General Pump KFZ Owner Manual

KKFFZZ

Owner’s Manual

• Installation

• Use

• Maintenance

GENERAL PUMP

INDEX

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

3.2 High pressure unit safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4

3.3 Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

3.4 General procedures for using nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

3.5 Safety during unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5

4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6

5. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7

6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7

7. INFORMATION REGARDING PUMP USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

7.2 Maximum flow and pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

7.3 Lowest operating RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8

7.4 Recommended lubricant types and Manufacturers . . . . . . . . . . . . . . . . . . . . .Page 8-9

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8. PORTS AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

9.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10

9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11

9.3 Version change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11-12

9.4 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12

9.5 Pump feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12

9.6 Suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12

9.7 Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13

9.8 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14

9.9 Internal diameter of hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14

9.10 V-belt transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15

9.11 Transmission definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16

9.12 Definition of belt static tension values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17

10. START UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18

10.1 Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18

10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19

11. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19

12. STOPPING THE PUMP FOR LONG PERIODS . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19

12.1 Inactivity for long periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19

12.2 Filling the pump with anti-corrosion emulsion or anti-freeze . . . . . . . . . . . . .Page 19

12.3 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

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GENERAL PUMP

INDEX (continued)

13. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

14. WARRANTY TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20-21

16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22-23

17. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24

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KFZ SERIES

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KFZ SERIES

1. INTRODUCTION

This manual describes the use and maintenance instructions of the KFZ stainless steel pump, and should be carefully read
and understood before using the pump.Correct use and adequate maintenance will guarantee the pumps trouble-free
operation for a long time. General Pump declines any responsibility for damage caused by misuse or the non-observance
of the instructions indicated in this manual.Upon receiving the pump, check that it is complete and in perfect condition..
Should anything be found out of order, please contact us 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-Electrocution Danger

Danger

Wear goggles

Danger

Wear protective gloves

Danger

Wear protective boots

Danger

Wear protective mask

3. SAFETY

3.1 General Safety Indications

The misuse of pumps and high pressure units, and the non-observance of installation and maintenance instructions may
cause severe injury to people and/or damage to property. Anyone requested to assemble or use high
pressure units must possess the necessary competence to do so, should be aware of the characteristics of the
components assembled/used, and must adopt all the necessary precautions in order to guarantee maximum safety in any
operating condition. In the interest of safety, no precaution that is reasonably feasible must be
neglected, both by the Manufacturer and the Operator.

3.2 High pressure unit safety requirements

1. The pressure line must always be equipped with a safety valve.

2. High pressure unit components, in particular for those units working outside, must be adequately protected against
rain, frost and heat.

3. The units electrical parts must be adequately protected from water spray, and must comply with the specific norms
in force.

4. High pressure hoses must be correctly sized for the unit’s maximum operating pressure, and must only be used
within the pressure range indicated by the hose manufacturer. The same conditions apply to all other unit accessories
where high pressure is involved.

5. The extremities of high pressure hoses must be sheathed and fastened to a steady structure in order to avoid
dangerous whiplashes should they burst or should their connections break.

6. Appropriate safety guards must be provided for the pump transmission systems (joints, pulleys and belts, auxiliary
drives).

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GENERAL PUMP

3.3 Safety During Operation

The working area of a high pressure system must be clearly signalled. Access must be prohibited to
non-authorized personnel and, if possible, the area must be fenced in. The personnel authorized to access this area must
be previously trained, and informed about the risks that may arise from failures or malfunctions of the high pressure unit.

Before starting the unit, the operator must check:

1. That the high pressure unit is correctly fed (see paragraph 9.5).

2. That pump intake filters are perfectly clean; we advise to use a device that indicates the filters clogging level.

3. That electrical parts are adequately protected and in perfect condition.

4. That high pressure hoses do not show apparent signs of abrasion, and that fittings are in perfect shape.

Any anamoly or reasonable doubt that may arise before or during operation must be promptly reported and verified by
competent personnel. In these cases, pressure must be immediately released and the high pressure unit stopped.

3.4 General Procedures For Using Nozzles

1. The Operator must always place his own and other worker’s safety before any other interest; his actions should always
be governed by good sense and responsibility.

2. The Operator must always wear a helmet with a protective visor, waterproof clothing, and appropriate boots capable
of guaranteeing grip on wet pavement.

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KFZ SERIES

Note: appropriate clothing will effectively protect against water spray, but it may not offer adequate protection against the
direct impact of water jets or sprays from a close distance. Some circumstances may require further protection.

3. We advise to employ a team of at least two Operators, able to provide mutual and immediate assistance if needed,
and to rotate their duties in case of long and heavy work.

4. Access to the work area that is within the water jets’ range must be absolutely forbidden; the area must be free of
objects that may be unintentionally hit by the pressurized jet, causing damage or dangerous situations.

5. The water jet must only and always be directed towards the work area, even during testing or preliminary
inspections.

6. The Operator must always pay attention to the trajectory of the debris removed by the water jet. If necessary,
adequate side guards must be provided by the Operator in order to protect anything that may be accidentally exposed.

7. For no reason must the Operator be distracted during operation. The personnel that needs to access the
working area must wait for the Operator to suspend his work, and then immediately make his presence known.

8. For safety reasons, it is important that each member of the team is perfectly aware of the intentions and actions
of other team members in order to avoid dangerous misunderstandings,

9. The high pressure unit must not be started and brought up to pressure unless each member of the team is in his

designated position, and the Operator has already directed the nozzle towards the work area.

3.5 Safety During Unit Maintenance

1. The maintenance of the high pressure unit must be done within the time intervals indicated by the Manufacturer, who

is responsible for the entire unit’s compliance with the norms in force.

2. Maintenance must always be carried out by specialized and authorized personnel.

3. Assembly and disassembly of the pump and its various components must be performed exclusively by

authorized personnel, using appropriate tools in order to avoid damage to components and connections.

4. To guarantee total reliability and safety, always use original spare parts.

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GENERAL PUMP

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4. PUMP IDENTIFICATION

Each pump (fig. 1) has its own serial number XX.XXX.XXX (see point 1) and is equipped with a rating plate that
indicates:

Pump model and version
Maximum RPM
Power absorbed Hp-kW
Flow Rate l/mn - GPM
Pressure bar/PSI

Pump model, version and serial number must always be specified when ordering spare parts.

fig. 1

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GENERAL PUMP

5. TECHNICAL FEATURES

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MODEL RPM

KFZ28A 1000 24.5 93 3000 207 50

KFZ30A 1000 28.0 106 2900 200 55

KFZ36A 8000 32.2 122 2300 160 50

KFZ36A 900 36.2 137 2050 140 50

KFZ36A 1000 40.0 153 1900 130 52

KFZ40A 900 45.0 170 1600 110 49

FLOW RATE PRESSURE POWER

GPM l/min PSI Bar EBHP

6. DIMENSIONS AND WEIGHT

For dimensions and weight of Standard Version pumps, please refer to fig. 2.

Weight: 150 Lbs./68 Kg.

fig. 2

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GENERAL PUMP

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7.INFORMATION ABOUT PUMP USE

The KFZ pump has been designed to operate with filtered water (see paragraph 9.7) and at maximum

temperature of 1040F (400C).

Other fluids may be used only upon the approval of The Customer Service Department .

7.1 Water Temperature

The max water temperature is 1040F (400C). Nonetheless, it is possible to use the pump at temperatures of
up to 1850F (850C) for short periods of time. In this case we advise consulting the Customer Service

Department.

7.2 Max Flow Rate and Pressure Values

The performance values indicated in the catalog refer to the maximum performance of the pump. Regardless
of the power used, pressure and maximum RPM values indicated on the plate may not be exceeded unless
expressly authorized by the Customer Service Department.

7.3 Lowest RPM

Any RPM value different from what is indicated in the performance table (see chapter 5) must be expressly
authorized by the Customer Service Department.

KFZ SERIES

7.4 Recommended Lubricant Oil Types & Manufacturers

The pump is delivered with lubricant oil compliant with room temperatures ranging between 320and 89.60F
(00and 300C ). Some recommended lubricant types are indicated in the table below; these lubricants are
treated with additives in order to increase corrosion protection and resistance to fatigue. As an alternative,
Automotive SAE 85W-90 gearing lubricants may also be used.

BRAND TYPE

GENERAL PUMP SERIES 220

ARAL Aral Degol BG220

BP ENERGOL HLP 220

CASTROL

ELF

ESSO NUTO 220

FINA Cirkan 220

FUCHS RENOLIN 220

MOBIL DTE OIL BB

SHELL TELLUS C 220

TEXACO RANDO HD 220

TOTAL CORTIS 220

Check the oil level by using the oil level dipstick with
minimum and maximum value notches (1), fig. 3. Refill if
needed. Correct oil level inspection is done with the pump
at room temperature; oil is changed with the pump at work­ing temperature, by removing the plug (2), fig 3. Checking
and changing oil is to be carried out as indicated in Chapter

11. The amount required is 128.5 oz. (3.85 liters).

Hyspin VG 220, Magna

POLYTELIS 220

220

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