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MEGA

THANK YOU CUSTOMER
You are a proud owner of a MEGA pump

The nameplates punched on the pump shows the Pump type (series & size), serial no. (works order no. ) and main operating data. Please quote the above information in all queries, repeat orders and particularly when ordering spares.

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2 2.2.4 6.1 3.1 3.4 3.3 2.1 2 2.3 6. 1 1 1 1 1 1 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 5 5 6 6 6 6 6 7 7 7 7 7 7 7 8 9 10 11 & 12 9 9.1 4.4.1 4.2.4 6 6.1 8 Description General Handling Installation(on site) Foundation Mounting Aligning Pump / motor Connecting the piping Auxillary connections Vacuum balance line Coupling guard Final check Commissioning / start-up.1 6.4.2 2.2 3.1.2 5.MEGA CONTENTS Sr.1 2.1 3.Cause & remedy Page no.2 6.1 6.1 2.2 4.3 3.2 3.4.2 3. shutdown Preparations Procedure Shaft seal Stuffing box Packing the stuffing box Priming & associated checks Checking the direction of rotation Start-up Shutdown Maintenance & lubrication Suprevision & operation Lubrication & lubricant change Grease change Oil change (if applicable) Dismantling General Dismantling Dismantling the bearing unit Removal of mechanical seal Reassembly Pump Replacement of wearing rings Replacing of bearings Deep groove ball bearings & lubricant fill Mecahnical seal Conversion kit Stuffing box compartment Spare parts Ordering spare parts Interchangeability of components & recommended spares for 2 years of continuous operation Sectional drawing List of components Faults.1.1.3.1 5.5 2.2.1.1.2. no.1.2 5 5.3 4 4.6 3 3.3 5.1 6. 1 1.5 7 7.4 2.1 10 .

this can be measured using calipers or a feeler gauge. Fig. cold alignment & hot alignment both should be carried out on pumpset. Prior to checking the alignment and /or aligning. loosen supporting foot (183) and tighten again without transmitting any strain. The alignment should be carried with & without pipe connections and should be within limits. In case you are using the pump for applications other than water. pump sizes. The type series. All shims must seat perfectly flush with the baseplate / frame. Please make sure to quote this information every time you write to us in respect of queries. 2.The gap between the two coupling halves must be the same at all points (minimum 3 points) on the circumference.1 Handling When handling the complete pumpset or bare pump attach ropes to the pump and motor as shown (not through the motor eyebolt).Baseplates have to be grouted with non-shrinking mortar up to the upper edge of the frame after having been fixed in position. position extra shims equidistant between them. 1 : Bare pump Fig. If the shims are more than 800 mm apart.MEGA 1 General 2 2. Please check the alignment of pump motor and coupling even though they are supplied ready mounted on baseframe.1 mm by installing dial indicaters as shown in fig.3 Aligning pump / motor After the baseplate has been fixed in position carefully check the coupling and if necessary. The surface of the foundation must be completely horizontal and perfectly flat. 2. between the baseplate / foundation frame and the foundation. The pumpset to be aligned radially and axially within 0. realign the pumpset (with the motor).1 Installation (on site) Foundation Your centrifugal pumps will only give you completely trouble free and satisfactory service on condition that it is installed with due care and properly maintained. Always fit shims to the left and right of the anchor bolts. 1. and the site engineer & the site operator is responsible for notifying our erection staff of any such regulations and seeing that they are complied with. Fig. Ensure the gap between the two coupling halves is as given on the general arrangement drawing. 3 : Fitting shims Uniformly tighten up securing means. This operating instruction manual dose not take any account of any safety regulations which may apply to the installation site. 4 : Aligning a coupling 1 . repeat orders and more particularly when ordering spare parts. For liquids handling more than 1050C. no. 4 and without pipe connection. main operating data and the works order number are all stamped on the name plate affixed to the pump. 2 : Pump & motor on a common baseframe Fig. no.2 Mounting Position the pumpset on the foundation and level using a precision spirit level on the discharge nozzle of pump. no. no. Make sure the concrete foundation has set before mounting the pumpset. please ensure that you have a specific confirmation from the dealer or KSB. It is absolutely essential that the instructions contained in this manual be strictly observed and that the pumps are not operated under conditions which differ from those specified under our `Operating Conditions'.

thoroughly clean. 5d) or as recommended in the performance curve.4 Connecting the piping Never use the pump itself as an anchorage for the piping. 5b : Suction pit above the pump. piping & connections. made of corrosion resistant material.e. depending on the type of the installation and pump. The conical strainer consists of a coarse strainer fronted by a fine strainer with a 2. (i. 5c. 5a .MEGA 2.(Fig. The pipelines should be anchored in close proximity to the pump and should be connected to the latter without transmitting any stress or strain. Fig. 2 . Fig. The total cross section of the holes in the strainer should be three times the cross section of the piping in order to avoid excessive pressure loss across the strainer due to clogging.5a : Piping & supporting of piping 1 2 3 4 5 Suction line Strainer holder Fine strainer Coarse strainer Pump suction nozzle Fig. suction pipe with downward slope towards pump. Fig. 5a. 5b.5c : Suction pit below the pump. Stainless Steel) ref. nor should weight of the piping be loaded on to the pump. so as not to impose any additional load on the pump. 5d). Any thermal expansion of the piping (due to high temperatures) must be compensated by suitable means. scale and other impurities get dislodged after a certain period of operation. We recommend the incorporation of suitable pressure gauges close to suction & discharge flanges and also check valves or non-return valves and isolating valves in the system. it is necessary to fit a strainer in the suction line to prevent these entering the pump. 5d : Suction pipe connections Fig. fig. Fig. Please ask dealer or KSB incase the nominal sizes are not conveyed. suction pipe with rising slope towards pump.5 mm diameter wire. flush and blow through all vessels. Welding beads. Suction lift lines should be laid with a rising slope towards the pump and suction head line with a downward slope towards the pump.The nominal sizes of the pipelines should be atleast equal to the nominal sizes of the pump nozzles.0 mm mesh and 0. 6 : Conical strainer for suction line Before commissioning a new installation.(fig. 6.

return valve C.2 Shaft Seal The shaft is sealed at its exit though the casing by a soft packed stuffing box or a mechanical seal.no. Fix the dipstick back in. 7 : Auxillary connections of pump 2. Code 1M1 1M2 3M 6D 7E 7S 8D 10E 10S 13E* 13D* Description Pressure guage Pressure guage Pressure guage Casing drain Cooling inlet Cooling outlet Drain (leakage) External sealing in External sealing out Oil filling / Dip stick Oil drain Conn. shutdown 3. Fill in oil through the hole left by the dipstick (fig. An additional line starting at the pump discharge-nozzle facilitates venting of the pump before start up.2 Vacuum balance line If the pump has to pump a liquid out of vessel under vacuum. 1 * MEGA pumps are supplied with grease lubricated bearings as a standard supply.1. it must be provided by the customer.4.2. It should be arranged to lead back into the vacuum vessel at a point above the permissible liquid level. Fig. Non.4. 3 Fig. Vacuum vessel Z. no. No greasing is required at site. A. 3 Commissioning / startup. Do not fill oil for grease lubricated bearings.1.7 & table no.6 Final check Conn. Intermediate flange 2. If the customer states specifically that the coupling guard is not to be supplied by us. type NPT NPT NPT NPT NPT NPT NPT NPT NPT G Size A-30 A-40 A-50 A-60 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 3/8" 3/8" 3/4" 3/4" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Ø 20 mm 1/4" 1/4" 1/4" 1/4" Recheck alignment as described in 2. Changeover from gland packing execution to mechanical seal & viceversa is possible by using conversion kit. Vaccum tight isolation valve V. the pump may only be operated if it is fitted with a coupling guard.2. This line should have a nominal size of 25 mm at least. If in doubt of type of bearings supplied please check with the dealer or KSB. no. 1.1 Auxiliary connections The size and location (connection code) of all auxiliary connections are shown in the fig. Vacuum balance line R. The vacuum tight isolating valve E in the connecting line should be closed after the venting procedure and should remain closed while the pump is running. Isolation valve E. For details refer dealer or KSB. it is advisable to install a vacuum balance-line. Main isolation valve. The main isolating valve C in the vacuum balance line must remain open at all times when the pump is running and should only be closed when the pump is shut down. 8 : Suction line and vacuum balance line.5 Coupling guard In compliance with the accident prevention regulations.3 It must be possible to rotate the coupling easily by hand. Table no. 2. Fig. After a short time check whether the oil level in the bearing bracket has dropped.1 Preparations Grease lubricated bearings : Grease lubricated bearings are pre-packed with grease for life time. 9 : Oil fill level 3.MEGA 2. then put more oil up to marking on the dipstick. Check the integrity of all connections.1 Procedure Pull out dipstick. no. 9 & 10). . suction B. Oil lubricated bearings : The bearing bracket should be filled with oil of the types & specifications as mentioned in 4. 3.

then the pump must be drained or otherwise protect it against freezing. the nuts on the stuffing box (452) gland should be tightened slowly and evenly while the pump is running.1. 4 . even a new packing cannot be expected to last very long in service.1.1. thoroughly clean stuffing box gland (452). Check this by switching the motor on and immediately switching it off again. The correct and even seating of the stuffing box gland (452) should be checked when the pump is subjected to suction pressure. on pumps which operate on suction lift pressure. If there is danger of freezing and/or if the pump is to be out of service for long period. After the pump has reached its working temperature and/ or if leakage occurs. Switch off the motor. tighten bolts (901. A newly packed stuffing box should leak profusely at first. Stuffing Box Soft-packed stuffing box reduce the flow of leakage liquid at the clearance gap between casing cover and shaft protection sleeve when the pressure inside the pump is higher than atmospheric. If the newly packed stuffing box starts to emit smoke when the pump is started up for the first time. If the pumpset is to remain out of service for long periods. Then the nuts (920) should be slackened again by one to two complete turns. The individual rings are pushed home into the packing compartment with the aid of the stuffing box gland (452). The first packing ring is then inserted and pushed home into the compartment with aid of the stuffing box gland (452). If this leakage does not cease of its own after a relatively short period of operation. If the shaft protection sleeve is scored or grooved. 3. the pump should be switched off. The following packing rings are then inserted into the packing compartment one by one. 3. The inserted packing rings should then be compressed moderately with the aid of the stuffing box gland (452) and the nuts (920). If the smoking persists after the pump has been started up again and operated several times in succession. (Open the shutoff valve in the vacuum line.no. The packing of the stuffing box should be carried out with great care. The discharge isolating valve can remain open if the discharge line is fitted with a non-return device on condition there is back-pressure. by inserting a feeler gauge between the stuffing box gland (452) and the shaft protection sleeve (524). fig. the soft-packed stuffing box prevents the ingress of air into the pump.2. the nuts on the gland should be slackened slightly.3 Shutdown Close the discharge isolating valve. 3. Mount the coupling guard. to enable the sealing liquid to enter. the rubbing faces of the individual rings should be lightly coated with MOLYKOTE before insertion in the packing compartment.1. or the stuffing box should be inspected if necessary. to avoid an excessively high radial pressing force of the packing rings against the shaft protection sleeve. Cut the packing ring to correct length and ends at 45º. The pressure of the liquid should be 1 to 4 bar above the pressure existing in the packing compartment of the stuffing box. if fitted and closed the vacuum tight shutoff valve “E”. 3. Conversely. Make sure that the stuffing box gland (452) is tightened evenly and not a skew. making sure the pump set runs down smoothly and evenly to a stand still. in relation to the butt joint of the preceding ring. until the stuffing box only drips slightly. packing compartment and shaft protection sleeve (524). and thereafter tightened lightly by hand. close the isolating valve in the suction line and close all connections. Sealing is effected by means of soft packings arranged in a number of rings in the annular space between the discharge cover (163) and the shaft protection sleeve (524) and lightly compressed by the stuffing box gland (452). The shutoff valve in the suction line must be completely open.2 Re-Packing the Stuffing Boxes Caution : The pump is despatched from our Works with the stuffing box packed. They should be inser ted in the packing compartment in such a way that a clear gap of 6 to 8 mm is left at the outer end of the compartment for the positive guide of the stuffing box gland (452). The packing rings should only be pressed lightly against one another. A lantern ring (458) is also inserted in the packing compartment.1. (See below "cutting the gland packing") If the packing rings are either too long or too short.2 Cutting the gland packing Start-up Start the pump against a closed discharge valve only. 8). the stuffing box will not be able to perform its function properly.4 Checking the direction of rotation The direction of rotation of the prime mover must match with the arrow on the pump.MEGA 3.01) with the pump disconnected / switched off. Before repacking. which might damage the latter. making sure that the butt joint of each ring is offset by 900 approx. In the case of asbestos-graphite packing material. The lantern ring must register beneath the drilled hole in the discharge cover (163).2. Once the pump has reached full speed. slowly open the discharge valve to set the duty point flow indicated on the name plate. at the position shown in the cross-sectional drawing. Ensure that the packing rings ends come into contact with one another on fitment. 3.3 Priming & associated checks Vent and prime the pump and suction line before startup. as otherwise the shaft protection sleeve (524) might be damaged.

no.1 Grease change The anti-friction bearings are prepacked with grease by the manufacturer. Pumps with mechanical seals experience minor or invisible (vapour) leakage. Remove supporting foot (183) from the baseplate and loosen bolts (901.11 The pump must run quietly and evenly at all times. Fig.2. 4. 2. Remove supporting foot (183) from the baseplate and loosen bolts (901. (With larger pumps. suspend or support bearing bracket to prevent the rotating assembly from falling over. 2 & 4. 9).no. 4. In this case use a brand name penetrating oil or suitable pull-off device. Do not run the pump for a long period against a closed discharge valve. 3. The pump casing must be empty and not under pressure. 10 : Oil lubrication Procedure : Remove the drain plug (903.2. 11 : Dismantling the pumpset For coupling without spacer / intermediate sleeve: 1. 5. 12 : Removal of impeller from pump shaft . 5. make sure the motor is disconnected from the power supply and cannot be switched on accidentally. The pump casing must have cooled down to ambient temperature. 2. no. Remove spacer/intermediate sleeve of the coupling. 4. When the bearing bracket is empty. Uncouple pump and motor.2 Lubrication and lubricant change 4. Remove coupling guard. The suction and discharge shutoff valves must be closed.1 Maintenance and lubrication Supervision and operation 5. For quantity.MEGA 4 4. Refer fig.11 & Cross sectional drawing. If the pump has been in operation for a long time some parts may be difficult to remove.06) and drain off the oil.) For coupling with spacer/intermediate sleeve During dismantling. Remove coupling half from the pump shaft. refit the drain plug & refill the bearing bracket with oil from vent plug hole.no.2 Fig. can remain on the : Servosystem 46 : Enclo 46 : Bharat Hydrol 46 1. The bearing bracket should be filled up to the mark with oil of any one of the following types and specifications. Loosen and remove motor form baseplate. the volute casing baseplate and in the pipeline. Remove discharge and suction branch from pipe line. 4. Refer fig. Under no circumstances use force! 5 5.no. For oil-lubricated pumps drain-off the oil as described in 4.2 Oil change ( If applicable ) The first oil change must be carried out after 300 hours of operation.01) on discharge cover. no. 6. The bearing temperature may be allowed 500C above room temperature. no necessity of greasing it for life time. The pump must never run dry.1 Dismantling General Before dismantling. Check oil level with dipstick (fig. Refer fig. all subsequent oil changes after 3000 hours. 3. Flexible parts of coupling which shows signs of wear should be replaced in good time. Stand-by pumps should be started up and immediately shut down again once a week to keep them operational. no.2. Pull out bearing bracket with discharge cover and complete rotor (assembled unit). Pull out bearing bracket with discharge cover and complete rotor (assembled unit). 3. 5 Fig. but must not exceed 800C(measured at the outside of the bearing housing). refer table no.2. Indian Oil Hindustan Petroleum Bharat Petroleum Table no.2 Dismantling Procedure : 1. 2. Disconnect motor from power supply. Disconnect from power supply. Detach all auxiliary supply pipe lines.11.01) on discharge cover. The seal is maintenance-free.

4 0.13c.445 0.42 0.32 0.31 0.32 0.13a : dismantling the bearing unit Replacement of Wearing Rings 1.31 0.445 0.405 0.42 0.445 0.445 0.425 0. Pump size 32-125 32-160 32-200 40-125 40-160 40-200 50-125 50-160 50-200 65-125 32-250 40-250 50-250 65-160 65-200 80-160 40-315 50-315 65-250 80-200 80-160 80-200 100-200 65-315 80-315 80-400 100-250 100-315 100-400 125-200 125-250 125-315 125-400 150-200 150-250 150-315 150-400 Table no.33 0.33 0. & the discharge cover (163) exceed three times the max.31 0.445 0. Remove bearing covers ( 360. 13b : Dismantling the bearings from the pump shaft.32 0.02) if neccessary. Fasten the shaft (with bearings) to the bench vice and detach bearings from shaft with an extractor or by means of a hammer and a punch.32 0.32 0.33 6 .01/02) and gaskets by unscrewing of hex.425 0.32 0.33 0.425 0.445 0.32 0.47 0.32 0.31 0.35 0. Coat the fits and screw connections with graphite or similar before reassembly.33 0.33 0. 6 6.33 0.425 0. make sure the new ones have the same thickness as the old ones.33 0.47 0.445 0.445 0.4 0.445 0.425 0. Fasten the bearing unit ( 330 ) firmly to the bench vice refer fig.445 0.405 0.0.32 0. In MEGA GC wearing ring 502. no.33 0.32 0.405 0.32 0.425 0.MEGA 5.42 0.1.42 0. 2.445 0.32 0.42 0.445 0. replace if necessary. Note : Always replace the bearings once they have been removed from the shaft with new ones. no.32 0. value as shown in the table no.32 0.425 0.33 0. The wearing rings have to be repalced when the clearences between the wearing ring (502. 13a.3 Dismantling the bearing unit Check oil seal & o-rings for its damage.32 0.33 0.5 mm on diameter 6.42 0.425 0. For permissible limits of diametrical wearing clearance between Impeller and wearing ring refer 6.42 0.33 0.33 0.33 0.445 0.31 0.3 or when the reduciton of efficiency of the pump is noticed.1 Reassembly Pump Reassembly in accordance with standard engineering practice.425 0.425 0.42 0. All gaskets must be renewed.445 0.2. it is necessary to dismantle the pump.33 0.445 0.445 0. fig.35 0.32 0.32 0.42 0.445 0.42 0.33 0.42 0.33 0.4 Removing of Mechanical seal To replace the mechanical seal.425 0.33 0.33 0.445 0.2 is not provided.32 0.32 0.32 0.445 0.445 0.47 0.445 0.445 0.33 0.32 0.405 0.425 0.445 0.0.445 0. 3.35 0. After removing the impeller (230) draw the mechanical seal (433) from the shaft by hand. 13b : Dismantling the pump shaft from bearing bracket Fig.445 0.445 0. Refer fig.33 0.405 0.425 0.445 0.32 0.32 0.445 0.32 0. 5.2 Fig. bolt ( 901. New wearing ring clearances are MEGA .35 0.2) & the impeller.01) & (502.31 0.33 0.no.33 0.32 0. Original clearances on the diameter Casing side Impeller side Maximum Minimum Miximum Minimum 0.33 0. no.445 0.33 0. no.42 0. Strike the pump shaft end with a soft hammer.33 0.445 0.33 0.445 0. 13b.445 0.32 0.no.31 0.32 0.32 0. Replace wearing rings(502.42 0.33 0.32 0.445 0.33 0. 3 Fig.42 0.3 mm on diameter MEGA GC .4 0.425 0.05).42 0.33 0.33 0.47 0.31 0.33 0.32 0.

6.no. clean the spacer sleeve (525).5 7 7. 14 : Mounting of bearings 6. Fig.2 0. 4. Fasten the shaft (210) to the bench vice using soft polish sheets between the vice clamp jaws to avoid damage. 3. When the stationary seal rings has been inserted.14. Refer fig.65 0.5 Stuffing box compartment Fig. Allow the bearings to cool down. 5.01/02) in the oven about 800C max.40 A . Heat the bearings (321. Check shaft surface under mechanical seal area.MEGA 6.1 Deep groove ball bearing & lubricant fill (Only increase of oil lubricated bearings) Bearing bracket A-30 A-40 A-50 A-60 Table no.4 Mechanical seal The following points should be observed when mounting the mechanical seal : Extreme care and cleanliness during assembly are the essential pre-requsites for the trouble-free operation of the mechanical seal. between centres. Fig.65 Fig. and push it on to the shaft. If the name plate is missing then check on the discharge flange for serial/work order no.4. no. Make sure that there are no scratches or grooves. 7 d1 35 45 60 70 Dimensions d2 l 55 71 65 71 85 90. Oil qty. The guard protecting the rubbing faces should only be removed before assembly takes place. Then tap it lightly against the shoulder using suitable pipe punch.3.50 A . 6.30 A . 4 Grease packed Bearing no. Before reassembly.60 Table no.in ltr. 2.1 Conversion kit Parts required for changeover from gland packing to mechanical seal are : 1.14. no.05mm. Check the shaft ( 210 ) with its spacer sleeve (525) / or shaft protection sleeve (524) (as applicable) for eccentricity. If not possible then replace the shaft by new ones. Maximum allowable eccentricity is 0. : Type Serial/work order no. Spacer sleeve (525) Mechanical seal (433) Seal cover (476) Studs & nuts Set of gaskets 6.5 95 90. no. 16 : Stuffing box compartment Dimensions of packing compartment in mm Bearing bracket # A . 3.1 Spare parts Ordering spare parts When ordering spare parts please indicate the following information which may be taken from the name plate of the pump. e. check its plane parallelism in relation to the casing component.3 Replacing of bearings 1.35 0.g. If it is found then touch up scratches / grooves.5 # See interchangeability of components for co-relation of shaft & pump sizes in table no. 15 : Mechanical seal 6. 2. no. : MEGA 50-250 : 955 1234-1235 . 6306 2Z C3 6308 2Z C3 6310 2Z C3 6312 2Z C3 Oil lubrication Bearing no. 6306 C3 6308 C3 6310 C3 6312 C3 0.

& above 1 1 1 2 2 2 2 3 3 30% 30% 30% Table no. each 9 nos.03 400.4 502.MEGA 8 Interchangeability of components & recommended spares for 2 years of continuous operation 524 / 525 Shaft Prot.50% discharge covers # Only for Oil lubricated bearings 8 940.1 32-125 32-160 32-200 40-125 40-160 40-200 50-125 50-160 50-200 65-125 32-250 40-250 40-315 50-250 50-315 65-160 65-200 65-250 80-160 80-200 80-250 100-160 100-200 65-315 80-315 80-400 100-250 100-315 100-400 125-200 125-250 125-315 125-400 150-200 150-250 150-315 150-400 A .2 901.60 40 13 4 41 14 4 37 4 4 4 4 4 4 4 4 4 4 4 12 10 38 4 4 4 4 4 4 4 4 4 4 4 12 10 Recommended spare parts for 2 years of continuous operation Quantity 2 5 nos. Sleeve / Spacer sleeve Deep groove ball bearing Description Volute casing Wearing ring Impeller ring Support foot Splash ring Seal cover Pump Size 635 / 913 Dip stick# / vent plug Bearing bracket Discharge cover Mechanical seal Bearing bracket Bearing cover Cooling cover O-ring @ Hex.30 2 4 6 7 8 9 10 11 12 13 15 16 21 17 22 18 19 23 20 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 1 1 2 1 1 2 1 1 2 1 3 3 8 3 8 4 5 7 4 6 7 6 6 11 11 12 10 11 12 9 10 11 12 9 10 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 2 3 1 2 3 2 3 3 3 4 4 6 4 7 5 4 6 4 4 7 6 6 10 8 9 10 8 9 8 8 9 11 9 9 12 12 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 2 3 4 5 6 7 8 9 10 11 12 13 18 14 19 15 16 20 17 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 1 1 1 2 2 3 4 4 4 5 1 2 2 4 5 5 5 6 7 7 7 8 8 6 7 9 8 8 8 10 10 10 10 11 12 13 13 13 13 13 13 13 13 13 13 3 3 14 3 14 15 15 16 15 18 16 18 18 17 17 10 10 17 10 10 10 17 10 10 10 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 3 2 3 2 2 3 2 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 5 5 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 A .3 400.2 901.1 400. each 150% @ Only for cooled No. of pumps Up to 3 nos.40 A .50 A .1 502.1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 Part no. bolt Impeller Washer Oil seal Gasket Gasket Gasket Gasket Shaft Key 940. Up to 7 nos. 6 2 1 2 2 2 2 3 3 3 . Up to 10 nos.2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4 102 163 165 183 210 230 321 330 360 421 433 471 507 554 Key .1/. bolt Hex. Up to 5 nos.50% 30% . each 8 nos.2 400. 412.

MEGA 9 Cross sectional drawing Details of cooling cover 9 .

01 / 02 507 524 550.01 .01 .01 / 02 412. head bolt Stud Hex.1 List of components Part No.02 Description Volute casing Discharge cover Cooling cover ( optional ) Support foot Shaft Impeller Deep groove ball bearing Bearing bracket Bearing cover Flat gasket Gasket O-ring ( for cooling cover ) O-ring Oil seal Gland cover Lantern ring Packing Wearing ring .06 412.05 411.01 / 02 330 360.Casing / impeller Splash ring Shaft protection sleeve Washer Washer for impeller Hex.01 / 02 452 458 461 502.01 .01 .MEGA 9. 102 163 165 183 210 230 321.10 913 920 940.06 902 903. head plug Vent plug Hex.03 421. nut Key 10 .01 / 03 554 901.01 / 02 400.

Fit larger impeller 2) Vent or prime the pump and piping completely Remove the deposites in the pump and / or piping Formation of air pockets in the piping Alter piping lyout. Change over two phases of the power supply cable. Increase the speed • • Ingress of air on shaft seal Reverse rotation Rotational speed is too low 2) • • Excessive wear of the pump internals Repalce worn components by new ones. Reduce speed 2) Renew seal between volute casing and the discharge cover 11 . Suction line or impeller clogged Reset duty point Check the plant for dirt.2) 2) Specifc gravity or viscosity of the fluid pumped is higher than that specified in the purchase order.MEGA 10 Pump delivers insufficient liquid Faults-cause & remedy Excessive temperature rise inside the pump Excessively high pump discharge pressure Excessive shaft sealing leakage Bearings overheating Rough pump running Motor overloaded Cause Remedy 1) Pump leaks • • • • • • • • • • • • • • • • • • The pump generates excessively high differential pressure Excessively high back pressure The pump and \ or piping are incompletely vented or primed. if necessary. arrange a sealing liquid supply from an outside source. If necessary. fit a vent valve NPSH avaliable is too low (on positive suction head installations) Check the liquid level. If necessary. Mount the pump at lower level. Defective seal Correct. or increase sealing liquid pressure. Open isolating valve in the suction line fully. Adjust duty point accurately. if the losses in the suction line are Sealing liquid passage is clogged. In case of persistant overloading. Alter suction line. Fit a new shaft seal \ gland packing. Pump back pressure is lower than that specified in the purchase order. trim the impeller. clean it out. Gland cover too tight or tightened askew Excessive rotational speed.

Correct the suction conditions. 2) Please refer KSB. Insrease the minimum rate of flow. or unsuitable lubricant quality. Increase the cross-section of the circulation in the liquid line. Increase the suction pressure at the pump suction nozzle. if necessary. The specified coupling gap has not been maintained. Check the electrical connections. Grooving. Check the piping connections and pump fixing bolts. Fit new shaft seal. or change lubricant quality. Reduce quantity or top up lubricant. Clean the balance holes in impeller. Faults in circulation liquid supply. Clean the rotor. • Too much or too little. score marks or roughness Renewshaftsleeve. Insufficient rate of flow. The pump is warped or resonance vibrations in the piping. • • • • • • • • Excessive axial thrust 2). Rebalance rotor. Defective bearings. Align pump. Restore correct coupling gap in accordence with the data on the installation plan. 1) The pump should be made pressureless before attempting to remedy in parts under pressure. The pump runs noisy.MEGA Excessive temperature rise inside the pump Excessively high pump discharge pressure Excessive shaft sealing leakage Pump delivers insufficient liquid Bearings overheating Rough pump running Motor overloaded Cause Remedy 1) Pump leaks • • • • Worn shaft seal Check flushing / sealing liquid pressure. Pump set misaligned. Renew shaft sleeve. Rebalance the rotor dynamically. Replace the defective fuse. Support piping using antivibration material. Fit new bearings. Fit new casing wearing rings. 12 . Reduce the gap between the pipe supports. on shaft protection sleeve / shaft surface. Rectify. The motor is running on two phases only. Fit new shaft seal. • • • • • The rotor is out of balance.