General Pump KL User Manual
K
K
Owner’s Manual
• Installation
• Use
• Maintenance
L
L
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.1 General warnings for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.2 High pressure unit 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
KL 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
10. START UP AND RUNNING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
10.1 Before start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
10.3 Water leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
11. MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
11.1 Crank mechanism maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
11.2 Fluid end maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
11.3 Pumping unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
12. SCREW CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
13. MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
14. PUMP STOPPED FOR LONG TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
15. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
17. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
Page 2
GENERAL PUMP
A member of the Interpump Group
KL SERIES
1. INTRODUCTION
KL high pressure water plunger pumps have been
designed for long life industrial duties and provided they
are correctly installed and maintained will give long
trouble-free operation. Read and understand this
manual before using your pump; it contains the
necessary information for the correct installation, use and
maintenance as well as some practical suggestion for
trouble shooting.
Upon receipt of your pump, inspect for overall good
condition and that no items are missing. Any missing
item or damage should be reported 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 warnings for safe operation
The misuse of a high pressure water unit and the nonobservance 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
KL 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 spar parts is strictly
forbidden.
Page 4
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. pump model and version
3. serial number
4. max RPM
5. max operating pressure (bar)
6. oil capacity (ltr) and oil specification
7. 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
KL SERIES
FLOW RATE PRESSURE POWER
MODEL RPM
GPM l/min PSI Bar Hp kW
KL30 1000 22.2 84 2600 500 39.6 29.1
KL33 1000 27.0 102 2150 400 39.8 29.2
KL36 1000 32.2 122 1750 320 37.4 27.5
KL40 850 33.8 128 1600 250 36.6 26.9
KL45 800 40.1 152 1450 180 39.6 29.1
KL50 700 43.3 164 1150 34.0 25.0
6. DIMENSIONS AND WEIGHT
Page 5
GENERAL PUMP
A member of the Interpump Group
KL SERIES
7. GENERAL INFORMATION ABOUT PUMP
USE
The KL pump has been designed to pump fresh filtered
water at room temperature. KLZ-N special stainless
steel versions are also available for critical fluids.
7.1 Water temperature
Water temperature is critical for the pump life, the higher it
is, the more likely it is to create cavitation, resulting in
premature seal and valve failures.
Below is the temperature chart
and relevant limitations:
<104oF
from
104oF
to
140oF
Water is considered to be at room
temperature.
feed the plunger pump with a centrifugal
pump supplying at least twice the plunger
pump volume at 30 to 45 PSI
reduce pump rated RPM by 30% to 50%
Make sure the crankshaft turns as
indicated by the arrows located neat the
drive shaft projection
8. CONNECTIONS AND PLUGS
KL pumps are provided with (Fig. 3):
1 - 2 x suction ports IN Ø G 1-1/2”
Suction line connection to any of the two inlet ports
is acceptable, the port not being used should be
sealed with the correct plug.
2 - 2 x outlet ports OUT Ø G 1”.
3 - 1 outlet port Ø G 1/4” (pressure gauge)
4 - 1 hole DRAIN provided underneath the crankcase
and designed to drain out the water leakage of the
pressure packings. This hole must always be left
open (see paragraph 10.3, Fig 7, page 9).
>140oC
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.
7.3 Lowest operating RPM
The lowest operating speed for all KL’s (all versions)
is 500 RPM
standard pump not suitable, contact our
Customer service Department
Page 6
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