Grundfos KP, KPV, KPVS Installation And Operating Instructions Manual

KP, KPV, KPVS

Split-case centrifugal pumps

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

KP, KPV, KPVS

Table of contents

English (US)

Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Français (CA)

Notice d'installation et de fonctionnement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Español (MX)

Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Annexe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Anexo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2

English (US) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos
KP, KPV, KPVS pumps.

Sections 1-6 give the information necessary to be able to unpack,
install and start up the product in a safe way.

Sections 7-11 give important information about the product, as
well as information on service, fault finding and disposal of the
product.

CONTENTS

Page

1. Limited warranty

2. General information

2.1 Symbols used in this document

2.2 Other important notes

3. Receiving the product

3.1 Unpacking the product

3.2 Inspecting the product

3.3 Temporary storage after delivery

4. Installing the product

4.1 Location

4.2 Pump foundation

4.3 Securing the baseplate

4.4 Mechanical installation

4.5 Electrical connection

4.6 Outlet pipe

4.7 Shaft seals

4.8 Coupling alignment (KP)

5. Starting up the product

5.1 Priming

5.2 Pre-start checklist

5.3 Motor direction of rotation

5.4 Starting the pump

6. Handling and storing the product

7. Product introduction

7.1 Applications

7.2 Pumped liquids

7.3 Pump identification

8. Servicing the product

8.1 Maintaining the product

8.2 Disassembling the pump

8.3 Reassembling the pump (KP, KPV, KPVS)

8.4 Recommended spare parts

8.5 KP, Horizontal, cross-section and parts list

8.6 KPV, Vertical, cross-section and parts list

8.7 KPVS, Vertical Split Coupling Split Case, cross-section
and parts list

8.8 Taking the product out of operation

9. Fault finding the product

10. Technical data

10.1 Operating conditions

11. Disposing of the product

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10
11

12

12
12
12
13

13
13

13
13
14

16

16
18
20
22
23
24

25
26

27
29

29

29

WARNING

Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.

English (US)

WARNING

The use of this product requires experience with and
knowledge of the product. Persons with reduced
physical, sensory or mental capabilities must not use

4
4

4
5

5

5
6
6

7

7
7
7
8
9

this product, unless they are under supervision or
have been instructed in the use of the product by a
person responsible for their safety. Children must not
use or play with this product.

CAUTION

Successful operation depends on careful attention to
the procedures described in this manual. Keep this
manual for future use.

3

English (US)

1. Limited warranty

New equipment manufactured by seller or service supplied by
seller is warranted to be free from defects in material and
workmanship under normal use and service for a minimum of
twelve (12) months from date of installation, eighteen (18) months
from date of shipment, unless otherwise stated in product
warranty guide (available upon request). In the case of spare or
replacement parts manufactured by seller, the warranty period
shall be for a period of twelve months from shipment. Seller's
obligation under this warranty is limited to repairing or replacing,
at its option, any part found to its satisfaction to be so defective,
provided that such part is, upon request, returned to seller's
factory from which it was shipped, transportation prepaid. Parts
replaced under warranty shall be warranted for twelve months
from the date of the repair, not to exceed the original warranty
period. This warranty does not cover parts damaged by
decomposition from chemical action or wear caused by abrasive
materials, nor does it cover damage resulting from misuse,
accident, neglect, or from improper operation, maintenance,
installation, modification or adjustment. This warranty does not
cover parts repaired outside seller's factory without prior written
approval. Seller makes no warranty as to starting equipment,
electrical apparatus or other material not of its manufacture. If
purchaser or others repair, replace, or adjust equipment or parts
without seller's prior written approval, seller is relieved of any
further obligation to purchaser under this paragraph with respect
to such equipment or parts, unless such repair, replacement, or
adjustment was made after seller failed to satisfy within a
reasonable time seller's obligations under this paragraph. Seller's
liability for breach of these warranties (or for breach of any other
warranties found by a court of competent jurisdiction to have
been given by seller) shall be limited to: (a) accepting return of
such equipment exw plant of manufacture, and (b) refunding any
amount paid thereon by purchaser (less depreciation at the rate
of 15 % per year if purchaser has used equipment for more than
thirty [30] days), and canceling any balance still owing on the
equipment, or (c) in the case of service, at seller's option, redoing
the service, or refunding the purchase order amount of the
service or portion thereof upon which such liability is based.
These warranties are expressly in lieu of any other warranties,
express or implied, and seller specifically disclaims any implied
warranty of merchantability or fitness for a particular purpose, and
in lieu of any other obligation or liability on the part of the seller
whether a claim is based upon negligence, breach of warranty, or
any other theory or cause of action. In no event shall seller be
liable for any consequential, incidental, indirect, special or
punitive damages of any kind. For purposes of this paragraph, the
equipment warranted shall not include equipment, parts, and
work not manufactured or performed by seller. With respect to
such equipment, parts, or work, seller's only obligation shall be to
assign to purchaser the warranties provided to seller by the
manufacturer or supplier providing such equipment, parts or
work. No equipment furnished by seller shall be deemed to be
defective by reason of normal wear and tear, failure to resist
erosive or corrosive action of any fluid or gas, purchaser's failure
to properly store, install, operate, or maintain the equipment in
accordance with good industry practices or specific
recommendations of seller, including, but not limited to seller's
installation and operation manuals, or purchaser's failure to
provide complete and accurate information to seller concerning
the operational application of the equipment.

2. General information

2.1 Symbols used in this document

DANGER

Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.

The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION will be structured in the following way:

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

Example

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.

4

2.2 Other important notes

3.1.1 Lifting and handling

A blue or grey circle with a white graphical symbol
indicates that an action must be taken to avoid a
hazard.

A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.

If these instructions are not observed, it may result in
malfunction or damage to the equipment.

Notes or instructions that make the work easier and
ensure safe operation.

3. Receiving the product

WARNING

Damage to personnel or product

Death or serious personal injury

- Allow only qualified personnel to handle the
product during receiving, inspecting, and
unpacking.

Do not use lifting lugs on the pump or eye bolts on
the motor to lift the entire pump assembly.

English (US)

Lifting equipment is the responsibility of the
customer. The following instructions are suggestions
only.

Before proceeding, read the warnings and
instructions in sections 2. General information
through 8.1 Maintaining the product.

Lifting KP (horizontal) pump without motor

1. Before unloading the product, move the shipping container to
an open area equipped with overhead lifting equipment.

2. Install a lifting strap on each side of the bearing housing. See
fig. 1.

3.1 Unpacking the product

WARNING

Overhead load

Death or serious personal injury

- Do not lift the product by the lifting lugs or eye
bolts on the motor.
Unload and handle the product with a sling.

- All complete horizontal KP pump units must be
lifted by fork truck from beneath the pump's steel
base.

WARNING

Crushing hazard

Death or serious personal injury

- Always lift the pump with lifting equipment.

- Use the correct lifting points.

TM04 0380 0608

Fig. 1 KP bare shaft pumps, correct lifting points

KP (horizontal) pumps, complete with motor

1. Before unloading the product, move the shipping container to
an open area equipped with overhead lifting equipment.

2. Lift complete horizontal KP pump units by fork truck from
beneath the pump's steel base.

TM06 8436 0517

Fig. 2 Horizontal KP complete pumps, correct lifting points

5

English (US)

Attach lifting
straps to the
pallet

Use lifting
straps to
rotate the
pallet with the
pump
assembly to
vertical
position

Strap

Lifting KPV, KPVS (vertical) pumps

Before unloading the product, move the shipping container to an
open area equipped with an overhead lifting mechanism.

1. Install a lifting strap on each of the pallet's 4 x 4 in. floor
boards. Attach the straps securely at the corners of the pallet
near the top of the pump motor. See fig. 3.

2. Attach the other end of the straps to a lifting hook.

3. Rotate the pump assembly to the vertical position.

4. Remove excess packaging for easier access to the pump
assembly.

5. Position two lifting straps around the motor, below the junction
box and 180 degrees apart. See fig. 4.

6. Tighten the straps securely.

7. Attach the free ends of the lifting straps to a lifting hook.

8. Tie a strap around the upper portion of the motor to hold the
lifting strips tight against the motor. Ensure the straps stay
tight against the motor while moving the pump assembly.

9. Utilize appropriately rated lifting equipment to move the pump
assembly to the installation location.

Fig. 3 KPV, KPVS pumps, correct lifting points for pallet

3.2 Inspecting the product

• Check that the product received is in accordance with the
order.

• Check that the voltage and frequency of the product match the
voltage and frequency of the installation site. See section

7.3 Pump identification.

• Check the product for defects and damage immediately upon
arrival. Any accessories ordered will be packed in a separate
container and shipped with the product.

• If any equipment is damaged in transit, promptly report this to
the carrier's agent. Make complete notations on the freight bill.

3.3 Temporary storage after delivery

If the product is not to be installed and operated immediately after
receiving it, store it in a clean, dry place at a moderate ambient
temperature. Protect the pump from moisture, dust, dirt and
foreign bodies. Prior to and during storage, we recommend these
precautions:

1. Ensure that the bearings are filled with the recommended

grease to prevent moisture from entering around the shaft.
See section 8.1.2 Lubricating the pump bearings.

2. Ensure that the inlet and outlet ports of the pump and all other

openings are covered with cardboard, wood or masking tape
to prevent foreign objects from entering the pump.

3. Cover the product with a tarpaulin or other suitable covering if

it is to be stored where there is no protective covering.

4. Rotate the shaft 2 turns every 2 weeks to coat the bearings,

stuffing box (packing), and shaft seal faces with lubricant to
impede oxidation and corrosion.

5. This equipment contains vegetable fiber gaskets that can dry

out during long storage periods. To avoid leaks, fill the pump
with water and let stand for 24 hours prior to startup or
pressure testing. Typically, this will allow the dry gaskets to

TM06 8345 0117 - TM06 8347 0117TM06 8348 0117

wick moisture back into themselves, sealing the pump.

6. Split case pumps must be pressurized only with the medium

they are intended to pump. Do not perform any pressurized
"air" test.

Fig. 4 KPV, KPVS pumps, correct lifting points

6

4. Installing the product

Grout

Base plate

Finished grouting

0.75 to 1.25 in.
(20 to 32 mm)
allowance for
grout

Formwork

Pipe sleeve

Washer

Lug

Top of foundation

Wedges or shims
left in place

0.25
KPV, KPVS
stand

Anchor bolts for
supporting the base

Wedges or shims
(as required)

Grouted pad for
anchoring/
housekeeping

All installations must be performed by personnel experienced with
the placement, connection, and alignment of pumping equipment.
The following instructions are general in nature, and may not deal
with the specifics of your installation. Read these instructions
thoroughly before installing and operating your KP, KPV, or KPVS
pump.

4.1 Location

• Locate the pump as close as possible to the liquid supply. Use
the shortest and most direct inlet pipe practical. Refer to
section 4.4.2 I nlet pipe.

• Locate the pump below system level wherever possible. This
will facilitate priming, assure a steady liquid flow, and provide
a positive inlet pressure.

• The Net Positive Suction Head (NPSH) available must always
be equal to or exceed the required NPSH specified on the
pump performance curve. Make sure that sufficient NPSH is
provided at the inlet.

• Always allow sufficient accessibility space for maintenance
and inspection. Provide a clearance of 24 in. (610 mm) with
ample head room for use of overhead lifting equipment strong
enough to lift the product.

• Do not expose the product to sub-zero temperatures to
prevent the pumped liquid from freezing. If there is frost during
shutdown periods, see the shutdown information included in
section 8.8 Taking the product out of operation.

4.2 Pump foundation

Install the pump permanently on a firm, raised concrete
foundation of sufficient size to dampen any vibration and prevent
any deflection or shaft misalignment. The foundation may float on
springs or be a raised part of the floor.

Proceed like this:

1. Pour the foundation without interruption to 0.75 - 1.5 in. (20-

35 mm) below the final pump level.

2. Scour and groove the top surface of the foundation before the

concrete sets to provide a suitable bonding surface for the
grout.

3. Place anchor bolts in pipe sleeves for positioning allowance.

See fig. 5 and fig. 6.

4. Allow enough bolt length for grout, base, flange, nuts, and

washers.

5. Allow the foundation to cure several days before proceeding

to install the pump.

English (US)

TM06 6124 0816

Fig. 6 KPV, KPVS anchor bolt installation

4.3 Securing the baseplate

When the raised concrete foundation has been poured and
allowed to set, proceed as follows:

1. Lower the base plate over the anchor bolts and rest it on loose
adjustment wedges or shims placed near each anchor bolt
and at intervals not exceeding 24 in. (610 mm) along each
side.

2. Place the shims or wedges so that they raise the bottom of the
base plate 0.75 in. - 1.25 in. (20-32 mm) above the pad,
allowing clearance for grout.

3. Level the pump shaft, flanges, and base plate using a spirit
level, adjusting the wedges or shims, as required.

Place a spirit level on top of the pump to check that it
is level.

4. Make sure that the pipes can be aligned to the pump flanges
without placing any strain on either flange.

5. After pump alignment has been established, put nuts on
anchor bolts and tighten them just enough to keep the base
plate from moving.

6. Construct a formwork around the concrete foundation and
pour grout inside and around the base plate. See fig. 5 for KP
and fig. 6 for KPV, KPVS. The grout will compensate for
uneven foundation, distribute the weight of the pump, and
prevent shifting.

Use an approved, non-shrinking grout.

7. Allow at least 24 hours for the grout to set before proceeding
with the pipe connections.

8. After the grout has thoroughly hardened, check the anchor
bolts and tighten them if necessary. Recheck the pump
alignment after tightening the anchor bolts.

Fig. 5 KP anchor bolt installation

TM05 4775 2512

7

English (US)

Correct

Eccentric
reducer

Taper is down

Air pocket

Wrong

Concentric
reducer

Correct

Air pocket

Wrong

4.4 Mechanical installation

4.4.1 Piping

Do not let the pump support the pipes. Use pipe
hangers or other supports at proper intervals to
provide pipe support near the pump.

• Make sure that both the inlet and outlet pipes are
independently supported and properly aligned so that no strain
is transmitted to the pump when the flange bolts are tightened.
Use of expansion joints or vibration pads does not preclude
the need to properly support the pipes. Make sure that the
pipes are as straight as possible, so as to avoid unnecessary
bends and fittings.

• KP, KPV, KPVS pumps have 250 lb flanges which are drilled
according to the pump's service. Non-standard hardware may
be required.

• Do not apply force to pipes when making connections.

4.4.2 Inlet pipe

Select and install the inlet pipe in a manner that minimizes
pressure loss and permits sufficient liquid flow into the pump
during starting and operation. Many NPSH issues can be traced
to improper selection and installation of the inlet pipe.

Observe the following precautions when installing the inlet pipe:

• Run the inlet pipe as straight as possible to avoid unnecessary
bends and fittings. Ideally, make sure that the length is at least
ten times the pipe diameter. A short inlet pipe can be the same
diameter as the inlet port. A long pipe must be one or two
sizes larger than the inlet port, depending on the length, and
with a reducer between the pipe and the inlet port.

• Use an eccentric reducer, with the tapered side down. See fig.

7.

• During pumping operation, the valves on the inlet line must
always be fully open.

• Install properly sized pressure gauges to enable the operator
to monitor the pump performance and determine whether the
pump conforms to the parameter of the performance curve. If
cavitation, vapor binding, or other unstable operating
situations occur, the pressure gauges will indicate wide
fluctuation in the inlet and outlet pressures.

TM05 4773 2512TM 05 4774 2512

Fig. 7 Inlet pipe

At no point must the diameter of the inlet pipe be
smaller than that of the pump inlet port.

• If possible, run a horizontal inlet line along an even gradient.
We recommend a gradual upward slope to the pump under
suction lift conditions, and a gradual downward slope under
positive inlet pressure conditions.

• Avoid any high points, such as pipe loops (see fig. 8), as this
may create air pockets and throttle the system or cause erratic
pumping.

• Install a gate valve in the inlet line to be able to isolate the
pump during shutdown and maintenance, and to facilitate
pump removal. Where two or more pumps are connected to
the same inlet line, install two gate valves to be able to isolate
each pump from the line.

• Always install gate valves or butterfly valves in positions that
prevent air pockets.

Do not use globe valves, particularly when NPSH is
critical.

Fig. 8 Air pocket prevention

8

4.5 Electrical connection

DANGER

Electric shock

Death or serious personal injury

- The electrical installation must be carried out by a
qualified electrician in accordance with local
regulations and the manuals provided with the
electrical accessories.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.

4.5.1 Motors

The motor control circuit must include the following components
in order to comply with the National Electrical Code:

Motor disconnecting device

• Install a motor disconnecting device that is capable of
disconnecting both the controller (motor-protective circuit
breaker) and the motor from their source of power.

• Locate the disconnecting device in such a way that the
controller (motor-protective circuit breaker) can be seen from
the disconnecting device. In all cases, the distance from the
disconnecting device to the controller must be less than 50 ft
(15.24 m).

In most installations, the disconnecting device will be a circuit
breaker or fusible disconnect switch.

Motor short circuit and ground fault circuit interrupter

A short circuit and ground fault circuit interrupter is usually a
circuit breaker or fusible disconnect switch.

• Select the circuit breaker or fuse in accordance with section
430-52 and table 430-152 of the National Electrical Code.

Motor controller with overcurrent protection (magnetic
starter)

• Install these components in accordance with applicable local
and state electrical codes in addition to the National Electrical
Code.

DANGER

Explosive environment

Death or serious personal injury

- Observe the rules and regulations generally or
specifically imposed by the relevant responsible
authorities or trade organizations in relation to
running powered equipment in an explosive
environment.

• The operating voltage and frequency are marked on the motor
nameplate.

• Check that the voltage, phase and frequency of the incoming
power source correspond to the voltage, phase and frequency
of the motor(s).

• Electrical characteristics must match those specified on the
motor nameplate.

• The electrical connections must be carried out as shown on
the motor nameplate or in the wiring diagram on the back of
the terminal box cover. If further information is needed, contact
the motor supplier.

• Mount the control panel or the motor-protective circuit
breaker(s) close to the pump to provide convenient control and
easy installation.

• Make sure that the starters and overload control devices are
suitable for operating the pump motors on the voltage, phase
and frequency available. Always follow the control
manufacturer's instructions for proper installation and
connection.

• Grease-lubricated motors are fully lubricated at the time of
manufacture and do not require further lubrication if prompt
installation follows. If the motor has been in storage for six
months or longer, refer to section 8.1.1 Lubricating the motor
and lubricate it before starting.

English (US)

9

English (US)

4.5.2 Variable frequency drive operation

• In principle, all three-phase motors can be connected to a
variable frequency drive.

• However, variable frequency drive operation will often expose
the motor insulation system to a heavier load and cause the
motor to be more noisy than usual due to eddy currents
caused by voltage peaks.

If in doubt whether the motor supplied can handle
variable frequency drive operation, contact the motor
supplier.

• In addition, large motors driven via a variable frequency drive
will be loaded by bearing currents.

• When the pump is operated via a variable frequency drive,
check the following operating conditions:

Operating
conditions

2-, 4- and 6-pole
motors of 45 hp
and up

Noise-critical
applications

Particularly noise­critical applications

Cable length Fit a cable that meets the specifications

Supply voltage up
to 500 V

Supply voltage
between 500 V and
690 V

Supply voltage of
690 V and upwards

Action

Check to make sure that one of the motor
bearings is electrically isolated. If not,
contact Grundfos.

Fit a dU/dt filter between the motor and the
variable frequency drive, it reduces the
voltage peaks and thus the noise.

Fit a sinusoidal filter.

laid down by the variable frequency drive
supplier. The length of the cable between
motor and variable frequency drive affects
the motor load.

Check that the motor is suitable for
variable frequency drive operation.

• Fit a dU/dt filter, it reduces the voltage
peaks and thus the noise,
or

• check that the motor has reinforced
insulation.

• Fit a dU/dt filter, it reduces the voltage
peaks and thus the noise,
and

• check that the motor has reinforced
insulation.

4.6 Outlet pipe

• A short outlet pipe can be the same diameter as the pump
outlet port. A long pipe must be one or two sizes larger than
the outlet port, depending on the length.

• It is best to use long horizontal outlet pipes.

• Install a gate valve near the outlet port to be able to isolate the
pump during shutdown and maintenance, and to facilitate
pump removal.

• Any high points in the outlet pipe may entrap air or gas and
thus impede pump operation.

• If water hammer occurs, that is if check valves are used, close
the outlet gate valve before pump shutdown.

4.7 Shaft seals

The KP pumps are available with stuffing boxes with packing
rings or mechanical shaft seals.

4.7.1 Stuffing boxes (KP)

The stuffing boxes are normally packed before shipment.
If the pump is installed within 60 days, the packing material will be

in good condition for operation with a sufficient supply of
lubricating liquid.

If the pump is stored for more than 60 days, it may be necessary
to repack the stuffing boxes.

The stuffing box must be supplied at all times with a source of
clean, clear liquid to flush and lubricate the packing rings.

4.7.2 Packing gland adjustment (KP)

Make sure that the flushing fluid lines are connected and their
valves are open.

With the pump running, adjust the packing gland to permit 40 or
60 drops per minute for shaft lubrication.

Tighten the packing gland evenly to provide uniform compression
on the packing material.

Do not operate packing dry, and do not over-tighten the packing
gland to eliminate leaking as this will cause the shaft sleeve to be
damaged.

After initial startup, additional packing and adjustment may be
required.

4.7.3 Mechanical seals

Mechanical shaft seals require no maintenance or adjustment.
KP, KPV, KPVS pumps equipped with mechanical shaft seals are

matched to the operating conditions for which the pump was sold.
Observe the following precautions to avoid shaft seal damage
and to obtain maximum shaft seal life:

Do not run the pump dry or against a closed valve.
Dry operation will cause shaft seal failure within
minutes.

Do not exceed temperature or pressure limitations
for the mechanical seal used.

Purge all air from the seal chambers and recirculation lines prior
to operating the pump.

• Clean and purge the inlet pipe in new installations before
installing and operating the pump. Pipe scale, welding slag
and other abrasives can cause rapid shaft seal failure.

• A mechanical shaft seal does not leak at all during normal
operation, therefore if any appreciable leakage occurs, the
seal must be removed, inspected and if necessary replaced.
We recommend keeping a stock of spare parts to reduce
equipment down time.

10

4.8 Coupling alignment (KP)

Outlet

Inlet

Clockwise (CW) rotation

Outlet

Inlet

Counterclockwise (CCW)
rotation

1. If the pump and motor were shipped mounted on a common
base frame as an assembly, remove the coupling guard.

2. Checking parallel and angular alignment
Place a straight edge and feeler gauges or a dial indicator
across both coupling hubs to check for horizontal, vertical,
and angular misalignment of the coupling hubs. See fig. 9.
Coupling alignment is correct when the measurements show
that all points of the coupling faces are within 0.005 in. (0.127
mm) of each other, or when the straight edge contacts both
hubs evenly in both horizontal and vertical positions. If
misalignment is detected, loosen the motor and shift or shim
as necessary to re-align. Then re-tighten the anchor bolts.
Always align the motor to the pump as pipe strain will occur if
the pump is shifted. Never reposition the pump on the base
frame.

3. Check shaft alignment once again after final piping
connections to the pump have been made, motor wiring
checked, correct direction of rotation has been established,
and pipes have been filled with liquid. See figs 10 and 11.

English (US)

TM05 9288 3173TM05 9289 3173

Fig. 10 KP, plan view clockwise (CW) rotation

Fig. 11 KP, plan view counterclockwise (CCW) rotation

WARNING

Moving machine parts or blades

Death or serious personal injury

- Ensure an approved coupling guard is in place
before operating the product. Failure to observe
this warning could result in injury to operating
personnel.

• Leave the coupling guards off until the pump priming
procedure has been completed.

• Install the coupling guards after installation has been

TM 05 4767 2512TM 05 4768 2512

completed to protect personnel from rotating machinery.

Fig. 9 KP, checking angular or parallel alignment

11

English (US)

5. Starting up the product

5.3 Motor direction of rotation

5.1 Priming

KP, KPV, KPVS pumps are non-self-priming and must be
completely primed, that is filled with liquid, before starting.

• If the pump will be operating with a positive inlet pressure,
prime it by opening the inlet valve and allowing liquid to enter
the pump housing. Open the vents at the top of the upper
pump housing and the top of each inlet dome, and make sure
that all air is forced out of the pump by the liquid before closing
the vents.

• IMPORTANT: Rotate the shaft by hand while priming and
venting to free entrapped air from the impeller passageways.

• If the pump will be operating with a suction lift, priming must
be accomplished by other methods. Use foot valves, ejectors
or vacuum pumps, or fill the pump housing and inlet line
manually with liquid.

Never run the pump dry in the hope that it will prime
itself. The result will be serious damage to the shaft
seals, pump wear rings and shaft sleeves.

5.2 Pre-start checklist

Do not operate the product above the range of the
nameplate conditions. This may damage the product.

Never check the motor direction of rotation unless
pump and motor couplings have been disconnected
and physically separated. Failure to follow this
instruction can result in serious damage to the pump
and the motor if the direction of rotation is wrong.

After the unit has been wired and checked to ensure that all
components in the system, such as disconnect devices, magnetic
starters, pilot devices and motors, are properly connected, check
the motor direction of rotation as follows:

• Make sure that the coupling is disconnected, then momentarily
energize the motors to ensure that the direction of rotation is
correct as indicated by the arrow cast into the pump housing.
If the direction of rotation is incorrect, interchange the two
wires at the motor-protective circuit breaker terminals T1 and
T2.

• For Wye-Delta motors the direction of rotation has to be
verified for both wye and delta connections.

• For proper direction of rotation, reference rotation drawing in
section 4.8 Coupling alignment (KP).

The pumps must not be operated while dry. Use
extreme caution that motors are energized only
momentarily to determine proper direction of rotation.

Make the following inspections before starting your KP, KPV,
KPVS pump.

1. Make sure that the inlet and outlet pipes have been cleaned
and flushed to remove dirt and debris.

2. Make sure that all wiring connections to the motor and starting
device are in accordance with the wiring diagram and produce
proper rotation.

3. If the motor has been in storage for a long time, either before
or after installation, refer to the motor instructions before
starting.

4. Check the voltage, phase, and frequency with the motor
nameplate.

5. Turn the impeller by hand to make sure that it rotates freely.

6. Tighten the plugs in the gauge and drain the holes. If the
pump is fitted with pressure gauges, keep the gauge cocks
closed when they are not in use.

7. Recheck the motor-to-pump alignment per section

4.8 Coupling alignment (KP).

8. Check inlet and outlet pipes for leaks, and make sure that all
flange bolts are securely tightened.

9. If the pump will run on a variable frequency drive, do not ramp
up the pump from reduced speeds. Go directly on-line at full
speed, especially at commissioning so adequate pressure is
generated to flush wear rings and create a hydrostatic bearing
effect.

12

5.4 Starting the pump

7. Product introduction

WARNING

Moving machine parts

Death or serious personal injury

- Mount an approved coupling guard before
operating the product.

For KPVS pumps, ensure the jacking screw (114) is
firmly seated and sealed by turning it
counterclockwise. This will prevent media leakage
during operation.

1. Install a coupling guard.

2. Fully open the gate valve (if any) in the inlet line, and close
the gate valve in the outlet line.

3. If applicable, turn on any external source of cooling or
lubricating fluid to the shaft seals.

4. Fill the inlet line with liquid and completely prime the pump.

5. Start the pump.

6. Immediately make a visual check of the pump and inlet pipe
for pressure leaks.

7. Immediately after the pump has reached full operating speed,
slowly open the outlet gate valve, and open the bleed valves
at system high points. Do not open the outlet gate valve
completely until the system is full of liquid, purged of air and
checked for leaks.

8. After entirely filling the system, fully open the outlet gate valve
and close the system bleed valves.

9. If the pump is fitted with pressure gauges, open the gauge
cocks and record pressure readings for future reference.
Verify that the pump is performing in accordance with the
parameters specified in the performance curves.

10. Check and record voltage, amperage per phase, and
kilowatts, if a wattmeter is available.

7.1 Applications

We recommend KP, KPV, KPVS pumps for these applications:

• circulation in heating and air conditioning systems, water
condensing and boiler feed systems

• liquid transfer and pressure boosting in various industrial
systems

• water distribution and water treatment in public water systems.

7.2 Pumped liquids

Use clean, thin, non-aggressive liquids, not containing solid
particles or fibers. Do not pump liquids that will attack the pump
materials chemically.

When pumping liquids with a density and/or viscosity higher than
that of water, pressure and flow will be reduced. Alternatively, use
motors with correspondingly higher outputs.

The stuffing box packing rings or the mechanical shaft seal O­rings chosen must be suitable for the liquid to be pumped.

Special stuffing box packing rings or shaft seal O-rings may be
required if the pump is used for pumping treated water:

• at temperatures above 176 °F (80 °C)

• containing additives to prevent system corrosion, calcareous
deposits, etc. (this may be the case in heating and ventilating
systems).

When pumping liquids other than water, select an appropriate
stuffing box or shaft seal. For further information, please contact
Grundfos.

The absolute maximum operating temperature for the
pump is 275 °F (135 °C).

English (US)

6. Handling and storing the product

See section 8.8 Taking the product out of operation.

13

English (US)

7.3 Pump identification

All PACO pumps are identified by catalog and serial numbers.
These are stamped on the pump nameplate, as shown in fig. 12,
affixed to the pump housing. Refer to these numbers in all
correspondence with Grundfos.

7.3.1 Nameplate

Fig. 12 KP, KPV, KPVS nameplate

7.3.2 KP KPV model number and construction code

Example 29 60123 140001 1852

Product code
Model code
Materials of construction
Motor code

Production code 29

29: Split case (KP, KPV)
31: Split coupled split case (KPVS)

7.3.3 Type key

Materials of construction 1 4 00 0 1
Packing or seal

3 = Standard packing
1 = Type 21, single seal, ceramic seat, Buna
2 = Type 21, single seal, Tungsten carbide seat,
Viton
6 = Type 21, single seal, Ni-Resist seat, Viton
7 = Type 21, single seal, Ni-Resist seat, Buna
8 = Type 1B, single seal, Ni-Resist seat, Buna
9 = Type 21, single seal, Ni Resist seat, Viton
A = Type 1, single seal, ceramic seat, Buna
B = Type 1, single seal, Ni-Resist seat, Viton
C = Type 1, single seal, Tungsten Carbide seat,
Viton
D = Type 1, single seal, Ni Resist seat, Buna
E = Type 1, single seal, ceramic seat, Buna

TM05 7638 1313

F = Type 1, single seal, Si Cbrd seat, EPDM
G = Type 8-1, single seal, Si C brd seat, Viton
H = Type 8-1, single seal, ceramic seat, Buna

ID of packing or seal

2 = 1"
3 = 1 - 1/4"
E = 1 - 1/2"
4 = 1 - 3/4"
5 = 2 - 1/4"
6 = 2 - 3/4"
7 = 3"
K = 3 - 1/2"
V = 4"
H = 4.1"
B = 4.7"
N = 5.5"

Model code 60 12 3
Pump outlet

20 = 2"*
30 = 3"
40 = 4"
50 = 5"
60 = 6"
80 = 8

Nominal maximum impeller diameter

95 = 9.5"
12 = 12"
13 = 13"
14 = 14"
15 = 15"
19 = 19"

Impeller design

Clockwise rotation:
1, 3, 5, 7, 9
Counterclockwise rotation:
0, 2, 4, 6, 8

* 2" outlet on pumps with impellers ≤ 13"

10 = 10"
12 = 12"
14 = 14"
16 = 16"
20 = 20"
24 = 24"

20 = 20"
24 = 24"
25 = 25"
27 = 27"
28 = 28"

14

Materials of construction 1 4 00 0 1
General configuration (Horizontal)

Code no. Item
00 Standard
01 Double wear rings
02 Oil lube bearings
03 (01) + (02)
04 (01) + (05)
05 Recirculation lines
20 Double ext shaft
21 Double wear rings
22 Recirculation lines
24 (21) + (22)
30 Double ext shaft
31 Double wear rings
32 Recirculation lines
34 (31) + (32)
70 250 lb flange
71 Double wear rings
72 (71) + (73)
73 Recirculation lines
90 250 lb flange
91 Double wear rings

General configuration (Vertical)

Code no. Item
50 Standard (Vesconite for KPVS)
51 Double wear rings
52 Sleeve bearing
53 (51) + (52)
80 250 lb flange for 300 psi CWP
81 Double wear rings
82 Sleeve bearing
83 (81) + (82)
92 250 lb flange for 400 psi CWP
93 Double wear rings
94 Sleeve bearing
95 (93) + (94)

Materials of construction 1 4 00 0 1
Shaft/sleeve metallurgy

0 = Steel/bronze
1 = Steel/stainless steel
3 = Stainless steell/bronze**
6 = Stainless steel/stainless steel or stainless steel/no sleeves

(KPVS)
7 = SS/hardened stainless steel
A = 316 SS/Ni Al Bronze
X = Special

Pump metallurgy

0 = Standard fitted
1 = Bronze fitted
2 = Standard all bronze
5 = All iron
8 = Ductile iron/bronze fitted
E = Ductile iron/stainless steel fitted
X = Special

** For packed pumps only (packed pumps standard with

distribution ring, recirculation lines, and hardened stainless
steel sleeves).

Motor code 1782
Enclosure

1 = ODP
2 = TEFC
3 = Explosion Proof

Voltage

1-phase 3-phase

Hp

115/230 V 200 V 230/460 V

1/3
1/2
3/4

1

1-1/2

2
3
5

7-1/2

10
15

20
25
30
40

50
60

75
100
125

150
200
250
300

RPM

1 = 3500
2 = 1750
3 = 1150

21
29
35
41
47

53
59
65
71
76

23
31
37
43
49

55
61
67
73
77

--

--

--

--

--

--

--

--

--

--

--

--

--

--

81
84
01
02
03

04
05
06
07

--

--

--

--

--

24
32
38
44
50

56
62
68
74
78

82
85
87
88
89

90
91
92
93
94

95
96
97
98

English (US)

15

English (US)

8. Servicing the product

8.1.2 Lubricating the pump bearings

8.1 Maintaining the product

8.1.1 Lubricating the motor

DANGER

Moving machine parts

Death or serious personal injury

- Before any inspection, maintenance, service or
repair of the product, make sure that the motor
controls are in the "OFF" position, locked and
tagged.

Always follow the motor manufacturer's lubricating instructions, if
they are available, and periodically check grease fittings and
drain plugs for leaks. If the lubricating instructions are not
available, refer to the table below for recommended lubricating
intervals.

• The motor can be lubricated both when it is running or when it
is at rest.
Remove the grease drain plug (if any) and filler plug on the
grease fitting. Grease with clean lubricant until grease
appears at the drain hole or along the motor shaft.

Recommended lubricating intervals

Motor rpm Motor hp Operating conditions

10-40 Standard Severe Extreme

1750 and

below

above

1750

Standard conditions:
Operating 8 hours per day, normal or light load, clean air, 100 °F
(37 °C), maximum ambient temperature.

Severe conditions:
Operating continuously 24-hours, shock loads or vibrations,
poor ventilation, 100-150 °F (37-65 °C), ambient temperature.

Extreme conditions:
Operating continuously, heavy shocks or vibrations, dirt or dust
in the air, extremely high ambient temperature.

The table below lists the recommended types of grease for motor
lubrication. These types have all been thoroughly tested and
must be used whenever possible.

50-150 1-3 years

200 and up 1 year 3 months 6 months

All hp

Recommended bearing grease for motors

Manufacturer Bearing lubricant

Chevron SRI grease NLGI No. 2

Texaco Polystar RB2 NLGI No. 2

1 year 3 months 6 months
1 year 3 months 3 months

6 months -

1 year

6 months -

1 year

WARNING

Catastrophic failure

Death or serious personal injury

- Maintain proper lubrication schedule

- Do not operate the unit without proper lubrication
as this can result in overheating of the bearings,
bearing failures, pump seizures and actual
breakup of the equipment, exposing operating
personnel to personal injury.

Recommended bearing grease for pumps

Manufacturer Lubricant

Shell Dolium

Exxon Polyrex

Chevron

Phillips Polytrac™

Texaco Polystar RB

Regreasable bearings are packed with grease at our factory prior
to shipping. This initial filling of grease is good for one year or
2000 hours of normal operation, whichever occurs first. After one
year or 2000 hours of normal operation, a regular grease
maintenance schedule must be implemented.

8.1.3 Grease replacement (KP, KPV)

1. Remove the four (4) cap screws and remove the bearing
covers (113C and 113D) to allow access to the bearing.

2. Use a clean rag to remove as much old grease as possible
from the bearing.

3. Re-pack the bearing with sufficient grease to completely fill
and cover the balls inside the bearing.

4. Turn the pump shaft to ensure even and complete lubrication.

5. For drive end bearing maintenance, slide the bearing cover
back as far as possible and visually inspect bearing for
grease.

6. Proceed as stated above removing old grease with a clean
rag. If the bearing covers cannot be moved sufficiently to
allow access to bearing, remove the coupling hub.

7. Reinstall the bearing covers when the task is complete.

Do not over-grease. Too much grease can cause
overheating and premature bearing failure.

Bearing manufacturers recommend that you fill the bottom third of
the bearing with grease. After filling the bottom third with grease,
rotate the shaft to cover the balls inside the bearing.

SRI Grease NLGI 22

Black Pearl NLGI 2

®

®

16

8.1.4 Oil lubrication (KP, KPV)

Follow a regular oil maintenance program. KP, KPV pumps with
oil lubricated bearings are fitted with a transparent reservoir, a
constant-level oiler, that maintains the oil level about the center
line of the lower bearing. See 85 in fig. 13. When necessary,
renew the oil supply in the reservoir of the constant-level oiler. To
refill it, remove the reservoir and fill it with oil. After filling the
reservoir with oil, replace it into operating position.

Fig. 13 Oil lubricated bearing construction

Change the oil after the first 200 hours of operation. To change
the oil, remove the drain plug (16K) at the bottom of the bearing
cover and the filler plug (16B), at the top of the bearing frame.
After draining the oil, replace the fittings and refill the reservoir
with an oil selected from the table List of acceptable oil lubricants
below. After the first oil change, the oil must be changed again at
2000 hours and then at intervals of 8000 hours or once a year
thereafter.

8.1.5 Stuffing box (packing) or shaft seal water lubrication

(KP)

The stuffing (packing) box must be supplied at all times with a
source of clean, clear liquid to flush and lubricate the packing.
Only a sufficient volume of sealing liquid to create a definite
direction of flow from the stuffing box inward to the pump casing
is required. Pipe from the pump outlet dome to the packing box is
supplied when requested.

8.1.6 Maintaining packing (KP)

Pack the stuffing box with fresh packing before initial startup,
after repairs to the pump, and in case of excessive leaks. Any
time the packing is replaced, inspect the shaft sleeves for wear,
roughness or scouring and replace with new ones if necessary.
For instructions on filling the stuffing box see section Replacing

packing, each side. For seal gland adjustment see section

8.2.2 Bearing, seal and packing replacement.

8.1.7 Flexible coupling maintenance (KP, KPV)

The coupling is pre-greased at the factory. After disassembly it

TM05 8898 2713

must be greased again. For annual greasing refer to the coupling
manufacturer's instructions.

English (US)

List of acceptable oil lubricants

Lubricant

manufacturer

Aral Refining Co. Aral Oil CMU Aral Oil Tu 518

British Petroleum Co. BP Energol TH 100-HB

Calypsol Oil Co. Calypsol Bison Oil SR 25 or SR 36

Standard Oil Co. Chevron Hydraulic Oil Circulating Oil 45

Esso Corporation Esso-Mar 52 Teresso 47 Esstic 50

Fina Oil Company Fina Hydran 43 Fina Cirkan 32

Gulf Refining Co. Gulf Harmony 47 Gulf Paramount 45

Socony Mobil Oil Co. Vac HLP 25 Mobilux D.T.E. 25

Shell Oil Company Shell Tellus Oil 29

Sundco Oil Company Sunvis 821

Texas Company Texaco Ursa oil P 20

Wisura Rining Co. Wisura Norma/Tempo 25 (36)

Bearing oil brand name

17

English (US)

8.2 Disassembling the pump

8.2.1 Preparations before disassembling the pump

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.

CAUTION

Toxic material

Minor to moderate personal injury.

- Wash down the pump before doing any work on it.

8.2.2 Bearing, seal and packing replacement

All normally required parts for KP pumps are available in kit form.
Refer to figs. 14 and 15.

Bearing replacement

1. Remove the motor.

2. Remove the coupling half from the pump shaft (51) using a
wheel puller and remove the coupling key (11A).

3. Remove the bearing covers (113C) and (113D).

4. Loosen the set screws in the eccentric locking rings of the
bearings (53 and 54) and turn the rings in the opposite
direction of the direction of rotation to loosen from the shaft, or
remove the retaining snap ring, whichever is applicable.

5. Remove the cap screws from each bearing housing (124) and
slide, with bearing, off its end of the shaft.

WARNING

Hot, caustic, flammable or toxic materials,
including vapors

Death or serious personal injury

- Be extremely cautious when venting and/or
draining hazardous liquids.
Wear protective clothing when there are caustic,
corrosive, volatile, flammable, or hot liquids.
Do not breathe toxic vapors.
Do not allow sparks, open fire, or hot surfaces
near the equipment.

KP, KPV, KPVS pumps are designed for ease of maintenance
and, as such, the seals, sleeves, wear rings, clearances and
bearings can be inspected without having to remove the complete
rotating element or having to disconnect the inlet or outlet pipes,
or disturbing the alignment of the pump set.

WARNING

Moving machine parts

Death or serious personal injury.

- Do not insert a screwdriver between the impeller
vanes to prevent rotation.

Work on this equipment is to be performed only by qualified
personnel. Read the following instructions completely before
performing any work on the pump.

Before beginning disassembly of the pump, proceed as follows:

1. Close the inlet and outlet isolation valves.

2. Turn off any external source of cooling or lubricating fluid to
the shaft seals.

3. Drain the pump case by opening the drain plug and vent
plugs.

4. Disconnect and lock off the motor power source.

A clearance of 24 in. (610 mm) on each side of the
pump will allow for maximum access while servicing.
A minimum of 24 in. (610 mm) clearance is required
to remove the upper pump housing when accessing
the rotating element.

Take care to ensure the seal seats in the bearing
housings of seal type pumps are not broken during
housing removal.

6. Remove the bearings (53, 54) from the bearing housings.

7. Install the new seals and seal seats.

8. Reinstall the bearing housings less the bearings, noting that
the slinger (79) is in the correct position. Take care not to
break the seal seats of the seal type pumps by striking them
against the shaft.

9. Clean out the bearing housings and slide the new bearings
over the shaft and into the bearing housings. Press only on
inner race of the bearing. Use a bearing warmer, if available.

10. Turn the eccentric locking rings in the direction of pump
rotation to tighten on the shaft and tighten the set screws, or
replace the spacer and the retaining snap ring, whichever is
applicable.

11. Pack the ball bearings and bearing cover cavities with clean
ball bearing grease. See section 8.1.2 Lubricating the pump

bearings.

12. Replace the bearing covers (113C, 113D).

13. If applicable replace the packing glands after following
packing instructions in section Replacing packing, each side.

14. Gently tap the coupling half on the shaft (51) over the key
(11A). Do not tap it if it can be pushed on. Using too much
force to drive on the coupling half can damage the ball
bearings and/or fracture the seal faces. If there is difficulty
pushing the coupling onto the shaft, heat up the coupling half
to a temperature of not more than 300 °F (148 °C) and then
use protective gloves to slide the coupling half onto the shaft.

15. Replace motor and realign.

On vertically mounted pumps, remove the rotating
assembly in order to replace the lower bearing and
seal assembly.

18

Mechanical seal replacement

1. Follow the above steps to remove the bearing housings (124).

2. Remove the old seal head and the seal seat from the shaft
sleeve and bearing housing or seal cap.

It is not necessary to remove the bearings from the
bearing housings. However, we recommend that you
replace the bearings.

3. Inspect the shaft sleeves (116) for scoring or pitting.

4. Replace if the surface is rough to your fingernail.

Proper seal seat installation

1. Clean the seal cap or bearing housing (124).

2. Lightly lubricate the new seat's rubber cap with liquid soap.

3. Press in the seal seat into the seal housing, making sure the
seat is seated squarely and all the way into seal cap or
bearing housing. Do not touch the seal seat or the head faces.

Proper seal head installation

1. Clean and lightly lubricate the shaft sleeves (116) or the shaft
(51). Make sure that there are no sharp edges or corners to
cut the seal's rubber parts.

2. Lightly lubricate the seal face elastomers with liquid soap.

3. Slide the assembly onto the sleeve or shaft until the spring
touches the shoulder. Do not compress the spring. Make sure
that the notches on the carbon ring match the retainer's lugs
and the spring is in position on the seal head.

4. Reinstall the bearing housings (124) with bearings, noting that
slingers (79) are in correct places. Take care not to strike seal
seats against shaft.

5. Follow remaining bearing replacement steps to complete
assembly.

Replacing packing, each side

1. Remove the packing gland.

2. Remove the old packing distribution ring, if any, and use a
packing hook to remove the packing behind the distribution
ring.

3. If the packing retainer comes out, replace it against the
retaining ring.

4. Insert two new packing rings one at a time, staggering the
joints 180 ° and pushing them firmly back against the packing
retaining washer.

5. Insert the distribution ring, if any.

6. Insert three more packing rings (applies to most sizes)
staggering joints 180 °. If no distribution ring is used, one
extra packing ring is required.

7. Replace the packing gland.

8. Adjust the packing gland to permit a leakage of 40 to 60 drops
per minute for shaft lubrication.

9. Never overtighten the packing gland. For suction lift
applications, should it become necessary to overtighten the
packing while starting the pump, make sure to loosen the
packing immediately after the pump is started, allowing a
leakage of a 40 to 60 drops per minute. After initial startup,
additional packing and adjustment may be required.

8.2.3 Bearing and seal replacement for KPVS

1. Remove the coupling guard and the coupling. See section

8.2.2 Bearing, seal and packing replacement.

2. Remove the seal housing cap screws and the seal housing
(124a).

3. Remove the seal head assembly (105) from the shaft (51).
Water-soluble lubricant may be applied to the shaft to ease
the removal of the seal head. Pull the seal head assembly
from the shaft, using a slight twisting motion (as necessary) to
loosen the bellows from the shaft.

4. Discard the seal, the spring and the retainer.

5. Remove and discard the seal seat and gasket from the seal
housing (124a) and thoroughly clean the inside cavity of the
seal housing and flange.

6. The interior surface of the bellows on the new shaft seal is
coated with a bonding agent that adheres to the pump shaft.
When the old shaft seal is removed, the bellows may crack or
split during removal. We recommend that you install a new
mechanical shaft seal if it becomes necessary to remove the
existing shaft seal from the shaft.

7. Clean and lubricate the pump shaft (51) with a water-soluble
lubricant and make sure that no sharp edges exist to cut or
scratch bellows of the new seal.

8. Install the new gasket onto the seal housing.

8.2.4 Disassembling Horizontal pumps (KP)

1. Remove the nuts and bolts that hold the pump housing halves
together (6A, 6B), and remove cap screws holding bearing
housing (124) to pump housing.

2. Remove roll pin (26B) then lift off upper pump housing (6A).

3. Place the gaskets in water to keep them from drying out and
shrinking.

4. Remove shaft assembly from the case.

5. To disassemble rotating assembly, refer to section Bearing

replacement.

6. Unscrew and remove shaft sleeves (116) or impeller locknuts
by turning them in direction of pump rotation. One has RH
(right-hand) threads. The other has LH (left-hand) threads.
Use a strap wrench. Do not place the wrench on the part of
sleeve that comes in contact with the seal or packing.

7. Remove the wear ring retaining parts as necessary, locking
pin (24) and/or rings (65).

8. Slide the wear ring (45) off the impeller.

9. Make an orientation mark for later reference on the impeller
(49) on the coupling side before removing it from the shaft, to
help ensure it will be reassembled identically.

10. Press the impeller (49) from the shaft (51) and the key (11).

English (US)

19

English (US)

8.2.5 Disassembling Vertical pumps (KPV)

1. Remove the coupling guard and remove the coupling grid.

2. Remove all the cap screws on the bearing housings (124)
except for the two on the lower pump housing (6B) to hold the
rotating assembly in place while removing the upper pump
housing (6A).

3. Remove the roll pin (26B) then lift off the upper pump housing
(6A).

4. Place the gaskets in water to keep them from drying out and
shrinking.

5. Remove the shaft assembly from the pump housing.

6. To disassemble the rotating assembly, refer to section Bearing

replacement.

8.2.6 Inspecting the components

1. While the pump is disassembled, inspect all components for
wear, damage, deterioration or erosion.

2. Inspect the shaft sleeves and replace them if they are worn or
deeply scored.

3. Check the impeller wear ring (if used) and the pump housing
wear ring (45) for erosion or wear and replace them if badly
deteriorated, to renew original pump performance. The design
clearance is 0.018 in. to 0.022 in. (0.457 mm to 0.558 mm)
diametrically. Clearances greater than 0.040 in. (1.016 mm)
will affect pump performance and new wear rings must be
installed.

4. Examine the lapped faces of the mechanical seals for scoring,
heat checking or cracking. Examine mechanical seal
elastomers (rubber components) for deterioration or
hardening. Replace mechanical seals if any damage exists.

5. Check any external source of cooling or lubricating fluid lines,
and/or recirculation lines and ports for clogs, kinks or other
restrictions.

6. Clean machined mating surfaces of all components to remove
grit, grime and/or old sealing material before reassembling
pump.

8.3 Reassembling the pump (KP, KPV, KPVS)

1. Reinstall the impeller (49) and the key (11) on the shaft (51),
centering the impeller on the shaft with respect to the sleeve
or the lock nut threads. Be sure the impeller is installed on the
shaft the same way it came off, with the vane curvature and
per the orientation mark made during disassembly. For proper
rotation, see figs. 10 and 11. Note that:

– The pump will deliver little or no water if the impeller is

installed backwards.

– Be sure a good O-ring gasket is in place on each sleeve, if

the shaft has sleeves. Replace as necessary.

2. Replace the shaft sleeves (116) or nuts, turning them in the
opposite direction of pump rotation. Do not place a wrench on
the part of the sleeve that comes in contact with the seal or
the packing. Tighten evenly so the impeller position will not
shift.

3. Replace the wear ring retaining ring (65) over the wear ring
(45).

4. Slide the wear ring (45) over each impeller hub.

5. Replace the wear rings (45) on the impeller (49). Replace with
new seals or packing. Replace the bearing housing (124) on
the shaft (51) carefully so as not to damage the seal (11B).
Replace the bearing (54) into the outboard housing and
washer and snap ring. Replace the coupling key (11A) with
the coupling half.

6. For packing type pumps, follow the steps in section

8.2.2 Bearing, seal and packing replacement then the steps in

section Replacing packing, each side.

20

8.3.1 Disassembling and reassembling the sleeve bearing

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.

Disassembling the sleeve bearing

1. Close the inlet and outlet side valves before starting
disassembly.

2. Remove the motor, after disconnecting all the electrical
connections.

3. Remove the coupling guard and remove the coupling grid.

4. Drain the pumped liquid from the pump. The pipe plug (20A)
and the recirculation lines can be used for draining.

5. Remove bearing covers (113C and 113D).

6. Loosen the set screws in the eccentric locking rings of the
bearing (53) and turn the ring in the opposite direction of the
pump rotation to loosen on the shaft, or remove the retaining
snap ring, or the lock nut and lock washer, whichever is
applicable.

7. Remove all the cap screws on the bearing housings (124)
except for the two on the lower pump housing (6B) to hold the
rotating assembly in place while removing the upper pump
housing (6A).

8. Remove the roll pin (26B) then lift off the upper pump housing
(6A).

9. Place the housing gasket, as well as all the other gaskets, in
water to keep them from drying out and shrinking.

10. Remove the shaft assembly from the pump housing.

11. Remove the sleeves and then the impeller.

Reassembling the sleeve bearing

1. Using an appropriately rated sling and overhead lifting
equipment, place the pump housing assembly on a flat
surface. Remove the hex head bolts. If required, clean both of
the machined faces on the pump housing assembly with fine
grit sand paper. Remove the two roll pins from the lower pump
housing. Using an appropriate eyebolt and overhead lifting
equipment, remove the upper pump housing and clean it if
necessary.

2. Align the two wear rings (45) with the wear ring register in the
lower housing. Use a soft-faced hammer and brass punch to
drive the roll pins into the drilled holes on the wear ring bores.

3. Slide the wear rings onto the impeller wear rings, ensuring
that your hole and roll pin orientation marks are facing
outward.

4. Position the impeller (49) in the lower pump housing.

5. Determine correct rotation (clockwise or counterclockwise).

6. Carefully spray the shaft (51) with solvent and wipe off with a
clean rag. Install the drive key into the center key slot on the
shaft by gently tapping it with a soft-faced hammer.

7. Slide the shaft (51) into the bore of the impeller.

8. Install the lower sleeve (202). Make sure that it engages all
the threads. The impeller butts against the lower sleeve or
sleeve nut depending the pump size. Install the sleeve and
sleeve nut on the other side of the impeller. Use a spanner
wrench to secure the sleeves against the impeller hubs.

9. Use an overhead lifting equipment to position the upper pump
housing over the four alignment studs and install onto the
lower pump housing. Use a soft-faced hammer to drive the
two roll pins into the lower pump housing and remove the four
alignment studs.

10. Place the long cap screws into the mounting holes located in
the center area of the upper pump housing and place the
remaining cap screws into the mounted hole located on the
flange area of the upper pump housing. First tighten the four
cap screws in the center area using a crisscross pattern and
then complete all.

11. Spray the mounting face surfaces and finished inside
diameters of the seal housing with solvent and wipe off with a
clean rag. Carefully align and place the seal seat into the seal
housing (124). Slide the seal head assembly onto the in-board
or drive end of the shaft and seat it up against the shaft
sleeve.

12. Carefully slide and position the seal housing so the two blades
on the seal housing are oriented at 11 and 1 o'clock. Make
sure that you have the slinger on the shaft.

13. Assemble the roller bearing. Secure the bearing cover with
screws.

14. Assemble the sleeve bearing housing (which is press fitted
with graphalloy sleeve bearing).

15. Make sure that the shaft is rotating after assembly the bearing
housings.

16. Assemble the recirculation lines and pipe plugs.

English (US)

21

English (US)

8.3.2 Split coupling removal and replacement (KPVS)
Removing the coupling guard (KPVS)

1. Shut off the liquid supply to the pump.

2. Remove the coupling guard.

3. Drain the liquid from the pump. The pipe plug on both top and
bottom seal housings can be used to drain the pump.

4. Turn the jacking screw (114) clockwise to engage and support
the shaft. Do not raise the height of the shaft to support it at its
current location. Note, the jacking screw has an O-ring which
seals against the seal housing when turned counterclockwise
until it bottoms out.

5. Remove nuts and bolts from the split coupling (203) and
remove each half of the split coupling from the pump and
motor shafts.

Reinstalling the coupling guard (KPVS)

1. Engage the half of the split coupling with the keyways to the
motor shaft and shaft collar (204).

2. Use the jacking screw (114) to adjust the pump shaft up or
down to align the pump shaft groove with the coupling.

3. Engage the coupling fully to both the motor and pump shafts.

4. Engage the second coupling half to both the motor and pump
shafts.

5. Install the coupling screws and nuts and tighten to 21 ft-lbs.

6. Turn the jacking screw counterclockwise until it bottoms out
and seals against the seal housing.

7. Reinstall the pipe plugs into the upper and lower seal
housings.

8. Reinstall the coupling guard.

8.3.3 Bearing and seal replacement (KPVS)

1. Remove the coupling guard and coupling. See section

8.2.2 Bearing, seal and packing replacement.

2. Remove the seal housing cap screws and the seal housing
(124a).

3. Remove the seal head assembly (105) from the shaft (51).
Apply water-soluble lubricant to the shaft to ease the removal
of the seal head. Pull the seal head assembly from the shaft,
using a slight twisting motion (as necessary) to loosen the
bellows from the shaft.

4. Discard the old seal, spring and retainer.

5. Remove and discard the old seal seat and gasket from the
seal housing (124a) and thoroughly clean the inside cavity of
the seal housing and flange.

6. The interior surface of the bellows on the new shaft seal is
coated with a bonding agent that adheres to the pump shaft.
When the old shaft seal is removed, the bellows may crack or
split during removal. We recommend that you install a new
mechanical shaft seal if it becomes necessary to remove the
existing shaft seal from the shaft.

7. Clean and lubricate the shaft (51) with a water-soluble
lubricant and make sure that no sharp edges can cut or
scratch the bellows of the new shaft seal.

8. Install the new gasket onto the seal housing.

9. Press the new shaft seal seat firmly into the seal housing.
Avoid direct contact between the seal face and metallic or
abrasive objects, and wipe the seal face clean after
installation to ensure an abrasive-free sealing surface.

10. Slide the new shaft seal assembly onto the shaft by applying
even pressure to the base of the assembly.

11. Reinstall the seal housing and screws.

12. Reinstall the coupling and coupling guard. See section

8.2.2 Bearing, seal and packing replacement.

8.4 Recommended spare parts

The recommended spare parts depend greatly on the run time
and application of the pump. As a minimum, we recommend that
you keep the following kits:

•Shaft seal kit

• Bearing kit.

• Gasket kit.

22

8.5 KP, Horizontal, cross-section and parts list

English (US)

Fig. 14 KP, Horizontal, cross-section

Pos. Component Material ASTM standard

6a Pump housing, upper Cast iron ASTM A48 CL35
6b Pump housing, lower Cast iron ASTM A48 CL35
11 Key Steel C1018, cold drawn steel

11a Key Steel C1018, cold drawn steel

17 Pipe plug Steel
20d Plug, shaft seal flushing Steel
20e Plug, suction chamber Steel

24 Locking pin, wear ring Steel ANSI/ASME B18.8
45b Wear ring with groove for retaining ring Bronze ASTM B148, C95200

49 Impeller Silicon bronze ASTM B584, C87600

51 Shaft Steel AISI 1144 Stress proof

53 Bearing, drive end Steel

54 Bearing, non-drive end Steel

65 Retaining ring Stainless steel, series 303

67a

67b

79 Slinger Neoprene
105 Shaft seal

113c Bearing cover, drive end Cast iron ASTM A48, CL30
113d Bearing cover, non-drive end Cast iron ASTM A48, CL30
113e Gasket Vegetable fiber
114a Screw Steel

124 Bearing housing Cast iron ASTM A48 CL30
195 Lubricating nipple Zinc coated steel

Impeller/shaft sleeve nut, right-hand (RH) thread Bronze lll932, C89835
Impeller/shaft lock nut, right-hand (RH) thread Stainless steel
Impeller/shaft sleeve nut, left-hand (LH) thread Bronze lll932, C89835
Impeller/shaft lock nut, left-hand (LH) thread Stainless steel

TM03 9952 2512

23

English (US)

8.6 KPV, Vertical, cross-section and parts list

Fig. 15 KPV, Vertical, cross-section

Pos. Component Material ASTM standard

6a Pump housing, upper Cast iron ASTM A48 CL35

6b Pump housing, lower Cast iron ASTM A48 CL35

45 Wear ring Bronze ASTM B148, C95200

49 Impeller Silicon bronze ASTM B584, C87600

51 Shaft Steel AISI 1144 Stress proof

53 Ball bearing, drive end Steel

113c Bearing cover, drive end Cast iron ASTM A48, CL30

124 Bearing housing Cast iron ASTM A48 CL30
200 Sleeve bearing Graphalloy Grade GM 343.3
201 Sleeve bearing housing Cast iron
202 Lower sleeve Stainless steel, series 416

24

TM05 9317 3713

8.7 KPVS, Vertical Split Coupling Split Case, cross-section and parts list

51

113

124a

49

6a

200

113

113d

114d

45

204

English (US)

Pos. Component Material ASTM standard

6a Pump housing Cast iron ASTM A48 CL35

45 Wear ring Bronze ASTM B148, C95200

49 Impeller Silicon bronze ASTM B584, C87600

51 Shaft Steel AISI 1144 Stress proof
113 Bearing housing Cast iron ASTM A48, CL30

113d Bearing cover, non-drive end Cast iron ASTM A48, CL30
114d Jacking screw
124a Seal housing Cast iron ASTM A48, CL30

200 Sleeve bearing Vesconite
203 Coupling Aluminum
204 Shaft collar Stainless steel

TM06 8407 0417

25

English (US)

8.8 Taking the product out of operation

The following shutdown procedures will apply for KP, KPV pumps
in most normal shutdown situations. If the pump will be
inoperative for a long time, follow the storage procedures in
section 8.8.3 Long-term shutdown.

8.8.1 General procedure

• Always close the outlet gate valve before stopping the pump.
Close the valve slowly to prevent hydraulic shock.

• Switch off and lock off the power supply to the motor.

8.8.2 Short-time shutdown

• For overnight or temporary shutdown periods under non­freezing conditions, the pump may remain filled with liquid.
Make sure that the pump is fully primed before restarting.

• For short or frequent shutdown periods under freezing
conditions, keep the liquid moving within the pump housing
and insulate or heat the pump exterior to prevent freezing.

8.8.3 Long-term shutdown

• For long shutdown periods or to isolate the pump for
maintenance, close the inlet and outlet gate valves. If no inlet
gate valve is used and the pump has positive inlet pressure,
drain all liquid from the inlet line to stop the liquid flow into the
pump inlet. If applicable, turn off any external source of
cooling or lubricating fluid to the shaft seals. Remove the
plugs in the pump drain and vent holes, as required, and drain
all liquid from the housing. Remove the packing, if applicable.

• If there will be freezing conditions during long shutdown
periods, completely drain the pump and blow out all liquid
passages and pockets with compressed air. Freezing of the
pumped liquid can also be prevented by filling the pump with
antifreeze solution.

• Rotate the shaft by hand monthly to coat the bearings with
lubricant and impede oxidation and corrosion.

• Follow the motor manufacturer's storage recommendations
where applicable.

26

9. Fault finding the product

DANGER

Electric shock

Death or serious personal injury.

- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.

CAUTION

Toxic material

Minor or moderate personal injury.

- Wash down the pump before doing any work on it.

Fault Cause Remedy

1. The outlet pressure is too low. a) The speed of rotation is too low. Reestablish the correct speed and direction of

b) The system pressure is lower than

anticipated.
c) There is air or gas in the pumped liquid. Remove the air from the pumped liquid.
d) The wear rings are worn. Replace the wear rings.
e) The impeller is damaged. Repair or replace the impeller.
f) The impeller diameter is too small. Replace the impeller with one of the correct

g) The direction of rotation is wrong. Interchange two wires in the power supply.
h) The pump has lost its prime. Re-prime the pump.
i) There is insufficient NPSH. Restore required NPSH.
j) Passages are restricted. Clean the impeller and pump housing

k) Joints or the stuffing box are leaking. • Tighten the joints or the stuffing box gland.

2. The inlet pressure is insufficient. a) The inlet line is drawing air. Tighten the connections.
b) The suction lift is too high or there is

insufficient NPSH.
c) Air or gas is trapped in the pumped liquid. Remove the trapped air or gas from liquid.
d) The strainer is clogged. Clean the strainer.

3. The noise level has increased. a) Poor alignment of the pump.
The inlet and outlet pipe clamps are loose.

b) Cracked foundation. Repair the foundation.
c) Worn ball bearings. • Replace the worn bearings.

d) The motor is unbalanced. • Disconnect the motor and operate it alone.

e) Hydraulic resonance. • Alter the resonant pipes.

DANGER

Hot, caustic, flammable or toxic materials,
including vapors

Death or serious personal injury.

- Be extremely cautious when venting and/or
draining hazardous liquids.
Wear protective clothing when there are caustic,
corrosive, volatile, flammable, or hot liquids.
Do not breathe toxic vapors.
Do not allow sparks, open fire, or hot surfaces
near the equipment.

rotation.

Check the system curve.

diameter.

passages.

• Replace the shaft sleeve.

• Replace the gaskets.

Reduce the suction lift or restore required
NPSH.

• Reestablish proper alignment of the pump
and the motor.

• Support the inlet and outlet pipes.

• Make sure the vibration dampers, flexible
pipes and conduit connectors are installed
correctly.

• Renew the lubrication.

• Remove large pieces of debris, such as
wood or rags from the pump.

• Clean out the pump, if necessary.

• Change the pump speed.

• Insert a pulsation damper on the pump or the
pipes.

• Insert a flow straightener.

English (US)

27

English (US)

Fault Cause Remedy

4. Insufficient flow. a) The pump is not primed. Prime the pump.
b) The system pressure exceeds the shut off

pressure.

c) The speed of rotation is too low. Reestablish the correct speed of rotation.
d) The suction lift is too high or there is

insufficient NPSH.
e) The strainer or the impeller is clogged. Clean the strainer and the impeller passages.
f) Wrong direction of rotation. Reestablish the correct direction of rotation.
g) The joints are leaking. Tighten the joints.
h) The shaft or coupling are broken. Repair or replace damaged parts.
i) The inlet valve is closed. If the inlet valve is closed, open it slowly.
j) There is not enough inlet pressure for hot

or volatile liquids.
k) The foot valve is too small. Replace the foot valve.
l) Worn or damaged hydraulic parts. Repair or replace the worn parts.
m) Excessive clearance between the wear

surfaces.

5. The pump loses its prime after
starting.

6. Excessive power is required. a) The speed of rotation is too high. Reduce the speed of rotation.

a) Joints or the stuffing box are leaking. • Tighten the joints or the stuffing box gland.

b) The suction lift is too high or there is

insufficient NPSH.

b) The pump is operating beyond its

recommended performance range.

c) The specific gravity or viscosity of the

pumped liquid is too high.

d) The shaft is bent. Replace the shaft.
e) The stuffing-box is too tight. Retighten the stuffing box if possible.

f) The impeller clearance is too small causing

rubbing or worn wear surfaces.

g) There is an electrical or mechanical defect

in the motor.

h) The pump is restricted in its rotation. Remove any obstacles or replace any worn

i) Incorrect lubrication of the motor. Reestablish correct lubrication of the motor.

• Increase the liquid level on the inlet side.

• Open the isolating valve in the inlet pipe.

Reduce the suction lift or restore required
NPSH.

Reestablish required inlet pressure.

See section 8.1 Maintaining the product.

• Replace the shaft sleeve.

• Replace the gaskets.
Reduce the suction lift or restore required

NPSH.

Set the duty point in accordance with the
recommended performance range.

If less flow is sufficient, reduce the flow on the
outlet side, or fit the pump with a more powerful
motor.

Alternatively, repair or replace the stuffing box.
Adjust the impeller clearance, if possible, or

replace the wear ring.
Contact your local service center for

diagnostics.

parts.

28