General Pump KS Owner Manual
KS
8
Owner’s Manual
• Installation
• Use
• Maintenance
General Pump is a
member of the
Interpump Group
Ref 300655 Rev D
09-12
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.1 General safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.2 High pressure unit safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.3 Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.4 General procedures for nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.5 Safety during unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
5. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5-6
7. GENERAL INFORMATION REGARDING PUMP USE . . . . . . . . . . . . . . . . . . . . .Page 6
7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.2 Maximum flow rate and pressure values . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.3 Lowest operating RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.4 Recommended lubricant oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6-7
A member of the Interpump Group
KS SERIES
8. PORTS AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
9.3 Version change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
9.4 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
9.5 Pump feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
9.6 Suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
9.7 Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
9.8 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
9.9 Internal diameter of the hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
9.10 V-belt transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
9.11 Transmission definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.12 Definition of belt static tension values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
10. START UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
10.1 Preliminary operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
10.2 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
11. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
12. STOPPING THE PUMP FOR LONG PERIODS . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
12.2 Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
13. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
14. WARRANTY TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
16. EXPLODED VIEW AND PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
20. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 23
Ref 300655 Rev D
Page 2
09-12
GENERAL PUMP
A member of the Interpump Group
KS SERIES
1. INTRODUCTION
This manual describes the use and maintenance instructions of the KS pump, and should be carefully read and
understood before pump operation. 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
Carefully read the indications in
this manual before operating the
pump.
Danger
Electrocution Danger
Danger
Use a face guard
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 Installer 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 hose/
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
Use protective glasses
Danger Signal
Use adequate hand protection
before operating the pump
Danger
Wear protective boots
Ref 300655 Rev D
09-12
Page 3
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 using nozzles
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.
A member of the Interpump Group
KS SERIES
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 during unit 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.
Ref 300655 Rev D
09-12
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:
1. Serial number
2. Pump model and version
Max RPM
Power absorbed
Max flow rate (l/min) and pressure (bar)
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 DATA
KS SERIES
MODEL RPM
KS28A
KS32A
KS36A
KS40A
o Reducer
N
With
Reducer
No Reducer 1200
With
Reducer
No Reducer 1200
With
Reducer
No Reducer 1200
With
Reducer
200
1
1500
1800
2200
1500
1800
2200
1500
1800
2200
1500
1800
2200
6. DIMENSIONS AND WEIGHT
Flow Rate Pressure Power
GPM L/min PSI Bar HP Kw
29.1 110 3625 250 71.4 52.5
38.3 145 2900 200 75.3 55.4
48.3 183 2320 160 76.0 55.9
59.7 226 2000 138 81.0 59.5
Figure 2a refers to pump with reducer
Ref 300655 Rev D
09-12
Page 5
GENERAL PUMP
A member of the Interpump Group
6. DIMENSIONS AND WEIGHT (continued)
KS SERIES
Figure 2b refers to pump without reducer
7. INFORMATION ABOUT PUMP USE
The KS pump has been designed to pump fresh filtered
(360 micron max) water at room temperature (1040F max).
7.1 Water temperature
The maximum water temperature allowed is 1040F.
Nonetheless, for short periods of time it is possible to operate the pump with a water temperature of 1400F. In this
case, we advise to contact the Technical or Customer
Service Department.
7.2 Max. flow rate and pressure values
The performance values indicated in this manual 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 Technical
Department or Customer Service Department.
7.3 Lowest RPM
Any RPM value different from what is indicated in the
performance table (see Section 5) must be expressly
authorized by the Technical or Customer Service
Department.
MANUFACTURER TYPE
GENERAL PUMP SERIES 220
AGIP AGIP ACER 220
BP BP ENERGOL HLP 220
CASTROL MAGNA 220
ELF ELF POLYTELIS 220
ESSO TERESSO 220
TEXACO RANDO HD 220
FINA FINA CIRKAN 220
MOBIL MOBIL DTE Oil 88
SHELL SHELL TELLUS C 220
TOTAL TOTAL CORTIS 220
Recommended Lubricant Oil Types
7.4
The pump is delivered with lubricant oil compliant with
room temperatures ranging from 32
mended lubricant types are listed 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.
0
to 860F. Some recom-
Check the oil level dipstick (pos. 3); refill if
necessary. 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 (pos. 2), fig 3.
Oil inspection and changing is to be carried out as indicated in Section 11.
Ref 300655 Rev D
09-12
Page 6
GENERAL PUMP
The amount required is:
• 5 quarts for versions with the reducer in positions 1 and 4 (see fig. 6). This amount will be slightly lower for
positions 2 and 3.
• 4.6 quarts for versions without a reducer.
IN ANY CASE, OIL MUST BE CHANGED ONCE A YEAR SINCE IT MAY DETERIORATE BY OXIDATION.
For room temperatures that differ from 320to 860F, follow the indications contained in the diagram below, keeping
in mind that the oil must have a minimum viscosity of 180 cST.
A member of the Interpump Group
KS SERIES
VISCOSITY / ROOM TEMPERATURE DIAGRAM
Exhausted oil must be collected in an appropriate container and disposed on in authorized locations.
In absolutely no case may it be disposed of into the environment.
Ref 300655 Rev D
Page 7
09-12
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