Owner`s Manual
Contents
1. Owner s Manual e Installation Use Maintenance General Pump is a member of the Interoump Group KF SERIES INDEX 1 A 3 o oS 10 11 12 13 14 15 16 17 18 20 INTRODUCTION uu oe bean ee kt oes E dope ed Ben dico 3 HEHE RR de RE N N RA Page 3 SYMBOL DESCRIPTIONS ers Page 3 SAFETY 22222 cous goes OE OE EE OE N Page 3 3 1 General safety instructions naana aaea Page 3 3 2 High pressure system safety requirements ese ee ee ee ee EE eae Page 3 3 3 Safety of operation anaana Faber AAN BERE DER BARE ER ABR Rd Page 4 3 4 General procedures for high pressure lance gun operation Page 4 3 5 Safety of maintenance a Page 4 PUMP IDENTIFICATION ennn RR RRRRRR ee Page 5 TECHNICAL FEATURES 2222932 2 99 92432 59 91 WEJAA 99 V 9 9 25 5 DO XR ERE Page 5 DIMENSIONS AND WEIGHT 0 00 00 ccc ee Page 5 GENERAL INFORMATION ABOUT SPECIFIC PUMP USE Page 6 J Water temperature 3353 534 mde Edu s 3 pO EE EE EE a Page 6 7 2 Maximum flow and PIS AMOS RA SEE ER EE EN EE Page 6 1 3 Lowest operating KP eis ie ceed een eb EES SES ET ha ee GEN Page 6 CONNECTION AND PLUGS SS SS SE SE SE ne Page 6 PUMP INSTALLATION SS ESE SE SE SE SE ees Page 7 S T POSITORBIFIO EE EE OE HOES EO OE EE OO NS AE EE Page 7 9 2 Direction of rotation 224424445544 EH SEA REEDE AUS BES RES EN e EA2. 11 1 2 Crank mechanism reassembling After washing the crankcase reassemble the power end as follows A Fit the piston guide seals into their seat thoroughly making sure they are correctly positioned B Introduce the units piston guide connecting rod into their seats to facilitate the tightening of the connecting rod cap position the connecting rod so you can easily read the number To install the crankshaft without key it is necessary to push the unit piston guide connecting rod backward GENERAL PUMP C Before reassembling the side covers check the seal lips for wear If they need replacing fit the new ring following the indications in Fig 12 RING POSITON ON FIRST ASSEMBLING Fig 12 Note Should the shaft show diameter wear in the seal position it is possible to avoid grinding it by fitting the seal further as indicated in Fig 12 Before installing the cover sight glass side check the shim rings have been placed To help the covers fit on the crankcase you can use 3 screws M6 x 40 and then finish screwing them with the original bolts M16 x 18 D Install the connecting rod cap taking care the numbers match and tighten the relevant bolts in 3 different stages P 1 Approach torque 6 8 Nm 2 Presetting torque 25 28 Nm 3 Tightening torque 38 Nm Note The screws must be greased on the thread and under the head E Fit the back cover putting the dipstick hole upward A member of t
3. O 2 lt D lt lt 2 lt D o n o D 3 lt OT OD cic OTTO ett olo 212 lt j lt sls dd ES oflo oro OT N ayn STD als c lt Ty mj m oO EE lt Q o O 3 o o D Oyo Ty TH TI OO o 2 2 D Q 2 o o o o o D 3 g lt o mE 36 EN MN Es BEE AE 38 UN E MEE HER ME E EE E EN E mE E NN IN mE mE MES FEE EE E mE RET Had ni fa Ed HEN GENERAL PUMP A member of the Interpump Group 17 TROUBLE SHOOTING THE PUMP DOES NOT PRODUCE ANY NOISE the pump is not primed and is running dry no water in the inlet line the valves are blocked the pressure line is closed and does not allow the air to get out the fluid end THE PUMP KNOCKS air suction insufficient feeding bends elbows and fittings along the suction line throttle the amount of water which passed through too small inlet filter dirty inlet filter the feeding pump where provided is not of the suitable type or provides insufficient pressure or volume the pump is not primed due to insufficient feeding or the delivery line is closed during start up the pump is not primed because some valves are stuck i e pump inactivity for long time jammed or worn out valves worn out pressure packings the pressure regulating valve does not work properly clearance in the drive
4. suggestions for trouble shooting Providing KF high pressure water plunger pumps are correctly installed and maintained they will give trouble free operation for a long time The manufacturer declines all responsibility for damages arising from the misuse and non observance of the instructions indicated in this manual On receiving the plump please check that it is complete and in good state Should you find anything out of order please contact your place of purchase before installing and starting the pump 2 SYMBOL DESCRIPTIONS Warning Potential Danger Read carefully and understand the manual before operating the pump Danger High Voltage Danger Wear protective mask Danger Wear goggles Danger Wear protective gloves Danger Wear protective boots KF SERIES 3 SAFETY 3 1 General safety instructions The misuse of a high pressure water unit and the non observance of the pump installation and maintenance instructions may cause serious damages and or injuries to people or properties or both Any Manufacturer Operator requested to assemble use a high pressure water unit should be competent to do so should have the necessary knowledge on every high pressure component installed in the unit and on the precautions to be taken in order to guarantee the largest safety margins during operation No precaution so far as is reasonably practical should be left out in the interest of safety both from the Manufacturer
5. 2 KF SERIES D Fit the fluid end back in place and tighten the bolts with a torque wrench set for the value indicated in the table on page 17 and in the sequence indicated here below B Remove the high pressure packings from the fluid end and the low pressure ones from their support by means of standard tools taking great care not to damage the seats Fig 23 Take note of the correct order of the entire package 11 2 5 Plunger components when dissassembling Fig 24 1 Head ring To replace the plunger if necessary do as follows 2 HP packing 3 Restop ring 4 Middle ring 5 LP packing 6 Back packing 7 Elastic Ring 8 O ring When reassembling make sure of the correct order of the A Loosen and remove the plunger screw 1 Fig 26 When dissassembling the pumping unit the o rings should always be replaced B To fit back the replaced components invert the order using a torque wrench set for the values indicated in the table OQOMOOOWMOOW C Reassembling In order to carry out the replacement more easily apply a very small quantity of silicone grease on the pressure packing lips and their seats on the fluid end It is necessary to help the sealing lips settle on the plunger GENERAL PUMP A member of the Interpnump Group KF SERIES 14 PUMP STOPPED FOR LONG TIME 12 SCREW CALIBRATION Before starting the pump for the very first time after a long peri
6. Noe len GR RE Page 9 3 Water connections vececcahedeeerenedeeteied bs use miu e mE i ed Page 9 4 Suction line uis cuc EN N DE OES EE N EN ES PIRE OE Page 7 Shoda e e ce 3 oc age EE OE EO ER EO OE ME OG RUE ENS REESE Page 8 9 6 Delivery line Page 8 S ve ARIE EER EN EE OS ER EN ERES NE EN ERE EN Page 9 START UP AND RUNNING PROCEDURES Page 10 10 1 Before start up iss 9 9 naana ana DEE SERS MELD RR HAD UR d haere ENE Page 10 102 SAUNG N GE N OE OE N EA N EE ON AN EO N Page 10 MAINTENANCE INSTRUCTIONS SS SS SS SS SS SS SE ee ee Page 11 11 1 Crank mechanism maintenance ESE SS cee eee ee Page 11 11 2 Fluid end maintenance ESE SE EE EE SE ee ees Page 15 SCREW CALIBRATION esseeee ee Page 17 MAINTENANCE TOOLS eere Page 17 PUMP STOPPED FOR LONG TIME lessen Page 17 PRECAUTIONS AGAINST FREEZING 0 0 0 0 0 0000 e Page 17 EXPLODED VIEWS AND PARTS 0 0 0 0 0 ccc es Page 18 TROUBLE SHOOTING iss soo hie ESE es REST ou tee DR E E Page 20 MAINTENANCE TOOLS SS SS SE SS SS eee Page 21 MAINTENANCE LOG eee Page 22 GENERAL PUMP A member of the Interpump Group 1 INTRODUCTION Please read this manual carefully before using your pump It contains the necessary information for correct installation use and maintenance as well as some practical
7. al scale indicating the diameters at a value of 80mm Example 2 With a flow of 70 l min and a water speed of 5 5 m sec the diagram line joining the 2 scales intersects the central scale indicating the diameters at a value of 16mm Optimal speeds suction 0 5 m sec delivery 5 m sec Q 700 600 500 400 300 200 150 100 90 80 70 60 50 40 30 20 l min i d mm DN A Cm 20 max 10 6 3 3 15 2 5 1 25 1 0 8 0 63 0 5 0 4 0 315 0 25 0 2 max 0 1 V m s suction line Delivery line 0 2 0 25 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 2 cn A uc c cc e The diagram does not take into consideration the pipe and valve resistance drop in pressure due to the pipe length the viscosity of the pumped fluid its temperature etc GENERAL PUMP A member of the Interpump Group 10 START UP AND RUNNING PROCEDURES 10 1 Before start up Before start up make sure that the following conditions have been complied with 1 2 3 Suction line should be connected the pump must never run dry Suction line must be perfectly airtight Any ON OFF valve in between the pump and water source should be open and make sure the water gets into the pump freely Set the pressure line in dump mode in order to let the air in the pump get out easily thus facilitating the pump priming Make sure all suction delivery line connections are f
8. and the Operator 3 2 High pressure unit safety requirements 1 Aa safety valve should be installed in any delivery line and should be sized to discharge or by pass the entire pump flow rate 2 High pressure unit components with particular regard for those units working outside should be adequately protected against rain frost and heat 3 Electric components and wiring should be provided with an adequate degree of protection able to protect them against spray coming from any direction They should also be suitable for working in a wet environment 4 High pressure hoses and any other accessory under pressure should be sized in accordance with the maximum unit working pressure and must always work within the safety margins indicated by the nose accessory Manufacturer 5 High pressure hose ends should be fastened to a steady object in order to prevent them from dangerous sweeping around should they burst or come off their end fittings 6 Proper safety guards should be provided to adequately cover transmission joints pulleys belts or auxiliary drives GENERAL PUMP A member of the Interpump Group A 3 3 Safety of operation The access into the area when a high pressure unit is working should be strictly prohibited to unauthorized personnel The area should be suitably enclosed and its perimeter so far as is reasonably practical cordoned off and proper warning notices displayed in prominent positions Personnel authori
9. cts or omission at work His actions should always be governed by his good sense and responsibility 2 The Operator should wear suitable waterproof protective clothing having regard to the type of work being undertaken The clothing set should include adequate hand protection suitable boots able to ensure proper grip on wet floors helmet provided with full face shield waterproof garment providing full cover to the Operator including his arms As most water jets produce noise levels in excess of KF SERIES 90 dB A suitable ear protection is advised NOTE It must be emphasized that whereas protective clothing provides adequate protection against spray and flying particles it does not constitute complete protection protection against the direct impact of the water jet Additional protections in the form of suitable metal shields or barriers may be necessary for certain jetting operation 3 n most jetting operations it is an accepted practice to employ a team of Operators consisting of two members at least in order to provide mutual assistance in case of need and to rotate their duties in case of long and heavy work While the first Operator holds the gun the second Operator attends the pump unit keeping close watch on the first Operator for signs of difficulty or fatigue and watching the surrounding area for intrusion by other persons or unsafe situations If required he will shut off the pressure unit until it is saf
10. e rods to the determine the shim set as indicated in the table crankshait otherwise calculate the shims again below as per point C GENERAL PUMP 11 2 Fluid end maintenance 11 2 1 Pump head The fluid end does not require periodical maintenance Service operations are limited to the component inspection and or replacement when necessary Valve Units A Loosen the valve cover screws B Extract the valve plugs with an extractor or a M8 threaded rod C Extract the valve unit with the same tool See Fig 19 Valve components of each valve unit are pressed together and therefore they can be easily replaced and installed back in place by means of simple tools ET Fig 20 Check the components for wear and replace if necessary Replace all o rings of the valve units and plugs at each inspection A member of the Interpump Group KF SERIES IMPORTANT NOTE BEFORE REPOSITIONING THE VALVE UNITS AND O RINGS CLEAN AND PERFECTLY DRY ALL VALVE HOUSINGS INSIDE THE FLUID END D To Reassemble the valves proceed the other way around and tighten the cover screws with a torque wrench The table on page 1 contains the screw tightening torque values and Fig 25 indicates the sequence 11 2 2 Seals The replacement of the seals is necessary when water drips through the holes provided on the crankcase For replacement do as follows A Remove the fluid end by loosening the 8 bolts see Fig 2
11. e to continue 4 The area in which the work is to proceed should be clear of loose items and debris to prevent tripping and slipping hazards 5 The water jet should be directed only and always against the workpiece even during preliminary operating tests prior to starting work 6 Where applicable proper side shields should be suitable placed to safeguard personnel and equipment against contact with grit or particles removed by the water jet 7 On no account must the Operator be distracted during operation until the jet has been stopped Personnel having reason to enter the water jetting area should wait until the jet is stopped and his presence known 8 Each team member must always be aware of the actions and intentions of other team members in order to prevent any dangerous misunderstanding occurring during jetting operation 9 The pump unit should not be started and brought up to pressure unless each team member is in his designated position the nozzle directed to the workpiece and the lance or gun securely held 3 5 Safety of maintenance Apart from the working pressure regulation no attempt should be made to adjust any nut hose fitting etc while that part of the system is under pressure The pump should be stopped and any pressure in the line released prior to making any adjustments 1 The high pressure water unit should be maintained in accordance with the Manufacturer s instructions 2 The unit should be mai
12. f the bearings from their covers and the inner ring nut together with the remaining part of the bearing from the 2 shaft ends by means of a standard pin extractor or similar tool See fig 15 and 16 rom 0 05 a 0 10 EN 1 1 rom 0 31 a 0 35 From 0 46 a 0 55 TI 0 10 1 35 1 From 0 61 a 0 70 E Fit the shims under the sight glass cover The new roller bearings can be mounted at room tightening it on the crankcase with the screws temperature with a press it is necessary to hold them on checking that the stall torque is between 4 Nm and the side surface of the ring nuts with suitable rings The 6 Nm driving operation can be facilitated by heating the parts at a temperature between 250 3009F making sure that the rng nuts are correctly fitted in their seats Note Take care not to invert the components of the 2 bearings outer ring nut of bearing 1 instead of the one of bearing 2 To maintain the right axial load the shim package has to be calculated again as follows A Install the crankshaft into the crankcase making sure that the PTO end comes out on the correct side B Fit the motor side flange on the crankcase with special attention to the seal lip as indicated on point 11 1 2 C Position the sight glass side flange using the 3 screws M6 x 16 until the crankshaft cannot be turned freely by hand D By means of a thickness gauge see Fig 17 F If the torque is correct connect th
13. gested Hydraulic by means of a flange Pulleys Cardan joint within the max working angles indicated by the manufacturer 9 2 Direction of rotation An arrow situated on the crankcase near the shaft indicates the correct direction of rotation Fig 4 shows the direction of rotation looking at the pump from the fluid end side LEFT SIDE clockwise RIGHT SIDE Anti clockwise KF SERIES 9 3 Water connections In order to isolate the high pressure equipment from the pump vibrations it is suggested where applicable to use flexible hoses for both suction and delivery lines at least for the first length The flexible hose must be rigid enough to prevent it from collapsing during the suction stroke when a partial vacuum may occur 9 4 Suction line The pump life is considerably effectiveness of the suction line the following characteristics 1 Internal diameter should be at least 1 2 in any point possibly larger depending on the drop in pressure due to the length and shape of the line 2 Should be as straight as possible minimizing changes in size and direction and positioned in such a way to allow air pockets and bubbles to escape 3 Should be perfectly airtight 4 Should be completely free from 909 elbows diameter reductions counter slopes T connections and should not be connected to other pipelines 5 Should be positioned in such a way to prevent the pipe emptying after the pump stops infl
14. he Interpump Group KF SERIES 11 1 3 Disassembling Reassembling of the bearings and shims The type of bearings conical roller ensures there is no end float on the crankshaft the shims must be determined to reach that purpose To disassemble reassemble and if required replace them it is absolutely necessary to do as indicated below Dissassembling Reassembling of the cranshaft without replacing the roller bearings After removing the side covers as indicated on point 11 11 1 check the rollers and races for wear if they are in good shape accurately clean the components with suitable degreaser and grease them again evenly with oil same as the pump oil The same shims can be used again taking care to fit them under the sight glass side cover After installing the complete unit sight glass side flange and crankshaft and motor side flange check that the rolling couple with connecting rods free is at least 4 Nm max 7 Nm To position the 2 side covers on the crankcase use 3 screws M6 x 40 first and then the original screws to fix them The rolling couple of the crankshaft with connecting rods coupled must not exceed 8 Nm screw M6x40 To position the cover Fig 14 GENERAL PUMP A member of the Interpump Group KF SERIES 11 1 4 Disassembling reassembling of the crankshaft with replacement of the bearings After disassembling the side covers as indicated in 11 1 1 remove the outer ring nut o
15. in the catalog and on the rating plate refer to the maximum performance of the pump The use of the pump below the rated performances does not allow the drop in power absorbed to be balanced by altering the pressure or volume of the pump above its maximum value 7 3 Lowest operating RPM The lowest operating speed of the crankshaft for all KF pumps all versions is 500 RPM on crankshaft KF SERIES 8 CONNECTIONS AND PLUGS KF pumps are provided with Fig 3 1 2 inlet ports IN 1 1 2 NPT Suction line connection to either inlet port is acceptable the port not being used should be sealed with the correct plug 2 2 outlet ports OUT 1 NPT 3 3 auxiliary ports 1 2 NPT usually used for pressure gauge GENERAL PUMP A member of the Interpump Group 9 PUMP INSTALLATION 9 1 Positioning The pump must be installed on a rigid and perfectly flat and horizontal base by means of the proper four M16 x 1 2 threaded feet The base should be rigid enough to avoid any misalignment or flexing on the pump transmission coupling axis due to the torque involved during operation The unit should not be rigidly fixed on the floor but be installed upon vibration dampeners The oil plug must absolutely be replaced by the oil stick and the oil level checked Make sure that you can easily reach the oil stick even after the unit has been assembled Never use rigid coupling on the shaft The following transmission types are sug
16. l removing plug 3 Fig 8 the pump should be at its working temperature Change oil every 1000 working hours oil capacity is 67 6 ounces In any case the oil should be changed at least once a year since oxidation deteriorates it A member of the Interpump Group KF SERIES Recommended SAE50W oils GENERAL PUMP SERIES 220 BP ENERGOLHLP220 Cirkan 220 CORTIS 220 Mineral or synthetic oils can be used but they must be chosen according to the working environment temperature Here below is a diagram indicating viscosity according to room temperature Oil grade SAE for engine oil Recommended according to the room temperature indicated in CO 30 25 20 15 10 410 15 20 425 30 435 40 KF SERIES 11 1 1 Crank mechanism disassembling Do as follows A Drain the oil from the pump and remove shaft key back cover connecting rod cap side covers To do so put 3 screws M6 x 50 wholly threaded into the holes drilled for that purpose See fig 9 B Push the piston guides and connecting rods forward SO you can remove the pump crankshaft from the side On the crankshaft you will find marks see Fig 10 that must be turned towards the operator so the crankshaft can be easily extracted Note to extract the piston guide it is necessary to remove the ceramic plunger and wiper first C Disassemble the crankshaft oil seals and the piston guides using standard tools
17. ntained only by competent personnel 3 Service and maintenance should be carried out with proper tools in order to prevent any damage on high pressure connections and fittings 4 Use of other than original spare parts is strictly forbidden KF SERIES 4 PUMP IDENTIFICATION Each pump is fitted with a rating plate see Fig 1 containing the following information pump model and version serial number max RPM power absorbed oil capacity Itr and oil specification max flow rate l min ND HMM EP Pump model pump version and serial number should be specified when ordering spare parts Should the pump be modified i e by changing the original version than any change should be mentioned on the rating plate for future reference 2 TECHNICAL FEATURES KF28A 1000 Km 5 KF30A 1000 Weight 150 Ibs GENERAL PUMP A member of the Interpump Group 7 GENERAL INFORMATION ABOUT PUMP USE AN The KF pump has been designed to pump fresh and filtered 360 micron max water at room temperature Special versions are available for pumping water up to 1859F and for reverse osmosis units 7 1 Water temperature The water temperature is critical for the pump life the higher the water temperature the more likely it is to create cavitation resulting in premature seal and valve failures For such conditions use HT series pumps 7 2 Max flow and pressure ratings The performance data indicated
18. od from the date of shipment check for the correct oil level The following table contains the screw check the valves as indicated in chapter tightening torque values to be set by 11 and then comply with the starting means of a torque wrench only procedures indicated in chapter 10 When a long inactivity is scheduled drain the entire suction and delivery line and then DESCRIPTION run the pump dry only for a few seconds in order to drain out the water collected Rear Cover A ores 1 3 10 1 inside the fluid end Screws Screws 15 PRECAUTIONS AGAINST FREEZING Fluid End Bolts 59 80 Suction Plug 110 6 Delivery Plug 110 6 The conrod screws must be tightened as After use drain the entire suction and delivery lines indicated In point D page 13 filler included by means of discharging devices The valve plate must be tightened following provided and positioned specifically for this purpose the sequence indicated in fig 24 along the lowest point of the lines In the risk of freezing the following precautions should be taken The fluid end screws must be tightened in 2 Run the pump only for a few seconds in order to uL ae he sequence indicated in drain the water collected inside the fluid end First stage 20 N m Second Stage 80 N m Or when applicable Add a recommended amount of anti freeze into the water tank and run the pump until the anti freeze works all through the system 13 MAINTENANCE TOOLS S
19. pport KF30 F71215470 Packing support KF36 F71215570 Packing support KF40 O ring 52 07 x 2 62 Restop ring KF28 F90277400 Restop ring KF30 F90281800 Restop ring FK36 30283800 90275800 90277000 Ty mj mj mj mj mj Tij Ti Co n mj TI 30282000 30383200 70100351 ront ring KF28 70100457 71100251 ront ring KF36 71100351 ront ring KF40 71121036 anifold KF28 30 fold 71121236 ifold 71125236 9 0 71210136 71211170 Valve plug 90525000 up ring 50 9 x 55 x 1 5 90388900 ring 48 89 x 2 62 36204551 i i 94755000 i 36204456 36204156 i i 36713701 i 36713601 i 94754000 i 10067720 99309900 Screw M8 x 35 71030001 99512000 crew M16 x 1 5 71223974 ifting eye bolt Ty mj TI mij Tij T Ty mij TI TI S 2 D o O A Tl C2 O oO Ty Tm z D 3 d a A T I T z z OT D 213 SS Qoo z z ol v Al A HJ TI Oo N Or Co gt gt Qo A TI Co eo gt H D S a Z 5 A Tl A o 2 wi n m7 mi mi mi mi m UJ lolo olg vjolo 3 2 slalsls e iw Oo on sl Is 9 HEE a Po N x x oy ala e Ulo olc 0 sl Oo 9 lt 3 Sio z z olo ale SIs ele 0 Q E Q D o Hn mj m o c G m e G 2 lt x lt od lt Go 9 D et D m7 m win oic OTTO Xj EE o c ajz oO 1E Aj lt OD lt M E 67 Qo A x 7 On e 7
20. system RPM are higher than rated THE PUMP DOES NOT DELIVER THE RATED VOLUME insufficient feeding due to the cause listed above RPM are less than rated excessive amount of water by passed by the pressure regulating valve worn out valves excessive leakage packings from pressure KF SERIES INSUFFICIENT PUMP PRESSURE the nozzle is or has become too large RPM are less than rated excessive leakage from pressure packings excessive amount of water by passed by the pressure regulating valve or faulty valve operation worn out valves EXCESSIVE WATER LEAKAGE FROM THE PUMP pressure packing are excessively worn out due to normal wear or excessive cavitation worn out plungers OVERHEATED PUMP the direction of rotation is not correct pump is overloaded pressure or RPM over the rated values the oil level is too low or the oil is not of a suitable type or fully used water in the oil excessive belt tension or incorrect alignment of the joint where provided excessive inclination of the pump during operation PIPE VIBRATIONS OR KNOCKING air suction the pressure regulating valve does not work properly the by pass line is undersized jammed up valves drive transmission motion is irregular KF SERIES 18 MAINTENANCE TOOLS 18 2 Piston guide oil seal assembling The pump maintenance can be carried out with simple tools for moun
21. tandard tools are required for the pump maintenance but to facilitate the mounting and dismounting operations of some pump components you will find the drawings to make some tools on page 21 If a pump is frozen or appears frozen ON NO ACCOUNT SHOULD THE PUMP BE OPERATED until the entire system has been thawed out GENERAL PUMP A member of the Interpump Group KF SERIES 16 EXPLODED VIEW AND PARTS LIST f oor i itp 49 44 48 47 52 45 4443 42 30 31 32 33 34 35 36 37 GENERAL PUMP A member of the Interpump Group Hem Pars Description CA 1 Froozz FST859000 5 Fa007s600 Oil level indicator F70211801 ET 8 _ F71150122 Oievel indicator side bearing cover T 9 F99786700 12 Fo8212000 14 F9040000 Oxng2215x3 TT 15 F98206000 16 Fss513800 Commecingrodscew fo 22 Feo0s0600 Rng 220 5 24 F97743000 740309 PungeKr 0 ar r04049 Pungekr3o E rro4os09 Pungekra E 30 F9oo7oroo rrzwTo PackmonnoKr30 E rrz oro PaciarngKr39 ar rrmzr PaconnoKF40 E L P packing KF28 F90276000 F90280000 E E Fraser Shim o38 1L EN ES REPAIR KITS fem 32343536 1445 47 4849 51 44 45 45 47 48 49 52 50 KF SERIES Packing support KF28 F71215370 Packing su
22. ting and dismounting the components but special tools can be made to facilitate the operations The drawings here below will help the operator make tools if he choosed to 18 1 Crankshaft oil seal assembling KF SERIES 19 MAINTENANCE LOG HOURS amp DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT GENERAL PUMP GP Companies Inc 1174 Northland Drive Mendota Heights MN 55120 Phone 651 686 2199 Fax 800 535 1745 Ref 300615 Rev F www generalpump com email sales gpcompanies com 03 11
23. uenced by the which must have 6 Do not use high pressure hydraulic fittings like 909 elbows high pressure adapters high pressure 3 or 4 way nipples and so on 7 Do not install any kind of detergent injector along the suction line 8 Do not install standing valves check valves or other kind of one way valves 9 Make sure that the feed tank capacity and the water minimum level do not give rise to turbulence at the tank outlet port which in turn might create cavitation at the pump 10 Do not connect the by pass line from the valve directly to the pump suction line 11 Connect the by pass line from the valve directly to the feed tank and make sure that both the by pass and tank feeding flows could not give rise to turbulence at the tank outlet port which in turn might create cavitation at the pump Proper baffle plates should be provided inside the tank 12 Before connecting the suction line to the pump inlet port make sure the pipe is perfectly clean inside KF SERIES 9 5 Filtration All pumps require a suitable filter The filter should be installed as close as possible to the pump should allow easy inspection and have the following characteristics 1 The filter capacity must be at least 3 times the rated pump volume 2 Filter port diameters must not be smaller than the pump inlet ports 3 Filtration degree in between 50 and 80 mesh 360 200 microns IMPORTANT NOTE in order to properly safeguard the p
24. ully tightened Joint alignment belt tightening and PTO shaft inclination tolerances should remain within the values indicated by the transmission Manufacturer Make sure the oil level is correct using the dipstick 1 Fig 7 and the oil sight glass 2 Fig 7 Note In case the pump has not run for a long period check the suction and delivery valves for scaling KF SERIES 10 2 Starting up 1 When starting the pump up for the first time check for proper direction of rotation Pump and motor engine must start offload set the regulating valve to zero or set the pressure line in dump mode by means of proper dumping devices During operation check the rotating speed making sure the speed does not exceed the rated value Before putting the pump under pressure let it run for at least 3 minutes Before stopping the pump release the pressure from the system by operating the dump device or by releasing the regulating valve and reduce RPM to a minimum diesel applications Note In case of feeding by a centrifugal pump make sure that the plunger pump starts only when the correct inlet pressure is provided GENERAL PUMP 11 MAINTENANCE INSTRUCTIONS 11 1 Crank mechanism maintenance Check oil level though the oil level indicator 1 Fig 8 at least on a weekly basis If necessary add the missing oil through the oil plug 1 Fig 8 Check oil level when the pump is at room temperature When changing the oi
25. ump it is very important to plan cleaning of the filter with a frequency depending on the water quality filtration degree and number of hours of each application It is recommended to use filters with a clogging signaling device 9 6 Delivery line For a correct delivery line comply with the following instructions 1 The first length of delivery hose should be flexible in order to isolate the pump vibrations from the rest of the system 2 Use only high pressure hoses and fittings able to guarantee the largest possible safety margins in any working conditions 3 A suitable relief valve should be installed in the delivery line 4 Use glycerine filled pressure gauges as the most suitable for pulsating loads o When designing the delivery line take into proper account the unavoidable drop in pressure due to its length and size 6 If necessary the effects of the pump pulsations can be reduced by installing a proper pulsation dampener on the pressure line 90 ELBOW T CONNECTIONS DIAMETER REDUCTION BY PASS BACK TO THE INLET LINE NEGATIVE SUCTION HEAD BAFFLE PLATE os mm BY PASS LINE GENERAL PUMP A member of the Interpump Group 9 7 Internal diameter of piping To determine the internal diameter of the piping follow the following diagram Example 1 KF SERIES With a flow of 150 Vm and a water speed of 0 45 m sec the diagram line joining the 2 scales intersects the centr
26. zed to enter that area should have been previously trained to do so and informed of the risks arising from failures misuse and any foreseeable circumstance which may occur during operation Before starting the pump unit and bringing it up to pressure the Operator is requested to carry out the following checks 1 Make sure that a correct water supply to the pump is provided 2 Make sure that water inlet filters are properly clean 3 Electrical components and wiring with special emphasis on connections junction boxes switches and supply cables should be free from external damage i e exposed and broken wires and adequately protected against water 4 High pressure hose should not show apparent external wear and the fittings at both ends should be free from signs of erosion or corrosion 5 Make sure that all fluids lubricating oil for pump and engine cooling water hydraulic fluids are at proper levels and in good condition 6 Make sure the safety guards are in good condition The work should stop immediately and the pressure must be released in the event that leakage becomes apparent or if any person becomes aware of any change in condition or any hazard existing or being introduced Any failure must be promptly reported and then checked 9 ds 3 4 General procedures for high pressure gun lance operation 1 The Operator should take reasonable care for the safety of himself and of other persons who may be affected by his a
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