Om9294 11 PDF

OM9294_11.
Operating Instructions
KRAL Screw Pumps.

L Series
OIL 01en
Edition 05/2016
Original instructions
www.kral.at
OM9294_11.2
Table of contents
KRAL Screw Pumps L Series
About this document Installation, removal and connection

General information 4 Installation 21
Target groups 4 Installing the pump 21
Symbols 4 Protect the pump against contamination 22
Connecting the pump to the pipe system 22
Danger levels 4
Assembling pump and motor 23
Associated documents 5
Connecting the motor 23
Safety Removing the pump 24
Proper use 6
Operation
Safety information 6
Commissioning 25
Labeling Cleaning the pipe system 25
Filling and venting the pump 25
Type code 7
Checking the direction of rotation 27
Rating plate 8 Commissioning the pump 27
Technical data During operation 28
Operating limits 9 Adjusting the overflow valve 28
Checking the operating pressure 29
Sound pressure levels 9
Switching off the pump 30
Required NPSH values 10
Taking the pump out of operation 30
Materials 10
Recommissioning the pump 30
Weights 11
Model LFI/LFM/LFT/LFW 11 Maintenance
Model LVI/LVT 11 Safety instructions 31
Heating system Required maintenance 31
Mechanical seal 31
General 12
Ball bearing 31
Electric heating system 12 Cleaning leakage vent holes 32
Mounting the electric heating system 12
Connect and commission the electric
Replacing the coupling 33
Removing the coupling 33
heating system 13
Installing the coupling 34
Fluid heating system 14
Replacing the mechanical seal 35
Mounting the fluid heating system 14
Removing the mechanical seal 35
Commissioning the fluid heating system 14
Installing the mechanical seal 36
Function description Replacing the radial shaft seal 38
Structure 15 Removing the radial shaft seal 38
Shaft seal 16
Mounting the radial shaft seal 38
Housing variants 17
Replacing the ball bearing 40
Removing the ball bearing 40
Overflow valve 17 Installing the ball bearing
Transportation, storage and disposal Mechanical seal version 41
Installing the ball bearing
Unpacking and checking the state Radial shaft seal version 42
of delivery 18
Lifting the pump/pump unit 18
Replacing the screw set 43
Removing the screw set 43
Storage 18 Installing the screw set
Preservation 19 Mechanical seal version 44
Preserving the internal surfaces Installing the screw set
of the pump 19 Radial shaft seal version 46
Preserving the external surfaces
of the pump 19 Troubleshooting
Removing the preservative 19 Possible faults 48
Disposing of the pump 20 Troubleshooting 48
2 OIL 01en Edition 05/2016 Operating Instructions

OM9294_11.2
Table of contents
KRAL Screw Pumps L Series

Spare parts
Overview 51
Maintenance kits 52
Maintenance kit mechanical seal,
standard or hard material
LFI/LVI/LFT/LVT 5 85 52
Maintenance kit standard radial shaft
seal + high temperature
LFI/LVI/LFT/LVT 5 85 54
LFM 5 85 55
LFW 5 85 56
Repair kits 57
Repair kit screw set 57
Repair kit overflow valve 58
Tool kits 59
Completions 60
Appendix
Tightening torques 62
Contents of the EC Declaration of
Conformity 62
Notes 63
Operating Instructions OIL 01en Edition 05/2016 3

OM9294_11.2
General information
About this document
General information
About this document
The operating instructions form part of the pump/pump unit and must be kept for future reference.
Furthermore please observe the associated documents.
Target groups
Target group Tasks

Operator-owner Keep these instructions available at the installation site for future
reference.
Ensure that employees read and observe these instructions and
the associated documents, in particular the safety instructions
and warnings.
Observe additional system-specific directives and regulations.
Specialist personnel, fitters Read, observe and follow these instructions and the associated
documents, in particular the safety instructions and warnings.
Symbols
Symbol Meaning
Warning personal injury
Notice
Procedures mechanical installation
Procedures electrical installation
Check or fault table
Request for action
Danger levels
Warning Danger level Consequences of non-observances
DANGER Immediate threat of danger Serious personal injury, death
WARNING Possible threat of danger Serious personal injury, invalidity
CAUTION Potentially dangerous situation Slight personal injury
CAUTION Potentially dangerous situation Material damage

OM9294_11.2
Associated documents
About this document

Associated documents
ATEX supplementary instructions for operation in areas at risk of explosions

Declaration of conformity according to EU Directive 2006/42/EC
Declaration of conformity according to EU Directive 2014/34/EU
Manufacturer's declaration as per EU Directive 97/23/EC (from 19.07.2016: 2014/68/EU)
Technical documentation for supplied components

OM9294_11.2
Proper use
Safety
Proper use
Safety
Use the pump only to deliver lubricating liquids that are chemically neutral and do not contain any
gas or solids content.
Use the pump only within the operating limits specified on the rating plate and in the "Technical data"
section. In the case of operating data that does not agree with the specifications on the rating plate,
please contact the manufacturer.
The pump is specifically configured for the operating pressure stated by the customer. In the case of
a significant difference between actual and configured operating pressure damages can occur even
inside the stated operating limits. This does apply to significant higher as well as to significant lower
operating pressure. By no means should the operating pressure fall below a minimum pressure of 2
bar. If there is any doubt please contact the manufacturer.
Safety information
The following general safety instructions must be observed:
No liability is accepted for damage arising through non-observance of the operating instructions.
Read the operating instructions carefully and observe them.
The operator-owner is responsible for the observance of the operating instructions.
Installation, removal and installation work may only be carried out by specialist personnel.
In order for the warranty to remain valid, corrective maintenance carried out during the warranty
period requires the express permission of the manufacturer.
Observe the general regulations for the prevention of accidents as well as the local health and
safety regulations.
Observe the valid national and international standards and specifications of the installation loca-
tion.
In case of systems with an increased potential of danger to humans and/or machines the failure
of a pump must not lead to injuries or damage to property.
Always equip systems with an increased potential of danger with alarm equipment.
Maintain and check the protective/alarm equipment regularly.
Pumped liquids can be dangerous (e.g. hot, dangerous to health, poisonous, combustible).
Observe the safety regulations for handling dangerous materials.
Pumped liquids can be subject to high pressure and can cause damage and/or personal injury
should leaks occur.

OM9294_11.2
Type code
Labeling
Type code
Labeling
2 4 6 1 Model
2 Size
3 Shaft seal
LFI - 42.ACAP.00001 4 Pressure stage valve
5 Heating system
6 Completion
1 3 5 7 7 Version index
Fig. 1 Type code
Item Designation Type

1 Model LFI: Pump with free shaft end
Pump housing with flanges inline PN25/PN63
Pump unit with or without pump bracket foot
LFT: Pump with free shaft end
Pump housing with flanges on top PN25/PN63
LFM: Pump with free shaft end
LFW: Pump with free shaft end
LVI: Pump with free shaft end and pedestal
Pump housing with flanges inline PN25/PN63
Pump unit pump with pedestal for vertical mounting
LVT: Pump with free shaft end and pedestal
Pump unit with pedestal for vertical mounting
2 Size Corresponds to flow rate in [l/min] at 1 450 min-1
3 Shaft seal A: Standard mechanical seal
B: Mechanical seal of hard material
C: Standard radial shaft seal
D: Magnetic coupling
F: Radial shaft seal, high temperature
H: Mechanical seal balanced
X: Special seal
4 Pressure stage B: Pressure stage 16 39.9 bar
valve C: Pressure stage 40 64 bar
X: Without valve
5 Heating system A: Without heating system
B: Electric heating system
C: Fluid heating system
X: Special heating system
6 Completion P: Pump with free shaft end
F: Pump unit with pump bracket foot
V: Pump unit without pump bracket foot
7 Version index For internal administration
Tab. 1 Type code

OM9294_11.2
Rating plate
Labeling
Rating plate
5 LFI - 42.ACAP.00001 6
4 1 Nominal delivery rate
204366 2010 2 Differential pressure/
operating pressure max.
3 -20 180 3 Temperature range
4 Serial number
Type
2 40/63 1450 7
5
6 Year of construction
1 32 380 8 7 Rotation speed
8 Nominal viscosity
Fig. 2 Rating plate

OM9294_11.2
Operating limits
Technical data
Operating limits
Technical data
L 5 85
Operating pressure max. [bar]
Pump housing with flanges PN25/PN63 63
Temperature max. of the pumped liquid [C]
Standard mechanical seal 150
Mechanical seal of hard material 180
Standard radial shaft seal 80
Radial shaft seal, high temperature 150
Magnetic coupling Customer-specific, contact KRAL
Ambient temperature min. [C] -10...50
Viscosity [mm2/s]
min.max. 1.5* 7000 * in agreement with KRAL
Rotation speed [min-1]
at 50 Hz 2900
at 60 Hz 3500
Feed pressure [bar]
Standard mechanical seal 6
Mechanical seal of hard material 6
Mechanical seal, balanced
Model LFI/LFT/LFW/LVI/LVT 20
Model LFM 6
Standard radial shaft seal 6
Radial shaft seal, high temperature 6
Magnetic coupling Customer-specific, contact KRAL
Tab. 1 Operating limits
Sound pressure levels

Guide values at 1 m distance, 1450 min-1, 20 bar
Sound pressure level 3 [dB(A)]

L 5 54 L 55 85
Pump 58.0 59.0
Motor max. 62.0 62.0
Pump + motor 63.5 64.0
Tab. 2 Sound pressure levels

OM9294_11.2
Required NPSH values

Technical data
Required NPSH values

The following table lists the required NPSH values during operation with a low-volatility pumped liquid
such as lubricating oil or hydraulic liquid. When pumped liquids have a readily volatile component
content, the required NPSH values increase notably:
Fuel oil requires an NPSH value of at least 6 mWC.
When the pumped liquid contains water (e.g. heavy fuel oil), the values in the table have to be
increased by the vapor pressure of the water at the specified operating temperature.
The required NPSH values also need to be increased if there are gas contents, regardless of whether it
is dissolved or not. In case of any doubt, please contact the manufacturer.
Size Viscosity NPSH value [mWC] at Size Viscosity NPSH value [mWC] at
[mm2/s] Rotation speed [min-1] [mm2/s] Rotation speed [min-1]
1 450 1 750 2 900 3 500 1 450 1 750 2 900 3 500
L5 6 2.0 L 32 6 2.0
37 2.0 37 2.0
152 2.0 152 2.0 2.3 2.7
380 2.0 380 2.1 2.2 3 3.5
L 7.5 6 2.0 L 42 6 2.0 2.2 2.7
37 2.0 37 2.0 2.2 2.7
152 2.0 152 2.0 2.9 3.5
380 2.0 2.3 2.5 380 2.3 2.6 3.9 4.8
L 10 6 2.0 2.1 2.0 L 54 6 2.0 2.1 3,0 3.7
37 2.0 37 2.0 2.3 3.4 4.2
152 2.0 2.3 152 2.5 2.7 4.1 5.1
380 2.0 2.3 2.5 380 2.9 3.2 5.0 6.3
L 15 6 2.0 L 55 6 2.0 2.3
37 2.0 37 2.0 2.3
152 2.0 2.2 152 2.0 2.6 3.1
380 2.0 2.6 2.9 380 2.2 2.4 3.4 4.1
L 20 6 2.0 2.1 L 74 6 2.0 2.5 3.1
37 2.0 2.1 37 2.0 2.5 3.0
152 2.0 2.4 2.8 152 2.0 2.1 3.3 4.1
380 2.1 2.3 3.1 3.7 380 2.5 2.8 4.4 5.6
L 26 6 2.0 2.2 2.7 L 85 6 2.0 2.8 3.5
37 2.0 2.2 2.7 37 2.0 2.6 3.3
152 2.0 2.9 3.5 152 2.0 2.3 3.7 4.7
380 2.3 2.6 3.9 4.8 380 2.6 3.0 5.0 6.5
Tab. 3 Required NPSH values
Materials
Material name Material no.

Pump housing EN-GJS-400-15 EN-JS 1030
Screw set 16MnCrS5 1.7139
End cover EN-GJS-400-15 EN-JS 1030
Seal housing EN-GJS-400-15 EN-JS 1030
Tab. 4 Materials

OM9294_11.2
Weights
Technical data
Weights
Model LFI/LFM/LFT/LFW
Motor Size
size 5 15 32 55
7.5 20 42 74
10 26 54 85
Weight of pump with free shaft end [kg]
9.0 16.0 20.0 33.0
Weight of pump bracket with pump bracket foot, coupling and screws [kg]
71 2.0
80 2.5 3.0
90S 2.5 3.5 3.5
90L 2.5 3.5 3.5
100L 4.0 4.5 4.5 5.5
112M 4.0 4.5 5.5
132S 7.0 7.0 7.0
132M 7.0 7.0 7.0
160M 9.0 9.0 10.0
160L 9.0 9.0 10.0
Tab. 5 Weights for LFI/LFM/LFT/LFW
Model LVI/LVT
Motor Size
size 5 15 32 55
7.5 20 42 74
10 26 54 85
Weight of pump with free shaft end [kg]
9.0 16.0 20.0 33.0
Weight of the pedestal [kg]
2.0 2.0 3.0 3.0
Weight of pump bracket with coupling and screws [kg]
71 1.5
80 1.5 2.0
90S 1.5 2.5 2.5
90L 1.5 2.5 2.5
100L 3.0 3.5 3.5 4.5
112M 3.0 3.5 3.5 4.5
132S 5.0 5.0 5.0
132M 5.0 5.0 5.0
160M 6.0 6.0 7.0
160L 6.0 6.0 7.0
Tab. 6 Weights for LVI/LVT

OM9294_11.2
General
Heating system
General
Heating system
The pumps can be equipped with an optional heating system. We recommend heating systems for high-
viscosity liquids that do not flow sufficiently if not heated. This can result in excessive power
consumption or lead to problems with cavitation or sealing.
Method of heating:
Electric heating system
Fluid heating system
2
3
1 Heating cover
2 Heating element
3 Connecting cable
Fig. 1 Electric heating system

The electric heating system consists of one heating element 2 that is integrated in a heating cover
attached additionally to the end cover 1. The output of the heating element corresponds to the radiation
and convection losses of the pump in the required temperature range so that overheating is not
possible.
Operating data:
Voltage: 230 V
Frequency: 50/60 Hz
Wire cross-section: 2 x 1 mm
Mounting the electric heating system
Scope of delivery:
Sizes L 5 85
1 Heating element
1 Heating cover
4 Socket screws
Pay attention to the following when installing the heating element:
Protect the area of the connecting head against liquid and pasty media (anti-friction agent, oil,
plastics, etc.) as well as their vapors, because leakage currents or flashovers otherwise occur at
the emersion point of the supply line.
Protect the supply lines against mechanical vibrations in the area of the emersion from the
heating element. Any vapors arising have to escape freely.
Store the heating element in an absolutely dry room or in hermetically sealed plastic bags. If the
heating element has absorbed humidity, dry it for 8 hours in a drying furnace at 180 C.

OM9294_11.2
Heating system
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover to the end cover using the supplied socket screws.
3. Screw the heating element into the heating cover.
4. Mount the rating plate on the heating cover.
Connect and commission the electric heating system

Required heating-up periods for temperature differences of 30 C or 50 C:
Size Wattage [W] Heating-up periods [min] at a temperature difference of

30 C 50 C
L 5 54 1 x 100 20 35
L 55 85 1 x 220 20 35
Tab. 1 Heating-up periods for electric heating system
DANGER
Risk of death resulting from electric shock.
The electric heating system may only be connected by an authorized electrician.

Ensure that the power supply is disconnected during the connecting work.
WARNING
Danger of the pump housing bursting and danger of injury through squirting pumped liquid through
the heat expansion of the pumped liquid.
Open all the valves during the heating process.
1. Connect the connecting cable of the heating element.

2. Switch on the electric heating system.

OM9294_11.2

Heating system
2
2
1 Heating cover
2 Piping connections
Fig. 2 Fluid heating system

The fluid heating system consists of a heating cover 1 attached additionally to the end cover through
which a heating fluid (e.g. vapor, thermal oil) flows.
Operating data:
Maximum pressure: 16 bar
Maximum fluid temperature: 200 C
Mounting the fluid heating system
Scope of delivery:
Sizes L 5 85
1 Heating cover
2 Screw plugs
4 Socket screws
1. Remove the socket screws and rating plate at the end cover of the pump.
2. Mount the heating cover to the end cover using the supplied socket screws.
3. Mount the piping.
4. Mount the rating plate on the heating cover.
Commissioning the fluid heating system

Required heating-up periods for the temperature difference of 50 C at a liquid temperature of 200 C:
Size Heating-up periods [min] at a temperature difference of 50 C

L 5 54 20
L 55 85 20
Tab. 2 Heating-up periods for fluid heating system
WARNING
Danger of the pump housing bursting and danger of injury through squirting pumped liquid through
the heat expansion of the pumped liquid.
Open all the valves during the heating process.
Observe the permissible operating limits of the pump when setting the supplied heating flow and its
temperature, see Tab. 1, page 9.

OM9294_11.2
Structure
Function description
Structure
4 5 6 7
3
8
9
1
12 11 10
Fig. 1 Structure of L-pump
1 End cover 5 Pump housing 9 Ball bearing

2 Balancing bush 6 Balancing cylinder 10 Counter pressure valve
3 Screw plug 7 Mechanical seal 11 Relief line
4 Overflow valve 8 Seal housing 12 Main screw
L1 L2 L3 L4 L5
Fig. 2 Structure of L-pump with coupling and motor
L1 Pump L4 Motor-side coupling half

L2 Pump-side coupling half L5 Motor
L3 Coupling intermediate ring
Screw pumps are rotating displacement pumps whose displacement effect results from the meshing of
three rotating screws and the enclosing housing 5. The radial support of the screws is effected by the
sliding contact in the housing which requires lubrication by the pumped liquid. Screw pumps are
therefore not suitable for dry running and can only be used up to specific pressure and viscosity limits.
Due to the narrow tolerances, pumping of suspended solids is not possible.

OM9294_11.2
Shaft seal
Axial support of the main screw 12 is carried out by a lifetime lubricated deep-groove ball bearing 9.
Different shaft seals 7 are available for sealing the main screw at the outlet from the housing. In order to
reduce the pressure at the shaft seal a balancing cylinder 6 is mounted at the main screw. The sealing
chamber is connected to the suction chamber via a relief line 11. The idle screws also have an axial
thrust relief through balancing bushes 2 at suction-side end of the screws and core drilled holes to the
pressure chamber. An internal overflow valve 4 protects against excessive pressure that could cause
housing parts to burst.
Standard direction of rotation: Clockwise, seen from the drive;
marked on the housing by an arrow, see Fig. 2, page 27
Direction of flow: marked on the housing by two arrows, see Fig. 2, page 27
Shaft seal
The following types of shaft seals are used:
Mechanical seal, standard or hard material
Radial seal shaft, standard or high temperature
Seal variant Description

Mechanical seal
The lubrication of the mechanical seal inevitably
2 results in minimal leakage that as a rule
evaporates and is therefore not conspicuous.
4 However, with low-volatility liquids such as heavy
5 oil, the leakage will be visible. The included
leakage vent hole allows draining of this leakage.
The drainage through this hole has to be kept
2 Mechanical seal free, see "Cleaning leakage vent holes",
3 Leakage vent hole page 32. Dry running must be avoided at all
3 4 Ball bearing costs, as the seal will overheat and be destroyed
5 Main screw in a matter of minutes.
Radial shaft seal
2 Radial shaft seals can be used for temperatures

1 up to 80 C or 150 C, depending
4 on the material. Each seal ring used has a lip for
5 sealing against the loss of liquid and the entry of
air.
1 Circlip
2 Radial seal ring
3 Leakage vent hole
3
4 Ball bearing
5 Main screw
Tab. 1 Seal variants

OM9294_11.2
Housing variants
Housing variants
Figure Model Description

LF/LV Pump housing with flanges in inline
configuration PN25/PN63
LFT/LVT Pump housing with flanges on top

PN25/PN63
LFW Pump housing with flanges on top

PN25/PN40
LFM Pump housing with flanges on top

PN6/PN40
Tab. 2 Housing variants
Overflow valve
2 3 4
1
1 Screw plug
2 Adjusting screw
3 Spring
4 Valve body
Fig. 3 Overflow valve mounting position

The integrated overflow valve prevents very high pressures which could result in housing parts bursting.
The valve is purely there as a safety element and should not be used for control or regulation such as
maintaining pressure. If the valve is kept open for too long under adverse operating conditions (high
differential pressures and/or low viscosities) it will only take a few minutes for the valve and the valve
seating to become damaged. As a result, the valve will leak permanently and there will be a
corresponding reduction in the delivery rate. In addition to this, circulation through the overflow valve for
too long heats the pump to excess. This reduces viscosity and can ultimately lead to pump failure.
Factory setting:
110 % of the nominal pressure
The valve is accessible via a screw plug 1 and can be adjusted from the outside, see "Adjusting the
overflow valve", page 28.

OM9294_11.2
Unpacking and checking the state of delivery

Transportation, storage and disposal
Unpacking and checking the state of delivery

1. Upon delivery, unpack the pump/pump unit and check for transport damage.
2. Report any transport damage immediately to the manufacturer.
3. Dispose of packing materials in accordance with the locally applicable regulations.
Lifting the pump/pump unit
Fig. 1 Attachment of hoisting equipment schematic diagrams
DANGER
Risk of injury and/or damage to equipment should the pump/pump unit fall.
Use intact and correctly dimensioned hoisting equipment suitable for the weight to be lifted.
Choose the attachment points of the hoisting equipment according to the center of gravity and
weight distribution.
Always use at least two slings.
For vertical transport: secure motor additionally against tilting.
Do not stand under raised loads.
Attach the hoisting equipment to the pump/pump unit, see Fig. 1, and lift the pump/pump unit.
Storage
During the test run, the internal components of the pump are wetted with test oil, which has a
preservative effect. The pipe connections are fitted with protective caps. Unless otherwise specified, the
external components of the pump are preserved with a single-coat PU-based two-component paint. The
preservative applied at the factory will protect the pump for about six weeks, if it is stored in a dry and
clean location. KRAL offers a long-term preservation for storage times of up to 60 months. With long-
term preservation the pump is additionally packed in hermetically sealing anti-corrosion paper.

OM9294_11.2
Preservation

Preservation
Preservation has to be carried out in the following cases:
For standard delivery: For storage periods exceeding six weeks and in case of adverse storage
conditions such as high humidity, salty air, etc.
For delivery with long-term preservation: If the packaging has been opened or damaged
Preserving the internal surfaces of the pump
1. Close the suction connection of the pump with a blind flange.

2. Pour non-corrosive, resin-free oil into the pressure connection until it reaches approx. 2 cm under
the pressure flange, while slowly turning the main screw against the direction of rotation.
3. Close the pressure connection of the pump with a blind flange.
After about 6 months storage check the oil level and to up if necessary.
Preserving the external surfaces of the pump

Aids:
Preservative (e.g. Castrol Rustilo DWX 33)
Paint or spray the preservative onto all plain and unpainted parts.
At intervals of about six months, check the preservative effect and if necessary repeat preservation.
Notice: Store the preserved pump in a cool and dry place and do not expose it to direct sunlight.
Removing the preservative
Aids:
Solvent
Steam-jet cleaning device with wax-dissolving additives
CAUTION
Risk of injury through emitted preservative oil.
Wear protective clothing during all the work.

Remove the blind flange with caution to relieve any pressure inside the pump.
Collect the emitted oil safely and dispose of it in an environmentally compatible manner.
1. Clean the outside of the pump with solvents, if necessary using a steam-jet cleaning device.
2. Remove the blind flange on the pressure side.
3. Drain the pump, collecting the preservative oil in a suitable vessel.
4. Remove the blind flange on the suction side.
5. To remove the residual oil, rinse the pump with the pumped liquid.

OM9294_11.2
Disposing of the pump

Disposing of the pump

Aids:
Solvents or industrial cleaners suitable for the pumped liquid
WARNING
Danger of poisoning and damage to the environment through pumped liquid or oil.

Before disposing of the pump, collect the discharging pumped liquid and oil and dispose of it in
accordance with the locally applicable regulations.
Before disposing of the pump neutralize any residues of the pumped liquid.
1. Disassemble the pump.

2. Clean residues of the pumped liquid from the individual parts.
3. Separate sealing elements made of elastomers and ceramics (SiC) from the pump and dispose of
them in the residual waste.
4. Recycle metal parts.

OM9294_11.2
Installation
Installation, removal and connection

Installation
Observe the following instructions:
When selecting the location take the operating limits, NPSH values and ambient conditions into
account, see "Technical data", page 9.
The function, safety and service life may not be impaired by humidity, temperature influences or
explosive atmospheres.
During the installation ensure that all the parts can be accessed easily and that the maintenance
work can be carried out easily.
Installing the pump

Screw pumps can be operated in any installation position. However, we recommend that the pump
should not be mounted above the motor since pumped liquid could enter the motor should a leak occur.
Fig. 1 Model LFI with or without pump bracket foot Fig. 2 Model LVI with pedestal
Prerequisite:
The pump connections are to be protected against particle contamination, for example by using
protective covers
CAUTION
Leaking pumped liquid can damage the motor.
Do not mount the pump above the motor.
CAUTION
Damage to the pump and piping through insufficient fastening.
Only fasten the pump on a stable load bearing surface.

Ensure that the fastening elements are tightened sufficiently.
1. Bring the pump into position. Ensure that the flow direction that is marked by arrows on the housing
is correct.
2. Fasten the pump with fastening elements securely to the mounting surface.

OM9294_11.2
Installation
Protect the pump against contamination
CAUTION
Damage through impurities in the pipe system.
During welding work attach protective covers to the connecting flanges.

Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and
the pump.
After the connecting work clean the pipe system thoroughly, see "Cleaning the pipe system",
page 25.
Connecting the pump to the pipe system

The pump connection to the pipe system must be stress-free.
CAUTION
Danger of damage or impaired functionality through mechanical stresses.
Ensure that the pump mounting on the pipe system is free of mechanical stress.
1. Turn the pump shaft or the fan impeller of the motor. This tests that the pump runs smoothly.
If the pump cannot be turned by hand, remedy the fault before installing the pump, see
"Troubleshooting", page 48.
2. During welding work attach protective covers to the connecting flanges.
3. Place the piping in position and support the weight of the piping.
4. Check the clearance and the angular, vertical and linear offset, adjusting where necessary.
5. Tighten the connecting screws crosswise with torque, see Tab. 1, page 62.
If the screws tighten easily, this is a sure sign that the installation is stress-free.

OM9294_11.2
Connecting the motor

Assembling pump and motor
a Lateral offset
b Angular offset
c Linear offset
Fig. 3 Measuring points for tolerances of the coupling alignment
Coupling diameter Lateral offset a Angular offset b Linear offset c

[mm] max. [mm] max. [] min. [mm] max. [mm]
40 0.2 0.9 2 3
55 0.2 0.9 2 3.5
65 0.25 0.9 2.5 4
80 0.3 1.0 3 4.5
95 0.3 1.0 3 5
120 0.4 1.1 4 6
135 0.4 1.2 4.5 7
160 0.5 1.2 5 8
Tab. 1 Limit values for aligning the shaft coupling
CAUTION
Incorrect alignment of the shaft coupling causes noise, vibrations and damage to the coupling and
bearing.
After the mounting check the alignment of the coupling.
1. Check the linear offset of the coupling using a slide gauge or feeler gauge.
If the limits stated in the above table are exceeded, loosen the fastening of the pump or motor and
move the device in order to adjust the linear offset.
2. Check the lateral offset of the coupling using a hairline gauge and feeler gauge. Check several
points along the periphery of the coupling.
move the device in order to reduce the lateral offset.
3. Check the angular offset of the coupling using a hairline gauge.
move the device in order to reduce the angular offset.
Connecting the motor
DANGER
The motor may only be connected by an authorized electrician.

Ensure that the power supply is disconnected.
Earth the pump carefully.
1. Observe the operating instructions of the motor.

2. Ensure that the operating data on the rating plate of the motor corresponds with the operating data
of the pump and with the local power supply.
3. Connect the motor in accordance with the circuit diagram in the motor terminal box.

OM9294_11.2
Removing the pump

Removing the pump

Aids:
Vessels for leaking pumped liquid
DANGER
Ensure that the power supply is disconnected.

The motor may only be separated from the power supply by an authorized electrician.
WARNING
Risk of injury through emitted hot, poisonous or corrosive pumped liquid when removing the pump.

Before carrying out work let the pump cool down to the ambient temperature.
Ensure that the pump is depressurized.
Collect the pumped liquid safely and dispose of it in an environmentally compatible manner.
1. Disconnect the motor from the power supply and secure it against being switched back on.
2. Close the pressure-side and suction-side shut-off fittings.
3. Empty the pump at the lower point using the draining plug. Collect the emitted pumped liquid in a
suitable vessel.
4. Loosen the connecting flanges.
5. Loosen the fasteners of the pump unit on the mounting surface and dismantle the motor and pump
bracket.

OM9294_11.2
Commissioning
Operation
Commissioning
Operation
The following instructions must always be observed:
The pump may only be commissioned by authorized qualified personnel.

Cleaning the pipe system

Before initial commissioning the complete pipe system has to be cleaned carefully to protect the pump
against particle contamination. If the pipe system has to be rinsed using the pump, an additional
commissioning filter has to be installed before the pump.
Mesh width of the commissioning filter:

0.02 mm
CAUTION
Damage to the pump through additional pressure loss in the commissioning filter.
Calculate the flow resistance and determine the remaining suction capacity.
Monitor the suction-side pressure.
Check and clean the commissioning filter regularly.
Recommended operation duration for rinsing with commissioning filter: 50 100 hours.
Filling and venting the pump

There are two possible ways to fill the pump:
via the suction or pressure connection

via the vent holes
1 4
1 Suction connection
5 2 Vent hole of the seal
3 Pressure-side vent hole
4 Pressure connection
5 Suction-side vent hole
Fig. 1 Vent holes

OM9294_11.2
Commissioning
Operation
Filling and venting the pump via the suction or pressure connection
DANGER
Risk of death through emitted pumped liquid.
Pumped liquids can be hot, poisonous or caustic and can spray out under high pressure.
Wear protective clothing during all the work. Ensure face protection.
Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible
manner.
1. Loosen the screw plug of the vent hole 2 by a max. of 2 rotations so that the air can escape during
the filling process.
2. Open the suction- or pressure-side shut-off device and fill the pump via the suction or pressure
connection until pumped liquid is emitted at the vent hole 2.
3. During the filling process turn the pump shaft or the fan impeller of the motor by hand to speed up
the filling process:
Filling via suction connection: Turn the pump shaft in the direction of rotation of the motor.
Filling via pressure connection: Turn the pump shaft against the direction of rotation of the motor.
4. Tighten the screw plug of the vent hole 2 again.
Filling and venting the pump via the vent hole
Prerequisite:
Shut-off devices in the suction and pressure line closed
WARNING
Risk of injury through emitted pumped liquid.
Pumped liquids can be hot, poisonous or caustic.
Wear protective clothing during all the work. Ensure face protection.
manner.
1. Remove the screw plug of the vent hole 2 so that the air can escape during the filling process.
2. Remove the screw plug of the pressure-side vent hole 3.
3. Fill the pump via the pressure-side vent hole 3.
4. During the filling process turn the pump shaft or the fan impeller of the motor by hand against the
direction of rotation of the motor in order to speed up the filling process.
5. Tighten the screw plug of the pressure-side vent hole 3 again.
6. Fill the sealing space of the pump via the vent hole 2 until the pumped liquid is emitted.
7. Tighten the screw plug of the vent hole 2 again.

OM9294_11.2
Commissioning
Operation
Checking the direction of rotation
The direction of rotation and the flow direction are indicated by arrows on the pump. The direction of
rotation of the motor determines the direction of rotation of the pump. That is to say, the fan impeller of
the motor must rotate in the direction in which the arrow on the pump is pointing to indicate direction of
rotation.
Standard direction of rotation: clockwise (as seen from the drive)
1 Rotation-direction arrow
2 2 2 Arrow for direction of flow
Fig. 2 Identifying direction of rotation and flow direction
CAUTION
Dry running can damage pump equipment.
Ensure that the pump is filled properly.

Switch the pump on for a maximum of 1 second and then off again immediately.
1. Switch on the power supply and then turn it off again immediately.
2. Compare the direction of rotation of the fan impeller with the arrow indicating the direction of rotation
on the pump flange.
3. If the directions do not match, swap over two electrical connection phases. Repeat Steps 1 and 2.
Commissioning the pump
Prerequisites:
Pump set up and mounted correctly
Motor connected correctly
Coupling protection mounted
Pipe system is free of contamination
Commissioning filter mounted, if the pipe system is to be cleaned with the pump
Pump is filled
Stopcocks in the suction and pressure line opened
WARNING
Risk of injury through rotating parts.
Ensure that the coupling protection is mounted.

OM9294_11.2
During operation
Operation
WARNING
Risk of injury through squirting pumped liquid.

Ensure that all the connections are connected sealingly.
CAUTION
Dry running can damage pump equipment.
Ensure that the pump is filled properly.

If the pump does not deliver after 10 15 seconds, abort commissioning.
1. Switch on the pump.

The pump will deliver when the pressure on the pressure side of the pump rises or an installation-
side flow indicator triggers.
2. If the pump does not deliver after 10 15 seconds, abort commissioning, establish the cause of the
fault and only then continue the commissioning procedure. Follow the instructions in the fault table,
see "Troubleshooting", page 48.
3. Run the pump for a few minutes to allow the pipe system to vent fully.
The pipe system is fully vented when there is a smooth operating noise and a pressure gauge on the
pressure side of the pump shows no more fluctuations.
During operation
Adjusting the overflow valve
2 3 4
1
1 Screw plug
2 Adjusting screw
3 Spring
4 Valve body
Fig. 3 Overflow valve mounting position

OM9294_11.2
During operation
Operation
Factory setting:
110% of the nominal pressure
Aids:
Pressure-side pressure gauge
Allen key
Size ISO 228-1 Allen key width across flats

5 10 G 1/2" 8
15 26 G 1/2" 8
32 54 G 3/4" 8
55 85 G 1 1/4" 12
Tab. 1 Widths across flats
WARNING
Risk of injury or poisoning through emitted pumped liquid.

Collect the emitted liquid safely and dispose of it in an environmentally compatible manner.
1. Switch on the pump.

2. Open the screw plug 1 of the overflow valve.
3. Increase the delivery pressure step-by-step to check the opening pressure of the valve. Keep an eye
on the pressure gauge and make sure that the pressure stays within the operating limits.
When the overflow valve opening pressure is reached, the displayed pressure noticeably drops.
4. Turn the adjusting screw 2 to adjust the opening pressure.
Turning clockwise: Increase the opening pressure.
Turning anticlockwise: Decrease the opening pressure.
5. Repeat Steps 3 and 4 until the desired opening pressure is reached.
6. Retighten the screw plug.
Checking the operating pressure
CAUTION
Stopcocks that are opened permanently can result in the pressure gauges leaking.
Close the pressure gauge stopcocks after completing reading.
Open the pressure gauge stopcock, read the operating pressure, close the pressure gauge
stopcock.

OM9294_11.2
Taking the pump out of operation

Operation
Switching off the pump
CAUTION
Damage to seals through pressurizing of the pump while it is standing still.
Ensure that while the pump is at a standstill, the pressure in the pump does not exceed the feed
pressure during operation.
1. Switch of the motor.

2. Close the pressure-side and suction-side stopcocks.
Taking the pump out of operation
WARNING
Risk of injury or poisoning through emitted pumped liquid.

manner.
Carry out the following measures during shutdowns:
Pump is Measure
shut down for longer period Depending on pumped liquid, see Tab. 3, page 30.
drained Close the pressure-side and suction-side stopcocks.
dismantled Disconnect the motor from the power supply and secure it
against being switched back on.
stored Observe measures for storing and preservation, see "Storage",
page 18 and see "Preservation", page 19.
Tab. 2 Measures during shutdowns
Behavior of the pumped liquid Duration of the shut down

Short Long
sediment solids Rinse the pump. Rinse the pump.
congealed/frozen, Heat or drain the pump. Drain the pump.
no corrosive burden
congealed/frozen Heat or drain the pump. Drain the pump.
corrosive burden Preserve the pump.
remains liquid
no corrosive burden
remains liquid Drain the pump.
corrosive burden Preserve the pump.
Tab. 3 Measures depending on the behavior of the pumped liquid
Drain the pump via the pressure and suction line and vent screws and screw plugs.
Recommissioning the pump

Carry out all the steps as for the commissioning process, see "Commissioning", page 25.

OM9294_11.2
Safety instructions
Maintenance
Safety instructions
Maintenance
The following safety instructions must be observed during all the repair work:
All the work may only be carried out by authorized qualified personnel.
Switch off the motor and secure it against being switched back on.
Before beginning any work let the pump/the pump unit cool down to the ambient temperature and
remove it from the pipe system.
Ensure that the pump is depressurized.
manner.
Required maintenance
The service life of the pump depends to a great extent on the operating conditions. If the operational
limits are observed, see "Technical data", page 9, the pump has a service life of many years.
Signs of progressive wear of individual pump elements:
Finding Cause Remedy

Increased running noises Incipient damage to bearing Replace the bearing.
Increased leaking Incipient damage to seal Replace the shaft seal.
Deposits on the seal Non-volatile liquids Clean the seal.
Increased play in the shaft Advanced wear of the coupling Replace the coupling
coupling intermediate ring intermediate ring.
Reduction in the flow rate/ Advanced wear of screws Replace the pump.
pressure under constant and housing
operating conditions
Tab. 1 Check table for required maintenance
1. Check the pump visually and acoustically every four weeks.

2. Check for signs of wear as listed in the table above and eliminate the cause.
Mechanical seal
Mechanical seals are subject to a natural wear that depends strongly on the respective conditions of
use. General statements about the durability can therefore not be given.
In case of heavy pollution with solidified and/or sticky leakage residues we recommend that you
dismantle the mechanical seal completely and carefully wash it, together with the inner surfaces of the
seal housing.
Ball bearing
The ball bearings used are lifetime lubricated. Maintenance is therefore not required. We recommend
renewing the ball bearings every 20,000 operating hours.

OM9294_11.2
Required maintenance
Maintenance
Cleaning leakage vent holes

The regular small amounts of leakage can result in deposits that can prevent free draining of further
leakage fluids after a longer operating period. The leakage vent hole must therefore be checked every
four weeks and if necessary cleaned.
Fig. 1 Cleaning leakage vent holes
CAUTION
Bearing damage due to insufficient drainage of shaft seal leakage.
Check permeability of leakage vent holes regularly.
1. Screw off any drainage line that is connected.

2. Check the permeability of the drainage line:
Check visually
- or -
Insert an arbor made of a soft material (wood, plastic, etc.), see Fig. 1.
3. Clean the line or leakage vent hole, if it is not free.
4. Reconnect any drainage line that is connected.

OM9294_11.2
Replacing the coupling
Maintenance
Removing the coupling
A A
001
180
525 180
052.2
B 052.1
C
001
914.5
529
A A
914.3
Fig. 2 Fig. 3
001 Pump 525 Coupling intermediate ring A Suction/pressure

052.1 Pump-side coupling half 529 Motor connection
052.2 Motor-side coupling half 914.3 Socket screws B Fixing screw
180 Pump bracket 914.5 Socket screws C Fixing screw
Aids:
Pulling-off device
Mounting lever
WARNING
Risk of injury and/or damage to equipment should the pump/pump unit fall.
Lift the large pump using the crane.

Do not stand under raised loads.
1. Before dismantling close the suction and pressure connection A of the pump with protective caps.
2. Loosen the connecting screws 914.3 between the motor 529 and pump bracket 180 and lift the
pump with pump bracket from the motor, see Fig. 2.
3. Loosen the fixing screw B on the motor-side coupling half 052.2.
4. Remove the coupling intermediate ring 525 and pull off the coupling half 052.2 using a suitable
device.
5. Loosen the connecting screws 914.5 between the pump and pump bracket 180 and remove the
pump bracket, see Fig. 3.
6. Loosen the fixing screw C on the pump-side coupling half 052.1 and remove the coupling half using
suitable mounting levers.

OM9294_11.2

Maintenance
Installing the coupling
180
001
052.1
180
C
001 525
052.2
914.5 B
529
X
914.3
Fig. 4 Fig. 5
001 Pump 525 Coupling intermediate ring B Fixing screw

052.1 Pump-side coupling half 529 Motor C Fixing screw
052.2 Motor-side coupling half 914.3 Socket screws
180 Pump bracket 914.5 Socket screws
Aids:
Measuring stick
1. Grease the shaft lightly.
2. Slide the pump-side coupling half 052.1 onto the shaft until it stops. Heating the coupling to 80 C
100 C facilitates mounting. Tighten the fixing screw C of the coupling half.
3. Place the pump bracket 180 on the pump and tighten the connecting screws 914.5.
4. Measure and write down the distance X between the face of the coupling and the connecting surface
of the pump bracket, see Fig. 4.
5. Pull the motor-side coupling half 052.2 onto the shaft end of the motor. Heating the coupling to 80 C
100 C facilitates mounting.
6. Check the distance between the face of the coupling teeth and the connecting surface of motor
flange, see Fig. 5. The distance has to be adjusted to the value X - c, see Tab. 1, page 23.
7. Insert the coupling intermediate ring 525 and tighten the fixing screw B at the coupling half 052.2.
8. Place the pump with the pump bracket on the motor.
9. Turn the pump slightly until the teeth of the pump-side coupling half 052.1 meshes correctly into the
spaces of the coupling intermediate ring 525.
10. Tighten the connecting screws 914.3 between the motor and pump bracket with torque, see Tab. 1,
page 62.

OM9294_11.2
Replacing the mechanical seal
Maintenance
Removing the mechanical seal
134 914.2
661.1
Fig. 6
866
134 471.
134 471.1 661.1 457.1
661.1
05
055.1
Fig. 7 Fig. 8 Standard mechanical seal

134 134
C
661.1 457.1 457.2
C
055.2*
Fig. 9 Mechanical seal of hard material Fig. 10
055.1 Supporting ring 457.2 Stationary seal ring 866 Feather key
055.2* Supporting ring 471.1 Circlip 914.2 Socket screws
134 Seal housing 661.1 Main screw C Threaded pin
457.1 Rotary ring
* not for Sizes 32 54
Aids:
Forcing screws
Plastic hammer
1. Remove the socket screws 914.2 and screw in two forcing screws.
In the process the seal housing together with the main screw 661.1 is pressed out of the pump
housing.
2. Pull the seal housing 134 together with the main screw out of the pump housing, see Fig. 6.
3. Remove the feather key 866. Remove the shaft circlip 471.1, remove the supporting ring 055.1, see
Fig. 7.
4. Drive the main screw 661.1 out of the seal housing 134 with light blows from a plastic hammer.
5. Standard mechanical seal: Remove the rotary ring 457.1 and spring from the main screw, see
Fig. 8.
Mechanical seal of hard material: Loosen the threaded pins C. Remove the rotary ring 457.1 and
corresponding parts of the mechanical seal spring from the main screw, see Fig. 9.
6. Remove the stationary seal ring 457.2 together with the mounted O-ring from the seal housing 134,
see Fig. 9. In the process take the position of the supporting ring 055.2* into account to facilitate re-
installation.

OM9294_11.2

Maintenance
Installing the mechanical seal
134 457.1
B
457.2 055.2* 661.1
Fig. 11 Fig. 12 Standard mechanical seal
C
457.1 C
B
661.1
Fig. 13 Mechanical seal of hard material
055.2* Supporting ring 457.2 Stationary seal ring A Mounting arbor, stationary
134 Seal housing 661.1 Main screw seal ring
457.1 Rotary ring B Mounting sleeve, main screw
C Threaded pin
Aids:
Mounting arbor
Mounting sleeves
White oil (e.g. Tevier Weil III)
Notice: We recommend the use of the specified aids when carrying out the mounting work. The aids are
available as accessories, see "Tool kits", page 59.
1. Clean the fitting surfaces, grease the O-rings lightly.

2. Press the supporting ring 055.2* into the seal housing. Use a suitable mounting arbor A to press the
stationary seal ring 457.2 with the mounted O-ring into the seal housing 134. Take the position of the
clearance for the dowel pin into account, see Fig. 11.
3. Clean the main screw around the mechanical seal carefully and grease it.
4. Standard mechanical seal: Slide the rotary ring 457.1 and spring onto the main screw 661.1. Use
the mounting sleeve B to do so, see Fig. 12.
Mechanical seal of hard material: Slide the rotary ring 457.1 and corresponding parts of the
mechanical seal onto the main screw 661.1. Use the mounting sleeve B to do so, see Fig. 13.
Tighten the threaded pins C.
5. Remove the mounting sleeve B, clean the slide surfaces of the mechanical seal and oil with white
oil.

OM9294_11.2
Maintenance
866
661.1
471.1
055.1
134
Fig. 14 Fig. 15
055.1 Supporting ring

134 Seal housing
471.1 Circlip
879.1 661.1 Main screw
661.1 134 914.2
866 Feather key
879.1 Straight pin
914.2 Socket screws
D Mounting sleeve, ball

bearing
Fig. 16
Aids:
Mounting sleeve
1. Press the main screw into the seal housing 134 until it stops, see Fig. 14. Use the mounting sleeve D
to do so and take the alignment of the supporting ring 055.2* into account (without figure).
2. Mount the supporting ring 055.1, circlip 471.1 and feather key 866, see Fig. 15.
3. Slide the main screw 661.1 with premounted seal housing 134 into the pump housing until the main
screw engages into the idle screws. Take the position of the straight pin 879.1 into account and turn
the main screw, see Fig. 16.
4. Tighten the socket screws 914.2 with torque, see Tab. 1, page 62.

OM9294_11.2
Replacing the radial shaft seal

Maintenance
Removing the radial shaft seal
055.2* Supporting ring

134 Seal housing
134 817 134
745.1 745.1 Radial seal ring
745.2 Circlip
C 817 Ball bearing
055.2* A Mounting arbor
745.2 A
C Pulling-off device
Fig. 17 Fig. 18 * not for Sizes 32 54
Aids:
Pulling-off device
Mounting arbor
1. Dismantle the pump, see "Removing the ball bearing", page 40, Steps 1 4.
2. Use a suitable pulling-off device to pull the ball bearing 817 out of the seal housing 134. Remove the
supporting ring 055.2* and circlip 745.2, see Fig. 17.
3. Use a suitable arbor to press the radial seal ring 745.1 out of the seal housing, see Fig. 18. As a rule
the radial seal ring is destroyed during dismantling.
Mounting the radial shaft seal
134 E B
134
E
A 745.1 661.1
745.2
Fig. 19 Fig. 20 Fig. 21
866
134
817 472 471.1
E
E
055.2* 055.1
661.1
Fig. 22 Fig. 23 Fig. 24
879.1
661.1 134 914.2
Fig. 25

OM9294_11.2
Maintenance
055.1 Supporting ring 745.1 Radial seal ring A Mounting arbor, radial seal
055.2* Supporting ring 745.2 Circlip ring
134 Seal housing 817 Ball bearing B Mounting sleeve, main screw
471.1 Circlip 866 Feather key D Mounting sleeve, ball bearing
472 Circlip 879.1 Straight pin E Positioning sleeve
661.1 Main screw 914.2 Socket screws
Aids:
Thread sealant (e.g. Loctite 572)
Molybdenum disulphide paste (e.g. Fenkart T4)
Mounting arbor
Mounting sleeves

2. Clean the seating of the radial seal ring in the seal housing 134 thoroughly and apply thread sealant.
The liquid is used as a lubricant while the seal ring is being mounted, after hardening to prevent
rotation.
Notice: The thread sealant must not contact the sealing lips!
3. Use the mounting arbor A to press the radial seal ring 745.1 carefully into the seal housing, see
Fig. 19. Observe the mounting direction, see Fig. 20. In case of excessive resistance apply
additional thread sealant as a lubricant.
Next mount the circlip 745.2.
4. Lubricate the space of the radial seal ring with molybdenum disulphide paste.
5. Slide the positioning sleeve E and mounting sleeve B onto the main screw, and slide the main screw
into the seal housing, see Fig. 21. Remove the mounting sleeve B.
6. Slide the supporting ring 055.2* and ball bearing 817 onto the main screw, see Fig. 22.
7. Press the ball bearing 817 onto the main screw. Use the mounting sleeve D to do so and take the
alignment of the supporting ring 055.2* (without figure) into account, see Fig. 23. Remove the
positioning sleeve E.
8. Mount the circlip 472, supporting ring 055.1, circlip 471.1 and feather key 866, see Fig. 24.
11. Before commissioning the pump let the thread sealant harden for 72 hours.

OM9294_11.2
Replacing the ball bearing

Maintenance
Removing the ball bearing
134 914.2
661.1
Fig. 26
134 866
055.1
134 817
661.1
C
472 471.1
Fig. 27 Fig. 28
055.1 Supporting ring 472 Circlip 866 Feather key

134 Seal housing 661.1 Main screw 914.2 Socket screws
471.1 Circlip 817 Ball bearing C Pulling-off device
Aids:
Forcing screws
Plastic hammer
Pulling-off device
housing.
3. Remove the feather key 866. Remove the circlip 472 and circlip 471.1, remove the supporting ring
055.1 and circlip 472, see Fig. 27.
5. Pull the ball bearing 817 out of the seal housing 134 using a suitable pulling-off device, see Fig. 28.

OM9294_11.2
Maintenance
Installing the ball bearing Mechanical seal version
661.1
134 055.2*
134
817
Fig. 29 Fig. 30
866
472 471.1
055.1
Fig. 31
055.1 Supporting ring

055.2* Supporting ring
134 Seal housing
879.1 471.1 Circlip
661.1 134 914.2 472 Circlip
661.1 Main screw
817 Ball bearing
866 Feather key
879.1 Straight pin
914.2 Socket screws
D Mounting sleeve, ball
bearing
Fig. 32 * not for Sizes 32 54
Aids:
Mounting sleeve

2. Insert the supporting ring 055.2* and ball bearing 817 into the seal housing, see Fig. 29.
3. Press the main screw into the seal housing 134 until it stops, see Fig. 30. Use the mounting sleeve D
to do so and take the alignment of the supporting ring 055.2* into account (without figure).

OM9294_11.2

Maintenance
Installing the ball bearing Radial shaft seal version
E B
817
E
134
E
055.2*
661.1
Fig. 33 Fig. 34
D
866
134
472 471.1
E
055.1
661.1
Fig. 35 Fig. 36
879.1
661.1 134 914.2
Fig. 37
055.1 Supporting ring 661.1 Main screw B Mounting sleeve, main screw
055.2* Supporting ring 817 Ball bearing D Mounting sleeve, ball bearing
134 Seal housing 866 Feather key E Positioning sleeve
471.1 Circlip 879.1 Straight pin
472 Circlip 914.2 Socket screws * not for Sizes 32 54
Aids:
Mounting sleeves
Positioning sleeve

3. Slide the supporting ring 055.2* and ball bearing 817 onto the main screw, see Fig. 34.
4. Press the ball bearing 817 onto the main screw. Use the mounting sleeve D to do so, see Fig. 35.
Remove the positioning sleeve E.

OM9294_11.2
Replacing the screw set
Maintenance
Removing the screw set
134 914.2
661.1
Fig. 38
866 457.1*
471.1 471.2
134
661.1
661.1
055.1 055.3*
042
Fig. 39 Fig. 40
048 661.2
070 222
914.1
879.2
Fig. 41
042 Balancing cylinder 222 Flat gasket 661.2 Idle screws
048 Balancing bushes 457.1* Rotary ring with spring 866 Feather key
055.1 Supporting ring 471.1 Circlip 879.2 Straight pin
055.3* Supporting ring 471.2 Circlip 914.1 Socket screws
070 End cover 661.1 Main screw 914.2 Socket screws
134 Seal housing
* only for version with mechanical seal
Aids:
Forcing screws
Plastic hammer
housing.
3. Remove the feather key 866. Remove the circlip 471.1, remove the supporting ring 055.1, see
Fig. 39.
5. Remove the rotary ring with spring 457.1*, supporting ring 055.3*, circlip 471.2 and balancing
cylinder 042 from the main screw, see Fig. 40.
6. Loosen the socket screws 914.1 at the end cover 070, remove the end cover. Remove the balancing
bushes 048, straight pin 879.2 and idle screws 661.2 from the pump housing, see Fig. 41.
7. Remove the residues of the flat gasket 222 from the end cover and pump housing.

OM9294_11.2

Maintenance
Installing the screw set Mechanical seal version
048 661.2
070 222
914.1
879.2
Fig. 42
661.1
457.1
055.3
661.1 042
134
471.2 B
Fig. 43 Fig. 44
866
471.1
055.1
Fig. 45
879.1
661.1 134 914.2
Fig. 46
042 Balancing cylinder 457.1 Rotary ring with spring 879.1 Straight pin
048 Balancing bushes 471.1 Circlip 879.2 Straight pin
055.1 Supporting ring 471.2 Circlip 914.1 Socket screws
055.3 Supporting ring 661.1 Main screw 914.2 Socket screws
070 End cover 661.2 Idle screws B Mounting sleeve, main
134 Seal housing 866 Feather key screw
222 Flat gasket D Mounting sleeve, ball
bearing
Aids:
Mounting sleeves

OM9294_11.2
Maintenance
2. Insert the idle screws 661.2 into the pump housing, mount the balancing bushes 048 and straight pin
879.2, see Fig. 42.
3. Bond the new flat gasket 222 onto the pump housing, place on the end cover, see Fig. 42. Tighten
the socket screws 914.1 with torque, see Tab. 1, page 62.
4. Clean the main screw 661.1 around the mechanical seal carefully and grease it. Press the balancing
cylinder 042 onto the main screw, mount the circlip 471.2, supporting ring 055.3 and rotary ring with
spring 457.1. Use the mounting sleeve B to do so, see Fig. 43. Remove the mounting sleeve B.
5. Press the main screw into the seal housing 134 until it stops. Use the mounting sleeve D to do so
and take the alignment of the supporting ring 055.2* (without figure) into account, see Fig. 44.

OM9294_11.2

Maintenance
Installing the screw set Radial shaft seal version
048 661.2
070 222
914.1
879.2
Fig. 47
E B
661.1 042 134

E
471.2 661.1
Fig. 48 Fig. 49
D 866
471.1
134
E
055.1
661.1
Fig. 50 Fig. 51
879.1
661.1 134 914.2
Fig. 52
042 Balancing cylinder 471.1 Circlip 879.2 Straight pin
048 Balancing bushes 471.2 Circlip 914.1 Socket screws
055.1 Supporting ring 661.1 Main screw 914.2 Socket screws
070 End cover 661.2 Idle screws B Mounting sleeve, main screw
134 Seal housing 866 Feather key D Mounting sleeve, ball bearing
222 Flat gasket 879.1 Straight pin E Positioning sleeve
Aids:
Mounting sleeves
Positioning sleeve

OM9294_11.2
Maintenance
2. Insert the idle screws 661.2 into the pump housing, mount the balancing bushes 048 and straight pin
879.2, see Fig. 47.
3. Bond the new flat gasket 222 onto the pump housing, place on the end cover, see Fig. 47. Tighten
the socket screws 914.1 with torque, see Tab. 1, page 62.
4. Carefully clean and grease the main screw 661.1. Press the balancing cylinder 042 onto the main
screw and mount the circlip 471.2, see Fig. 48.
6. Press the main screw into the seal housing 134 until it stops. Use the mounting sleeve D to do so
and take the alignment of the supporting ring 055.2* (without figure) into account, see Fig. 50.
Remove the positioning sleeve E.

OM9294_11.2
Possible faults
Troubleshooting
Possible faults
Troubleshooting
Faults can have different causes. The following tables list the symptoms of a fault, the possible causes
and measures for elimination.
Fault Cause/Remedy
No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 33
Delivery rate too low 2, 3, 4, 9, 10, 11, 12, 13, 14, 15, 16
Pump runs noisily 2, 3, 4, 6, 10, 12, 14, 18, 19, 20, 21, 22
Motor overload 9, 10, 13, 22, 23
Uneven delivery rate 2, 3, 4, 6, 10, 12, 14, 15
Leaking shaft seal 17, 24, 25, 26, 27, 28
Pump has seized up 29, 30, 31, 32
Troubleshooting
No. Cause Remedy

1 Pump suction pipe closed Check shut-off devices in the suction pipe and open
them, if necessary.
2 Suction valve or pipe obstructed Check the suction valve and pipe for clear passage.
3 Suction pipe or shaft seal leaks Check suction pipe or shaft seal for leaks. Pay
particular attention to leakage at valves and
connection points. If necessary, replace parts.
4 Suction head too high Reduce difference of level
- or -
Reduce pipe length
- or -
Increase pipe diameter
- or -
Heat the liquid to reduce viscosity
- or -
Install suction filter with greater mesh width.
Ensure that the permissible mesh width is not
exceeded, see "Cleaning the pipe system",
page 25.
5 Level of liquid in the intake container Top up the pumped liquid.
too low
6 Dirty filter/strainer Clean the filter/strainer.
7 Pump intake capacity reduced Fill pump with liquid.
by inadequate wetting
8 Incorrect pump direction of rotation Make the electrical connection such that the
direction of pump rotation matches that of the arrow
on the flange cover, see "Connecting the motor",
page 23.
9 Differential pressure too high Check the installation and reduce the differential
pressure.
10 Viscosity of the pumped liquid too high Increase the temperature of the pumped liquid
- or -
Reduce the rotation speed.
11 Viscosity of the pumped liquid too low Decrease the temperature of the pumped liquid
- or -
Increase the rotation speed.

OM9294_11.2
Troubleshooting
Troubleshooting
No. Cause Remedy
12 Airlock or gas in the liquid Test the pipe system for ingress of air and replace
parts if necessary.
Reduce the suction head
- or -
Increase the feed pressure.
13 Motor running at wrong voltage or Ensure that the motor voltage and frequency match
frequency the operating voltage.
Compare the speed of the motor with the pump
rating plate. If the data does not match, adjust the
speed of the motor.
14 Overflow valve opens during normal Set opening pressure above value of operating
operation pressure, see "Adjusting the overflow valve",
page 28.
15 Overflow valve leaks Clean the overflow valve and reseat if necessary.
16 Advanced wear of rotating Check screw set and housing and replace if
pump components necessary.
17 Advanced wear of sealing surfaces Replace the seal and check the pumped liquid for
abrasive content.
18 Inadequate alignment of the Align the shaft coupling correctly, see "Assembling
shaft coupling pump and motor", page 23.
19 Pump distorted Support the weight of the pipework.
Loosen pipe connections and mount stress-free, see
"Connecting the pump to the pipe system", page 22.
20 Resonance in the installation Provide a flexible bearing arrangement for the pump
unit
- or -
Make the connections with hoses.
21 Speed of flow in suction or pressure Set the flow speed in the suction pipe so that it does
pipe too high not exceed 1 m/s.
Set the flow speed in the pressure pipe so that it
does not exceed 3 m/s.
22 Ball bearing damaged Replace the ball bearing, see "Maintenance",
page 31.
23 Lack of lubrication or foreign bodies Check the screw set and the housing. If necessary
have caused superficial damage to replace the pump with free shaft end.
rotating pump components
24 Dry running has damaged the shaft Replace the shaft seal, see "Maintenance", page 31.
seal When starting up the pump, pay attention to venting.
25 Feed pressure too high Reduce the feed pressure at the installation.
26 Thermal or chemical loading of Check the maximum operating temperature.
elastomer seals exceeded Check the resistance of the elastomers with regard
to the pumped liquid.
27 Cold start when delivering high- Install a heating system.
viscosity liquids
28 Seal overload during To prevent thermal expansion of the liquid causing a
heating process build-up of pressure, open the pressure- or suction-
side shut-off devices.

OM9294_11.2
Troubleshooting
Troubleshooting
No. Cause Remedy

29 Foreign bodies in the pump Dismantle the pump and clean it.
Smooth the superficial damage to the housing and
the rotating parts with an oilstone. If necessary,
replace the pump.
30 Differential pressure is too high and Dismantle the pump and clean it.
has overloaded the idle screws Smooth the superficial damage to the housing and
replace the pump.
Reduce the differential pressure.
31 Viscosity is too low and has Dismantle the pump and clean it.
overloaded the idle screws Smooth the superficial damage to the housing and
replace the pump.
Increase the viscosity, for example by reducing the
operating temperature.
32 Dry running has damaged the pump Dismantle the pump and clean it.
equipment Smooth the superficial damage to the housing and
replace the pump.
When resuming operation, take action to prevent dry
running, see "Recommissioning the pump", page 30.
33 Pump does not vent Vent the pressure pipe at the highest point.
Tab. 1 Fault table

OM9294_11.2
Overview
Spare parts
Overview
Spare parts
Model/Size Type Variant Internal

LFI/LVI/LFT/LVT 5 85 Maintenance kit Mechanical seal, standard or hard mate- OPW 34
rial
Maintenance kit Standard radial shaft seal + high tempe- OPW 35
rature
LFM 5 85 Maintenance kit Mechanical seal, standard or hard mate- OPW 22

rial
LFW 5 85 Maintenance kit Mechanical seal, standard or hard mate- OPW 21

rial
LFI/LVI/LFT/LVT/LFM Repair kit Screw set OPR 07

Repair kit Overflow valve OPR 08
Tool kit Mechanical seal OPT 05
Tool kit Radial shaft seal OPT 06

OM9294_11.2
Maintenance kits
Spare parts
Maintenance kits
Maintenance kit mechanical seal, standard or hard material

LFI/LVI/LFT/LVT 5 85
055.1
165.3 471.1
165.2 914.2 055.2*
165.2
739
729.1
472
817
222
914.1
165.2
729.2
165.2
165.1
914.6**
055.3 457**
866
879.2
Notice: Only the numbered parts are included in the maintenance kit. Before installation read and
observe the operating instructions of the pump/station.
Stk./Qty. Pos. Nr./Pos. no. Teil Part

1 055.1 Sttzscheibe Supporting ring
1 055.2* Sttzscheibe Supporting ring
1 165.1 Verschlussschraube Screw plug
1 222 Flachdichtung Flat gasket
1 457** Gleitringdichtung Mechanical seal
1 471.1 Wellensicherungsring Circlip
1 472 Sicherungsring Circlip
1 729.1 Flachdichtung Saugflansch Flat gasket
1 729.2 Flachdichtung Druckflansch Flat gasket
1 739 O-Ring O-ring
1 817 Kugellager Ball bearing
1 866 Passfeder Feather key
1 879.2 Zylinderstift Straight pin
4 914.1 Zylinderschraube Socket screw

OM9294_11.2
Maintenance kits
Spare parts
4 914.6*** Zylinderschraube Socket screw
1 Silikonfett 1g Silicon grease 1g
* Nicht fr Baugren 32 54 Not for sizes 32 54
** Standard oder Hartstoff Standard or hard material
*** Fr LVI/LVT: ersetzt 914.1 For LVI/LVT: replacement of 914.1

OM9294_11.2
Maintenance kits
Spare parts
Maintenance kit standard radial shaft seal + high temperature

LFI/LVI/LFT/LVT 5 85
055.1
165.3
471.1
165.2 914.2 055.2*
165.2
739
729.1
472
817
222
914.1
165.2 729.2
165.2 745.1
165.1 745.2
914.6**
055.3
866
879.2

1 729.1 Flachdichtung Saugflansch Flat gasket suction flange
1 729.2 Flachdichtung Druckflansch Flat gasket pressure flange
1 739 O-Ring O-ring
1 745.1 Radialwellendichtring Radial seal ring
4 914.6** Zylinderschraube Socket screw
1 MoS2-Paste 15 g MoS2 paste 15 g
* Nicht fr Baugren 32 54 Not for sizes 32 54
** Fr LVI/LVT: ersetzt 914.1 For LVI/LVT: replacement of 914.1

OM9294_11.2
Maintenance kits
Spare parts
LFM 5 85
165.2 165.3
165.2 729.2
165.2 472 471.1
729.1 914.2 055.2*
165.2
055.1
817
222
739
914.1
866
165.1
055.3 457**
879.2

1 729.1 Flachdichtung Flat gasket
1 729.2 Flachdichtung Flat gasket
1 739 O-Ring O-ring
1 Silikonfett 1g Silicon grease 1g
* Nicht fr LFM 32 54 Not for LFM 32 54

OM9294_11.2
Maintenance kits
Spare parts

LFW 5 85
165.2 165.3
165.2
165.2 472 471.1
165.2 914.2 055.2*
055.1
817
222
739
914.1
866
165.1
055.3 457**
879.2

1 739 O-Ring O-ring
* Nicht fr LFW 32 54 Not for LFW 32 54

OM9294_11.2
Repair kits
Spare parts
Repair kits
Repair kit screw set

LFI/LVI/LFT/LVT/LFM
048
471.2
042
879.2
661
048
Notice: Before installation read and observe the operating instructions of the pump/station.

1 042 Ausgleichszylinder Balancing cylinder
1 048 Ausgleichsbchse Balancing bush
1 661 Spindelsatz Srew set

OM9294_11.2
Repair kits
Spare parts
Repair kit overflow valve

LFI/LVI/LFT/LVT/LFM
222
914.1
165.1
305
501
164
Notice: Only the numbered parts are included in the repair kit. Before installation read and observe the
operating instructions of the pump/station.

1 164 Verstellschraube Adjusting screw
1 305 Ventilkrper Valve body
1 501 Druckfeder Spring

OM9294_11.2
Tool kits
Spare parts
Tool kits
Tool kit mechanical seal
LFI/LVI/LFT/LVT/LFM
Werkzeugsatz Gleitringdichtung /Tool kit mechanical seal

Stk./Qty. Teil Part
1 Montagedorn Gegenring Mounting arbor stationary seal ring
1 Montagehlse Hauptspindel Mounting sleeve main screw
1 Montagehlse Kugellager Mounting sleeve ball bearing
Tool kit radial shaft seal
LFI/LVI/LFT/LVT/LFM
Werkzeugsatz Radialwellendichtung /Tool kit radial shaft seal

Stk./Qty. Teil Part
1 Montagedorn Radialwellendichtring Mounting arbor stationary seal ring
1 Montagehlse Hauptspindel Mounting sleeve main screw
1 Montagehlse Kugellager Mounting sleeve ball bearing
1 Positionierhlse Positioning sleeve

OM9294_11.2
Completions
Spare parts
Completions
052 914.3
525
180
914.5
894
526
914.4
Fig. 1 Completion LFI/LFT/LFM/LFW models
914.3
180
525 052
914.5
663
914.6
Fig. 2 Completion LVI/LVT models

OM9294_11.2
Completions
Spare parts
Pos. no. Part Pos. no. Part
052 Coupling 894 Hexagon nut
180 Pump bracket 914.3 Socket screw
525 Coupling intermediate ring 914.4 Socket screw
526 Pump bracket foot 914.5 Socket screw
663 Pedestal 914.6 Socket screw
Tab. 1 Spare parts completions

OM9294_11.2
Tightening torques
Appendix
Tightening torques
Appendix
Tightening torque [Nm] for screws with metric threads + head contact surfaces With thread measured
in inches
+ wedge lock Stainless steel Screw plugs with
washers screws A2 and A4 elastomer seal
Galvanized
stainless
Rust-
Property
Property
class 70
class 80
Thread
Thread
8.8 + proof
steel
5.6 8.8 10.9 Alu* 8.8 A4-70
+
M3 0.6 1.5 1.2 1.5 1.1 G 1/8" 13
M4 1.4 2.9 4.1 2.3 3 2 G 1/4" 30
M5 2.7 6.0 8.0 4.8 6.0 3.9 3.5 4.7 G 3/8" 60
M6 4.7 9.5 14 7.6 10.3 6.9 6 8 G 1/2" 80
M8 11.3 23.1 34 18.4 25 17 16 22 G 3/4" 120
M 10 23 46 68 36.8 47 33 32 43 G 1" 200
M 12 39 80 117 64 84 56 56 75 G 1 1/4" 400
M 14 62 127 186 101 133 89 G 1 1/2" 450
M 16 96 194 285 155 204 136 135 180 * Reduced tightening
M 18 133 280 390 224 284 191 torque when screwing
M 20 187 392 558 313 399 267 280 370 into aluminum
M 24 322 675 960 540 687 460 455 605
Tab. 1 Tightening torques
Contents of the EC Declaration of Conformity

The screw pumps described in these operating instructions are machinery in the sense of the Directive
2006/42/EC. The original of the EC Declaration of Conformity is enclosed with the machinery at delivery.
The machinery fulfills all the relevant provisions of the following directives:
Number Name Remark

2006/42/EC Machinery Directive
97/23/EC Pressure Equipment Directive
(from
19.07.2016:
2014/68/EU)
2014/30/EU Directive on Electromagnetic Compatibi- Only for machinery with electrical com-
lity ponents
2014/35/EU Low Voltage Directive Only for machinery with electrical com-
ponents
2014/34/EU Directive on Use in Potentially Explosive Only for machinery in ATEX version
Areas (ATEX)
Tab. 2 Directives observed

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OM9294_11.

KRAL Screw Pumps.

About this document Installation, removal and connection

2 OIL 01en Edition 05/2016 Operating Instructions

KRAL Screw Pumps L Series

Operating Instructions OIL 01en Edition 05/2016 3

Target group Tasks

Warning personal injury

Procedures mechanical installation

Procedures electrical installation

Check or fault table

Request for action

Warning Danger level Consequences of non-observances

DANGER Immediate threat of danger Serious personal injury, death

WARNING Possible threat of danger Serious personal injury, invalidity

CAUTION Potentially dangerous situation Slight personal injury

CAUTION Potentially dangerous situation Material damage

4 OIL 01en Edition 05/2016 Operating Instructions

About this document

ATEX supplementary instructions for operation in areas at risk of explosions

Operating Instructions OIL 01en Edition 05/2016 5

The following general safety instructions must be observed:

6 OIL 01en Edition 05/2016 Operating Instructions

Item Designation Type

Tab. 1 Type code

Operating Instructions OIL 01en Edition 05/2016 7

Fig. 2 Rating plate

8 OIL 01en Edition 05/2016 Operating Instructions

Tab. 1 Operating limits

Sound pressure levels

Sound pressure level 3 [dB(A)]

Tab. 2 Sound pressure levels

Operating Instructions OIL 01en Edition 05/2016 9

Required NPSH values

Required NPSH values

Tab. 3 Required NPSH values

Material name Material no.

10 OIL 01en Edition 05/2016 Operating Instructions

Tab. 5 Weights for LFI/LFM/LFT/LFW

Tab. 6 Weights for LVI/LVT

Operating Instructions OIL 01en Edition 05/2016 11

Fig. 1 Electric heating system

Pay attention to the following when installing the heating element:

12 OIL 01en Edition 05/2016 Operating Instructions

Electric heating system

Connect and commission the electric heating system

Size Wattage [W] Heating-up periods [min] at a temperature difference of

Tab. 1 Heating-up periods for electric heating system

The electric heating system may only be connected by an authorized electrician.

Open all the valves during the heating process.

1. Connect the connecting cable of the heating element.

Operating Instructions OIL 01en Edition 05/2016 13

Fluid heating system

Fluid heating system

Fig. 2 Fluid heating system

Commissioning the fluid heating system

Size Heating-up periods [min] at a temperature difference of 50 C

Tab. 2 Heating-up periods for fluid heating system

Open all the valves during the heating process.

14 OIL 01en Edition 05/2016 Operating Instructions

Fig. 1 Structure of L-pump

1 End cover 5 Pump housing 9 Ball bearing

Fig. 2 Structure of L-pump with coupling and motor