Operating Instructions: BKF0004EN

Operating instructions
BKF0004EN
Transfer Gear Pumps KF 4...112
BKF0004EN_D0024710002-07
Englisch
2011-03-24
Table of Content
1 General points 5
1.1 About the documentation 5

1.2 Manufacturer´s address 5
1.3 Intended use 5
2 Safety 7
2.1 Safety instructions and symbols 7

2.2 Staff qualification and training 7
2.3 General safety instructions 7
2.4 Hazard statements 8
3 Device description 13
3.1 General points 13

3.2 Basic construction 14
3.2.1 KF 4...112 R/L/B (with cover) 14
3.2.2 KF 4...112 R/L - D (with pressure relief valve) 16
3.2.3 KF 4...25 U (with universal valve) 18
3.3 Types of seals 22
3.4 Type key 23
3.5 Important special numbers 24
4 Technical data 25
4.1 General characteristics 25

4.2 Overview of nominal sizes 26
4.3 Permissible speed 26
4.4 Overview materials 27
4.5 Operating pressure and fluid temperature 28
4.6 Dimensions 29
5 Transport and storage 30
5.1 Transport damage 30

5.2 Transport 30
5.3 Corrosion protection 32
6 Installation 33
6.2 Noise reduction 34
6.3 Definition of the direction of rotation and pumping 34
flow
6.3.1 KF 4...112 (with end cover or pressure relief valve) 35
6.4 Change of the direction of rotation 37
6.5 Design of suction and pressure line 39
6.5.1 Suction line 39
6.5.2 Pressure line 42
6.6 Mounting the clutch 44
6.7 Mechanical installation 47
6.8 Assembly with further components and devices 50
6.9 Electrical connection 50
7 Operation start-up 51
7.1 Preparation 51
7.2 Pumps with liquid seal (quenching connection) 53
7.2.1 General points 53
7.2.2 Seal variants with liquid seal 54
7.3 Setting the pressure relief valve 55
7.4 Further operation start-up 57
8 Removal 58

8.2 Disassembling the pump 58
9 Maintenance 60

9.2 Unusual noise 62
9.3 Cleaning 63
9.4 Static seals 63
9.5 Confining fluid level 63
9.6 Rotary shaft lip seal 63
9.7 Mechanical seal 64
9.8 Clutch 64
9.9 Screw joints 64
9.10 Damage 64
9.11 Surface temperature 64
9.12 Bearing, gear, wheel chamber housing 65
10 Repairs 66

10.2 Troubleshooting 66
10.3 Elimination of damage 66
10.4 Return 66
10.5 Disposal 67
10.6 Detecting and eliminating problems 67
1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-

nance of the transfer gear pumps KF 4...112, also referred to below as the
device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter 3 “Device
description” and in the chapter 4 “Technical data”.
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Manufacturer´s address
Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: +49 (0) 23 92 / 935-0
fax: +49 (0) 23 92 / 935-209
email: info@kracht.eu
web: www.kracht.eu
1.3 Intended use
The device is a pump for continuous delivery of liquids. The various seal var-
iants and materials enable use with different media.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
The medium must not contain any abrasive constituents.
Petrols, solvents, etc. are not permissible.
Use in explosive areas is not permissible.
The operator must guarantee that the medium to be conveyed is compatible
with the materials used in the device (see "Overview materials" in the chapter
4 “Technical data”). Chemical expertise is required for that.
BKF0004EN_D0024710002-07 2011-03-24 5
The maximum permissible operating data listed in the chapter 4 “Technical

data” must always be observed.
Deviations from the above-mentioned data and operating conditions require
express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
illegible or irrecognisable.
In cases of noncompliance, all warranty claims and manufacturer responsi-
bility shall be void.
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2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Staff qualification and training
The staff designated to install, operate and maintenance the device must be
properly qualified. This can be through training or specific instruction. Staff
must be familiar with the contents of this operating manual.
2.3 General safety instructions
The operational safety of the device delivered is only guaranteed when it is

used for the intended purpose (see chapter 1 “General points”).
The limit values given must never be exceeded (see chapter 4 “Technical
data”).
National regulations concerning accident prevention and health and safety
at work must be observed, as well as internal regulations laid down by the
operator, even if these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
staff responsible at all times.
BKF0004EN_D0024710002-07 2011-03-24 7
2.4 Hazard statements
DANGER
Danger due to breakage or squirting fluids!
Operating the device with impermissibly high pressures can lead to damage
to the device and to the up or downstream plant elements. Breakage can
lead to parts flying around uncontrolled or to fluids squirting out which can
lead to accidents and severe injuries or even result in death.
● Never allow positive displacement pumps to pump against "closed
gates".
● A pressure relief valve or other kind of over-pressure safeguard must
be installed as close as possible to the pump pressure connection. The
pressure relief device must be dimensioned so that the entire delivery
volume can be conducted through it with the lowest possible pressure
or must be depressurized.
● Do not put the device into operation without a pressure relief device.
DANGER
Using unsuitable connections and lines can lead to breakage. Parts flying
around uncontrolled or squirting fluids can lead to accidents with severe
injuries or even lead to death.
● Use only connections and lines approved for the expected pressure
range.
● Comply with each manufacturer's regulations.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, which can lead to accidents and severe
injuries or even result in death.
● Immediately replace damaged connections, pipes and hose lines.
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DANGER
Hazard caused by incorrect direction of rotation!
Operating the device with the incorrect direction of rotation can lead to
damage to the device and to the up or downstream plant elements. Break-
age can lead to parts flying around uncontrolled or to fluids squirting out
which can lead to accidents and severe injuries or even result in death.
● Always pay attention to the correct direction of rotation when installing
the pumps.
● Always pay attention to the correct direction of rotation when connecting
the motors.
● Secure the fitting keys against flying off when monitoring the direction
of rotation.
DANGER
Danger due to electric voltage!
Danger of death due to electric shock.
● Follow the special safety regulations during all work on electrical instal-
lations.
● Only allow electricians to work on electrical systems.
BKF0004EN_D0024710002-07 2011-03-24 9
WARNING
Hazard caused by rotating parts and fluid squirting out!
During all work on the device, rotating parts and squirting fluids can lead to
accidents and severe injuries or even restult in death..
● Depressurize all connections lines during all work on the device.
● Depressurize or disconnect the driving motor during all work on the de-
vice.
● Securely prevent the motor and device from restarting during work.
● Wear suitable protective clothing.
WARNING
Danger due to hazardous fluid!
Danger of death upon contact with hazardous fluids and when inhaling va-
pours from these liquids.
● Comply with the safety data sheets and regulations on handling the
hazardous liquids!
● Collect and dispose leaks of hazardous materials so that no hazards
arise for people or the environment.
● Comply with national and international rules at the place of installation.
WARNING
Hazard caused by rotating parts!
Rotating parts can cause accidents with severe injuries or result in death
due to body parts, hair or clothing getting caught or wrapped up.
● Protect rotating parts (e.g., coupling and shaft ends) against uninten-
tional contact.
● Close any maintenance openings when using bell housings.
● Do not operate the device without safeguards.
WARNING
Danger due to exposed gears!
Gears can pull in and crush or cut off fingers and hands.
● Do not reach into the gears.
● Put the device into operation with connected lines only.
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WARNING
Danger due to falling and or loads falling over!
Due to the size and weight of the unit, accidents can occur resulting in se-
vere injuries or death during transport and shipping.
● Compliance with applicable industrial safety requirements is mandatory.
● Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
● Attach lifting tackle only to suitable points (see table 5.1 and table 5.2).
● Attach the lifting tackle in such a manner that it cannot slip.
● The device's centre of gravity must lie between the lifting tackle mount-
ing points on the device.
● Secure the device so that toppling over and falling down is impossible.
● Always avoid jerks, impacts and strong vibrations during transportation.
● Never walk under suspended loads, never work under suspended
loads.
● To prevent damage to the device, be extremely cautious when shipping
or transporting.
BKF0004EN_D0024710002-07 2011-03-24 11
CAUTION
Danger due to hot surfaces!
When operating the device with hot media, there is a danger of being
burned and scalded when touching the hot surfaces.
● At medium temperatures above 60 °C, take measures against uninten-
ded contact.
● Wear safety gloves.
CAUTION
● Let the device cool off first when the medium temperature is over 48 °
C.
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3 Device description
3.1 General points
KF series pumps are external gear pump types that work according to the
positive displacement principle.
When rotated, two gears being engaged with each other cause volume ex-
pansion by opening the tooth gaps in the pump inlet (suction side) so that the
medium can enter while a corresponding volume is being displaced in the
pump outlet (pressure side) through engagement of the teeth into the filled
tooth gap. Fluid transport takes place through entrainment in the tooth gaps
along the wall of the wheel chamber. The so-called geometric flow rate Vg is
being displaced per wheel rotation. A value that is stated in technical docu-
ments as rated volume Vgn to specify the pump size.
The actually delivered amount of liquid does not correspond with the theo-
retical value, it is being reduced through losses due to the necessary toler-
ances. The losses are less the lower the operating pressure and the higher
the viscosity.
Gear pumps are self-priming within wide limits. The displacement cycle de-
scribe initially takes place without exhibiting appreciable pressure build-up.
Only after setting external loads, for example, through delivery head, outlet
resistances, line elements, etc. the required working pressure will arise to
overcome these resistances.
As usual with so-called rigid pumps, i.e. non-axial play compensated pumps,
the lateral clearance between gear and front face has been set in such a way
that the maximum allowable operating pressure is managed in an adequate
and secure way.
The medium lubricates the pump's friction bearings and shaft seal. The
pump's operating life will be reduced if the medium contains abrasive ingre-
dients.
The shaft sealing pocket is connected to the pump's suction side. Therefore,
the max. permissible suction-side pressure is dependent on the type of seal.
Tab. 3.1: Functional principle external gear pumps
pe = Suction side
pb = Pressure side
BKF0004EN_D0024710002-07 2011-03-24 13
3.2 Basic construction
3.2.1 KF 4...112 R/L/B (with cover)
Tab. 3.2: Basic construction KF 4...112
* Direction of rotation "B" (Right and left)
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Tab. 3.3: Basic construction KF 4...112
Description
1. Cover 8. Retaining ring
2. O-Ring 9. Parallel key
3. Housing 10. Hexagonal screw
4. Driven shaft 11. Adapter sleeve
5. Driving shaft 12. Valve
6. Plain bearing bush 13. Adjusting washer
7. Rotary shaft lip seal 14. Retaining ring
See section section 3.3 “Types of seals” for further seal types.
BKF0004EN_D0024710002-07 2011-03-24 15
3.2.2 KF 4...112 R/L - D (with pressure relief valve)
Tab. 3.4: Basic construction KF 4...112 R/L - D
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Tab. 3.5: Basic construction KF 4...112 R/L - D
Description
1. Valve cover 10. Set screw
2. O-Ring 11. Hexagonal nut
3. Housing 12. Retaining screw
4. Driven shaft 13. O-Ring
5. Driving shaft 14. Compression spring
6. Plain bearing bush 15. Valve cone
7. Retaining ring 16. Adapter sleeve
8. Rotary shaft lip seal 17. Hexagonal screw
9. Parallel key
BKF0004EN_D0024710002-07 2011-03-24 17
3.2.3 KF 4...25 U (with universal valve)
Tab. 3.6: Basic construction KF 4...25 U
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Description
1. Valve housing 14. Valve washer
2. Gasket 15. Valve cone
3. Adapter piece 16. Socket head cap screw
4. Plain bearing bush 17. Socket head cap screw
5. O-Ring 18. Rotary shaft lip seal
6. Driven shaft 19. Retaining ring
7. Driving shaft 20. Parallel key
8. Plain bearing bush 21. Cover
9. Housing 22. O-Ring
10. Roller bearing 23. Rod
11. Retaining ring 24. Compression spring
12. Hexagonal screw 25. Centering star
13. Retaining ring 26. Piston
BKF0004EN_D0024710002-07 2011-03-24 19
* View without connection elbow

** View without universal device
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Description
1. Hexagonal screw 15. Parallel key
2. Screw plug 16. Retaining ring
3. Gasket 17. Roller bearing
4. Socket head cap screw 18. Retaining ring
5. Connection elbow 19. Rotary shaft lip seal
6. Gasket 20. Housing
7. Socket head cap screw 21. Plain bearing bush
8. Rod 22. Driving shaft
9. Piston 23. Driven shaft
10. Valve cone 24. O-Ring
11. Compression spring 25. Cover
12. Valve housing 26. Valve
13. O-Ring 27. Adjusting washer
14. Cover 28. Retaining ring
BKF0004EN_D0024710002-07 2011-03-24 21
3.3 Types of seals
Tab. 3.10: Type of seals KF 4...112
Pump with single rotary Pump with single rotary Pump with double rota- Pump with double rota-
shaft lip seal shaft lip seal and out- ry shaft lip seal with ry shaft lip seal for vac-
Mounting: F / W board bearing connection borehole G uum operation with
Sealing materials: Mounting: G / X 1/8 for liquid seal connection borehole G
1: NBR Sealing materials: (quench) 1/8 for liquid seal
2: FKM 1: NBR Mounting: F / W (quench)
3: PTFE 2: FKM Sealing materials: Special number 74
9: EPDM 3: PTFE 4: PTFE Mounting: F / W
23, 31: FKM (low tem- 7: FKM Sealing materials:
perature) 19: NBR 4: PTFE
32: EPDM 7: FKM
19: NBR
32: EPDM
Pump with triple rotary Pump with mechanical Pump with mechanical Pump without shaft
shaft lip seal for vac- seal seal and connection G seal
uum and normal oper- Mounting: F / W 1/8 (KF 4...25) or G 1/4 Mounting: F / W
ation with connection Sealing materials: (KF 32...80) for liquid Sealing material:
borehole G 1/8 for liq- 5: FKM seal (quench) 30: FKM (O-Ring)
uid seal (quench) 6: PTFE Special number 198
Mounting: F / W 20: EPDM Mounting: F / W
(on request) Sealing material:
5: FKM
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3.4 Type key
Tab. 3.11: Ordering example KF 4...112
KF 40 R F 1 /... - D 15 - ...
1. 2. 3. 4. 5. 6. 7. 8.
Tab. 3.12: Explanation of type key KF 4...112
Explanation of type key KF 4...112

1. Product name
2. Nominal size
Vg Size 1: 4, 5, 6, 8, 10, 12, 16, 20, 25 cm3
Size 2: 32, 40, 50, 63, 80 cm3
Size 3: 100, 112 cm3
3. Direction of rotation
R Right B Right and left
L Left U Universal (Direction of rotation right and
left, direction of discharge consistent)
4. Mounting
F DIN flange without outboard bear- W Mounting angle without outboard bearing
ing
G DIN flange with outboard bearing X Mounting angle with outboard bearing
5. Seal type
1 Single rotary shaft lip seal BABSL 18 Single rotary shaft lip seal BAUMX7 FKM
NBR
2 Single rotary shaft lip seal BABSL 19 Double rotary shaft lip seal BABSL NBR
FKM
3 Single rotary shaft lip seal PTFE 20 Mechanical seal with EPDM secondary
seal (not resistant to mineral oil)
4 Double rotary shaft lip seal PTFE 23 Singel rotary shaft lip seal MSS-1 FKM
(low temperature)
5 Mechanical seal with FKM secon- 30 Without shaft seal, O-Ring FKM
dary seal (external leak oil discharge)
6 Mechanical seal with PTFE secon- 31 Single rotary shaft lip seal BABSL FKM
dary seal (low temperature)
7 Double rotary shaft lip seal BABSL 32 Double rotary shaft lip seal EPDM
FKM (not resistant to mineral oil)
9 Single rotary shaft lip seal EPDM
(not resistant to mineral oil)
6. Special number for specific types
See section 3.5 “Important special numbers”
BKF0004EN_D0024710002-07 2011-03-24 23
Explanation of type key KF 4...112

7. Pressure relief valve (only for direction of rotation R or L)
D 15 Adjustable from 0 - 15 bar D 25 Adjustable from 15 - 25 bar
8. Housing and cover material
Not specified: EN-GJL-250 (GG-25)
GJS EN-GJS-400-15 (GGG-40)
3.5 Important special numbers
Tab. 3.13: Important special numbers KF 4...112
Special Description
num-
bers
74 Pump with double rotary shaft lip seal for vacuum operation and connection for liquid
seal (quench), inner rotary shaft lip seal mounted with sealing lip towards shaft end
158 SAE ¾ connections for KF 4...12, SAE 1 connections for KF 16...25
197 Noise-optimized version for aerated oils and vacuum
198 Mechanical seal with connection for liquid seal (quench)
232 SAE 2 connections for KF 50...80, SAE 2 1/2 connections for KF 100...112
304 Bearing bushings Iglidur® X, Δpmax = 10 bar
317 Noise-optimized version for aerated oils and vacuum, bearing bushings Iglidur® X,
Δpmax = 10 bar
332 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at Δpmax = 10 bar
353 Noise-optimized version for aerated oils and vacuum, bearing bushings DP4 (leadfree)
355 Bearing bushings Iglidur® X, SAE ¾ connections for KF 4...12, SAE 1 connections for
KF 16...25, Δpmax = 10 bar
363 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at Δpmax = 10 bar, SAE ¾ connections for KF 4...12, SAE 1
connections for KF 16...25
391 Noise-optimized version for aerated oils and vacuum, SAE 2 connections for KF 50...80,
SAE 2 1/2 connections for KF 100...112
Particularities in noise-optimized pumps

● Air trapped in the medium or too high negative pressure can result in
delivery rate reduction for pumps in noise-optimized version.
● Measures for noise optimisation are only feasible for one rotational di-
rection and only effective for aerated oils or vacuum.
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4 Technical data
4.1 General characteristics
Tab. 4.1: General characteristics KF 4...112
General characteristics KF 4...112

Construction External gear pump
Materials See section 4.4 “Overview materials”
Fixing type Flange DIN ISO 3019
End of drive shaft ISO R 775 short-cylindrical
Pipe connection KF 4...12 Whitworth pipe thread G 3/4
KF 4...12/158 Flange connection SAE 3/4
KF 16...25 Whitworth pipe thread G 1
KF 16...25/158 Flange connection SAE 1
KF 32...80 Flange connection SAE 1 1/2
KF 50...80/232
Flange connection SAE 2
KF 100...112
KF 100...112/232 Flange connection SAE 2 1/2
Installation position KF ...R/L/B... ohne Quench Arbitrary*
KF ...R/L/B... mit Quench Horizontal, quenching connec-
tion on top
KF ...U... Horizontal, perssure connection
on top
Viscosity νmin 12 mm2/s**
νmax 20000 mm2/s
Ambient tempera- ϑu min -20 °C
ture ϑu max 60 °C
Speed n See section 4.2 “Overview of nominal sizes”
Fluid temperature ϑ
Operating pressure pe and See section 4.5 “Operating pressure and fluid temperature”
pb
Filtering Filter porosity ≤ 60 µm
Permissible media Fluids without abrasive components which are compatible with the
pump materials used. The fluids must guarantee minimum lubrica-
tion. Media-specific characteristics must be taken into account.
Petrols, solvents, etc. are not permissible.
* A reduced service life must be expected for the shaft seal when vertically installed.
** Lower viscosities only in connection with GJS housings and reduced pressures (consult manu-
facturer).
BKF0004EN_D0024710002-07 2011-03-24 25
4.2 Overview of nominal sizes
Tab. 4.2: Nominal sizes KF 4...112
Nominal Geom. Speed Permissi- Sound lev- Weights

size* delivery ble radial el***** kg
volume nmin nmax force** LpA with cover with D- with
Vg Fradial db(A) valve univer-
rpm rpm
cm3 N sal de-
(n=1500 vice
rpm)
4 4,03
5 5,05
6 6,38 2,9*** 3,7***
6,9
8 8,05 4,2**** 5,0****
10 10,11 200 3000 700 ≤ 67
12 12,58
16 16,09
3,5*** 4,3***
20 20,10 7,5
4,8**** 5,6****
25 25,10
32 32,12
40 40,21 7,7 9,5 27,5
50 50,20 200 3000 1500 ≤ 68
63 63,18
9,4 11,2 29,5
80 80,50
100 101,5
200 3000 1500 ≤ 69 15,9 19,0 -
112 113,5
* See type key and type designation at pump: KF ...
** Radial forces only at version with outboard bearing. Fradial on central shaft end.
*** Valid for pump KF 4...25 with Whitworth pipe thread.
**** Valid for pump KF 4...25 with flange connection SAE.
***** n= 1500 rpm; v= 34 mm2/s ; p= 5...25 bar
4.3 Permissible speed
Tab. 4.3: Permissible speed depending on the viscosity
Kinematic viscosity ν in mm2/s

< 300 300 500 1000 2000 3000 6000 10000 20000 30000
≥ 1450 1250 1000 750 600 500 400 300 200 100
Speed nmax in rpm
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4.4 Overview materials
Tab. 4.4: Materials KF 4...112
Seal Housing / cover Gear Bearing Shaft seal O-Rings

type*
1 NBR NBR
2 FKM FKM
3 PTFE FEP
4 PTFE FEP
5 CrMo-casting/ FKM
Carbon in syn-
thetic resin,
FKM, 1.4571,
1.4401
6 SiC-Si/SiC-Si FEP
(KF 4...25), SiC-
DU, P10 Si/Carbon in
synthetic resin
(Steel,
(KF 32...80),
sintered bronze,
EN-GJL-250 FFKM, 1.4571
PTFE, Pb)
7 (GG-25) Carburising steel FKM FKM
Iglidur® X
EN-GJS-400-15** (1.7139)
9 DP4 EPDM EPDM
(GGG-40)
18 (Steel, FKM FKM
sintered bronze,
19 NBR NBR
PTFE)
20 SiC-Si/Carbon, EPDM
CrNi-steel,
CrNiMo-steel
23 FKM (low tem- FKM (low
perature) tempera-
ture)
30 Without shaft FKM
seal
31 FKM (low tem- FKM (low
perature) tempera-
ture)
32 EPDM EPDM
** For version in EN-GJS-400-15 type designation: KF ... - GJS
BKF0004EN_D0024710002-07 2011-03-24 27
4.5 Operating pressure and fluid temperature
Tab. 4.5: Operating pressure and fluid temperature KF 4...112
Type of Operating pressure Fluid temperature

seal* Suction side Pressure side
pe min bar abs.** pe max bar pb bar pb max bar ϑmin °C ϑmax °C
(perm. conti- (pressure
nous pressure) peaks)
1 90
...6****
2 150
3
2 200
4
5 150
10
6 - 10 200
7 ...6**** 150
9 0,6 *** 120
0,5
18 150
19 ...6**** 25***** 40 90
20 10 120
23 0,5 -30
30 25 -10 150
31 1 -30
32 0,5 120
4/74 200
7/74 -10 150
0,1 0,2
19/74 90
32/74 120
** Heed restrictions of pe min = -0,65 bar absolute for universal design (KF .. U).
*** Temporary during starting state: 0,4 bar absolute
**** See table 4.6 for permissible pressures
***** Type of seal 31: pb = 20 bar
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Tab. 4.6: Permissible operating pressures pe max for seal types 1, 2, 7 and 19
Max. speed nmax in rpm KF 4...80 KF 100...112

Permissible pressure pe max in bar Permissible pressure pe max in bar
750 6 6
1000 5 5
1500 4 3,5
2000 3 2,5
3000 2 1,5
NOTICE
Danger of property damage due to overload
Overloads in pumps with Iglidur® X bearings can cause the bearings to
wear prematurely.
● Never exceed the max. permissible Δp = 10 bar.
NOTICE
Danger of property damage when simultaneously utilizing multiple
operating limits
When simultaneously utilizing multiple operating limits (see chapter 4
“Technical data”), the pump could become damaged or prematurely wear.
● Do not use minimum and maximum parameters at the same time.
For example, maximum operating pressure ist not permissible in con-
nection with low speed and/or low viscosity.
NOTICE
Danger of property damage when pumping aqueous fluids
When pumping aqueous dispersions or solvents, low pressure on the inlet
port can lead to cavitation damage on the pump.
● Comply with the media-specific attributes.
● When designing the inlet line, make sure the inlet port pressure on the
pump inlet during operation is always higher than the steam pressure
of the pumping fluid. While doing so, also take the altitude of the site of
the device over mean sea level into consideration.
● For aqueous dispersions and solvents, limit the operating temperature
to max. 50 °C, install the pump underneath the liquid level and limit the
rotational speed to maximal 1500 rpm.
4.6 Dimensions
Dimensions of the device can be found in the relevant technical data sheets.
BKF0004EN_D0024710002-07 2011-03-24 29
5 Transport and storage
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
WARNING
Danger due to falling and or loads falling over!
Due to the size and weight of the unit, accidents can occur resulting in se-
vere injuries or death during transport and shipping.
● Compliance with applicable industrial safety requirements is mandatory.
● Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
● Attach lifting tackle only to suitable points (see table 5.1 and table 5.2).
● Attach the lifting tackle in such a manner that it cannot slip.
● The device's centre of gravity must lie between the lifting tackle mount-
ing points on the device.
● Secure the device so that toppling over and falling down is impossible.
● Always avoid jerks, impacts and strong vibrations during transportation.
● Never walk under suspended loads, never work under suspended
loads.
● To prevent damage to the device, be extremely cautious when shipping
or transporting.
30 2011-03-24 BKF0004EN_D0024710002-07
Handling aid
● When transporting individuals devices, the eyebolts can be screwed into
the connectiing flange as a handling aid.
Tab. 5.1: Example for safe transport of pumps
WARNING
Hazard from falling and tipping loads
Due to the size and weight of the device, accidents can occur resulting in
severe injuries or death during transport and shipping.
● For pump devices: do not use eyelets on the motor to transport the
pump devices. They can only support the weight of the motor.
Tab. 5.2: Examples for safe transport of pump units
BKF0004EN_D0024710002-07 2011-03-24 31
5.3 Corrosion protection
The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
Clean bare outer metal parts have also been protected by anti-corrosive oil
or protective metal paint for a period of 6 months against corrosion.
The device must not be exposed in the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protecting oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.
NOTICE
Corrosion damage on units with EPDM seals
The functionality of units with EPDM seals is not tested. There is no pres-
ervation of the interior parts. If the unit is not put into operation immediately,
corrosion damage can occur.
● Protect the unit by using suitable corrosion-preventing measures.
NOTICE
Chemical impact on the device and the sealing materials
Incompatibility between the preservation agents and the materials and
elastomers used in the device can lead to damage of the device and the
seals being used.
● Check to make sure the preservation agent is compatible with the ma-
terials and elastomers used in the device.
● Check to make sure the preservation agent is compatible with the media
to be pumped.
32 2011-03-24 BKF0004EN_D0024710002-07
6 Installation
6.1 General points
WARNING
vice.
NOTICE
Danger of property damage due to insufficiently qualified personnel
Improper work can lead to damages and malfunctions in the device and in
the plant.
● Permit only expert and technically qualified personnel to work on the
device.
NOTICE
Danger of property damage due to a lack of cleanliness
During installation, foreign bodies can get into the interior of the device or
the plant due to a lack of cleanliness and cause malfunctions there.
● Pay attention to cleanliness during all work.
BKF0004EN_D0024710002-07 2011-03-24 33
6.2 Noise reduction
Measures for sound optimizing

● In view of optimising noise protection, it is advisable to mount a bell-
housing with vibration damper between pump and motor as well as
vibration damper between motor and mounting surface. Suction and
pressure piping must be able to move freely or it needs to be elastically
suspended.
● Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hose manufacturers offer special, highly flex-
ible suciton hoses for this purpose.
● Installation of the pump above the liquid level diminished the noise level
of hydraulic systems. The pressure pe on the pump's intake should be
approx. 0.8...0.9 bar absolute.
6.3 Definition of the direction of rotation and pumping flow
DANGER
the pumps.
the motors.
of rotation.
34 2011-03-24 BKF0004EN_D0024710002-07
6.3.1 KF 4...112 (with end cover or pressure relief valve)
Tab. 6.1: Rotation and delivery direction KF 4...112
The following definition shall apply with respect to the rotation and delivery
direction of external gear pumps in case of pump connections being posi-
tioned below the drive shaft:
Looking at the pump shaft end, the Looking at the pump shaft end, the
pumping flow is from left to right pumping flow is from right to left
when the shaft is moving clock- when the shaft is moving anticlock-
wise. wise.
Without pressure relief valve
ps = Suction side pd = Pressure side

With pressure relief valve
BKF0004EN_D0024710002-07 2011-03-24 35
Tab. 6.2: Rotating and delivery direction KF 4...25 U
With regard to the direction of rotation and pumping flow of pumps with
universal device KF 4...25 the following definition shall apply when looking
at the pump shaft end:
Direction of rotation right Direction of discharge consistent
and left
Tab. 6.3: Rotating and delivery direction KF 32...80 U
With regard to the direction of rotation and pumping flow of pumps with
universal valve KF 32...80...U2 the following definition shall apply when
looking at the pump shaft end:
Direction of rotation right and left Direction of discharge consistent
36 2011-03-24 BKF0004EN_D0024710002-07
6.4 Change of the direction of rotation
Change of the direction of rotation in the case of KF...R... and KF...L... pump
types, i.e. pure clockwise or anticlockwise rotating pumps, is only possible by
converting the pump.
The manufacturer normally carries out the conversion work and the customer
should do this only in case of an emergency.
Pumps in noise-optimized version cannot be converted.
Guarantee and manufacturer responsibility

● All warranty claims and manufacturer responsibility shall be void when
improper conversation work takes place.
NOTICE
Danger of property damage due to incorrect installation
Improper retrofitting can lead to damages and malfunctions in the unit and
in the plant.
device.
NOTICE
Danger of leaks on the unit
When altering the unit, seals that are removed, damaged or jammed can
lead to leaks during operation.
● Do not remove, damage or jam seals.
NOTICE
Danger of damage on the device
The cover or pressure relief valve and housing are fixed to each other with
adapter sleeves or dwowel pins. If the bearings are damaged when as-
sembling or dismantling the cover or pressrue relief valve, e.g. by bending
out of line, there could be malfunctions and a decrease of the service life.
Furthermore, the seal faces on the cover or pressure relief valve could be
damaged. That can lead to leaks during operation.
● When mounting and dismantling the cover or pressure relief valve, do
not damage the bearings, e.g. by bending out of line.
● When dismantling the cover or pressure relief valve, do not lever in the
joint with a screwdiver or similar tools.
BKF0004EN_D0024710002-07 2011-03-24 37
Tab. 6.4: Change of the direction of rotation KF ...R... und KF ...L...
ps = Suction side * Fastening screws

pd = Pressure side ** Leak oil hole
In case of a pump's change of the direction of rotation the cover and/or pres-
sure relief valve must be rotated through 180°.
● Loose fastening screws.
● Remove the cover or the pressure relief valve respectively from the pump
housing and put it back on rotated by 180°.
● Tighten all fastening screws applying the below mentioned tightening
torques (see table 6.5).
When checking, pay attention to the following points:
● Pumps without pressure relief valve must have their leak oil hole on the
interior cover side at the pump's suction side.
● Pumps with pressure relief valve must have their pressure relief valve
adjusting screw point toward the pump's pressure side.
Tab. 6.5: Tightening torques for fastening screws
Nominal size* 4 ... 25 32 ... 80 100 ... 112

Tightening torque 25 Nm 49 Nm 79 Nm
In the case of pumps having seal type 6, the mechanical seal must be re-
placed in addition. During this process, the spring coiling direction must be
observed. Heed the assembly instructions of the respective manufacturer
when replacing the mechanical seal.
38 2011-03-24 BKF0004EN_D0024710002-07
6.5 Design of suction and pressure line
DANGER
range.
NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
● Pipelines must be fitted absolutely tension-free to the device connec-
tions.
● Pipelines must be designed in such a way that no tension e.g. caused
by changes in length due to fluctuations in temperature can be trans-
ferred to the device.
NOTICE
Danger of property damage caused by foreign bodies in the device
During installation, when using unsuitable sealing materials foreign bodies
can get into the interior of the device or the plant due to a lack of cleanliness
and cause malfunctions there.
● During installation, do not use any hemp or filler as sealing material.
Suction and pressure hoses

● Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hose manufacturer offer special, highly flexi-
ble suction hoses for this purpose.
● Lay pressure hoses in sufficiently large radii.
6.5.1 Suction line
NOTICE
Malfunction due to incorrectly designed inlet line
Due to excessive underpressure, an incorrectly designed inlet line can lead
to a reduction of the delivery rate, increased noise emissions and cavitation.
● Design the inlet line with extreme care since it will strongly influence the
pump's performance.
BKF0004EN_D0024710002-07 2011-03-24 39
The suction line must be piped as short as possible and in a straight line.
Avoid large suction heights.
Additional line resistance such as formed parts, fittings and closed meshed
suction filters increase the pipe resistance of the suction line and must be
avoided.
The negative pressure in the suction line is calculated from the sum of all
suction-side resistances and the suction height considering the media-spe-
cific data.
Check the underpressure

● The negative pressure can be controlled by fitting a vacuum gauge to
the pump suction line connector.
Ensure proper suction when piping the suction line and the distances to the
floor and to the bulkhead partitions must be sufficiently large.
The inlet port must have a sufficient distance to the lowest fluid level.
Nominal width of the suction line

● The nominal width of the suction line may actually be selected to be
larger than the pump connection.
Expansion of the suction cross section

● Funnel-shaped formation of the suction port at the pump suction side or
obliquely cutting the suction pipe end is recommended of enlargement
of the suction cross section.
When hose lines are used on the pump suction side, care must be taken to
ensure that the hoses are sufficient stability so that they will not be constricted
through the sucking action.
The media-specific data need to be observed, for example, the device must
be arranged below the fluid level in case of aqueous dispersions and solu-
tions.
NOTICE
Danger of property damage when pumping aqueous fluids
When pumping aqueous dispersions or solvents, low pressure on the inlet
port can lead to cavitation damage on the pump.
● Comply with the media-specific attributes.
● When designing the inlet line, make sure the inlet port pressure on the
pump inlet during operation is always higher than the steam pressure
of the pumping fluid. While doing so, also take the altitude of the site of
the device over mean sea level into consideration.
● For aqueous dispersions and solvents, limit the operating temperature
to max. 50 °C, install the pump underneath the liquid level and limit the
rotational speed to maximal 1500 rpm.
40 2011-03-24 BKF0004EN_D0024710002-07
The recommended flow velocity in the suction line is max. 1,5 m/s.
Tab. 6.6: Piping the suction line as siphon
If there is a possibility that the suction line

can run dry if the pump stops, piping the
suction line as siphon is an option to avoid
suction problems. This way, the pump will
remain permanently filled after initial com-
missioning.
The air in the pressure line can be conduc-
ted directly into the tank via a nozzel (see
section 6.5.2 “Pressure line”).
It is appropriate to employ a foot valve or a
non-return valve in case of longer suction
lines that can run dry while the pump is at
rest. These must have been designed for
use in suction lines and should offer as low
a flow resistance as possible.
Tab. 6.7: Suction line at vacuum operation
If the pump is to intake from a tank under

vacuum, the pump must be arranged ap-
prox. 0.8 m below the tank. The suction line
must run in a straight line and without any
resistances.
The tank may be subjected to vacuum only
then when the pipework and the pump have
been filled with liquid.
For this application, only pumps designed
as a vacuum system may be employed.
* = Vacuum
NOTICE
Malfunction due to excessive underpressure
Undercutting the permissible underpressure can lead to a decrease in the
delivery rate (due to short filling of the pump), high noise emission and cav-
itation. Furthermore, in shaft seals the sealing lip can lift up allowing air to
be sucked in.
● The permissible pressure at the pump inlet shall not be lower than value
pe min as stated in the chapter 4 “Technical data”.
An exception to this is the pump's starting state during which a pressure of

0.4 bar absolute is tolerable for max. 30 minutes.
BKF0004EN_D0024710002-07 2011-03-24 41
NOTICE
Damage or failure of the shaft seal due to high supply pressure
Exceeding the permissible supply pressure can lead to a failure of the shaft
seal or to impermissible heating and increased wear.
● The permissible pressure at the pump inlet must not exceed the value
pe max as stated in the chapter 4 “Technical data”.
6.5.2 Pressure line
DANGER
gates".
The nominal width of the pressure line must be selected such that the maxi-
mum permissible pressures are not exceeded.
The pressure must be checked by a manometer installed as closely as pos-
sible to the pressure connection.
To avoid pump overload caused by an impermissibly high pressure, a pres-
sure relief valve or a rupture disc with return to the supply tank must be
installed as closely as possible to the pump's pressure connection.
Another option of pressure limiting is to mount a pressure relief valve directly
to the pump.
During operation of a pump that has to pump media via a non-return valve in
a pressurized circuit (e.g. reserve pump in a lubricant circuit), intake problems
can occur if the inlet pipe is filled with air. In this case the pressure pipe must
be bled directly upstream of the non-return valve.
This can be carried out by a bleeding valve with return or a throttled bypass,
for example.
42 2011-03-24 BKF0004EN_D0024710002-07
Tab. 6.8: Bleeding valve and throttled bypass
Bleeding valve with return Throttled bypass
If none of the measures described is carried out, the volume of the pressure
pipe between the pump and the non-return valve must be at least 75 % of the
inlet pipe volume.
BKF0004EN_D0024710002-07 2011-03-24 43
6.6 Mounting the clutch
NOTICE
Danger of property damage due to falsely dimensioned coupling.
An incorrect design can lead to premature failure of the coupling due to
breakage or wear.
● When dimensioning the coupling, pay attention to safe dimensioning to
be able to transfer the expected maximum torque reliably and perma-
nently.
● Take the vibrations, peak torques and temperatures into consideration.
The permissible values from the coupling manufacturer must not be ex-
ceeded.
● Comply with the coupling manufacturer's installation rules.
When mounting the clutch, keeping the "E" measure exactly is of the essence
so that the clutch will remain axially movable when used. In order to avoid
any frontal pressure against the elastic gear rim, measure "E" should each
be considered as minimum in the case of an axial displacement.
If the shaft clearance is less than clutch clearance "E", one of the shaft ends
can easily extend into the gear rim. Size "dW" corresponds to the max. shaft
diameter that may extend with the parallel key into the gear rim, size "dH". If
there is the chance to offset the parallel key, i.e. only the shaft extends into
the gear rim, the size of the shaft may be increased up to 2 mm below the
specified "dH" size in order not to obstruct the gear rim in its axial movability.
The permissible displacement values of the elastic clutches stated represent
general guide values taking a clutch loading up the the clutch nominal torque
and an operating speed n = 1500 rpm as well as an occurring ambient tem-
perature of +30 °C into account. Consultation with the manufacturer is
necessary for deviating operating conditions.
The displacement data may only be used individually in each case and in case
of simultaneous appearance in proportion only.
Increasing the service life of the coupling

● Careful and exact shaft alignment inreases clutch life.
44 2011-03-24 BKF0004EN_D0024710002-07
Fig. 6.1: Displacements - aligning the clutch
* Clutch clearance "E"

** Shaft with parallel key extends into the gear rim (dw)
Tab. 6.9: Types of coupling
19 24 28 38 42 48 55 65 75
Type of coupling*
19/24 24/28 28/38 38/45 42/55 48/60 55/70 65/75 75/90
Clutch clearance** E 16 18 20 24 26 28 30 35 40
Dimension** s 2 2 2,5 3 3 3,5 4 4,5 5
Dimension** dH 18 27 30 38 46 51 60 68 80
Dimension** dW 12 20 22 28 36 40 48 55 65
Max. axial displace- ΔKa 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0
ment**
Max. radial displace- ΔKr 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48
ment**
n=1500 1/min
Max. angular dis- ΔKw 1,2° 0,9° 0,9° 1,0° 1,0° 1,1° 1,1° 1,2° 1,2°
placement
n=1500 rpm
* Example: RA19-Z25/14-Z25/19 or RA19/24-Z25/14-Z25/24
** Dimensions in mm
NOTICE
Danger of property damage when mounting other types of couplings
If other coupling types are used, when mounting the coupling the instruc-
tions from the respective manufacturer is binding.
● The respective manufacturer's installation instructions must be com-
plied with when using other coupling types.
BKF0004EN_D0024710002-07 2011-03-24 45
NOTICE
Danger of property damage if installation is not correct
Do not strike the shaft when installing the respective coupling half on the
motor and pump shaft. There is a danger that the built-in bearing could be
damaged.
● Do not knock onto the shafts during installation of the clutch halves!
Easing coupling installation

● The hubs should be heated for mounting the clutch and slid onto the
shaft while hot.
Using a pinion gear drive, it must also be heated and slid onto the shaft
end while hot.
NOTICE
Danger of property damage due to displacement of the coupling
halves
When the coupling hub is not secured against axial displacement on each
shaft, there is a danger that the coupling hub will shift during operation. That
can lead to a failure of the coupling.
● Prevent axial displacement on every coupling hub on cylindrical shafts
with a threaded pin that presses against the fitting key or the shaft.
46 2011-03-24 BKF0004EN_D0024710002-07
6.7 Mechanical installation
WARNING
vice.
NOTICE
Malfunctions due to leaking lines and connections
Leaks can occur and air can be sucked in if lines or connections are not
tight. Suctioned air leads to a decrease of the delivery rate and foams up
the medium.
● Make sure all lines and connections are tight.
● Before installation, the device must be checked for transport damage and
soiling.
● Any preserving agents must be removed before installation using ben-
zine or solvent.
● Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation.
Welded pipes in particularly must be pickled or flushed. Cotton waste
must not be used for cleaning.
● Mount clutch and clutch halves respectively to pump and drive (see sec-
tion 6.6 “Mounting the clutch”").
WARNING
tional contact.
● Mount pump to bellhousing, foot or housing and pay attention to careful

alignment and correct fitting position (see chapter 4 “Technical data”).
● Tighten all fastening screws applying the torque as prescribed by the
manufacturer of the bellhousing avoiding any twisting of the pump in the
process without fail.
BKF0004EN_D0024710002-07 2011-03-24 47
● Remove the protective plugs in the pump's suction and pressure con-
nections.
WARNING
WARNING
hazardous liquids!
● Wet devices interiors with fluid being pumped.
DANGER
range.
NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
● Pipelines must be fitted absolutely tension-free to the device connec-
tions.
● Pipelines must be designed in such a way that no tension e.g. caused
by changes in length due to fluctuations in temperature can be trans-
ferred to the device.
48 2011-03-24 BKF0004EN_D0024710002-07
● Connect suction and pressure side according to the marking on the pump
or the information on the type plate (see section 6.3 “Definition of the
direction of rotation and pumping flow”).
● Connect the pipework to the suction and pressure piping. Always heed
the respective manufacturer's instructions.
● Mount a suitable tank for the liquid seal (see chapter 7 “Operation start-
up”, if applicable) when operating the pump with liquid seal (quench).
DANGER
gates".
CAUTION
ded contact.
NOTICE
Danger of malfunctions through polluted medium
When filling the storage tank with the medium, impurities or small parts can
get into the tank and cause damage or malfunctions on the unit and in the
system.
● When filling the storage tank pay attention to the greatest possible
cleanliness.
● Before opening, clean filler screw and shutoff on fluid transport and stor-
age tank.
● Check media tank for contamination and clean if necessary. On no ac-
count remove the filter screen on the filler neck or the filter insert during
the filling process.
BKF0004EN_D0024710002-07 2011-03-24 49
● Filling the media tank with the prescribed fluid.

● Ensure sufficient filling of the media tank!
6.8 Assembly with further components and devices
NOTICE
Danger of property damage if installation is not correct
Incorrect assembly with components or devices from other manufacturers
can lead to breakdowns.
● Comply with each manufacturer's operating instructions when assem-
bling with additional components or devices.
6.9 Electrical connection
DANGER
lations.
DANGER
the pumps.
the motors.
of rotation.
● All data stated on the motor type plate must be checked for conformity
to the required operating data.
● Adjust the overload protection to the correct value.
● Check the rotational drive direction of the pump before switching on.
50 2011-03-24 BKF0004EN_D0024710002-07
7 Operation start-up
7.1 Preparation
WARNING
tional contact.
WARNING
WARNING
hazardous liquids!
CAUTION
ded contact.
BKF0004EN_D0024710002-07 2011-03-24 51
NOTICE
Danger of property damage due to incorrect commissioning
Improper commissioning can lead to damages and malfunctions in the de-
vice and in the plant.
device.
● Comply with the permissible operating data such as rotational speed,
pressure temperature, permissible media, etc. (see chapter 4 “Techni-
cal data”).
● Before starting the system make sure that a sufficient quantity of the
service fluid is extant to avoid dry running.
● Before starting the plant, pumps and inlet line must be filled with oper-
ating fluid to prevent damage to the pump and the shaft seal during dry
runs. That also guarantees pump suction.
● For pumps with liquid seal (quench), fill the sealing cavity with a suitable
confining fluid before it is used for the first time.
● Make sure that all lines and connections are tight and that no leakages
can occur or air can be sucked in.
● Check the permissible operating data against the operating states to be

expected.
● Check all fastening screws on the device.
● Fill the pump and suction line with the operating fluid.
● In the case of pumps with liquid seal (quench), fill the sealing cavity using
an appropriate confining fluid (see section 7.2 “Pumps with liquid seal
(quenching connection)”).
● Checking the direction of rotation. See section "Change of the direction
of rotation" in chapter 6 “Installation” for any change in rotational direc-
tion.
52 2011-03-24 BKF0004EN_D0024710002-07
7.2 Pumps with liquid seal (quenching connection)
7.2.1 General points
NOTICE
Danger of the failure of the seal due to a lack of sealing fluid
A lack of sealing fluid can lead to a failure of the shaft seal and to increased
temperatures and increased wear.
● Fill the pump's sealing cavity with a suitable sealing medium. The seal-
ing fluid must be compatible with the seals and materials used as well
as with the pumping medium.
● The confining fluid's minimum and maximum filling level must be en-
sured using appropriate technical and/or organisational measures.
● The liquid seal in the quenching connection must not be subjected to
pressure or vacuum.
If fluids are delivered,

● that cure in air,
● crystallise in contact with air humidity,
● the leakage of which must not be released into the environment,
● are under vacuum and their seal shall be gastight,
than the employment of a double seal with liquid seal is necessary.
● A tank for the liquid seal is to be connected to the quenching connection.
Suitable tanks are available from the manufacturer.
● The tank for the liquid seal must be placed above the pump.
● The installation position is restricted and the quenching connection shall
be directed upward..
● Check of the fluid level in the tank must be possible at any time.
Flushing connection sealing cavity

● A second port on the device enables purging of the sealing cavity and
draining of the seal liquid.
BKF0004EN_D0024710002-07 2011-03-24 53
7.2.2 Seal variants with liquid seal
Tab. 7.1: KF 4...112 with liquid seal (Quench)
Types of seals: Types of seals: Triple rotary shaft lip Type of seal: 5
4, 7, 19, 32 4, 7, 19, 32 seal Special number 198
Special number 74 (on request)
54 2011-03-24 BKF0004EN_D0024710002-07
7.3 Setting the pressure relief valve
Applies for pumps with built-on pressure relief valve

(Type designation: KF ... - D15 or KF ... - D25)
Fig. 7.1: Pressure setting KF 4...112 - D..
- response pressure lower

+ response pressure higher
NOTICE
Danger of the pump overheating
The series D.. pressure relief valves are exclusively used to protect the
pump. The valves must only respond for short durations. Permanent drain-
ing of the volumetric flow through the valve will destroy the pump through
overheating.
● Make sure the valve responds only briefly.
For pressure setting on the pressure relief valve see figure 7.1:
● loosen the hexagon nut (1)
● adjust set screw (2)
clockwise = response pressure higher
anticlockwise = response pressure lower
● secure the set screw (2) using hexagon nut (1) once the desired pressure
has been adjusted.
BKF0004EN_D0024710002-07 2011-03-24 55
DANGER
When securing screw (3) is loose, set screw (2) can be screwed into the
valve until the valve is completely shut. That can result in inadmissibly high
pressures in the system if there is no other pressure relief device. Breakage
can lead to parts flying around uncontrolled or to fluids squirting out which
can lead to accidents and severe injuries or even result in death.
Fluid can spurt out from the valve if set screw (2) is completely screwed
out. That can lead to accidents with severe injuries or result in death.
● Never operate the unit with securing screw (3) loosened.
● Never completely screw set screw (2) into the valve.
● Never completely unscrew set screw (2) out of the valve.
56 2011-03-24 BKF0004EN_D0024710002-07
7.4 Further operation start-up
● The pumps may only start without or with low pressure load. For this
purpose, open the existing shut-off elements and adjust the pressure
relief valve incorporated in the pressure pipe to the lowest opening pres-
sure.
● Start-up takes place by repeated quick on-off switching of the driving
motor (jog mode) without reaching full speed until proper operation of the
device is evident. This applies particularly when a cold pump is to start
with already heated medium. The reason for this is to achieve slow heat-
ing of the pump and prevent the pump seizing through thermal shock.
● Proper function indicated by noise generation or on the pressure gage
should be reached after max. 30 seconds.
● First of all, run the pump at zero pressure or low pressure for a couple
of minutes after switching on the motor.
● Bleed the plant on the distribution pipes, preferably at the highest point.
● Pressure loading can be gradually increased up to the desired operating
pressure (max. permissible pressures, see chapter 4 “Technical data”)
● Check the temperature of the medium and that of the pump after the
intended operating characteristics have been reached. Checkpoints on
the pump are the bearing locations, the housing and the shaft seal. The
temperatures observed on the pump surface may be approx. 10 °C
above medium temperature.
● Check the fluid level of the plant once more and top up if necessary.
● Check the final operating temperature after several hours running time
(see chapter 4 “Technical data” for max. permissible temperatures).
● Check the static seals on the suction and pressure connections and the
pump's joints for leakages.
● Check the threaded connections for leakages. Such leakages can be
easily eliminated by simply retightening the threaded connections.
● Also check all motor and pump fastening screws after a few hours of
operation.
BKF0004EN_D0024710002-07 2011-03-24 57
8 Removal
8.1 General points
NOTICE
the plant.
device.
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
● Close all openings with protective caps to prevent dirt from penetrating
into the system.
8.2 Disassembling the pump
WARNING
vice.
58 2011-03-24 BKF0004EN_D0024710002-07
WARNING
hazardous liquids!
CAUTION
C.
● Remove the depressurised pipelines from the pump.

● Seal the pump connections and pipelines to prevent dirt penetration.
● Disassemble the pump
● Pull off clutch hub resp. the driving pinion from shaft end using an ex-
tractor.
NOTICE
Danger of malfunction due to curing liquids
Curing liquids can engage the device mechanically and make it unusable.
● Immediately clean the pump or store it in such a way that curing is def-
initely prevented in cases where the pump was operated with curing
liquids.
BKF0004EN_D0024710002-07 2011-03-24 59
9 Maintenance
9.1 General points
NOTICE
the plant.
device.
NOTICE
Danger of damages and malfunctions due to a lack of maintenance
If the device is not regularly maintained, damage that is not discovered or
not repaired can lead to malfunctions and to the failure of the device.
● Maintain the device regularly.
● Check the device initially right after commissioning.
● Adapt the scope and time between maintenance intervals to the de-
mands posed by the location.
● During visual inspections, look purposefully for possible damages.
● The device must not be used if visible damages are found.
● Document the type and extent of the maintenance work. That allows the
fastest possible detection of a change in operating performance.
When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The scope and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.
Barriers and instructions

● All removed barrieres and warning signs must be put back to their orig-
inal position on completing maintenance and/or repair.
Checking the operating data

● Regular checking of all operating data such as pressure, temperature,
current consumption, degree of filter soiling etc. contributes to early
problem detection.
60 2011-03-24 BKF0004EN_D0024710002-07
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
● Close all openings with protective caps to prevent dirt from penetrating
into the system.
NOTICE
Malfunctions due to leaking lines and connections
Leaks can occur and air can be sucked in if lines or connections are not
tight. Suctioned air leads to a decrease of the delivery rate and foams up
the medium.
● Make sure all lines and connections are tight.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, which can lead to accidents and severe
injuries or even result in death.
● Immediately replace damaged connections, pipes and hose lines.
DANGER
lations.
WARNING
vice.
BKF0004EN_D0024710002-07 2011-03-24 61
DANGER
gates".
WARNING
hazardous liquids!
CAUTION
C.
9.2 Unusual noise
Some damage is indicated by unusual noises. If there is a change in the dec-

ive's operating noise, a thorough examination of the cause must always take
place.
62 2011-03-24 BKF0004EN_D0024710002-07
9.3 Cleaning
The pump shaft as well as the associated hardware must not run in dust ac-
cumulations.
Regular cleaning of the pump and its environment is therefore necessary.
Cleaning the pump using a steam jet cleaner is not permissible.
9.4 Static seals
The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.
9.5 Confining fluid level
Checking the confining fluid filling level is mandatory for safe pump operation.
Top up the confining fluid as required.
If there is no automatic monitoring, the filling level must be checked at least
befor each shift begins.
The outer but also the inner shaft seal could be leaking if the filling level should
dorp unusually fast within a short period of time. The confining fluid will then
leak into the coupling space or it will be sucked into the pump thereby mixing
with the medium.
If the filling level should rise, the inner shaft seal may probably be leaking and
the confining fluid is begin mixed with the pressurised medium.
Stop plant operation immediately in both cases.
9.6 Rotary shaft lip seal
Rotary shaft lip seals are particulary prone to wear for functional reasons and
must accordingly be carfully checked. Excessicely high supply pressure or
negative suction pressure, wrong rotational direction or pollution leads to in-
creased wear, increased and impermissible temperature rises.
Small amounts of leakage, however, are indispensable for function. The per-
missible amount of leakage, though, is highly dependet on the operational
conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the rotary shaft lip seal.
BKF0004EN_D0024710002-07 2011-03-24 63
Increased wear on the rotary shaft lip seal should be taken into account in the
case of vertical pump installation.
9.7 Mechanical seal
Mechanical seals are particularly prone to wear for functional reasins and
must accordingly be carfully checked. Too high admission pressure, wrong
rotational direction, frequent star-ups, gas or air portions in the oil or contam-
ination lead to increased wear, increased leckage and impermissible tem-
perature rises.
Small amounts of leckages, however, are indispensable for mechanical seal
function. The permissible amount of leackage, though, is highly dependent
on the operational conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the mechanical seal. In so doing, heed the assembly instructions of
the mechanical seal manufacturer.
Increased wear on the mechanical seal should be taken into account in the
case of vertical pump installation.
9.8 Clutch
Clutches must be maintained according to the specifications of the respective

manufacturer.
9.9 Screw joints
All the screw joints must be checked at regular intervals to make sure they
are tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium stregth).
9.10 Damage
Check the pump as well as its environment regularly for damage such as
dents in the clutch guard.
9.11 Surface temperature
For identifying premature wear or pump overload, it is useful to check the

temperatures on the pump surface at regular intervals.
64 2011-03-24 BKF0004EN_D0024710002-07
This temperatures should never be much higher (max. 10 °C) than the media
temperature at the pump inlet. Checkpoints on the pump are the bearing lo-
cations, the housing and the shaft seal.
If the measured temperatures are higher than the permissible values, this is
an indication of wear or bearing damages. The pump must be replaced in this
case.
9.12 Bearing, gear, wheel chamber housing
Like shaft seals, bearings, gear and wheel chamber housings are wear items.
Wear largely depends on the occurring loads, life cycle as well as type and
proportion of solids in the medium. Wear cannot be identified from the outside.
The condition of a pump, however, can be analysed by the volumetric effi-
ciency factor. Decrease of the efficiency factor would normally indicate wear.
Therefore, a check on all operating data such as delivery, pressure, temper-
ature, drive data, degree of filter contamination should also be carried out
during maintenance work.
Further investigations into the cause are necessary in the event of major de-
viations (> 10 %) to the reference values. This helps detecting premature
pump failure in time. The pump must immediately be taken out of service at
a drop of delivery or pressure to 80 % of the original values. The achieved
values at initial commissioning serve as reference in this case.
BKF0004EN_D0024710002-07 2011-03-24 65
10 Repairs
10.1 General points
The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason for the damage.
● Elimination of the damage, in other words eliminating the primary cau-
ses and replacing or repairing faulty components.
10.2 Troubleshooting
Leaks are the most frequent problem. If these occure on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced.
10.3 Elimination of damage
Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If corresponding expertise and sufficient equipment is available, the consum-
er or OEM can also make the repairs. For support, spare parts lists and
sectional drawings are available. They can be requested from the manu-
facturer.
NOTICE
Danger of property damage due to incorrect work and use of non-
original spare parts
the plant. That also applies to the use of non-original spare parts.
device.
● Use only genuine original spare parts.
10.4 Return
If the device has to be repaired or checked over the manufacturer's premises,

it must be packed suitably for transport. In addition, a safety data sheet for
the medium used must be enclosed with the device. In case of well-known
mineral oils, at least the exact type description is required.
66 2011-03-24 BKF0004EN_D0024710002-07
If harding or agglutinative media are involved, the device must be cleaned

befor it is returned.
Cleaning is also necessary if the device has been operated with hazardous
fluids.
Any openings must be closed.
10.5 Disposal
Disposal of the packaging and used parts must be garried out according to
the regualtions valid in the country where the device is installed.
10.6 Detecting and eliminating problems
The following table lists the possible causes of the most frequently occuring
malfunctions and notes on possible remedies.
If the problems cannot be identified, please request help from the manufac-
turer.
Tab. 10.1: Transfer pumps: Faults and causes
Fault Potential causes

Increased Pump ● Negative pressure too high causing pump short filling
noise cavitation ● Suction height too high
● Suction filter plugged or too small
● Inner diameter of suction line too small
● Suction line too long
● Too many bends in the suction line
● Too many local constrictions in the suction line
● Suction line plugged or leaking
● Too high viscosity
● Temperature too low
● Wrong direction of rotation
● Place of installation too high
BKF0004EN_D0024710002-07 2011-03-24 67

Foaming ● Suction line leaking
or trap- ● Fluid level in supply tank too low
ped air in
● Too little oil supply
medium
● Return line to tank leaking
● Wrong tank dimensioning
● Shaft seal or seal on suction line leaking
● Return line end above the fluid level in the supply tank
● Insufficient venting
● Too strong foaming in the gear
Mechani- ● Incorrectly aligned or loose clutch
cal vibra- ● Magnetic coupling defective
tions
● Faulty or insufficient line fastening
● Wobbling pressure relief valve
● No noise-optimized design (missing dampers)
● Unfavourable place of pump installation
● Pump worn out, tooth flanks worn out
● Disturbances in pump operation
Pump does ● Too high negative pressure
not suck ● Fluid level in supply tank too low
● Magnetic coupling torn off
● Wrong direction of rotation
● Throttled shut-off element in the suction line
● Suction line too long
● Suction line leaking
● Suction resistance too high
● Foreign objects in suction line
● Volume of pressure pipe between pump and non-return valve too
little, pump cannot compress the air contained in the suction line
● Non-return valve not bled
● Too high start-up pressure if suction line is filled with air
● Speed too low
68 2011-03-24 BKF0004EN_D0024710002-07

Insufficient ● Too high negative pressure
delivery ● Throttled shut-off element in the suction line
● Fluid level in supply tank too low
● Suction filter plugged or too small
● Too high viscosity
● Too low viscosity
● Too high speed
● Too high pressure
● Pressure relief valve set too low
● Pump sucks air
● Pump worn out
● Too high proportion of air in the oil
● Universal valve defective
Insufficient Delivery ● Too low viscosity
pressure too low, ● Pressure relief valve set too low or does not shut
work
● Too low speed
drags in
pressure ● Driving power too low
pipe too ● Pump worn out
low
Excessive ● Too high pressure
power con- ● Too high viscosity
sumption
● Driving power too low
● Motor winding defective
Excessive ● Pressure relief valve set too high
operating ● Speed too high
temperature
● Cooling and heat dissipation insufficient
● Supply of fluid too low
● Fluid is being delivered into the supply tank via pressure relief valve
under load
Impermissi- ● Delivery-side valve cone not completely shut
ble pump ● Directly mounted pressure relief valve set too low
heating
(does not apply for the "universal valve" and "T-valve" versions)
● Too high pressure
● Gland lid overtightened
● Separating can insufficiently bled
● Admission pressure impermissibly high
● Pump worn out
BKF0004EN_D0024710002-07 2011-03-24 69

Leakages ● Admission pressure impermissibly high
on shaft seal ● Wrong direction of rotation
● Too high radial shaft loading
● Temperature at sealing point too high
● Wrong seal material
● Missing confining fluid
● Separating can defective
● Sealing wear due to poorly lubricating medium
● Sealing wear through abrasive components in medium
● Sealing wear through curing medium
● Gland lid not sufficiently tightened
Clutch wear ● Incorrectly aligned or loose clutch
● Axial clutch clearance insufficient
● Clutch overloaded
● Temperature too high
Magnetic ● Magnetic coupling under-dimensioned
coupling ● Pressure too high
torn off
● Driving motor oversized
● Too high starting torque
● Too high operating temperature
● Pump is blocking due to foreign objects
Short opera- Wear on ● Wear through abrasive components
tional lives bearing, ● Wear due to poorly lubricating medium
gear and
housing
parts ● Check corrosion, material compatibility
● Too high operating pressure for the media properties
70 2011-03-24 BKF0004EN_D0024710002-07

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Operating instructions

Transfer Gear Pumps KF 4...112

1.1 About the documentation 5

2.1 Safety instructions and symbols 7

3.1 General points 13

4.1 General characteristics 25

5.1 Transport damage 30

8.1 General points 58

9.1 General points 60

10.1 General points 66

1.1 About the documentation

These operating instructions describe the installation, operation and mainte-

1.2 Manufacturer´s address

1.3 Intended use

The maximum permissible operating data listed in the chapter 4 “Technical

2.1 Safety instructions and symbols

Notice: Flagging of notices to prevent property damage.

2.2 Staff qualification and training

2.3 General safety instructions

The operational safety of the device delivered is only guaranteed when it is

2.4 Hazard statements

3.1 General points

Tab. 3.1: Functional principle external gear pumps

3.2 Basic construction

3.2.1 KF 4...112 R/L/B (with cover)

Tab. 3.2: Basic construction KF 4...112

* Direction of rotation "B" (Right and left)

Tab. 3.3: Basic construction KF 4...112

3.2.2 KF 4...112 R/L - D (with pressure relief valve)

Tab. 3.4: Basic construction KF 4...112 R/L - D

Tab. 3.5: Basic construction KF 4...112 R/L - D

3.2.3 KF 4...25 U (with universal valve)

Tab. 3.6: Basic construction KF 4...25 U

Tab. 3.7: Basic construction KF 4...25 U

3.2.4 KF 32...80 U (with universal valve)

Tab. 3.8: Basic construction KF 32...80 U

* View without connection elbow

Tab. 3.9: Basic construction KF 32...80 U

3.3 Types of seals

Tab. 3.10: Type of seals KF 4...112

3.4 Type key

Tab. 3.11: Ordering example KF 4...112

Tab. 3.12: Explanation of type key KF 4...112

Explanation of type key KF 4...112

Explanation of type key KF 4...112

3.5 Important special numbers

Tab. 3.13: Important special numbers KF 4...112

Particularities in noise-optimized pumps

4.1 General characteristics

Tab. 4.1: General characteristics KF 4...112

General characteristics KF 4...112

4.2 Overview of nominal sizes

Tab. 4.2: Nominal sizes KF 4...112

Nominal Geom. Speed Permissi- Sound lev- Weights

4.3 Permissible speed

Tab. 4.3: Permissible speed depending on the viscosity

Kinematic viscosity ν in mm2/s

4.4 Overview materials

Tab. 4.4: Materials KF 4...112