General Pump KE Owner Manual
K
8
K
E
E
Owner’s Manual
• Installation
• Use
• Maintenance
General Pump is a
member of the
Interpump Group
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.2 High pressure system safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.3 Safety of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.4 General procedures for high pressure lance/gun operation . . . . . . . . . . . . . . .Page 4
3.5 Safety of maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
5. TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
7. GENERAL INFORMATION ABOUT SPECIFIC PUMP USE . . . . . . . . . . . . . . . . .Page 6
7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.2 Maximum flow and pressure ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.3 Lowest operating RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
A member of the Interpump Group
KE SERIES
8. CONNECTION AND PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.1 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.3 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.4 Suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.5 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.6 Delivery time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.7 Hose Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
10. START UP AND RUNNING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
10.1 Before start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
11. MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
11.1 Crank mechanism maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
11.2 Fluid end maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15
12. SCREW CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
13. MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
14. PUMP STOPPED FOR LONG TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
15. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
17. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20
18. MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21
19. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22
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GENERAL PUMP
A member of the Interpump Group
KE SERIES
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 suggestions for trouble shooting. Providing KE
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
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 and the
Operator.
3.2 High pressure unit safety requirements
1. A 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.
Danger
Wear protective gloves
Danger
Wear protective boots
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GENERAL PUMP
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 authorized 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 an change in condition
or any hazard existing or being introduced. Any failure
must be promptly reported and then checked personnel.
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 acts 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
A member of the Interpump Group
KE 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. In 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 safe 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 maintained 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.
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GENERAL PUMP
A member of the Interpump Group
4. PUMP IDENTIFICATION
Each pump is fitted with a rating plate (see Fig. 1)
containing the following information:
2. serial number
3. pump model and version
4. max RPM
5. power absorbed
6. max operating pressure (bar)
6. max flow rate (l/min)
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.
5. TECHNICAL FEATURES
FLOW RATE PRESSURE POWER
MODEL RPM
GPM l/min PSI Bar Hp kW
KE SERIES
KE20A 1450 8.3 31.4 4350 300 24.5 18
KE22A 1450 10.0 38 3625 250 24.7 18.16
KE24A 1450 11.9 45.2 3045 210 24.7 18.16
KE28A 1450 16.3 61.6 2175 150 24.0 17.6
KE30A 1450 18.5 70.7 1885 130 23.9 17.6
6. DIMENSIONS AND WEIGHT
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GENERAL PUMP
A member of the Interpump Group
KE SERIES
7. GENERAL INFORMATION ABOUT PUMP
USE
The KE pump has been designed to pump fresh and
filtered (360 micron max.) water at room temperature.
Special versiona are available for pumping water up to
185oF 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 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.
8. CONNECTIONS AND PLUGS
KE pumps are provided with (Fig. 3):
1 - 2 inlet ports IN Ø 1” 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 Ø 1/2” NPT
3 - 3 outlet ports OUT Ø 1/4” NPT (designed for
pressure gauge and safety valve only)
7.3 Lowest operating RPM
The lowest operating speed of the crankshaft for all KE
pumps (all versions) is 500 RPM.
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GENERAL PUMP
A member of the Interpump Group
KE SERIES
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 M12
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 suggested:
- 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.
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 influenced by the
effectiveness of the suction line which must have
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 90oelbows, diameter
reductions, counter slopes, “T” connections and
should not be connected to other pipelines.
5. Should positioned in such a way to prevent the pipe
emptying after the pump stops.
6. Do not use high pressure hydraulic fittings like 90
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.
o
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