Kirloskar “KOSN Series”Centrifugal Submersible Pump

A Kirloskar Group CompanyKIRLOSKAR BROTHERS LIMITED

INSTALLATION, OPERATION & MAINTENANCE MANUAL

KOSN Series

CM - 9862

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

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

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

KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group Company

A View of KBL Dewas Manufacturing Plant

06019860

FOR PROMPT SERVICE & SPARESRegister on our website : www.kirloskarpumps.com

Our products are meant for pumping

water and they do not have any significant effect

on environment during their use, if properly

selected and used as per instructions

given in this manual.

Customers are advised to dispose unusable

components through appropriate disposal agencies to

avoid the impact on work environment.

CONGRATULATIONS............

Congratulations......... on your acquiring one of the finest pumps in the

country.

The Kirloskar Openwell Submersible New- version Series in your

possession is scientifically designed by using the state of art design software

(Pro/E, ANSYS, CFD) for better aesthetics, performance, optimum material

Contents etc. These pumps are reliable, robust, compact in size and cheaper in

their class. Careful selection of materials, manufacturing and testing assures

you a satisfactory performance over a long period of time.

These pumps will give you years of trouble free performance if it is

handled with due care. This booklet is a step in this direction. It covers general

instructions on installation, operation and maintenance of KOSN Pumps. Please

read this booklet comply with the instructions and your pump is bound to serve

you well.

1. HANDLING 01

2. PUMP DESIGNATION KEY 01

3. FEATURES & APPLICATION 01

4. OPERATING CONDITION 02

5. INSTALLATION 02

6. ELECTRICAL CONNECTION 04

7. PRIMING 05

8. MAINTENANCE 05

9. TROUBLE SHOOTING CHART 06

10. CAUSE AND REMEDY CHART 07

11. DISMENTLING PROCEDURE 12

12. DISPOSAL 12

13. EXPLODED VIEW 13

14. PART LIST 14

15. OUTLINE DRAWING 15

16. PUMP MODELS 16

17. PRODUCT RANGE 17

18. WARRANTY CERTIFICATE 18

CONTENTS

1. Handling : When the entire pump is to be lifted in vertical direction, then it isrecommended to lift the pump at the Lifting bolt by means of straps/ropes as shown infigure 1.1 If pump to be moved from one place to another place then it is recommended tolift the pump at mounting casing by means of hand.

figure 1.1

2. Pump designation key : Following 7 key characters designate Kirloskar KOSNseries monoblocs.

Example KOSN-128 K O S N 1 28

Name of Type of Type of Version Power Head at 0firm pump pump rating in HP discharge

Kirloskar Open Well Submersible New 1 for 1 HP Shut of1.5 for 1.5 headHP etc

3. Features:

Kirloskar Openwell Submersible New version Pumps of designed for a wide

range of applications.

Designed for underwater applications - No need of priming and foot valve.

Easy installation - Foundation and installation platform or pump house not

required .

Can withstand wide voltage fluctations from 160-260 V.

Desined to prevent overloading and motor burning.

1

LIFTING ROPE

Dynamically balanced rotating parts to ensure minimum vibrations during

running .

Replacable wearing parts and hence longer life .

Easy maintenance and spares availability .

Applications :

Submerged pump in Fountains, Wells, Sumps and Water tanks .

Water supply for domestic use in high rise Apartments, Buildings and Hotels.

Gardening and sprinklers/conventional irrigation .

Industries, for clear water handling .

2

4. Operating Conditions :

4.1 Pumped Liquids :

Kirloskar Openwell Submersible New version Pumps are suitable only to pump

thin, non-explosive liquids, not containing solid particles. The liquid must not attack the

pump materials chemically. When pumping liquids with density and/or viscosity higher

than that of water, suitability of motor winding with correspondingly higher outputs must

be checked, if required.

4.2 Submerged Condition :The pump must be submerged in water more than 1 meter .

4.3 Technical Data :Maximum Liquid Temperature - 500 CRated voltage - 210 volt for single phase

- 380 volt for three pahseVoltage Range - 160-260 for single phase

350-415 for three phaseType of Duty - S 1 continuosDirection of rotation - Anti-clock wise form suction side.Frequency - 50HzSound Level - 80dBDegree of protection - IP-68Class of Insulation - ‘PP’

5. INSTALLATION

5.1 Guidelines :

For avoiding the un-necessary troubles in Installation, Operation Ma i n te n a n ceand for Utmost Performance of the Pump, we are suggesting few guidelines. We hope byfollowing these guidelines our customer will able to install the pump easily and operatethe pump at optimum performance.

3

WRONG WRONG

Fig. 5.1

5.2 Guideline for Installation :5.2.1 Location : The pump should be installed in horizontal position and submerged in

the water more than 1 meter . This will eliminate dry run and pump will give betterperformance. The pump does not require any foundation ; however if installing dugcum borewell , surface should be plain . The pump should not be installed in tiltedposition. (Ref. fig. 5.1)

5.2.2 Guideline for Piping :ØPipe size should be as per flange size to get higher discharge. It is not

recommended to reduce pipe size. If length of delivery pipe is more than 3 m., usehigher pipe (Please refer table 1.1 and 1.2 for proper pipe size) .

ØThe piping should be airtight. Any leakage in pipe may drasticallyaffect the performance of the pump. ( ref. fig. 5.2 )

ØThe suction pipe should be as short as possible for getting better discharge.( in case of dug cum borewell type arrangement. )

ØNo. of bends and other fittings should be as minimum as possible to reducefrictional losses. ( ref. fig. 5.3 )

ØAdequate supports should be provided to pipes so that its dead weight shouldnot fall on delivery casing completely.

RIGHT

Fig. 5.2

RIGHT

6 Guideline for Electrical Connections :

ØProper earthing connection should be made at the bolts provided for earthing.

ØProper size of cable should be used between supply and motor terminals to

minimize voltage drop and to carry full load current (FLC) as well as the maximum

current in the operating voltage range specified.

4

ØFor delivery pressure more than 20 meters, it is recommended to install a check( non-return ) valve in the discharge line. The check valve placed near the pumpis to protect the pump from excessive backpressure to prevent the water runningback through the pump in case of sudden failure of prime mover .

No. OF LEADS 3

V1 U1

W1U1

V2W2

CONNECTIONSTAR OR DELTA No. OF LEADS 3

V

U W

TO LINES

STAR DELTA STARTINGNo. OF LEADS 6

V2U2

V1

W2

W2 U1

CONNECTION DIAGRAM OFTHREE PHASE MOTORS

LEADS FROMMOTOR

SINGLE PHASE 50 HzSUPPLY

CONNECTION DIAGRAM OFSINGLE PHASE MOTOR

PHASE NEUTRAL

ØNuts at terminal should be tightened properly.

ØNo. of joints in cable should be less as possible, preferably joints should be

avoided.

Fig. 5.3

WRONG CORRECT

5

ØWires and connections should be properly insulated. If not it may lead to fatal shock.

ØProper backup protection (reputed make starter, main switch and fuse) should

be used.

Guideline for Starting the Pump

7.1 Check following before starting the pump :

ØThe shaft rotates freely by hand.

ØElectrical connection is proper as per above mentioned diagram .

ØThe motor is filled with clear cold water by opening both the lifting bolts. The

water should be filled through one hole till the water comes out of the other .

ØUsage of bend at suction.

ØRemove Suction and Delivery Rubber Packing before Installation

7.2 Check following during running condition :

ØThe direction of rotation is correct.

ØThe pump is running smoothly.

ØSee that the prime mover is not overloaded .

ØAvoid idle running on operation against closed discharge valve for a longer

period of time .

Maintenance :

8.1 When the pump will not be used for a long time :

ØWhen pump is kept unused for a long time, switch off the power. Drain water

in the pump and tank to avoid damages, i.e. r isk of water freezing.

Unscrew drainage screw. Protect water supply pipe and accessories from frost :

insulate them or store them inside.

ØThere is a possibility for the motor not to start in spite of switching on the

power because of the sticking and solidification of the dirty particle in the

pump head. In that case, it requires some service before usage. Switch off the

power, then rotate the stiff shaft at the back of the motor with a

screwdriver to make it easy, safety and reliable for its operation as usual.

8.2 Recommended spares for two years of normal working

1. Impeller.

2. Bush bearings.

3. Capacitors (In case of single phase pump)

4. Paper packing.

5. Oil seal .

6. Teflon coated plate .

8.3 Check the following periodically ( six monthly )

1. Impeller wear out

2. Oil seal wear out

3. Bearing bush wear out

4. Pipe connections

5. Strainer chocking

7

8

6

9. TROUBLE SHOOTING CHART :

Types of Failure

Failu

re t

o d

eliv

er

wate

r

Pum

p d

oes n

ot

deliv

er

rate

d d

ischarg

e

Pum

p d

oes n

ot

deliv

er

rate

d h

ead

Pum

p l

osses w

ate

raft

er

ats

rt

Pum

p o

ver

loads

pri

me m

ove

r

Vib

ration

Beari

ng

wear

rap

idly

Seiz

ed p

um

p

Irre

gu

lar

deliv

ery

Wrong direction of rotation

Inlet insufficiently submerged

Pump not upto rated speed

Viscosity/specific gravity greater than rated

Impeller blocked or damaged

Internal leakage

Gas or vapour in liquid

Speed to high

Total head lower than recommended

Worn or loose thrust plate

Rotor out of balance

Bent shaft

Thrust plate rubbing on bush

Excessive thrust

Lack of lubrication

Pump does not deliver rated capacity

Pipes exert forces on pump

foreign matters in pump

Viscosity lower than rated

Speed to low

Lead in delivery pipe work

üü

üü ü ü

üüü

üü

üü

üü

ü

ü

üü ü

ü

ü

ü ü

ü

ü

ü

ü

ü

ü

ü

ü

ü ü ü

ü

ü

üüü

ü

ü

üü

ü

ü

ü

ü

ü

CA

US

E &

RE

ME

DY

CH

AR

T (

In c

as

e o

f an

y p

rob

lem

, p

leas

e c

hec

k t

he u

nd

erl

ined

in

str

ucti

on

s).

1. P

UM

P D

OE

S N

OT

WO

RK

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

1 2 3 4 5 6 7

No

pow

er

in m

ain

contr

ol

panel/cap

acitor

box.

Defe

ctive

cap

acitor

box/

sta

rter

or

incorr

ect

wir

ing

.

Fau

lty

pre

ssu

re s

witch

& o

ther

contr

ol

devi

ces f

or

defe

cts

.P

um

p h

as b

een

sto

red u

nfa

vora

ble

cond

ition

for

a l

ong

tim

e b

efo

re i

nsta

llatio

n o

r defe

ctive

sub

mers

ible

moto

r or

cable

Defe

ctive

cap

acitor

(for

sin

gle

ph

ase

pum

pset)

.P

um

p c

hoke

d.

Roto

r seiz

ed

du

e t

o p

rolo

ng

ed s

hu

t dow

n o

fp

um

pset.

Ch

eck

for

blo

wn o

ut

fuses i

n m

ain

.

Ch

eck f

or

trip

ped c

ircuit b

reake

rs.

Check t

he w

irin

g,

con

nection,

voltage,

rela

yand

coil

siz

e o

f th

e s

tart

er.

Ch

eck

pre

ssu

re s

witch

& o

ther

con

trol

devi

ces f

or

defe

cts

.S

witc

h o

ff t

he m

ain

pow

er

line,

de-lin

kp

um

p p

ow

er

leads f

rom

cap

acitor

box/

sta

rter.

Check t

he m

oto

r w

ind

ing i

nsu

lation

resis

tance w

ith t

he h

elp

of

a m

eg

ger

to s

ee

wheth

er

the i

nsula

tion r

esis

tan

ce r

eadin

g i

satleast

20m

. ohm

and

check

for

defe

ctive

cab

le.

Sw

itch

off

th

e m

ain

pow

er

line.

Dis

ch

arg

eth

e c

apacito

r an

d c

heck

the c

ond

ition.

Rem

ove

the p

um

p f

rom

the w

ell.

Ensure

wh

eth

er

the p

um

p r

ota

tes f

reely

an

d t

he

pum

p i

s f

ree f

rom

exc

essiv

e s

and,

silt

&m

ud.

Rem

ove

the p

um

p f

rom

the w

ell

ensure

that

the m

oto

r shaft

rota

tes f

reely

.

Rep

lace b

low

nout

fuses.

If n

ew

fuse a

lso

blo

ws o

ut

rech

eck

all

ele

ctr

ical

wir

ing

and

eart

hin

g.

Check

fuse w

ire s

ize a

gain

st

actu

al

requ

irem

en

t.C

heck

the w

irin

g t

o c

ap

acito

r box/

sta

rter. I

fth

e c

ircuit b

reake

rs t

rips a

gain

, re

check

all

ele

ctr

ical

wir

ing i

nclu

din

g e

art

hig

.R

ectify

or

rep

lace d

efe

ctive

part

s o

f cap

acitor

box/

sta

rter. R

econ

nect

the c

apacitor

box/

sta

rter

corr

ectly

. C

hange t

he r

ela

y and c

oil

siz

e o

f th

e c

ap

acitor

box/

sta

rter

for

actu

al

requ

irem

en

t.R

ep

air

or

rep

lace f

aulty

pre

ssure

sw

itch

or

con

trol

devi

ces.

When m

egger

read

ing s

how

s l

ess t

han 2

0m

.ohm

rem

ove

the p

um

pset

and c

ab

le a

nd

recheck

valu

es o

n t

he g

rou

nd.

Rep

air o

rre

pla

ce m

oto

r and

/or

cable

.

Repla

ce t

he c

apacitor

if r

equ

ired.

If t

he p

um

p p

ort

ion i

s d

am

aged,

repair o

rre

pla

ce t

hepart

s.

Incase o

f re

pair

ing,

make

su

re t

hat

the p

um

p i

s r

insed w

ith w

ate

r befo

rein

sta

llation

.R

epair

or

repla

ce t

he r

oto

r.

7

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

3. P

UM

P D

EL

IVE

RS

INS

UF

FIC

IEN

T W

AT

ER

OR

VE

RY

LO

W T

OTA

L H

EA

D

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

1 2 3 4 5 6 7

Gate

valv

e/c

heck v

alv

e f

itte

d i

n t

he r

iser

pip

ed

efe

ctive

/clo

se

d.

Lo

w w

ate

r le

vel.

Wate

r in

let

str

ain

er

of

the p

um

p i

s c

logged.

De

fective

pu

mp

.

Pum

pin

g s

yste

m t

ota

l is

hig

her

than t

he p

um

ph

ead c

ap

acity.

Low

voltag

e o

r lo

w f

req

uen

cy

of

su

pp

lyre

su

ltin

g l

esser

speed

.

Defe

ctive

cap

acitor

(for

sin

gle

ph

ase

pum

pset)

.

Insp

ect

the g

ate

valv

e/c

heck v

alv

e.

Ch

eck

dra

w d

ow

n l

eve

l. E

nsu

re t

hat

the

pum

p i

s s

ubm

erg

ed i

n b

y atle

ast

2 f

eet

belo

w t

he d

raw

dow

n w

ate

r le

vel.

Rem

ove

pum

p f

rom

the w

ell

an

d i

nsp

ect.

Rem

ove

the p

um

p f

rom

the w

ell

ensure

that

the p

um

p r

ota

tes f

reely

and t

he p

um

p i

sfr

ee f

rom

exc

essiv

e s

and,

silt

and

mu

d.

Ch

eck

the s

ele

ction o

f th

e p

um

pin

g s

yste

m.

Ch

eck t

he v

olta

ge a

t sta

rter

/ capacito

r b

ox

wh

en

pum

p o

pera

tes.

Ch

eck p

ow

er

cable

siz

e a

nd

dro

p c

ab

le s

ize.

Sw

itch

off

th

e m

ain

pow

er

line.

Dis

ch

arg

eth

e c

apacito

r an

d c

heck

the c

ond

ition.

If c

losed

open

the g

ate

valv

e /

check

valv

e.

Ifd

efe

ctive

, re

ctify

or

rep

lace i

t.If

possib

le l

ow

er

the p

um

pset. W

hen t

he y

eild

of

the w

ell

not

matc

hes w

ith t

he p

um

ps

dis

charg

e.

Fit o

ne g

ate

valv

e i

n d

eliv

ery

pip

eand t

hro

ttle

accord

ing t

o t

he y

eild

. In

sta

ll th

ed

ry r

un

pre

ven

tor.

Cle

an t

he s

train

er,

if t

he s

train

er

is d

am

aged,

repla

ce i

t.W

hen t

he p

um

p p

ort

ion i

s d

am

aged,

repair o

rre

pla

ce t

he p

art

s.

In c

ase o

f re

pair

ing,

make

su

re t

hat

pu

mp i

s r

insed w

ith w

ate

r befo

rere

insta

llation

.S

ele

ct

and c

hang

e t

he p

um

pset

suita

ble

for

the s

yste

m h

ead.

Wh

en c

able

siz

e a

re f

ound

in

adiq

uate

chan

ge

cab

le a

nd

repla

ce t

o a

dequ

ate

siz

e.

Re

pla

ce t

he c

apacitor

if r

equ

ired.

1 2 3 4

Well

wate

r ye

ild r

ed

uced

.

Leak

in r

iser

pip

e a

nd /

or

surf

ace p

ipe a

nd /

or

valv

es.

Wate

r in

let

str

ain

er

to t

he p

um

p p

art

ially

blo

cked

Worn

out

impelle

r, b

ushes,

thru

st

assem

bly.

Check

dra

w d

ow

n w

ate

r le

vel. E

nsu

re t

hat

the p

um

p i

a a

lways

su

bm

erg

ed i

n w

ate

rd

uri

ng o

pera

tion

.C

heck f

or

leaka

ge.

Rem

ove

the p

um

p a

nd i

nspect.

Rem

ove

the p

um

p f

rom

the w

ell,

ensure

that

the w

ate

r is

fre

e f

rom

exc

essiv

e s

an

dsilt

and m

ud.

If p

ossib

le l

ow

er

the p

um

pset, a

dju

st

the g

ate

valv

e o

f th

e r

iser

pip

e t

o m

atc

h t

he y

eild

of

the

bore

well

insta

ll d

ry r

un

pre

ven

tor.

Re

move

th

e l

eaka

ges.

Cle

an t

he s

train

er,

if d

am

aged r

epla

ce i

t.

Rep

air o

r re

pla

ce p

um

p p

art

s.

8

3. P

UM

P D

EL

IVE

RS

INS

UF

FIC

IEN

T W

AT

ER

OR

VE

RY

LO

W T

OTA

L H

EA

D

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

5 6 7 8 9

Wro

ng d

irection o

f ro

tation

(th

ree p

hase)

Part

ially

clo

sed

gate

valv

e/c

heck v

alv

e.

Lo

w V

oltag

e.

Ris

er

pip

e i

nner

passag

e c

oate

d w

ith

deposits

fro

m w

ate

r. C

logged i

mpelle

r.

Sm

alle

r siz

e r

iser

pip

e i

s u

sed.

Refe

r ele

ctr

ical

Dra

win

g.

Insp

ect

the g

ate

valv

e /

check v

alv

e.

When t

he p

um

p o

pera

tes,

check t

he v

oltage

at

cap

acitor

box/

sta

rter. C

heck p

ow

er

cable

siz

e a

nd

dro

p c

ab

le s

ize.

Rem

ove

the p

um

p a

nd

inspect

the w

ate

rin

let

str

ain

er

and i

mpelle

r.

Exc

essiv

e h

ead

loss d

ue t

o s

malle

r dia

pip

e.

Inte

rch

ang

e a

ny

two p

hase o

r th

e p

ow

er

line

con

nectio

ns.

Op

en t

he v

alv

e f

ully

, if s

tuck

free t

he v

alv

e.

Wh

en c

ab

le s

ize a

re f

oun

d i

nad

equ

ate

chan

ge

cab

le a

nd

repla

ce t

o a

dequ

ate

siz

e.

Cle

an o

r re

pla

ce t

he p

ipes.

Dis

mantle

and

cle

an t

he i

mpelle

rs o

r re

pla

ce t

he p

um

p p

art

s.

Cle

an o

r re

pla

ce t

he d

am

ag

ed s

train

er.

Chang

e w

ith

adeq

uate

capacity

pip

es.

4. T

RIP

PIN

G O

F C

IRC

UIT

BR

EA

KE

RS

OV

ER

LO

AD

PR

OT

EC

TO

RS

OR

FU

SE

S B

LO

WN

UP

DU

RIN

G O

PE

RAT

ION

OF

PU

MP

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

1 2 3 4

Low

or

hig

h v

oltage.

Defe

ctive

cap

acitor

box/

sta

rter

or

incorr

ect

wir

ing

.

Defe

ctive

cap

acitor

(for

sin

gle

ph

ase

pum

pset)

.P

ow

er

line c

able

sh

ort

aed,

eart

hed o

r cab

lein

su

lation

dam

aged.

Check v

oltage a

t sta

rter/

capacitor

box

wh

eth

er

it i

s w

ith i

n 1

0%

. C

heck

pow

er

cable

an

d d

rop c

ab

le s

ize.

Check t

he w

irin

g,

con

nection,

voltage,

rela

yand

coil

siz

e o

f th

e s

tart

er.

Sw

itch

off

th

e m

ain

pow

er

line.

Dis

ch

arg

eth

e c

apacito

r an

d c

heck

the c

ond

ition.

Sw

itch o

ff t

he m

ain

pow

er

line a

nd i

nspect.

Wh

en c

ab

le s

ize a

re f

oun

d i

nad

equ

ate

chan

ge

cable

and

rep

laces t

o a

dequ

ate

siz

e.

Rectify

or

rep

lace d

efe

ctive

part

s o

f cap

acitor

box/

sta

rter. R

econ

nect

the c

apacitor

box/

sta

rter

corr

ectly

. C

hange t

he r

ela

y and c

oil

siz

e o

f th

e c

ap

acitor

box/

sta

rter

for

actu

al

requ

irem

en

t.R

epla

ce t

he c

apacitor

if r

equ

ired.

If r

equ

ired

change t

he c

able

.

9

5. P

UM

P S

TAR

TS

VE

RY

OF

TE

NS

. N

o.

CA

US

ES

HO

W T

O C

HE

CK

RE

ME

DIE

S

1 2 3 4

Impro

per

sett

ing

of

pre

ssu

re s

witch o

rd

efe

ctive

pre

ssu

re s

wit

ch

.Leaka

ge i

n t

he s

yste

m.

Wate

r le

vel

monitor

is n

ot

pro

perly

set

or

defe

cti

ve.

Inadequate

siz

e o

f ta

nk.

Ch

eck

the p

ressu

re s

witch s

ettin

g a

nd

exa

min

e d

efe

ct

in t

he s

witch

.C

heck

all

pip

es,

valv

es,

tank

and a

llplu

mbin

gs f

or

leaks

.C

heck

the w

ate

r le

vel

monito

r settin

g a

nd

insp

ect

for

defe

cts

.C

heck

tank s

ize a

gain

st

consu

mptio

n a

nd

pum

p d

ischarg

e c

apacity.

Adju

st

an

d r

eset

the p

ressu

re s

witch

or

rep

lace t

he s

witch i

f d

efe

ctive

.A

rrest

leaka

ge o

r re

pla

ce c

om

pon

en

tw

here

ver

ne

ce

ss

ary

.A

dju

st

and

reset

the w

ate

r le

vel, r

epla

ce

mon

itor

if d

efe

ctive

.C

hange t

o a

n a

dequate

siz

ed t

ank.

6. A

BS

OR

BE

D P

OW

ER

/ C

UR

RE

NT

IS E

XC

ES

SIV

E.

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

1 2 3 4 5 6 7 8

De

fective

fuse o

r sin

gle

ph

asin

g.

Abra

ssiv

e w

ear

of

pu

mp

bu

shes a

nd t

hru

st

assem

bly

.

Well

wate

r ye

ild r

ed

uced

.

Lo

w v

olt

ag

e.

Hig

h v

olta

ge/h

igh

fre

qu

ency.

Resulti

ng i

n h

igh

moto

r speed

.C

ab

le d

efe

ctive

.

Loose c

onn

ection

s.

Impro

per

sele

ctio

n o

f pu

mpset.

Check f

or

blo

wn o

ut

fuses.

Ch

eck

for

hig

her

san

d c

onte

nt, s

olid

s &

mud.

Ch

eck d

raw

dow

n w

ate

r le

vel

an

d e

nsu

reth

at

the p

um

pset

is a

lways

sub

merg

ed i

nw

ate

r d

uri

ng

op

era

tion

.W

hen t

he p

um

p o

pera

tes,

check t

he v

oltage

at

cap

acitor

box/

sta

rter. C

heck p

ow

er

cable

siz

e a

nd

dro

p c

ab

le s

ize.

Check t

he v

oltag

e f

req

uency

at

capacitor

bo

x/s

tart

er.

Ch

eck

the c

able

for

dam

age.

Ch

eck

for

loose c

on

nection

s,

as l

oose

con

nection

will

dro

p m

ore

voltag

e r

esu

lts

as l

ow

voltag

e.

Veri

fy t

he p

um

pset

data

s w

ith

fie

ldcon

ditio

ns.

Rep

lace b

low

nou

t fu

ses.

If n

ew

fuses a

lso

blo

ws o

ut

rech

ack

all

ele

ctr

ical

wir

ing

and

eart

hin

g.

Check f

use w

ire s

ize a

gais

t actu

al

requ

irem

en

t.R

em

ove

th

e p

um

pset

from

the w

ell

and

insp

ect.

Repla

ce t

he w

orn

out

pu

mp

bu

sh

es

an

d t

hru

st

assem

bly

.If

possib

le l

ow

er

the p

um

pset

ad

just

the g

ate

valv

e o

f th

e r

iser

pip

e t

o m

atc

h t

he y

eild

of

the

bore

well

insta

ll dry

run

pre

vent.

Wh

en c

ab

le s

ize a

re f

oun

d i

nad

equ

ate

chan

ge

cab

le a

nd

repla

ce t

o a

dequ

ate

siz

e.

Use a

n a

ppro

priate

voltag

e s

tabili

zer.

Wh

en c

ab

le s

ize a

re f

oun

d i

nad

equ

ate

chan

ge

cab

le a

nd

repla

ce t

o a

dequ

ate

siz

e.

Ch

eck

the j

oin

ts a

nd c

onnectio

ns,

connect

the

join

ts p

erm

an

ently.

Avo

id e

xcessiv

e j

oin

ts.

If t

he p

um

p s

ele

ctio

n i

s w

ron

g s

ele

ct

the

suitable

pum

p.

10

7. P

UM

P R

UN

S R

OU

GH

LY A

ND

NO

ISY

/ E

XC

ES

SIV

E V

IBR

AT

ION

S.

No

.C

AU

SE

SH

OW

TO

CH

EC

KR

EM

ED

IES

1 2 3 4 5

Abra

siv

e w

ear

of

pum

p b

ush

es a

nd t

hru

st

assem

bly

.

Clo

gged i

mpelle

r /

str

ain

er.

Mechanic

al

fric

tion

.

Wate

r le

vel

of

well

is i

nsuff

icie

nt.

Vib

ration

of

deliv

ery

pip

e.

Ch

eck

for

hig

her

san

d c

onte

nt, s

olid

s &

mud.

Rem

ove

the p

um

p a

nd

inspect

the w

ate

rin

let

str

ain

er

and i

mpelle

r.

Du

e t

o d

ry r

unnin

g o

f pum

p a

nd f

ailu

re o

fth

rust

assem

bly

.C

heck d

raw

dow

n w

ate

r le

el

an

d e

nsu

reth

at

the p

um

p i

s a

lways

subm

erg

ed

in

wa

ter

du

ring

op

era

tion

.

Check w

heth

er

the v

alv

es a

re p

rop

erl

yfu

nctio

nin

g o

r not.

Rem

ove

th

e p

um

pset

from

the w

ell

and

insp

ect.

Repla

ce t

he w

orn

out

pu

mp

bu

sh

es

an

d t

hru

st

assem

bly

.D

ism

antle

and c

lean t

he i

mpelle

rs o

r re

pla

ce

the p

um

p p

art

s.

Cle

an o

r re

pla

ce t

he d

am

aged

str

ain

er.

Rem

ove

th

e p

um

pset

from

the w

ell

and

insp

ect.

Rep

lace t

he w

orn

out

pum

p p

art

s.

When t

he y

eild

of

well

not

matc

hes w

ith t

he

pu

mps d

isch

arg

e,

fit

one g

ate

valv

e i

n d

eliv

ery

pip

e a

nd t

hro

ttle

accord

ing t

o t

he y

eild

. In

sta

ll a

dry

ru

n P

reve

nto

r.C

han

ge t

he d

efe

ctive

check v

alv

e o

r gate

valv

e.

Pro

vid

e p

rop

er

su

pp

ort

s t

o t

he d

eliv

ery

pip

e.

1112

11 Dismantling Procedure

Remove the suction housing and delivery pipe.

Unscrew the nut and remove the suction and delivery flange.

Unscrew the nut and remove the delivery casing from the mounting casing .

Unscrew the nyloc nut and remove washer and impeller from shaft .

Remove oil seal from mounting casing.

Unscrew the nut from tie rod and remove mounting casing from motor body.

Unscrew the cable plug and remove cable grommet.

Remove cover NDE. Please ensure that cable does not get damaged.

Remove the shaft along with the rotor.

12 Disposal

Our products are meant for pumping water and they do not have any significant

effect on environment during their use. If properly selected and used as per

instructions given in the manual. Customers are advised to dispose off unusable

components through government or private disposal waste collection to avoid the

harmful impact (if any ) on the environment .

13. EXPLODED VIEW

13

PART LIST

14

Part descriptionPart No.

Gasket for Delivery Flange

Gaske for Suction Flange

Nut for Suction Flange

Stud for Del. Casing & Suc. Flange

Suction Flange

Drain Plug for Casing

Stud for Del. Casing & Del. Flange

Nut for Delivery Flange

Delivery Flange

Delivery Casing

Stud for Delivery Casing

Impeller Nut

Washer for Impeller Nut

Packing for Del. Casi. Mounti. Casi.

Nut for Del. Casi. & Mounti. Casing

Impeller

Mounting Casing

Lifting Bolt

Packing for Lifting Bolt

‘O’ Ring betn Motor Body & Mont Cas.

Collared Bush

Cap for Winding

Motor Body

Screw for Clamping Plate

Clamping Plate

Diaphragm

End Cover

Stator

Circlip

Rotor Shaft

Thrust Plate

Locating Pin/Dowel Pin

Key for Impeller

Rotor (Motor)

Tie Rod

Rubber pad for Motor Support

Nut for Motor Body Housin. Cover NDE

Cover NDE

Qty.

0513.1

0513

580.1

590

490.1

0601

0590.1

0580

0490

0101

0593

0330

0621

0510

0586

0151

0296.1

0303

0516

1161

1091

1228

0130

1340

2103

0919

1187

0911

2069

0189

1234

0611

0320

0164

0341

1174

3032

4015

1

1

2

2

1

1

1

2

1

1

4/6

1

1

1

4/6

1

1

2

2

2

2

2

1

2

1

1

1

1

2

1

2

2

1

1

3

1

3

1

15

14. OUTLINE DRAWING :

KOSN - SERIES PUMP

KOSN - 0520 PUMP

16M

OD

EL

SU

C.

DE

L.

LW

HW

1W

2H

1H

2H

3A

BC

DP

NS

KO

SN

-05

16

KO

SN

-08

27

KO

SN

-11

6

KO

SN

-12

3

KO

SN

-12

8

KO

SN

-12

8

KO

SN

-12

8

KO

SN

-13

4

KO

SN

-1.

522

KO

SN

-1.

525

KO

SN

-1.

540

KO

SN

-21

6

KO

SN

-22

5

KO

SN

-05

23

KO

SN

-05

27

25 25 50 32 25 40 50 25 50 50 32 65 50 25 25

25 25 40 25 25 40 40 25 40 40 25 40 40 25 25

295

373

373

365

378.

5

380.

5

380.

5

373

397

390

385

430.

5

416.

5

333

333

171

176.

5

189.

5

190.

5

186

187.

5

187.

5

176.

5

189.

5

187.

5

225

176

190.

5

185

185

26

8

250

.5

27

6

28

1

27

3

27

1

27

1

250

.5

27

6

27

1

29

8

26

0

28

1

26

2

26

2

82 86.8

88.5

91.5

90 91 91 86.8

88.5

91

112

.5

80 91.5

89.2

89.2

89 89.7

101

99 96 96.5

96.5

89.7

101

96.5

112

.5

96 99 95.5

95.5

110

10

5

110

10

5

10

5

10

5

10

5

10

5

110

10

5

12

5

10

0

10

5

97 97

128

115.

5

135

145

135

135

135

115.

5

135

135

146

132

148

135

135

30 30 28 28 30 28 28 30 28 28 24 28 28 27 27

25 73 71 70 78.5

64 64 73 71 64 66 73.5

73.7

78.5

78.5

30 30 32 25 30 32 32 30 32 32 25 32 32 27 27

23

21

28

27.5

23.5

23.5

23.5

21

28

23.5

21

34.5

29

23.5

23.5

14

2.7

13

3.7

19

8.2

12

5.7

13

9.2

12

6.7

12

6.7

13

3.7

19

8.2

19

1.2

12

1.7

20

0.7

20

0.7

14

1

14

1

39 39 39 39 39 39 39 39 39 39 39 50 39 44 44

133

163

163

163

163

163

163

163

187

187

187

204

204

140.

5

140.

5

68 68 68 68 68 68 68 68 68 68 68 68 68 33 33

17

Product range manufactured by Kirloskar Brothers Limited, Dewas

For details contact the dealer

Pump Series

KDS+/++

KDT+

KS+

KOS

SP

KJV/H,KJ+

MINI,DC,DHX

SubmersibleKu4 Winner

NW,KE,KHKHDT+,SR

KV, DV

Alternator

Motor

Construction Feature

Monobloc

Monobloc

Monobloc

Monobloc

Monobloc/Coupled

Monobloc

Monobloc

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

Coupled

Monobloc/Coupled

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

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

Drive Unit

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

Engine / Motor

Electric Motor

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

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

Power Rating

1.5 HP - 30.0 HP

1.0 HP - 20.0 HP

3.0 HP - 10.0 HP

0.5 HP - 10.0 HP

0.5 HP - 5.0 HP

0.5 HP - 3.0 HP

0.25 HP - 1.0 HP

0.5 HP - 75.0 HP

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

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

2 KVA - 50 KVA

0.5 HP - 120 HP

18

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

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

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

Product Model:_________________________________________________

Sr. No. :______________________________________________________

Date of Purchase :_______________________________________________

Bill/Cash Memo No. :____________________________________________

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

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

Dealer’s stamp and signature :___________________