INSTALLATION, OPERATION

AND

MAINTENANCE MANUAL

CM - 0104

KIRLOSKAR MONOBLOC

KAM

Agri

KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group company

WORKS :Ujjain Road, Dewas - 455 001 (M.P.) Phone : +91 7272 227401/2/5/9 Fax : +91 7272 228747 Toll Free No. 1800 103 4443

CORPORATE OFFICE :“YAMUNA”, Survey No. 98 (3-7), Baner, Pune 411 045 (India)Phone : +91 20 27214444 E-mail : kblin@kbl.co.in Visit us at : www.kirloskarpumps.com

REGISTERED OFFICE :Udyog Bhavan, Tilak Road, Pune - 411 002 (India)Tel. : +91 20 24444444 Fax : +91 20 24444198E-mail : kbl@kbl.co.in

KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group Company

A View of KBL Dewas Manufacturing Plant

06010190

FOR PROMPT SERVICE & SPARES

Register on our website : www.kirloskarpumps.com

Our products are meant for pumpingwater and they do not have any significant effect

on environment during their use, if properlyselected and used as per instructions

given in this manual.

Customers are advised to dispose unusablecomponents through appropriate disposal agencies to

avoid the impact on work environment.

2

üInstallation 3

üPiping 3

üElectrical Connections 4

üConnection Diagram 5

üElectrical Details 6

üOperational Instruction 6

üPriming 7

üMaintenance 7

üOperational Problems & Causes 9

üExploded View (M. Seal) 12

üExploded View (G.P.) 13

üPart List 14

üProduct Range 15

üWarranty Certificate 16

Content

3

The piping should be airtight. Any leakage in suction pipe may

drastically affect the performance of the pump.

The suction pipe should be as short as possible for getting better

discharge.

No. of bends and other fittings should be as minimum as possible to

reduce frictional lossses.

Adequate supports should be provided to pipes so that its dead weight

should not fall on delivery casing completely.

The horizontal length of the suction pipe should be straight to avoid

air trapping in pipe. It should not be inclined towards the pumps.

For deliverypressure more than 20 meters, it is recommended to

install a check (non-return) valve in the discharge line. The check

valve placed near the pump is to protect the pump from excessive

back-pressure to prevent the water running back through the pump

in case of sudden failure of prime mover.

It is recommended to use KIRLOSKAR low friction foot valve having

‘K’ factor less than 0.8 for better discharge.

ELECTRICAL CONNECTIONS :

Proper earthing connection should be made at the bolts provided for

earthing.

WRONG RIGHT

WRONG RIGHT

4

Proper size of cable should be used between supply and motor

terminals to minimise voltage drop and to carry full load current (FLC)

as well as the maximum current in the operating voltage range speci

fied.

Nuts at terminal should be tightened properly.

No. of joints in cabls should be as minmum as possible preferably,

joints should be avoided.

Wires and connections should be properly insulated. lf not it may

lead to fatal shock.

Proper backup protection (reputed make starter, main switch and

fuse) should be used.

CONNECTION DIAGRAM

1.0 DOL or Auto transformer with 3 Ieads or 6 Ieads

5 6

MOTOR RATING IN

kW/HP

POLES NO. OFPHASES

RATED VOLTAGE(VOLTS)

FULL LOADCURRENT

(AMPS)

MAX OPERATINGCURRENT

(AMPS)

CURRENT FORREPLAY

SELECTION(AMPS)

TYPE OFSTARTING

VOLTAGERANGE

KAM ELECTRICAL DETAILS

0.37/0.5

0.56/0.75

0.75/1.0

1.1/1.5

2.2/3.0

3.7/5.0

5.5/7.5

7.5/10.0

9.3/12.5

11.0/15.0

2

2

2

2

2

2

2

2

2

2

1

1

1

1

3

3

3

3

3

3

200

200

210

230

400

400

415

415

415

415

3.40

5.10

8.80

9.50

8.00

11.40

15.00

18.50

21.50

29.00

4.30

6.40

11.00

11.90

10.00

14.25

18.75

23.13

26.88

36.25

4.30

6.40

11.00

11.90

10.00

8.27

10.88

13.42

15.59

21.03

DOL

DOL

DOL

DOL

DOL

Star Delta

Star Delta

Star Delta

Star Delta

Star Delta

120-220

120-220

180-240

180-240

300-440

300-440

300-440

300-440

300-440

300-440

7

PROCEDURE FOR FITTING THE MECHANICAL SEAL IN CASE OF

MECHANICAL SEAL ARRANGEMENT :

l Apply soap solution of rubber cap of stationary part.

l Insert the stationary part of mechanical seal and press it upto the

bore face of the mounting casing.

l Insert upper part of mechanical seal (i.e. Rotating part) on the

shaft.

l Insert the spacer.

RECOMMENDED SPARES FOR TWO YEARS OF NORMAL WORKING :

1. Impeller.

2. Ball bearings.

3. Mechanical seal (In case of mechanical seal pumps).

4. Gland packing (In case of gland packed pumps).

5. Shaft sleeve (In case of gland packed pumps).

6. Bush bearing (If provided).

7. Wearing ring (if provided).

8. Capacitors (in case of single phase monobloc pumps).

9. Water deflector.

10. Paper packing.

8

OPERATIONAL PROBLEMS AND CAUSES :

TY

PE

OF

TH

E F

AIL

UR

E

Fa

ilure

to d

eliv

er

wate

r

Pu

mp

do

es n

ot de

lvie

rra

ted

dis

ch

arg

e

Pu

mp

do

es n

ot de

live

rra

ted

hea

d

Pu

mp

loo

se

s w

ate

r a

fte

rsta

rt

Pu

mp

overlo

ads

Prim

em

ove

r

Vib

ratio

n

Stu

ffin

g B

ox o

ve

rhe

ats

Be

arin

g o

ve

rhe

at

Be

arin

g w

ea

r ra

pid

ly

Moto

r h

ea

ting

up

Se

ize

d p

um

p

Irre

gula

r d

eliv

ery

Pu

mp

doe

s n

ot p

rim

e

No

isy P

um

p

REASON FOR FAILURE

Worong direction of rotation

Pump not primed or filled with liquid

Suction line not filled with liquid

Air or vapour pocket in suciton line

Inlet or suciton pipe insufficiently submerged

NPSH available too low

Pump not upto rated speed

Air leaks in suction line or stuffing box

Foot valve too small

Foot valve clogged

Viscosity greater than rated

Wear rings worn

Impeller damaged

Internal leakage (gasket)

Priming air/vent valves open

Gas or vapour in liquid

9

OPERATIONAL PROBLEMS AND CAUSES :

TY

PE

OF

TH

E F

AIL

UR

E

Fa

ilure

to d

eliv

er

wate

r

Pu

mp

do

es n

ot de

lvie

rra

ted

dis

ch

arg

e

Pu

mp

do

es n

ot de

live

rra

ted

hea

d

Pu

mp

loo

se

s w

ate

r a

fte

rsta

rt

Pu

mp

overlo

ads

Prim

em

over

Vib

ratio

n

Stu

ffin

g B

ox o

ve

rhe

ats

Be

arin

g o

ve

rhe

at

Be

arin

g w

ea

r ra

pid

ly

Moto

r h

ea

ting

up

Se

ize

d p

um

p

Irre

gula

r d

eliv

ery

Pu

mp

doe

s n

ot p

rim

e

No

isy P

um

p

REASON FOR FAILURE

Speed too high

Total head lower than recommended

Viscosity and/or specific gravity higher than rated

Starved suction

Wom or loose bearings

Rotor out of balance

Impeller blocked or damaged

Bent shaft

Foundation not rigid or poor mixture

Gland packing too tight

Gland packing not lubricated

Wrong grade of gland packing

Insufficient cooling water

Stuffing box badly packed

Wrong grade of Grease

Dirt in bearings

10

OPERATIONAL PROBLEMS AND CAUSES :

TY

PE

OF

TH

E F

AIL

UR

E

Fa

ilure

to d

eliv

er

wate

r

Pu

mp

do

es n

ot de

lvie

rra

ted

dis

ch

arg

e

Pu

mp

do

es n

ot de

live

rra

ted

hea

d

Pu

mp

loo

se

s w

ate

r a

fte

rsta

rt

Pu

mp

overlo

ads

Prim

em

ove

r

Vib

ratio

n

Stu

ffin

g B

ox o

ve

rhe

ats

Be

arin

g o

ve

rhe

at

Be

arin

g w

ea

r ra

pid

ly

Moto

r h

ea

ting

up

Se

ize

d p

um

p

Irre

gula

r d

eliv

ery

Pu

mp

doe

s n

ot p

rim

e

No

isy P

um

p

REASON FOR FAILURE

Moisture in lubricant

Failure of lubricating system

Bearings to tight

Excessive thrust

Lack of lubrication

Bearing badly installed

Too much grease in bearings

Pump does not deliver rated capacity

Pipes exert forces on pump

Vibration

Foreign matter in pump

Viscosity lower than rated

Speed too low

Foundation bolts loose, motor/pump bolts loose

leak in delivery pipe-work

Mechanical seal fault

11

EXPLODED VIEW OF KAM

FIG 1 EXPLODED VIEW OF KAM (M. SEAL) PUMPS

12

EXPLODED VIEW OF KAM

FIG 2 EXPLODED VIEW OF KAM (G.P.) PUMPS

13

PART LIST (GENERAL) FOR MONOBLOC PUMPS

14

15

Product range manufactured by Kirloskar Brothers Limited, Dewas

For details contact the dealer

Pump Series

KDS+/++

KDT+

KS+

KOS

SP

KJV/H,KJ+

MINI,DC,DHX

SubmersibleKu4 Winner

NW,KE,KHKHDT+,SR

KV, DV

Alternator

Motor

Construction Feature

Monobloc

Monobloc

Monobloc

Monobloc

Monobloc/Coupled

Monobloc

Monobloc

------------

Coupled

Monobloc/Coupled

------------

------------

Drive Unit

Electric Motor(1 and 3 Phase)Electric Motor(1 and 3 Phase)Electric Motor(1 and 3 Phase)Electric Sub. Motor(1 and 3 Phase)Electric Motor(Monobloc)Electric Motor(1 and 3 Phase)Electric Motor(1 and 3 Phase)Electric Sub. Motor(1 and 3 Phase)

Engine / Motor

Electric Motor

----------------

----------------

Power Rating

1.5 HP - 30.0 HP

1.0 HP - 20.0 HP

3.0 HP - 10.0 HP

0.5 HP - 10.0 HP

0.5 HP - 5.0 HP

0.5 HP - 3.0 HP

0.25 HP - 1.0 HP

0.5 HP - 75.0 HP

---------------------

---------------------

2 KVA - 50 KVA

0.5 HP - 120 HP

16

This product is warranted against manufacturing defects and workmanship under normal use and service for the period of 24 months from the date of manufacturing OR 12 months from date purchase of the end user whichever is earlier.

We undertake to repair or replace the product at our discretion or any partthereof, for which we are satisfied that it was originally defective in material or workmanship, provided that product or its parts are returned to our nearestregional office / dealer on freight paid basis, within the warranty period. Thiswarranty does not cover any consequential damage of any nature.

This warranty excludes every condition, whether statutory or otherwise, whatsoever is not expressly set out here.

Product Model:_________________________________________________

Sr. No. :______________________________________________________

Date of Purchase :_______________________________________________

Bill/Cash Memo No. :____________________________________________

SPECIAL INSTRUCTIONS: “ Customers are advised to go through the product manual carefully for proper installation, use and servicing product & genuine spare parts. It is also advisable to go through the company’s published literature, catalogue or other official publication. Any deviation, if made by the customers will void the warranty obligations. Repair by trained mechanics will get you better results.”

This card must be produced at the time of claiming the warranty along with purchase documents.

Dealer’s stamp and signature :___________________