.7.4 In case the pump with balancing disc without lift off device, move the pump rotor towards the driven end by
approx. 1 mm before you turn it by hand, see figure Rotatability of the pump rotor.
Rotatability of the pump rotor ( example )
1.8 Mounting the Connecting Coupling

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

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

1.10.1 Check all the instruments in accordance with the individual manufacturer’s documentation for correct
measuring data and adjust the instruments, if required.
OIMPG COMM 34
_____________________________________________________________________
_____________________________________________________________________________________
Caution All measuring instruments supplied with the pump should be calibrated
before commissioning of the pump set.
_______________________________________________________________________
1.10.2 Set the Alarm & Trip values in accordance with the Logic Diagram, in cooperation with control engineering
specialists.
_____________________________________________________________________________________
Caution The pump should never be run below the speed of 1000 rpm, even during
the starting process. The acceleration time from switch on (zero rpm) to
1000 rpm should be less than 10 seconds. Specific care is necessary for
the pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
2. Commissioning, Start-up
2.1 Prerequisites
2.1.1 Installation and alignment have been performed in accordance with good engineering practice, recorded
and accepted by the Operator.
2.1.2 The pump rotor’s rotatability by hand has been checked.
2.1.3 All pump set components have been checked in accordance with the relevant manufacturer’s
documentation.
2.1.4 The direction of rotation of the drive has been checked.
2.1.5 All guards preventing accidental contact have been mounted.
2.1.6 All pipes have been cleaned and connected.
2.1.7 All instruments have been fitted and checked for correct functioning.
2.2 Priming
2.2.1 Close all drains and drain pipes.
2.2.2 Fully open the cooling water main valve and all cooling water throttle valves.
2.2.3 Vent the complete cooling water circuit.
2.2.4 Vent the complete mechanical seal cooling circuit.
2.2.5 Monitor the cooling water flow at the sight glasses or flow indicators.
_____________________________________________________________________________________
Caution Do not cool the cooling chamber and heat exchangers with aggressive
untreated water.
_______________________________________________________________________
2.2.6 If applicable, check the filter in the mechanical seal’s cooling circuit and clean, if required.
2.2.7 Open the valves in the minimum flow line.
2.2.8 Check the oil levels and top up with oil, if required.
_____________________________________________________________________________________
Caution During operation, the oil level in the bearing housing falls!
Check the oil levels only during standstill of the pump!
______________________________________________________________________
2.2.9 If there is no bypass, open the gate valve in the suction piping by 10 to 20 %.
2.2.10 Prime the suction piping, pump and discharge piping up to the closed discharge gate valve.
2.2.11 Vent all pressure gauge lines until there is no more air to escape.
2.2.12 Fully open the valve in the suction piping.
2.2.13 Check whether suction pressure is available.
OIMPG COMM 35
_____________________________________________________________________
2.3 Checks Prior to Starting

2.3.1 The suction tank, suction piping, pump and discharge piping have been primed and vented.
2.3.2 The valve in the suction piping is fully open.
2.3.3 The valve in the discharge piping is fully closed.
2.3.4 The connection for tapping, if applicable, is closed.
2.3.5 The shut-off valves in the stand-by heating system, if applicable, are closed.
2.3.6 The shut-off valves in the minimum flow line are open.
2.3.7 The cooling water system is in operation.
2.3.8 The cooling liquid pressure at the inlet must not exceed 6 bar.
2.3.9 The cooling liquid temperature at the outlet must not exceed 550 C.
2.3.10 All temperatures indicated are below the limit values.
2.3.11 In the case of a pump set with variable speed coupling, check the scoop tube position for compliance with
the manufacturer’s documentation and readjust, if required.
2.3.12 Check all pipes, flanges, screw/bolt connections and pipe unions for leakage.
2.4 Starting and Trial Run

_______________________________________________________________________
Caution Should alarm signals or problems occur during starting or trial run,
proceed as described in chapter Trouble shooting!
_______________________________________________________________________
_______________________________________________________________________
Caution The minimum discharge head of 150 m must not be underrun, except the
start-up and shutdown phases.
The pump should never be run below the speed of 1000 rpm, even during
the pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
2.4.1 Switch on the drive as described in the manufacturer’s documentation.

2.4.2 For pump set with variable speed coupling :
2.4.2.1 The drive is operating at maximum speed. Due to the scoop tube position, however, the pump is operating
at a minimum speed of 1000 rpm or a minimum head of Hmin = 150 m.
2.4.2.2 Adjust the pump to minimum flow by changing the scoop tube position.
2.4.3 Monitor the temperature and smooth running of the bearings.
2.4.4 Monitor the pump pressures and differential pressures.
2.4.5 Make sure the minimum flow control valve works (hydrodynamic noise).
_____________________________________________________________________________________
! The minimum flow pipe gets hot.

____________________________________________________________
2.4.6 Check the mechanical seals. Mechanical seal must not drip.
2.4.7 For pump set with variable speed coupling:
2.4.7.1 For minimum speed or minimum head (pump) set the limiting cams of the scoop tube positioning device to
approx. 80% (can be read on the scale).
2.4.7.2 Increase the pump speed until the operating speed is reached.
2.4.8 Slowly open the valve of the discharge pipe until it is completely open.
OIMPG COMM 36
_____________________________________________________________________
2.4.9 Permanently monitor the pump set’s operating behaviour.

2.4.10 Open the shut-off valves upstream and downstream of the orifice plate in the stand-by heating system, if
applicable.
_____________________________________________________________________________________
Caution Close the shut-off valves of the standby heating system only for
maintenance work of the pump.
_______________________________________________________________________
2.4.11 For mechanical seals with circulating cooling :
If there is a magnetic separator, check after its commissioning/start-up whether the temperature of the
circulation liquid remains constant.
3. Shutdown
3.1 Pump set remains ready for Operation
3.1.1 Close the valve in the discharge pipe.
3.1.2 Make sure the minimum flow control vale works.
_____________________________________________________________________________________

_______________________________________________________________________
_______________________________________________________________________
Caution The minimum discharge head of 150 m must not be underrun, except in
the start-up and shutdown phases.
pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
3.1.3 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or
minimum speed is reached.
3.1.4 Switch off the drive, making sure it runs smoothly down to a standstill.
3.1.5 Note the run down time.
3.1.6 The cooling water remains on!
3.2 For Maintenance of the Pump Set or Prolonged Standstill

3.2.1 Close the valve in the discharge pipe.
3.2.2 Make sure the minimum flow control valve works.
_____________________________________________________________________________________

____________________________________________________________
OIMPG COMM 37
_____________________________________________________________________
_______________________________________________________________________
Caution The minimum discharge head of 150 m must not be underrun, except in
the start-up and shutdown phases.
pumps with variable frequency drive & pumps with hydraulic coupling.
_______________________________________________________________________
3.2.3 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or
minimum speed is reached.
3.2.4 Switch off the drive, making sure it runs smoothly down to a standstill.
3.2.5 Note the run down time.
_____________________________________________________________________________________

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

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

4.1.2.1 Put the pump into operation as described in Commissioning, Start-up section of this chapter.
4.1.2.2 Switch off the pump after approx. 10 minutes as described in Shutdown section of this chapter.
4.1.2.3 Check at the connecting coupling whether pump rotor runs down smoothly to a standstill.
4.1.3 Every two months (in the case of pump set with variable speed coupling)
If the scoop tube actuator was used during stand-by operation, re-lubricate the guide bush; see the
manufacturer’s documentation.
4.2 For Maintenance of the Pump set
_________________________________________________________________________
! The pump has been depressurized and the casing temperature is < 500 C,
measured at the pump nozzles!
______________________________________________________________
4.2.1 Secure all valves against opening.
4.2.2 Open all drains and/or drain pipes.
4.2.3 Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.
OIMPG COMM 38
_____________________________________________________________________
_____________________________________________________________________________________
! If the medium handled is toxic, inflammable, explosive or hazardous in a

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

4.3.1 General information
_____________________________________________________________________________________
Caution In the case of dander of frost, the pump must be drained and preserved as
described under Detailed Description of Preservation for Standstill in this
chapter.
_______________________________________________________________________
4.3.1.1 Secure all valves against opening.
4.3.1.2 Close all openings and supply pipes.
4.3.2 Standstill > 2 Weeks

4.3.2.1 Preserve the pump as described under Detailed Description of Preservation for Standstill in this chapter.
4.3.2.2 Protect the pump set components such as gear or variable speed coupling against water ingress and
humidity as described in the manufacturer’s preservation instructions.
5. Detailed Description of Preservation for Standstill

________________________________________________________________________
! The pump has been depressurized and the casing temperature is < 500 C,
measured at the pump nozzles!
_________________________________________________________________________
5.1 Secure all valves against opening.
5.2 Open all drain and/or drain pipes.
5.3 Collect the fill in an appropriate container and dispose of according to anti-pollution regulations.
________________________________________________________________________________________
! If the medium handled is toxic, inflammable, explosive or hazardous in a

different way, the pump must be flushed thoroughly to avoid that any
residues remain in the pump.
_________________________________________________________________________
5.4 Close all drains and/or drain pipes.
5.5 Fill the pump with glycol/water mixture at a proportion of 1 : 2.
0
Important : This mixture ensures protection against frost up to approx. – 20 C.
A mixture at a proportion of 1 : 1 increases the protection up to –420C.
5.6 Dismantle and store the coupling guards mounted on the pump set.
5.7 Dismantle and store the connecting coupling spacer in accordance with the manufacturer’s documentation.
5.8 If necessary, fill the bearing housing with oil.
5.9 Rotate the pump rotor once or twice a month to prevent a separation of the preservation fill, check the fill level
and top up, if required.
OIMPG COMM 39
_____________________________________________________________________
Supervision of Rotor Position (only for the pumps with Balancing Disc)
The Rotor Position Indicator is mounted on the discharge side of the pump. There are two types of Rotor Position
Indicators.
The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearing
end cover, which is the stationary part, and the rotating indicator (624) is screwed in the shaft threading.
The bush has two scriber marks, at right angles to shaft axis, which are 1.5 mm apart.
1. If the balancing device is new, the position of the indicator (624) must be as shown in the figure “Pump running
normally”.
2. In the case of maximum wear of the balancing device the position of the indicator (624) is as shown in the
figure “Time to shut down the pump”.
Pump running normally Time to shut down the pump
623 624 623 624
0
Rotor position indicator Rotor position indicator
OIMPG SUPERVISION 02
_____________________________________________________________________
Pump Supervision Plan
For exact description of pump as well as scope of supply of accessories & instrumentation etc.,
Point to be supervised Supervisory action Value to be met

0
Pump Bearings : Plain Checking the temperature once a week < 90 C
Checking the oil level once a week Middle between minimum and
(only for pumps with ring oil lubrication) maximum marks
Checking for smooth operation The pump set shall run smooth
Once a week and free from vibrations.
0
Thrust Bearing – Tilting pads Checking the temperature once a week < 90 C
Once a week and free from vibrations.
(if applicable)
0
Lift-off device with antifriction bearings Checking the temperature once a week < 90 C
Checking the oil level once a week Middle of oil level sight glass
(if applicable) Once a week and free from vibrations.
0
Lift-off device with Tilting pads bearings Checking the temperature once a week < 90 C
(if applicable) Once a week and free from vibrations.
Indicator Checking the rotor position once a week See section Rotor Position in
(only for pumps with balancing disc) this chapter
≤ 80 C
0
Mechanical seal (433) Checking the temperature once a week
Checking the leakage once a week 15 drops per minute
Differential pressure gauge Checking the differential pressure < 0.3 bar
Strainer I suction pipe (if applicable) Once a week
Differential pressure gauge Checking the differential pressure
Duplex filter (if applicable) Once a week
Measuring instrument, suction side ps Checking the pressure once a week
(gauge holder ) (if applicable)
Measuring instrument, discharge side pd Checking the pressure once a week
Measuring instrument, tapping Checking the pressure once a week
Measuring instrument, balancing water pE Checking the pressure once a week PE ≥ ps + 0.5 bar
Thermometer Checking the temperature once a week
(Suction nozzle/discharge nozzle)
(if applicable)
≤ 45 C
0
Thermometer Checking the temperature once a week
(cooling water inlet) (if applicable )
∆t ≤ 10 C
0
Cooling water pipe Checking the temperature once a week
(supply and return flow) (if applicable)
Sight glass Checking the cooling water flow once a Water is flowing
(cooling water inlet pipe) (if applicable) week
Oil pressure gauge Checking the pressure once a week
(gauge holder) (if applicable)
Level indicator Checking the oil level once a week - 20 mm
(Oil supply system) (if applicable)
Connecting coupling Checking for leakage once a week No leakage permitted
(only for coupling with pressure oil lubr.)
In case of deviations, proceed in accordance with the “Cause – Remedy” specified under
the chapter “Trouble – shooting”.
We recommend recording the information tabulated above in a logbook, in the form of enclosed
LOG SHEET.
OIMPG SUPERVISION 06
LOG SHEET
PUMP TYPE SERIAL NO.
CUSTOMER ITEM NO.
NO. DESCRIPTION UNIT READING

PRESSURE AT
1 Suction nozzle kg/cm2
2 Differential across suction strainer kg/cm2
3 Discharge nozzle kg/cm2
4 Balancing line kg/cm2
5 Oil inlet to bearing (forced oil lubrication)
5.1 Suction side bearing kg/cm2
5.2 Discharge side bearing kg/cm2
5.3 Lift off / Thrust bearing kg/cm2
TEMPERATURE AT
6 Suction nozzle Deg C
7 Discharge nozzle Deg C
8 Balancing line Deg C
9 Bearings
9.1 Suction side Deg C
9.2 Discharge side Deg C
9.3 Lift off / Thrust Deg C
10 Oil inlet to bearing (forced oil lubrication)
10.1 Suction side Deg C
10.2 Discharge side Deg C
11 Flushing liquid
11.1 Shaft seal - Suction Deg C
11.2 Shaft seal - Discharge Deg C
Cooling Water Inlet / outlet
11.3 Suction Deg C
11.4 Discharge Deg C
12 ROTOR POSITION
13 Amplitude RMS Velocity

VIBRATIONS AT microns (peak to peak) mm / s
H V A H V A
13.1 Suction side bearing housing
13.2 Discharge side bearing housing
13.3 Lift off / Thrust bearing housing
13.4 Suction flange
13.5 Discharge flange
13.6 Suction side support foot
13.7 Discharge side support foot
13.8 Base Frame
H = Horizontal ; V = Vertical ; A = Axial.
DATE / TIME SIGNATURE OF OPERATOR
LOG SHEET
B1
_____________________________________________________________________
Servicing
We recommend that KSB’s specialist personnel be present during the servicing of the
pump!
________________________________________________________________________________________
Caution Improper handling of preservatives, oil and grease causes hazardous

environmental impact.
Handling and disposal only by qualified personnel!
_________________________________________________________________________
1.2 Required documentation
1.2.1 The following documents are necessary for servicing of pump set.
Sectional Drawing, Pump
List of Components, Pump
Documentation of the Mechanical Seal (if applicable)
1.2.2 Documentation of Connecting Coupling
1.2.3 Documentation of Drive
1.2.4 Documentation of the Minimum Flow System (if applicable)
1.2.5 Documentation of Valves and Equipment (if applicable)
1.2.6 Documentation of the Instrumentation (if applicable)
1.3 Prerequisites
1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown
sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work.
_____________________________________________________________________________________
! Secure the drive against unintentional starting

____________________________________________________________
1.4 Service Intervals
________________________________________________________________________________________
Caution Perform a visual inspection of the pump set – as far as accessible – about
500 operating hours after commissioning/start-up.
_________________________________________________________________________
1.4.1 The periods of the time indicated are recommendations for normal operating conditions at trouble-free
operation, which have to be adapted to the actual operating conditions, for example the dirt accumulation,
switching frequency, load, etc.
1.4.2 In the case of problems and unusual operating conditions that represent electric or mechanical overloads,
off-schedule servicing must be performed.
2. Dismantling the Guards Preventing Accidental Contact

Dismantle / remove the guards preventing accidental contact mounted to the pump set as described in the
Dismantling the Guards Preventing Accidental Contact section in chapter “Maintenance”.
OIMPG SERVICING 01
_____________________________________________________________________
3. Pump Servicing Plan

after Commissioning/Start-up and Stand-by
Location to be Checks Servicing Intervals Servicing Work

serviced
Bearing Oil level, oil quality First oil change after 300 See the Servicing Work
(Ring oil lubricated) operating hours section in this chapter
Subsequent oil changes
after 8000 operating hours,
(if applicable) at least after 1 year
Bearing Oil level, oil quality First oil change after 300
(Forced oil lubricated) operating hours
Subsequent oil changes
after 8000 operating hours,
(if applicable) at least after 2 years
Connecting Coupling Grease fill See manufacturer’s See manufacturer’s
(if applicable) documentation documentation
Checking the axial After approx. 8000 See manufacturer’s
(if applicable) movability operating hours documentation
Drive See manufacturer’s See manufacturer’s See manufacturer’s
(if applicable) documentation documentation documentation
Instruments Perfect condition and See manufacturer’s Replace defective equipment;
functioning documentation see manufacturer’s
(if applicable) documentation
Pressure gauge Perfect condition and
(if applicable) functioning
Differential pressure Perfect condition and
gauge functioning
Opening and closing
(if applicable) points
Temperature measuring Perfect condition and Every 3 months; Replace defective equipment;
instruments functioning See the manufacturer’s see manufacturer’s
(if applicable) Switching points documentation documentation
Vibration measurement Perfect condition and
(if applicable) functioning
Shaft positioning Perfect condition and
monitoring (if applicable) functioning
Inspection Perfect condition and After approx. 8000 Replace defective equipment;
(axial thrust measurement) functioning operating hours, at least see manufacturer’s
(if applicable) after 2 years documentation
In case of deviations, proceed in accordance with the (Cause – Remedy” specified under
the chapter (Trouble – shooting”.
OIMPG SERVICING 02
_____________________________________________________________________
4. Servicing Work
4.1 Oil Change

4.1.1.1 Oil quantity and quality, refer Technical Appendix.
4.1.1.2 Filter the oil prior to topping up; filter mesh size 30 µm.
4.1.2 Bearing with Oil Sight Gauge (639)

4.1.2.1 Remove the screwed plug (13 B.1 and/or 13 B.2), completely drain off the oil fill and dispose of in
accordance with the local anti-pollution regulations.
4.1.2.2 Screw the screwed plug (including sealing element) back again.
4.1.2.3 Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the
4.1.2.4 Fit the vent plug (913.01 or 672) back again.
4.1.3 Bearing with Constant Level Oiler (638) (if applicable)

4.1.3.1 Remove the screwed plug (13 B.1), completely drain off the oil fill and dispose of in accordance with the
local anti-pollution regulations.
4.1.3.2 Screw the screwed plug (including sealing element) back again.
4.1.3.3 Remove the vent plug (913.01 or 913.02 or 672).
level oiler until oil appears ii the vertical portion of the connecting elbow of the constant level oiler, see
figure Constant level oiler.
4.1.3.7 Fit the vent plug (913.01 or 913.02 or 672) back again.
4.1.3.8 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one
third of the reservoir filled at all times. If the oil level is underrun, top up with oil.
_____________________________________________________________________________________
Caution The oil level must always be below the level of the vent opening arranged
at the top edge of the connecting elbow. Make sure the opening is always
dry.
_______________________________________________________________________
Position of
reservoir for
topping up oil
Oil level
4.1.4 Other Pump set Components

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

Top up with oil in accordance with the manufacturer’s documentation.
4.3 Connecting Coupling (if applicable)
4.3.1 Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting
Coupling and Mounting the Connecting Coupling in chapter “Maintenance”.
4.3.2 Perform all servicing work in accordance with the manufacturer’s documentation.
OIMPG SERVICING 04
_____________________________________________________________________
Maintenance
________________________________________________________________________________________
Caution During the warranty period, pumps should be dismantled only by KSB
personnel!
_________________________________________________________________________
1.2 Required documentation
1.2.1 The following documents are necessary for servicing of pump set.
Sectional Drawing, Pump
List of Components, Pump
Documentation of the Mechanical Seal (if applicable)
1.2.2 Documentation of Connecting Coupling
1.2.3 Documentation of Drive
1.2.4 Documentation of the Minimum Flow System (if applicable)
1.2.5 Documentation of Valves and Equipment (if applicable)
1.2.6 Documentation of the Instrumentation (if applicable)
1.3 Prerequisites
1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown
sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work.
1.3.2 All spare parts required are available.
1.3.3 Proper hoisting tackle and means of transport are available and ready for use.
1.3.4 Sufficient room space and appropriate tools are available.
1.3.5 The drive has been secured against unintentional starting.
2. Dismantling the Guards Preventing Accidental Contact

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

________________________________________________________________________________________
Caution Do not damage the seal elements and sealing surfaces!
_________________________________________________________________________
_____________________________________________________________________
2.2.1 Remove all pipes on the cover.
2.2.2 Remove the taper pins and screw of the cover split joint.
2.2.3 Use the eye bolt as transport aid as shown in the figure Coupling cover.
2.2.4 Unscrew the screws in the upper part of the flange.
2.2.5 Remove the upper half of the coupling cover.
2.2.6 Remove the internal injection lines.
2.2.7 Disconnect the lower half of the coupling cover from the flange and store it.
2.3 Guard Preventing Accidental Contact for Shaft Seal.

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

3.1 Dismantling the Coupling Connection
3.1.1 Give due attention to markings on the coupling, if any, or mark the coupling to rule out later mix-ups.
3.1.2 Dismantle the connecting coupling spacer as described in the manufacturer’s documentation.
____________________________________________________________________________________
! Secure the spacer against falling down.
____________________________________________________________
3.1.3 Store the parts appropriately.
3.2 Removing the Coupling Hubs

3.2.1 Dismantle the retaining ring, if applicable, from the coupling hub.
3.2.2 Remove the grub screws (if provided).
0
3.2.3 To facilitate removing, the coupling hub may be heated uniformly to a temperature of 80 C max.
_____________________________________________________________________________________
Use protective gloves!
! Risk of fire in case of open flames.
Remove flammable substances from the danger area.
_______________________________________________________________________
3.2.4 Elastomeric parts must be removed before heating!

_____________________________________________________________________________________
Caution Elastomeric parts which have been heated must not be used any more.
Use new parts for reassembly.
_______________________________________________________________________
3.2.5 Remove the coupling hubs as shown in the figure Removing the coupling hubs.
_____________________________________________________________________
_____________________________________________________________________________________
! Secure the coupling against falling down.

_____________________________________________________________________________________
_____________________________________________________________________________________
Caution Remove the coupling hubs using only the appropriate device to prevent
the shaft bearings form damage by axial frictional force. Impacts on the
coupling are not permitted.
_______________________________________________________________________
3.2.6 Mark the keys prior to removing them.

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

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

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

4.2.1 Unscrew the fastening studs at the pump feet; see the figure Fastening of the pump feet.
1 2 3
6 5 4
1-Pump foot, 2-Nut, 3-Disc, 4-Shims, 5-Stud, 6-Base plate
4.2.2 Loosen nuts and adjusting screws at the guide block; see figure Adjusting screw at the guide casing.
Adjusting screws at the guide casing ( example )
_____________________________________________________________________
4.3 Transporting the Pump to the Place of Dismantling
_______________________________________________________________________________________
The pumps have to be lifted and transported in accordance with the
Caution guidelines laid down in the chapter “Transport / Interim Storage”.
Do not fasten the ropes to the shaft ends or the bearing housings.
_______________________________________________________________________________________
4.3.1 Lift the pump from the baseframe, transport it to the place of dismantling and set it down on assembly
supports.
_____________________________________________________________________________________
! Secure the pump against overturning.

_____________________________________________________________________________________
_____________________________________________________________________________________
Mark the matching shims between the pump feet and baseframe so that
Caution they can be inserted in the same place on subsequent reassembly, and
store them appropriately.
_______________________________________________________________________
_____________________________________________________________________
5. Dismantling the Bearings
5.1 Preparations
5.1.1 Prior to dismantling, drain the oil fill of the bearing housings and the thrust bearing housing and dispose of
in accordance with the local anti-pollution regulations.
5.1.2 If applicable, dismantle the cooling liquid pipes and oil supply pipes as far as necessary.
5.1.3 If applicable, dismantle the oil sight gauge (639) and/or constant level oiler (638) as well as the
thermometer (692.01 or 692.02) and/or RTDs.
5.1.4 If applicable, remove the splash ring (507.01 and/or 507.02) on the driven end from the shaft (210) after
loosening the grub screws (904.05, if applicable).
5.2 Dismantling the Add-on Parts (for example flanged-on oil pump, shaft position
indicator, etc.) (if applicable)
5.2.1 For applicable add-on parts, refer Sectional Drawing and P&I Diagram.
5.3 Dismantling the Lift-off Device, with Antifriction Bearings (if applicable)
5.3.1 Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11).
5.3.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).
5.3.3 Pull the bearing cartridge (381) including the two angular contact ball bearings (320) out of the thrust
bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01.
Dismantle further, if required.
_____________________________________________________________________________________
In case of slight discolourations (incl. rust stain) or any damage, the bearings
Caution must be replaced.
Clean used bearings with cleaning oil! After cleaning immediately spray the
bearings with oil!
_____________________________________________________________________________________
5.3.4 Take the springs out of the thrust bearing housing (354).
5.3.5 Take away the thrust bearing housing (354) including O-ring (412.10).
5.3.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).
5.3.7 Remove the spacer ring (504.01) from the shaft (210).
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing (if applicable)\
5.4.1 Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11).
5.4.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).
5.4.3 Pull the bearing cartridge (381) including the thrust bearing, thrust bearing plate (384) and counter thrust
bearing plate (388) out of the thrust bearing housing (354) using the appropriate device as described in the
work instruction UA3 13473 01. Dismantle further, if required.
_____________________________________________________________________________________
Caution In case of slight discolourations (incl. rust stain) or any damage, the
bearing segments must be replaced!
_______________________________________________________________________
5.4.4 Take the springs out of the thrust bearing housing (354).
5.4.5 Take away the thrust bearing housing (354) including O-ring (412.10).
5.4.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).
5.4.7 Take away the key out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).
5.5 Dismantling the Thrust Bearing (if applicable)

5.5.1 Unscrew the hex nuts (920.11) and remove the bearing end cover (361) including thrust bearing (314), O-
ring (412.11), circlip (932.03) and shaft seal (420.01, 562.02).
5.5.2 Screw nut (920.09) from the shaft (210).
5.5.3 Remove the spacer sleeve (525.05) from the shaft (210).
_____________________________________________________________________
5.5.4 Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in the
work instruction UA3 13475 01 or UA3 14758 01.
5.5.5 Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).
5.5.6 Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and
remove them together with the adjoining segments.
5.5.7 Pull the thrust bearing (314) out of the thrust bearing housing (354) using the appropriate device as
described in the work instruction UA3 13475 01 or UA3 14758 01.
5.5.8 Unscrew the hex socket head cap screws (614.04) and take the thrust bearing housing (354) including
parallel pin (562.02), shaft seal ring (420.01) circlip (932.03) and O-ring (412.10) out of the bearing housing
(350.01).
_____________________________________________________________________________________
Caution In the case of slight discolourations (incl. rust stain) or any damage, the
______________________________________________________________________
5.6 Dismantling the Radial Bearings

______________________________________________________________________________________
Caution When the bearing shells are dismantled, the shaft must not rest on the
bearing housing or labyrinth rings!
________________________________________________________________________
_____________________________________________________________________________________
Caution Mark the bearing shells to ensure their correct assignment to the bearing
housings! Protect the bearing shells against damage!
_____________________________________________________________________________________
_____________________________________________________________________________________
Caution In the case of slight discolourations (incl. rust stain) or any damage, the
_______________________________________________________________________
5.6.1 HG Pump Sizes 1 and 2
5.6.1.1 Unscrew the hex head bolts (901.01 and 901.03) and remove the bearing cover (360) and bearing end
cover (361) including O-ring (412.09).
5.6.1.2 Remove the pins (560.01) including washers (550.07) and nuts (920.07) as well as hex socket head cap
screw (914.05) including circlips (932.05) and take away the upper part of the bearing housing (350.01)
including the upper half of labyrinth ring (423.01).
5.6.1.3 Remove the upper bearing shell (370) and lubricating ring (644, if applicable).
5.6.1.4 Remove the lower half of labyrinth ring (423.01) and lower bearing shell (370); for that purpose lift the shaft
(210) using a wooden rod.
5.6.2 HG pump sizes 3 to 6
5.6.2.1 Unscrew the hex head bolts (901.01 and 901.06) and remove the bearing cover (360) and bearing end
cover (361) including O-ring (412.09).
5.6.2.2 Remove the hex head bolt (901.13) including washers (550.12) and gasket (411.03).
5.6.2.3 If applicable, undo the grub screw (904.06) and dismantle the lubricating ring (644).
5.6.2.4 Remove the bearing shell (370) and glued-in labyrinth ring (423.01) and O-ring (412.18) from the shaft,
using the appropriate device as described in the work instruction UA7 23062 01.
_____________________________________________________________________
5.7 Dismantling the Bearing Housings
5.7.1.1 Remove the hex head bolts (901.05) and nuts (920.14).
5.7.1.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing
housing (350.01).
5.7.1.3 Remove the splash ring (507.01 or 507.02) from the shaft (210).
5.7.2 HG Pump Size 3
5.7.2.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts
(921.14).
5.7.2.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing
housing (350.01).
5.7.2.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws
(904.05, if applicable).
5.7.3 HG Pump Sizes 4 to 6.
5.7.3.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts
(921.14).
5.7.3.2 Unscrew the nuts (920.04) at the studs (902.01) and take away the bearing housing (350.01).
5.7.3.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws
(904.05, if applicable).
_____________________________________________________________________
6 Dismantling the Shaft Seal

6.1 Preparations
Dismantle any cooling, flushing, quenching pipes, wherever applicable. All the openings should be plugged.
6.2 Dismantling the Mechanical Seal.

(Part numbers, specified in the following description are only representative)
_______________________________________________________________________________________
Caution Refer order specific sectional drawing of mechanical seal for correct part
numbers as well as description!
Refer Manufacturer’s documentation!
_______________________________________________________________________________________
6.2.1 Make : Eagle Poonawalla

6.2.1.1 Shaft Seal
6.2.1.1.1 Loosen the hex bolt (14) and locate the sliding washer (13) into the groove provided on the sleeve (6)
and tighten the hex bolt (14).
6.2.1.1.2 Loosen socket screws (12) and dog point screws (17).
6.2.1.1.3 Unscrew and remove fixing screws of gland plate (4).
6.2.1.1.4 With the help of jacking bolts, provision made on gland plate (4), remove cartridge off the shaft (210).
Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.1.2 Dismantling of Cartridge (if required).
6.2.1.2.1 Remove hex bolt (14) and sliding washer (13). For removing sliding washers, slightly compress the
springs (e) of the mechanical seal.
6.2.1.2.2 Remove socket screws (12) and dog point screw (17) from the drive collar (11).
6.2.1.2.3 Remove drive collar (11) from the sleeve (6).
6.2.1.2.4 Remove the mechanical seal rotary head assembly consisting of components a,b,c,d,e,f.
_____________________________________________________________________________________
Caution Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical
seal components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution In the event of slight scoring marks on the rubbing faces of seal ring (b)
and mating ring (2), they can be sent back to the manufacturer for
touching up.
_____________________________________________________________________________________
6.2.2 Make : Flowserve Sanmar

6.2.2.1 Shaft Seal
6.2.2.1.1 Loosen the cap screw (K) and locate retaining plate (15) into the groove provided on the sleeve (10)
and tighten the cap screw (K).
6.2.2.1.2 Loosen set screws (13) of sleeve collar (9).
6.2.2.1.3 Unscrew and remove fixing screws of gland ring (1).
6.2.2.1.4 With the help of jacking bolts, provision made on gland ring (1), remove cartridge off the shaft (210).
Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.2.2.1 Remove cap screw (K) and retaining plate (15). For removing retaining plate, slightly compress the
spring’s (c) of the mechanical seal.
6.2.2.2.2 Remove socket screws (13) and dog point screw (12) from the sleeve collar (9).
6.2.2.2.3 Remove sleeve collar (9) from the sleeve (10).
6.2.2.2.4 Remove the mechanical seal rotary head assembly consisting of components 3,4,45,5,c,d,e,p.
_____________________________________________________________________
_____________________________________________________________________________________
Caution Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical
seal components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution In the event of slight scoring marks on the rubbing faces of seal ring (b)
and mating ring (2), they can be sent back to the manufacturer for
touching up.
____________________________________________________________________________________________
6.2.3 Make : Burgmann

6.2.3.1 Shaft Seal
6.2.3.1.1 Loosen the hex bolt (15) and locate the assembly fixture (14) into the groove provided on the sleeve (6)
and tighten the hex bolt (15).
6.2.3.1.2 Loosen set screws (13) of clamping ring (11).
6.2.3.1.3 Unscrew and remove fixing screws of gland (4).
6.2.3.1.4 With the help of jacking bolts, provision made on gland (4), remove cartridge off the shaft (210). Follow
the same procedure to pull out the mechanical seal cartridge on the discharge side.
6.2.3.2.1 Remove hex bolt (15) and assembly fixture (14). For removing assembly fixture, slightly compress the
springs (1.4) of the mechanical seal.
6.2.3.2.2 Remove set screws (12) and (13) from the clamping ring (11).
6.2.3.2.3 Remove clamping ring (11) from the sleeve (6).
6.2.3.2.4 Remove the mechanical seal rotary head assembly consisting of components 1.1,1.2,1.3,1.4,1.5,1.6.
_____________________________________________________________________________________
Caution Damaged sleeve (6), seal face (1.1), seat (2) and other mechanical seal
components should be replaced by new ones.
_______________________________________________________________________
_____________________________________________________________________________________
Caution In the event of slight scoring marks on the rubbing faces of seal face (1.1)
and seat (2), they can be sent back to the manufacturer for touching up.
______________________________________________________________________________________________
6.3 Dismantling the Casing Parts

6.3.1.1 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part
(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).
6.3.2 HG Pump Sizes 3 to 6
6.3.2.1 If applicable, loosen and remove the hex socket head cap screws (914.08, non-driven end).
6.3.2.2 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part
(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).
6.3.2.3 If applicable, loosen and remove the hex nuts (920.04 or 920.05) on the studs (902.01, on either end or
902.05, on the driven end).
6.3.2.4 Fasten the seal casing (441 or 441.01 or 441.02 as per the execution) to the crane by means of eyebolt
and rope, force off with screws and remove it. Unscrew the hex socket head cap screws (914.09, if
applicable).
6.3.2.5 On the driven end, loosen and remove hex nuts (920.05) on the studs (902.05) or the hex socket head cap
screws (914.15, if applicable), fasten the casing part (130) to the crane by means of eyebolt and rope,
force off with screws and remove it.
_____________________________________________________________________
7. Dismantling the Balancing Device
7.1 HG Pump Sizes 1 and 2
7.1.1 Remove the spacer ring (504.02) and if applicable spacer sleeve (525.02) from the shaft (210).
7.1.2 Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the
work instruction UA2 13474 01
7.1.3 Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as
described in the work instruction UA2 13474 01
7.1.4 Check the balancing disc (601.01) and counter balancing disc (602.01) for signs of damage.
7.2 HG Pump Size 3

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

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

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

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

8.1 Meticulously clean all dismantled components, in particular the fit and sealing surface areas.
________________________________________________________________________________________
Caution Do not damage the locating and sealing surfaces!

________________________________________________________________________________________
8.2 If required, remove any lime and incrustation from the cooling chambers.
8.3 Check all dismantled components for signs of damage.
8.4 If required, use new parts.
8.5 As a general rule, always use new O-rings and gaskets for reassembly.
________________________________________________________________________________________
Caution Do not take the O-rings out of their original packing until those are actually
required to be fitted and protect them from mineral oil and grease!
_________________________________________________________________________
_________________________________________________________________________
Caution Do not fit the O-rings in dry condition but wet them with silicone grease! In
exceptional cases, soapy water may be used.
________________________________________________________________________
8.6 Prior to reassembly coat the screw/bolt connections and pipe unions as well as the fits of the individual
components using respective specified lubricating agent as described in the work instruction UA4 28699 01.
8.7 Reassembly must be performed in accordance with the rules of good engineering practice.
9. Checking the Balancing Device with the Contact Fluid “Engineers Blue”.
The steps 9.1 to 9.3 are required only if balancing piston (603.02) or counter
balancing disc (602.02) were remachined or replaced.
9.1.1 Meticulously clean the axial running face of the counter balancing disc (602.02).
9.1.2 Insert the grooved pin (561.03) in the discharge casing (107).
_____________________________________________________________________
9.1.3 Fit the counter balancing disc (602.02) without O-rings (412.04 and/or 412.05). The grooved pin (561.03)
must engage in the groove of the counter balancing disc (602.02).
9.1.4 Adjust the pump rotor position; see figure Adjusting pump rotor position.
5 0 2 .0 2 2 3 0 .0 2
1 7 1 .0 2
S a 1
S a 2
A d ju s tin g t h e p u m p r o t o r p o s itio n
9.1.4.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the non-
driven end.
_____________________________________________________________________________________
Caution This rotor position must not be changed when measuring the balancing
device!
_____________________________________________________________________________________
9.1.5 Adjust the balancing disc (601.01); see figure Adapting the balancing piston.
b1 Sl2
a1
Machine here
504.02 601.01
602.01
Adapting the Balancing disc
9.1.5.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of
the last stage.
9.1.5.2 Shorten the balancing disc (601.01) to the dimension “b1” as sown in the figure Adapting the balancing
disc: b1 = a1 – SL2 (SL2, see table of clearances).
9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.
_____________________________________________________________________
x x
a b a y b
504.02 601.01 602.01 504.02 525.02 601.01 602.01
Varient without spacer sleeve Varient with spacer sleeve (525.02)
Adjusting the spacer ring
9.1.6.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the shaft collar.
9.1.6.2 Determine the dimension “b” between the running face and face of balancing disc (601.01) as well as the
length “y” of the spacer sleeve (525.02, if applicable).
9.1.6.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b or a = x - b-y. The maximum permissible
deviation from plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution As a general rule, always use a new spacer ring (504.02)!

_______________________________________________________________________
9.1.7 Insert the key (940.04).

9.1.8 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the
balancing piston (601.01) without O-ring (412.02) on the shaft (210).
9.1.9 Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210)
9.1.10 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.
9.1.11 Mount the shaft sleeve (524.01, pump with gland packings).
9.1.12 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section so far
as to make the free rotation of the pump rotor possible.
9.1.13 For the check with the contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it
slowly.
9.1.14 Move the pump rotor to the non-driven end and dismantle all pump components including the counter
balancing disc (602.01) in reverse order.
9.1.15 At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the
contact fluid in the upper zone. If this is not the case, remachining the counter balancing disc (602.01) on a
lathe and repeat the contact fluid checks.
9.1.16 After completion of the contact fluid check, clean the axial running faces of the balancing piston (601.01)
and counter balancing disc (602.01).
9.2 HG Pump Size 3

9.2.3 Fit the counter balancing disc (602.01) without O-rings (412.04 or 412.05). The grooved pin (561.03) must
engage in the groove of the counter balancing disc (602.01).
9.2.4 If applicable, slide throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and hey (940.03)
until abutting against the impeller (230.02).
9.2.5 Adjust the pump rotor position; see figure Adjusting the pump rotor position.
_____________________________________________________________________
5 0 2 .0 2 2 3 0 .0 2
1 7 1 .0 2
S a 1
S a 2
A d ju s tin g t h e p u m p r o t o r p o s itio n
9.2.5.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the non-
driven end.
_____________________________________________________________________________________
Caution The rotor position must not be changed when the measuring the balancing
device!
_______________________________________________________________________
9.2.6 Adapt the throttle sleeve (522.01) and/or balancing disc (601.01); see figure Adapting the throttle sleeve or
figure Adjusting the balancing disc.
Machine
here
602.01 504.02 601.01 522.01
Adapting the throttle sleeve
Machine
here
602.01 504.02 601.01
Adapting the balance disc
_____________________________________________________________________
the last stage and, if required, the dimension “c1” of the balancing disc (601.01).
9.2.6.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the
throttle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc
: b1 = a1 – c1 – Sl2 or b1 = a1 – Sl 2 (Sl2 see tables of clearances).
9.2.7 Adapt the spacer ring (504.2) or spacer sleeve (525.02); see figure Adapting the spacer ring or see figure
Adapting the spacer sleeve.
504.02 601.01 602.01 522.01 525.02 601.01 602.01 522.01

Adapting the spacer sleeve
Adapting the spacer ring
9.2.7.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring
(501.01).
9.2.7.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01).
9.2.7.3 Shorten the spacer ring (504.02) or spacer sleeve (525.02) to the dimension “a” : a = x – b. The maximum
permissible deviation form plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution As a general rule, always use a new spacer ring (504.02)or spacer sleeve
(525.02)!
_______________________________________________________________________

9.2.9 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the
balancing disc (601.01) without O-ring (412.02) on the shaft (210).
9.2.10 Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210).
9.2.11 Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over
them.
9.2.12 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.
9.2.13 Fit the driven-end and non-driven end bearings in accordance with the Mounting the Bearings section, so
far as to make possible the free rotation of the pump rotor.
9.2.14 For the check with contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly.
9.2.15 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing
disc (602.01) in reverse order.
contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.02) on a
lathe and repeat the contact fluid check.
9.2.17 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and
counter balancing disc (602.01).
9.3 HG Pump Size 4

9.3.1 Meticulously clean the axial running face of counter balancing disc (602.01).
_____________________________________________________________________
9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttle
sleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).
x
a b
504.02 601.01 602.01 522.01

(501.01).
9.3.7.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from
plane parallelism is 0.02 mm.
_____________________________________________________________________________________

_______________________________________________________________________
9.3.9 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing
disc (601.01) without O-ring (412.02) on the shaft (210).
9.3.10 Slide the spacer ring (504.02) over the shaft (210).
9.3.11 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the
balancing disc (601.01), using hex socket head cap screws (914.10).
9.3.12 Mount the casing part (130) and seal casing (441) without O-rings.
9.3.13 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so

9.4.2 Fit the throttle bush (542.01) without O-ring (412.05).
9.4.3 Insert the parallel pin (562.03) in the discharge casing (107).
9.4.4 Insert the key (940.03) and slide the throttle sleeve (522.01) without O-ring (412.02) over the shaft (210)
and key (940.03) until abutting against the impeller (230.02).
_____________________________________________________________________
9.4.5 Fit the counter balancing disc (602.01) without O-ring (412.16) and fasten with the hex socket cap screws
(914.06). The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01).
9.4.6 Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pump
rotor position.
502.02 230.02
171.02
Sa1
Sa2
Adjusting the pump rotor position

_____________________________________________________________________________________
Caution This rotor position must not be changed when measuring the balancing
device!
_______________________________________________________________________
9.4.7 Adapt the throttle sleeve (522.01); see figure Adapting the throttle sleeve.
c1 b1 Sl2
a1
Machine
here
602.01 542.01 504.02 601.01 522.01
Adapting the throttle sleeve
_____________________________________________________________________
last stage and the dimension “c1” of the balancing disc (601.01).
9.4.7.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttle
sleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).
x
a b
504.02 601.01 602.01 522.01 542.01

(501.01).
9.4.8.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from
plane parallelism is 0.02 mm.
_____________________________________________________________________________________

_______________________________________________________________________
9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing
disc (601.01) without O-ring (412.02) on the shaft (210).
balancing disc (601.01), using hex socket head cap screws (914.10).
9.4.13 Mount the casing part (130) and seal casing (441) without O-rings.
9.4.14 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so
_____________________________________________________________________
10. Mounting the Balancing Device
______________________________________________________________________________________
If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing

Caution disc (602.01) were remachined or replaced, the check with the contact
fluid “engineer’s blue” as outlined in sections 9.1 to 9.4 must be performed!
_____________________________________________________________________________________

10.1.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)
502.02 230.02
171.02
3mm

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

10.2.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)
10.2.3 If applicable, slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key
(940.03) until abutting against the impeller (230.02).
_____________________________________________________________________
502.02 230.02
171.02
3mm
10.2.4.1 Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to the
non-driven end.
10.2.5 Insert the key (940.04).
10.2.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc
(601.01) over the shaft until abutting against the counter balancing disc (602.01).
10.2.7 Slide the spacer ring (504.02) or spacer sleeve (525.02) over the shaft (210).
10.2.8 Insert the key (940.07) and split ring (501.01) in the shaft keyway and slide the retainer ring (505.01) over
them.
10.3 HG Pump Size 4

10.3.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex
socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin
(562.03) must engage in the groove of the counter balancing disc (602.01).
10.3.3 Insert the key (940.04) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210)
and key (940.04) until it abuts against the impeller (230.02).
10.3.4 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump
rotor position.
10.3.5 Insert the key (940.04).
_____________________________________________________________________
502.02 230.02
171.02
Sa1
Sa2
10.3.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01)
over the shaft (210) until it abuts against the counter balancing disc (602.01).
balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant
work instruction.
10.3.9 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

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

11.1.2.1 In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in
position.
11.1.2.2 Insert O-ring (412.19) in the groove of the casing part (130, non driven end) and fit the casing part to
the discharge casing (107).
11.1.2.3 Depending upon the execution, fit the washers (550.05 or 550.09) and hex nuts (920.05 or 920.04), or
hex socket head cap screws (914.09) and tighten them; tightening torque, see the relevant work
instruction.
11.1.2.4 Depending upon the execution, fit again the studs (902.01 or 602.05) on the non driven end, if they
have been removed.
11.1.2.5 Fit the seal casing (441 or 441.01 and 441.02, depending upon the execution) including O-rings
(412.07 and 412.08) to the suction casing (106) and/or casing part (13.0). Fit the hex socket head cap
screws (914.09, if applicable).
11.2 Assembling the Shaft Seal

(Part no.s specified in the following description are only representative)
Caution Refer order specific sectional drawing of mechanical seal for correct part
numbers as well as description.
Refer manufacturer’s documentation.
_______________________________________________________________________________________
11.2.1 Make : Eagle Poonawalla

11.2.1.1 Slide mechanical seal cartridge [attached to gland plate (4)] on the shaft until the gland plate (4) gets
located on seal casing (441).
11.2.1.2 Tighten the nuts of gland plate.
11.2.1.3 Tighten set screws (12 and 17) of drive collar (11).
11.2.1.4 Loosen the bolt (14) and take aside the sliding washer (13) from the groove of the sleeve (6).
11.2.1.5 Slip splash ring (507) onto the shaft.
11.2.2 Make : Flowserve Sanmar

11.2.2.1 Slide mechanical seal cartridge [attached to gland ring (1)] on the shaft until the gland ring (1) gets
located on seal casing (441).
11.2.2.2 Tighten the nuts of gland plate.
11.2.2.3 Tighten set screws (13) of sleeve collar (9).
11.2.2.4 Loosen the cap screw (K) and take aside the retaining plate (15) from the groove of the sleeve (10).
11.2.3 Make : Burgmann

11.2.3.1 Slide mechanical seal cartridge [attached to gland (4)] on the shaft until the gland (4) gets located on
seal casing (441).
11.2.3.2 Tighten the nuts of gland.
11.2.3.3 Tighten set screws (13) of clamping ring (11).
11.2.3.4 Loosen the hex bolt (15) and take aside the assembly fixture (14) from the groove of the sleeve (6).
_____________________________________________________________________
12. Mounting the Bearings
12.1 Mounting the Bearing Housing and Lifting the Pump Rotor
12.1.1.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210).
12.1.1.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten
the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.
12.1.1.3 On the driven end, slide the bearing cover (360) including O-ring (412.09) and if applicable the splash
ring (507.01 and/or 507.02) over the shaft (210). Do not yet fasten the bearing cover to the bearing
housing.
12.1.1.4 Fit the pump coupling hub as described under Mounting the connecting coupling.
12.1.1.5 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work
instruction UA7 28679 01.
12.1.1.6 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift
up”. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor
has increased within the permissible limits, half the clearance increase must be added to the lifting
values.
_____________________________________________________________________________________
Caution When the bearing shells and labyrinth rings are dismantled the shaft must
not rest on the bearing housing!
_______________________________________________________________________
12.1.1.7 On the driven and non driven ends insert the lower bearing shells (370) and read the vertical pump
rotor displacement at the dial gauges. To facilitate inserting the bearing shells (370), lift the shaft (210)
using a wooden rod.
12.1.1.8 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head
bolts (901.05).
_____________________________________________________________________________________
Caution This adjustment may only be effected by trained specialist personnel!

_______________________________________________________________________
12.1.1.9 In order to check the measured values, remove the bearing shells (370) and insert them again. The
measured values must be reached again. Enter the lifting values in the check data sheet.
12.1.1.10 The bearing housings (350.01) are aligned laterally by means of the horizontally fitted hex head bolts
(901.05). The exact lateral alignment has been achieved when the lower bearing shells (370) can be
placed easily from either side in their fits between shaft (210) and bearing housing (350.01).
____________________________________________________________________________________

_______________________________________________________________________________
12.1.1.11 After having completed rotor lifting, lock the hex head bolts (901.05) with nuts (920.14) and tighten the
hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.

12.1.2.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210).
12.1.2.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten
the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.
12.1.2.3 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work
instruction UA7 23062 01.
12.1.2.4 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift up”.
They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased
within the permissible limits, half the clearance increase must be added to the lifting values.
_____________________________________________________________________
_____________________________________________________________________________________
Caution When the bearing shells and labyrinth rings are dismantled the shaft must
not rest on the bearing housing!
_______________________________________________________________________
12.1.2.5 On the driven and non driven ends insert the half ring (tool 969.85) in accordance with the work instruction
UA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting of
the half rings (tool 969.85), lift the shaft (210) using wooden rod.
12.1.2.6 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head
bolts (901.05).
_____________________________________________________________________________________

_______________________________________________________________________
12.1.2.7 In order to check the measured values, remove half rings (969.85) and insert them again. The measured
values must be reached again. Enter the lifting values in the check data sheet.
12.1.2.8 Check the position of the shaft in relation to the bearing housing by means of the instrument holder
(699.71) and fitted measuring instrument (690) and adjust the position, if required, by means of the hex
bolts (901.05); see work instruction UA7 23062 01.
____________________________________________________________________________________

_______________________________________________________________________________
12.1.2.9 After having completed rotor lifting, tighten hex nuts (920.04 and/or 920.05) uniformly; tightening torque,
see the relevant work instruction; and fix the bearing housing (350.01) with the taper pins (560.02); if
necessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten the
grub screws (904.05, if applicable).
12.2 Mounting the Radial Bearings

_____________________________________________________________________________________
Caution When mounting the bearings, the holes for thermometers in the bearing
shells and the associated thermometer connections in the bearing
housings must be aligned!
_____________________________________________________________________________________

12.2.1.1 Turn the lower bearing shells (370) and lower labyrinth ring half (423.01) in the bearing housing bottom
part (350.01); for that purpose lift the shaft (210) using a wooden rod.
12.2.1.2 Fit the lubricating ring (644, if applicable) and the upper bearing shell (370) including parallel pin (562.01).
12.2.1.3 Place the upper labyrinth ring half (423.01) including the parallel pin (562.10) in the bearing housing top
part (350.01).
12.2.1.4 Mount the bearing housing top part (350.01) including the upper labyrinth ring half (423.01) and fix with
the taper pins (560.01). The parallel pin (560.01) must engage in the groove of the bearing housing top
part (350.01).
12.2.1.5 Fit the hex socket head cap screws (914.05) including circlips (932.05) and tighten them uniformly;
tightening torque, see the relevant work instruction.
12.2.1.6 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten
the hex head bolts (901.01 or 901.03) uniformly; tightening torque, see the relevant work instruction.
_____________________________________________________________________
Additional Work for Pumps with Balancing Disc :
12.2.1.7 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.2.1.8 For rotor position indicator the description under “Supervision of Rotor Position” in the section “Pump
Supervision Plan”.
12.2.2.1 Place the bearing shell (370) with glued-in labyrinth ring (423.01) and O-ring (412.18) in the bearing
housing (350.01).
_____________________________________________________________________________________
Caution The labyrinth ring has been glued in the bearing shell with Loctite 75/AVV
or equivalent!
12.2.2.2 Fit and tighten the hex head bolts (901.13) including washer (550.012) and gasket (411.03); the bolt must
engage in the bearing shell groove.
12.2.2.3 If applicable, fit the lubricating ring (644).
12.2.2.4 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten
the hex head bolts (901.01 or 901.06) uniformly; tightening torque, see relevant work instruction.
Additional Work for Pumps with Balancing Disc :

12.2.2.5 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.2.2.6 For rotor position indicator the description under “Supervision of Rotor Position” in the section “Pump
Supervision Plan”.
12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings.
12.3.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).
12.3.2 Fit the thrust bearing housing (354) including O-ring (412.10) and springs (950).
12.3.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against
12.3.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with rolling element bearing.
a
c
b
y
Adjusting the lift-off device

12.3.4.1.1 Measure the dimension “a” from the face of the thrust bearing housing (354) to the bottom faces of the
springs (950), dimension “b” between the contact face of the angular contact ball bearing and the
springs’ contact face of the bearing cartridge (381) as well as the distance “c” from the face of the
thrust bearing housing (354) to the shaft collar.
_____________________________________________________________________
12.3.4.2 Calculate the auxiliary dimension “x” : x = a – b – 30 mm. (30 mm = installation length of the prestressed
springs).
12.3.4.3 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation from
parallelism is 0.02 mm.
_____________________________________________________________________________________

_____________________________________________________________________________________
12.3.6 Mount the bearing cartridge (381) including two angular contact ball bearings (320) and the circlip
(932.04).
12.3.7 Screw in the hex socket head cap screw (914.03), fit and tighten the shaft nit (920.09).
12.3.8 Check the lift-off limitation “z” : when the balancing disc (601.01) abuts against the counter balancing disc
(602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); see figure
Adjusting the lift-off device with rolling element bearing.
12.3.9 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).
12.3.10 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with tightening torque given in the
relevant work instruction.
12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Thrust Bearing
12.4.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).
12.4.2 Fit the thrust bearing housing (354) including O-ring (4121.10) and springs (950).
12.4.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the
12.4.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with tilting-pad thrust bearing.
a
c
e
b
Slg1
d
z y f
x
Adjusting
12.4.1.1 Measure the dimension the lift-off
“a” from device
the face of with tilting-pad
the thrust thrusthousing
bearing bearing (354) to the bottom faces of
springs (950), dimension “b” from the thrust bearing plate (384) to the springs’ contact faces on the
bearing cartridge (381), distance “c” from the face of the thrust bearing housing (354) to shaft collar as
well as the dimension “d” of the thrust bearing plate.
12.4.1.2 Calculate the auxiliary dimension “x” : x = a – b + d – 30 mm. (30 mm = installation length of the pre-
stressed springs.
12.4.4.2 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation from
parallelism is 0.02 mm.
_____________________________________________________________________________________

_____________________________________________________________________________________
_____________________________________________________________________
12.4.6 If parts of the lift-off device have been reworked or replaces, adjust the thrust bearing clearance “Slg1”
as shown in the figure Adjusting the lift-off device with tilting-pad bearing.
12.4.6.1 Measure the distance “e” from the contact face of the bearing cartridge (381) to the circlip (932.04).
12.4.6.2 Determine the total length “f” of the thrust bearing (314) and thrust bearing plate (384).
12.4.6.3 Shorten the counter thrust bearing plate (388) to the dimension “x” : x = e – f – Slg1 (Slg1, see
table of clearances). The maximum permissible deviation from plane parallelism is 0.02 mm.
_____________________________________________________________________________________
Caution As a general rule, always use a new counter thrust bearing plate (388)!
_______________________________________________________________________
12.4.7 Mounting the bearing cartridge (381) :
12.4.7.1 Fit the parallel pin (562.02) and shaft seal (420.01) in the bearing cartridge (381) and fasten them
with the circlip (932.03).
12.4.7.2 Fit the thrust bearing (314) including parallel pin; the parallel pin must engage in the groove of the
bearing cartridge (381).
12.4.7.3 Insert the thrust bearing plate (384).
12.4.7.4 Fit the parallel pin (562.02) and shaft seal (420.01) to the counter thrust bearing plate (388) and
fasten with the circlip (932.03).
12.4.7.5 Mount the counter thrust bearing plate (388) so that the groove in the counter thrust bearing plate
is in alignment with the hole in the bearing cartridge (381) and insert the circlip (932.03).
12.4.8 Insert the key (940.05) and slide the completely assembled bearing cartridge (381) on the shaft (210).
12.4.9 Screw in the hex socket head cap screw (914.03), and fit and tighten the shaft nut (920.09).
12.4.10 Check the lift-off dimension “z” : when the balancing disc (601.01) abuts against the counter balancing
disc (602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); see
figure Adjusting the lift-off device with tilting-pad thrust bearing.
12.4.11 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).
12.4.12 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with the tightening torque given in
the relevant work instruction.
12.5 Mounting the Thrust Bearing (if applicable)

_____________________________________________________________________________________
Caution When mounting the bearings, the holes for thermometers in the bearing
shells and the associated thermometer connections in the bearing
housings and/or bearing end cover must be aligned!
_______________________________________________________________________
12.5.1 Fit the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01), circlip (932.03)
and O-ring (412.10) in the bearing housing (350.01).
12.5.2 Fit the hex socket head cap screws (914.04) including the gaskets (411.02) and tighten the screws with the
tightening torque given in the relevant work instruction.
12.5.3 Mount the thrust bearing (314) including all segments and fit it in the thrust bearing housing (354).
12.5.4 Move the pump rotor in the direction of the driven end until the balancing piston (603.02) abuts against the
12.5.5 Adjust the axial clearance “Sl3” at the balancing piston and “Slg2” at thrust bearing as shown in the figure
Adjusting the thrust bearing.
_____________________________________________________________________
d
c
a b
Slg2
Adjusting the thrust bearing
12.5.5.1 Measure the distance “a” from the bearing face of the thrust bearing (314) to the shaft collar.
12.5.5.2 Shorten the spacer ring (504.01) to the dimension “b” : b = a – Sl3 (Sl3 see table of clearances). The
maximum permissible deviation from the plane parallelism is 0.02 mm.
_____________________________________________________________________________________

______________________________________________________________________
12.5.5.3 Measure the distance “c” from bearing face of the thrust bearing (314, in bearing end cover) to the contact
face of the bearing end cover (361), distance “d” from the bearing face of the thrust bearing (314, in the
thrust bearing housing) to the contact face of the thrust bearing housing (354), and width “e” of the thrust
bearing plate (384).
12.5.5.4 Calculate the bearing clearance : Slg2 = c + d – e.
12.5.5.5 If the bearing clearance is within the permissible limits given in the table of clearances, the thrust bearing
may be mounted. If the clearance is too large, the contact face of the bearing end cover (361) must be
remachined. If the clearance is too small, the contact face of the thrust bearing (314) in the bearing end
cover (361) must be remachined.
12.5.6 Slide the spacer ring (504.01) over the shaft (210) and insert the key (940.05) into the shaft keyway.
12.5.7 Slide the thrust bearing plate (384) and spacer sleeve (525.05) on the shaft (210).
12.5.8 Screw the nut (920.09) on the shaft (210) and tighten it.
12.5.9 Fit the studs (902.11) to the bearing end cover (361).
12.5.10 Fit the bearing end cover (361) including thrust bearing (314), O-rings (412.11 and 412.12), parallel pin
(562.02), shaft seal ring (420.01) and circlip (932.03) and tighten the hex nuts (920.11) uniformly;
tightening torque, see the relevant work instruction.
_____________________________________________________________________
13. Mounting the Piping and Instruments
All pipes and instruments, which have been dismantled in connection with maintenance work, must be re-
installed as described in the chapter Installation on Site.
14. Mounting the Connecting Coupling

14.1 Fitting the Coupling Hubs
14.1.1 Thoroughly clean the shaft ends and bores of the coupling hubs and check them for dimensional accuracy.
_____________________________________________________________________________________
Caution Check the shaft ends for run-out prior to mounting the coupling hubs.
Permissible tolerance < 0.03 mm (see figure Run-out check of the shaft
ends). If the tolerance is exceeded, please inform KSB.
Observe the manufacturer’s mounting/dismantling instructions.
The pump shaft’s check values shall be read after each 900 turn.
_____________________________________________________________________________________
Run-out check of the shaft ends (example)
14.1.2 Slightly deburr the hub keyway and insert the keys.
14.1.3 Check the protrudent dimension of the keys. Tolerance in accordance with figure Clearance between
keyway and key.
0.2-0.3mm
Clearance between keyway and key
_____________________________________________________________________
14.1.4 To facilitate fitting, the coupling hub may be heated uniformly to a temperature of 800 C max.
_____________________________________________________________________________________
Use protective gloves.
! Risk of fire in case of open flames.
Remove flammable substances from the danger area.
______________________________________________________________________
14.1.5 Elastomeric parts must be removed before heating!
_____________________________________________________________________________________
Caution Elastomeric parts which have been heated must not be used anymore.
Use new parts for reassembly.
_____________________________________________________________________________________
14.1.6 Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft ends and the hub faces
are in alignment.
_____________________________________________________________________________________
Caution Fit the coupling hubs using only the appropriate device to prevent the
shaft bearings from damage by axial friction force. Impacts on the coupling
hubs are not permitted.
14.1.7 Securely tighten the grub screws (wherever applicable).
14.1.8 Fit the retaining ring, if applicable, to the coupling hub.
_____________________________________________________________________
14.2 Aligning the Connecting Coupling
Align the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapter
Installation on Site.
14.3 Mounting the Coupling Connection

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

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

________________________________________________________________________
Coupling guard ( example )
15.1.1 Align the coupling guard over the connecting coupling.

15.1.2 Make sure the distance between the shaft ends and the coupling components is sufficient.
15.2 Coupling Cover

______________________________________________________________________________________
Caution The pump must not be operated without a coupling cover!

________________________________________________________________________
Couplin cover (example )
_____________________________________________________________________
15.2.1 Meticulously clean the locating and sealing surfaces.
_____________________________________________________________________________________
Caution Do not damage the seal elements and sealing surfaces!

_____________________________________________________________________________________
15.2.2 Insert the gasket and O-ring.

15.2.3 Mount the lower cover half and fasten it to the backing ring.
15.2.4 Adjust the injection nozzles (if applicable) as shown in the figure Installation of the injection nozzles.
15.2.5 Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature resistant sealing agent (up
0
to 120 C).
15.2.6 Use eyebolt as a transport aid as shown in the figure Coupling cover.
15.2.7 Fix the cover halves with two taper pins.
15.2.8 Fasten the upper and lower halves with screws.
15.2.9 Connect the pipes to the cover.
15.3 Guard Preventing Accidental Contact for Shaft Seal

_____________________________________________________________________________________
Caution The pump must not be operated without a guard preventing accidental
contact!
_____________________________________________________________________________________
Fasten the guard preventing accidental contact to bearing housing using screws.
15.4 Sound Insulating Hood (if applicable)

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

16.1 Maintenance of the Connecting Coupling
See the manufacturer’s documentation.
16.2 Maintenance of Drive

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

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

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

17. Spare Parts

17.1 Ordering Spare Parts
Please direct your orders to the nearest KSB Customer Service Center or Sales Office.
When ordering spare parts, please quote

17.1.1 The KSB work orders number as indicated on the title page of this instruction manual or the pump name
plate.
17.1.2 The required pump set component, part no., designation and quantity required in accordance with the
list of components and sectional drawing.
17.2 Spare Parts Stock

For quick elimination of possibly occurring problems, we recommend to keep a stock of spare parts.
17.3 Storage
The parts should be stored as described under Interim Storage in the chapter Transport/Interim Storage.
_____________________________________________________________________
Trouble Shooting
________________________________________________________________________________________
Caution During the warranty period, pumps must be attended only by KSB
personnel!
________________________________________________________________________________________
1.1 For exact description of the pump design as well as the pump set components and
accessories supplied by KSB, please refer to P & I Diagram.
1.2 Requisite Documentation

For the elimination of problems described in the tables on the subsequent pages, the technical documentation
of the order pump set components is required in addition to this instruction manual. If these components are
included in kSB’s scope of supply, the relevant documents are appended to this instruction manual.
- Technical Data
- Operating Data
- General Arrangement Drawing
- P & I Diagram
- Table of Clearances
- Table of Tightening Torques
- Cross Sectional Drawing, Pump
- List of components, Pump
- Cross Sectional Drawing, Mechanical seal (if applicable)
- Documentation of Mechanical seal (if applicable)
- Work Instructions
- Documentation of the Connecting Coupling
- Documentation of the Drive
- Documentation of the Minimum Flow System (if applicable)
- Documentation of the Valves and Equipment (if applicable)
- Documentation of the Sound Insulating Hood, i.e. Acoustic Enclosure (if applicable)
- Documentation of Oil Supply Unit, i.e. Lube Oil Plant (if applicable)
- Documentation of Gear/Variable Speed Coupling (if applicable)
1.3 Prerequisites
1.3.1 All spare parts required are available.
1.3.2 Proper hoisting tackle and means of transport are available and ready for use.
1.3.3 Sufficient room space and appropriate tools are available.
1.3.4 For the work required as per the tables on the subsequent pages, the pump set has been taken out of
service in accordance with the Shutdown and Work after Shutdown sections in chapter Commissioning,
Start-up/Shutdown.
1.3.5 The drive has been secured against unintentional starting.
_____________________________________________________________________________________
Caution Before rectifying any faults, check all measuring instruments for proper
functioning!
_____________________________________________________________________________________
OIMPG TROUBLE-SHOOTING 1
_____________________________________________________________________
In case of problems not described in the following table, consultation with
KSB’s Customer service is required.
Problem (what) Possible causes Measures

Flow rate of pump > specified Pump delivers against an excessive high Open the valve in the discharge pipe further until the
value Duty point is adjusted
Excessive back pressure Mount larger impeller(s)
Contact KSB’s Service Center
Increase the speed of the turbine or internal combustion
engine
Check plant for impurities
Pump or piping are not completely vented or Vent and/or prime
primed
Inlet pipe or impeller(s) clogged Remove deposits in the pump and/or piping
Formation of air pockets in the piping Alter the piping layout
Fit a new valve
NPSHavailable too low (inlet) Correct the liquid level
Fully open the valve in the inlet pipe
Change the inlet pipe, if the resistances in the inlet pipe
are too high
Inlet pipe is too big
Check the strainers installed
Observe the permissible speed of pressure fall
Suction head is too high Clean the strainer element and inlet pipe
Correct the liquid level
Change the inlet pipe
Air intake at the gland packing Replace the gland packing
See chapter ‘Commissioning Startup/Shutdown’ &
Maintenance
Wrong direction of rotation Interchange 2 phases of the power supply
Speed is too low Increase the speed
Increase the voltage
Alter the impeller diameter
Wear of internal pump parts (check in Replace defective parts
accordance with the Tables of clearances)
Motor is running on 2 phases only Replace defective fuses
Check the power cable connections
Pump discharge pressure > Speed is too high Alter the impeller diameter
specified value Contact KSB’s Service Center
OIMPG TROUBLESHOOTING 2
_____________________________________________________________________

Pressure ps > specified value Damaged measuring instrument Replace the measuring instrument
Differential pressure in the strainer element is Dismantle and clean the strainer element
too high
Valve in the inlet pipe is not fully open Open the valve
Pressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressure
Pressure p d > specified value Damaged measuring instrument Replace the measuring instrument
Speed is too low Check the drive
Inlet pressure is too low Check the inlet pressure and inlet vessel
In case of tapping, quantity tapped is too high Throttle the tapping quantity
Temperature of the medium pumped is too low Increase or reduce the temperature
or too high
Defective minimum flow system Check the minimum flow system
Shaft seal leakage Defective shaft seal Check; replace, if required
Score marks or roughness on shaft protection Replace the shaft protection sleeve (524) or sleeve of
sleeve (524) and/or sleeve of mechanical seal mechanical seal
Gland (gland plate / gland ring) have been Check
tightened incorrectly
Wrong packing material Replace
See chapter ‘Commissioning/Startup/Shutdown’ &
Maintenance
Pump runs rough Correct the suction conditions
Re-align the pump
Re-balance the pump rotor
Increase pressure at the suction nozzle
Pump set alignment Check the coupling; re-align, if required
Pump is warped Check the piping connections and the fastening of the
pump
Insufficient quantity of cooling liquid Increase the cooling liquid quantity
Dirty cooling liquid chamber or cooler Clean the cooling liquid chamber and/or cooler
Check the cooling liquid; purify/clean, if required
Fault in the circulation liquid pipe Increase the effective cross section
Check the pipes
Surface pressure on the sealing clearance is Check the installation dimensions
too high, lack of lubricant or circulation liquid
_____________________________________________________________________

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

Unbalance of the pump rotor Clean the pump rotor
Balance the pump rotor
Pump set not correctly aligned Check the coupling and re-align, if required
pump
Coupling hub distance Check the coupling hub distance for compliance with the
GA Drawing; correct, if required
Temperature of pump > Pump or piping are not completely vented or Vent and/or prime
specified value primed
Change in the inlet pipe, if resistances in the inlet pipe

are too high
Inlet pipe is too long
Flow rate < specified value Increase the minimum flow
Pump leakage Defective O-rings and/or metallic sealing Replace O-rings and/or remachine the metallic sealing
surfaces surfaces

Tie rods have loosened Tighten
In accordance with the relevant work instruction
_____________________________________________________________________

Pump runs rough Pump or piping are not completely vented or Vent and/or prime
primed
Change the inlet pipe, if the resistances in the inlet pipe
are too high
Wear of internal pump parts ( check in Replace defective parts

Backpressure of pump is lower than specified Adjust the duty point accurately by means of the valve in
in the purchase order the discharge pipe
In the case of permanently overload, turn down the
impeller(s), if necessary

Pump set alignment Check the coupling and re-align, if required
pump
Oil quantity Check the oil quantity; top or replace, if required

Oil quality Check
See Technical Appendix
Unbalance of the pump rotor Clean the pump rotor
Balance the pump rotor
Defective bearing Replace
Flow rate < specified value Increase the minimum flow
Cavitation noise in the pump Damaged inlet pipe Check the inlet pipe
and/or piping Valve in the inlet pipe is not fully open Open the valve
Pressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressure
NPSHavailable / NPSHrequired too low Check the inlet pipe
Change the inlet pipe
Excessive speed of pressure fall
Air intake at the seal elements/valves/shaft seal Check the piping; check shaft seal for leakage
Pump or piping are not completely vented or Vent and/or prime
primed
_____________________________________________________________________

Pressure and/or quantity of Pump or piping are not completely vented or Vent and/or prime
balancing liquid fluctuates primed
Change the inlet pipe, if resistances in the inlet pipe are
too high
Wear of internal pump parts ( check in Replace the defective parts

Increased axial thrust Replace the casing wearing ring
Change in cross section of balancing liquid pipe Check the mode of operation
Excessive resistances Check the return pipe
Joining of several pipes near the pump
Balance flow leakage counter balancing disc / Check the pump pressures
final stage diffuser
Wear on the balancing device Check the rotor clearances and balancing device
Drive is overloaded Wear of internal pump parts ( check in Replace the defective parts

Back pressure of pump is lower than specified Adjust the duty point accurately by means of the valve in
in the purchase order the discharge pipe
In the case of permanently overload, turn down the

impeller(s), if necessary

Higher density or viscosity of the medium Contact KSB’s Service Center
pumped than specified in the purchase order
Gland tightened excessively or askew Alter
Speed is too high Alter the impeller diameter

Reduce the speed of the turbine or internal combustion
engine
pump
Operating voltage is low Check the power cable connections
Motor is running on 2 phases only Replace defective fuses
Check the power cable connections
_____________________________________________________________________
Tables of Clearances
Diametrical Clearances :
Pump size Hydraulics Nominal diametrical clearances [mm]

S6 S7 S8 S9 Sl2 Sl3
1 1; 2 0.25 – 0.34 0.35 – 0.50 0.27 – 0.36 0.90 – 1.40
2 3;4 0.90 – 1.50 0.50 – 1.0
3 5 0.30 – 0.36 0.40 – 0.51 0.35 – 0.45 1.0 – 1.5
6 0.30 – 0.37 0.25 – 0.40
4 7;8 0.35 – 0.41 0.45 – 0.51 0.32 – 0.39 1.0 – 1.6
5 9 ; 10 0.35 – 0.47 0.80 – 1.2
6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48
Max. permissible diamet- 1.0 1.0 1.0 2.0
rical clearance (mm)
S8
S6
2
2
S7
2
Sl2 Sl3 Sl2
Clearance between balance disc seat Clearance between double balance

and throttle sleeve or balance disc drum and balance disc seat
S9
2
Clearance between suction

casing or inlet ring and shaft
OIMPG CLEAR AF 1
_____________________________________________________________________
Theoretical Total Axial Clearance
Sa1 + Sa2 [mm]

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

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

1-6 0.30 - 0.50
Slg1
Lift-off Device with Tilting-pad Thrust Bearing
OIMPG CLEAR PLANE 1

_____________________________________________________________________
Bearing Clearances
Bearing design : Tilting-pad Thrust Bearing
Bearing clearance Slg2 [mm]

Pump size (Diametrical clearance)
3, 4 0.34 - 0.60
5, 6 0.40 - 0.75
Diametrical Clearances :
Pump size Hydraulics Nominal diametrical clearances [mm]

S6 S7 S8 S9 Sl2 Sl3
1 1; 2 0.25 – 0.34 0.35 – 0.50 0.27 – 0.36 0.90 – 1.40
2 3;4 0.90 – 1.50 0.50 – 1.0
3 5 0.30 – 0.36 0.40 – 0.51 0.35 – 0.45 1.0 – 1.5
6 0.30 – 0.37 0.25 – 0.40
4 7;8 0.35 – 0.41 0.45 – 0.51 0.32 – 0.39 1.0 – 1.6
5 9 ; 10 0.35 – 0.47 0.80 – 1.2
6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48
Max. permissible 1.0 1.0 1.0 2.0
diamet-
rical clearance (mm)
OIMPG CLEAR PLANE H 1

_____________________________________________________________________
Table of Tightening Torques

Tightening Torques [Nm]
HG Pump Sizes 1 – 6
1. Prerequisites
1.1 The threads of the screws/bolts and nuts are not damaged.
1.2 The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred and cleaned thoroughly.
1.3 The threads move smoothly.
1.4 The washers are plane, deburred and cleaned thoroughly.
2. Pump
Observe the tightening torques for the screwed/bolted connections as per relevant work instruction.
3. Fastening of Pump Feet

Thread Tightening torque MA [Nm]
M 20 190
M 24 330
M 30 660
M 36 1160
4. Flange Connection
If the bolting for the flanged connections are in the KSB’s scope of Supply, the tightening torques will be as
specified in the table on the following pages.
OIMPG TIGHT TRQ 1

_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle

The tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.
Flanges as per DIN

Nominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]
160 90
25 250 140
64 140
40 160 160
250 240
64 160
50 160 270
250 240
64 140
65 160 240
250 270
64
80 160 250
250 370
64
160 350
250 530
100 320
400
500
160 500
250 490
320
125 400
500
160 490
250 650
150 320
400
500
160 660
250 1150
200 320
400
500
160 1260
250 250
320
400
OIMPG TIGHT TRQ 2

_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle

Flanges as per ANSI

Nominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA
[Nm]
600 80
1” 1500 240
600 140
1 ½” 1500 350
600 90
2” 1500 240
600 140
2 ½” 1500 270
600
3” 900 240
1500 490
600 490
900
1500 650
4” 2500
900 650
1500 1100
5” 2500
900 490
1500 830
6” 2500
900 830
1500 1350
8” 2500
900 840
10” 1500
2500
OIMPG TIGHT TRQ 3

_____________________________________________________________________
Bolts for Flange Connection, Suction Nozzle

Flanges as per DIN

Nominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]
16 50
65 40 70
16 50
80 40 70
16 70
125 40 150
16 130
150 40 200
16 130
200 25 190
40 240
16 210
25 290
250 40 380
16 210
25 240
300 40 320
Flanges as per ANSI

Nominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA [Nm]
2 ½” 300 90
3” 300 90
5” 300 210
6” 300 120
8” 300 210
10” 300 260
12” 300 320
OIMPG TIGHT TRQ 4

_____________________________________________________________________
Table of Weights
HG Pump Size 1
_____________________________________________________________________________________
Caution Weights ≥ 25 kg
_____________________________________________________________________________________
Pump Components
Part No. Designation Weights (reference values in kg)

106 Suction Casing 35.0
107 Discharge Casing 58.0
210 Shaft for 3 stages 17.9
each additional stage 1.2
350.01 Bearing Housing 25.0
Rotor 3 stages 31.0
Each additional stage 4.0
Pump
Number of stages Weights (reference values in kg)

Without water fill Water fill
3 234 8.0
4 250 809
5 266 9.7
6 282 10.6
7 298 11.5
8 314 12.4
9 330 13.3
10 346 14.2
11 362 15.1
12 378 16.0
13 394 16.9
14 410 17.8
15 426 18.7
16 442 19.6
17 458 20.5
18 474 21.4
19 490 22.3
20 506 23.2
OIMPG WEIGHT 1
_____________________________________________________________________
Table of Weights
HG Pump Size 2
_____________________________________________________________________________________
_____________________________________________________________________________________
Pump Components

108 Stage Casing 25.0
Rotor 3 stages 52.0
Pump

3 410 19.0
4 440 21.6
5 470 24.2
6 500 26.8
7 530 29.4
8 560 32.0
9 590 34.6
10 620 37.2
11 650 39.8
12 680 42.4
13 710 45.0
14 740 47.6
15 770 50.2
16 800 52.8
17 830 55.4
18 860 58.0
OIMPG WEIGHT 2
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
_____________________________________________________________________________________
Pump Components

108.01 Stage Casing 38.00
130 Casing Part, for double piston 25.0
For mechanical seal 30.5
354 Thrust Bearing Housing, thrust bearing/plain bearing 25.0
361 Bearing End Cover, thrust bearing/plain bearing 29.0
441 Seal Casing 39.0
Rotor 3 stages 83.0
Pump

3 736 27.0
4 774 30.0
5 812 33.0
6 850 36.0
7 888 39.0
8 926 42.0
9 964 45.0
10 1002 48.0
11 1040 51.0
12 1078 54.0
13 1116 57.0
14 1154 60.0
15 1192 63.0
16 1230 66.0
OIMPG WEIGHT 3
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
_____________________________________________________________________________________
Pump Components

106 Suction Casing < 320 bar 210.0
≤ 420 bar 250.0
107 Discharge Casing < 320 bar DN 80 255.0
< 250 bar DN 100 285.0
>320 bar DN 100 315.0
≤ 420 bar DN 100 530.0
DN 125 550.0
130 Casing Part, for double piston 25.0
For mechanical seal 30.5
131 Inlet Ring 80.0
350.01 Bearing Housing, suction side 57.0
Heavy bearing housing 61.0
350.02 Bearing Housing, discharge side 150.0
Rotor 3 stages 83.0
Pump

3 736 27.0
4 774 30.0
5 812 33.0
6 850 36.0
7 888 39.0
8 926 42.0
9 964 45.0
10 1002 48.0
11 1040 51.0
12 1078 54.0
13 1116 57.0
14 1154 60.0
15 1192 63.0
16 1230 66.0
OIMPG WEIGHT 4
_____________________________________________________________________
Table of Weights
HG Pump Size 4
_____________________________________________________________________________________
_____________________________________________________________________________________
Pump Components


130 Casing Part 33.0
131 Inlet Ring 110.0
350.01 Bearing Housing, suction side 57.0
350.02 Bearing Housing, discharge side 150.0
603.02 Balancing Piston 28.0
905 Tie Rods for 3 Stages M 45 10.3
Rotor 3 stages 130.0
Pump

3 1380 41.8
4 1477 47.4
5 1574 53.0
6 1671 58.6
7 1768 64.2
8 1865 69.8
9 1962 75.4
10 2059 81.0
11 2156 86.6
12 2253 92.2
13 2350 97.8
14 2447 103.4
15 2544 109.0
16 2641 114.6
OIMPG WEIGHT 5
_____________________________________________________________________
Table of Weights
HG Pump Size 5
_____________________________________________________________________________________
_____________________________________________________________________________________
Pump Components
106 Suction Casing DN 200 622.0
≤ 420 bar DN 200 819.0
DN 250 635.0
≤ 420 bar DN 150 1020.0
≤ 420 bar DN 200 1170.0
108.02 Stage Casing, Hydraulic 9 93.0

Hydraulic 10 84.0
108.03 Stage Casing, Hydraulic 9 100.0
13-6 Casing Insert 96.0
130 Casing Part 59.0
131 Inlet Ring 180.0
171.01 Diffuser 25.0
171.02 Diffuser 25.0
360.01 Bearing Cover 36.0
361 Bearing End Cover 44.0
601 Balancing Disc 25.0
905 Tie Rods for 3 Stages M 45 12.9
Tie Rods for 3 Stages M 52 17.5
Rotor 3 stages 243.0
Pump
3 2775 80
4 2930 90
5 3085 100
6 3240 110
7 3395 120
8 3550 130
9 3705 140
10 3860 150
11 4015 160
12 4170 170
13 4325 180
OIMPG WEIGHT 6

A. - Pump OIM - 3

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_______________________________________________________________________________________________

Chapter : General OIMPG General 1

Chapter : Transport / Interim Storage

Contents OIM Pages 3 1/7

DESCRIPTION PAGE REFERENCE

Chapter : Installation on Site

Contents OIM Pages 3 2/7

DESCRIPTION PAGE REFERENCE

Chapter : Commissioning, Start-up/Shutdown

Chapter : Pump Supervision Plan OIMPG SUPERVISION 06

Contents OIM Pages 3 3/7

DESCRIPTION PAGE REFERENCE

Chapter : Servicing OIMPG SERVICING 01

Chapter : Maintenance OIMPG MAINTENANCE 01

5. Dismantling the Bearings OIMPG MAINTENANCE 06

6. Dismantling the Shaft Seal OIMPG MAINTENANCE 13

Contents OIM Pages 3 4/7

DESCRIPTION PAGE REFERENCE

8. General Information on Reassembly OIMPG MAINTENANCE 27

9. Checking the Balancing Device with Contact Fluid OIMPG MAINTENANCE 27

10. Mounting the Balancing Device OIMPG MAINTENANCE 36

11. Mounting the Shaft Seal OIMPG MAINTENANCE 40

12. Mounting the Bearings OIMPG MAINTENANCE 43

13. Mounting the Piping and Instruments OIMPG MAINTENANCE 49

14. Mounting the Connecting Coupling OIMPG MAINTENANCE 49

Contents OIM Pages 3 5/7

DESCRIPTION PAGE REFERENCE

16. Maintenance of the Other Pump Set Components OIMPG MAINTENANCE 52

17. Spare Parts OIMPG MAINTENANCE 53

Chapter : Trouble Shooting OIMPG TROUBLE-SHOOTING 1

Chapter : Tables of Clearances

Contents OIM Pages 3 6/7

DESCRIPTION PAGE REFERENCE

Chapter : Table of Tightening Torque

Chapter : Table of Weights

Contents OIM Pages 3 7/7

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

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

We recommend to call in KSB’s experienced personnel for installation,

Prior to returning any pump set components, carefully follow the

Caution All measuring instruments supplied with the pump should be

3. Conformity with EU Regulations (if applicable)

Marking of Instructions in the Instruction Manual

The electrical danger warning sign is

Personnel Qualification and Training

Non-compliance with Safety Instructions

In particular, non-compliance can, for example, result in:

Safety Instructions for the Operator/User

Safety Instructions for Work on the Pump Set

Unauthorized Modification and Manufacture of Spare Parts

Unauthorized Modes of Operation

Observe the applicable local safety regulations.

1.1 Hoisting Tackle (e.g. ropes, gear)

3.1 Transport of the Pump Set

Caution Do not damage any built-on accessories and pipes.

Transport of pump sets mounted on baseplates ( examples )

3.2 Transport of the Pump

3.3 Transport of the Other Pump Set Components

3.4 Transport of the Pump Rotor

3.5 Transport of Pump Set Accessories

4.1.1 Weights with packaging : see packing list.

4.3 Period of Storage up to 12 Months