General Pump KT User Manual
KT
8
Owner’s Manual
• Installation
• Use
• Maintenance
General Pump
is a member of
the Interpump Group
KT16A, KT18A, KT20A, KT22A
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KT24A, KT28A, KT30A, KT32A, KT36A, KT40A
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
2. DESCRIPTION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
3.2 High pressure unit safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
3.3 Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
3.4 General procedures for using lances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
3.5 Safety during unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
5. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
7. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
7.2 Maximum flow and pressure rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
7.3 Minimum RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
7.4 Recommended lubricant types and Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
A member of the Interpump Group
KT SERIES
8. PORTS AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
9.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.3 Version change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.4 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
9.5 Pump power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
9.6 Suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
9.7 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15
9.8 Outlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
9.9 Internal diameter of hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
9.10 V-belt transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
9.11 Transmission definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
9.12 Definition of static pull to apply on belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21
9.13 Transmission of power from the second PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 23
10. START UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
10.1 Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
11. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 25
12. PUMP STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26
12.1 Long-term inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26
12.2 Filling the pump with anti-corrosion emulsion or anti-freeze . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26
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GENERAL PUMP
INDEX
13. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26
14. WARRANTY TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26
15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 27
16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 28
17. FLUSHING CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 33
18. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 34
A member of the Interpump Group
KT SERIES
Ref 300941 Rev.A
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GENERAL PUMP
A member of the Interpump Group
KT SERIES
1. INTRODUCTION
This manual describes the use and maintenance instructions of the KT Series 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
Danger
Wear protective mask
Danger
Wear goggles
Danger
Wear protective gloves
Danger
Wear protective boots
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GENERAL PUMP
A member of the Interpump Group
KT SERIES
3. SAFETY
3.1 General Safety Indications
Improper use of pumps and high pressure systems, and the non-compliance with installation and maintenance
instructions may cause severe injury to people and/or damage to property. Anyone assembling or usinge high pressure
systems must possess the necessary competence to do so, should be aware of the characteristics of the components
assembled/used, and must take all precautions necessary to ensure maximum safety in any operating condition. In the
interest of safety, both for the Installer and the Operator, no reasonably applicable precaution should be omitted.
3.2 High pressure unit safety requirements
1. The pressure line must always be equipped with a safety valve.
2. High pressure system components, in particular for those units working outside, must be adequately
protected against rain, frost and heat.
3. The electrical control system must be adequately protected from water spray, and must comply with the
specific regulations in force.
4. High pressure hoses must be properly sized for maximum operating pressure of the system and always and only
used within the operating pressure range specified by the hose manufacturer. The same rules should be observed
for all other auxiliary systems affected by high pressure.
5. The ends of high pressure hoses must be sheathed and secured to a solid structure to prevent dangerous
whiplash in case of bursting or broken connections.
6. Appropriate safety guards must be provided for the pump transmission systems (couplings, pulleys and belts,
auxiliary drives).
3.3 Safety During Operation
The working area of a high pressure system must be clearly marked. Access must be prohibited to un-authorized
personnel and, wherever possible, the area should restricted or fenced. The personnel authorized to access this area
should first be 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 system is properly powered (see paragraph 9.5).
2. That pump intake filters are perfectly clean; we advise the use of a device that indicates the filters clogging level.
3. Electrical parts are adequately protected and in perfect condition.
4. The high pressure hoses do not show apparent signs of abrasion, and that fittings are in perfect shape.
Any fault or reasonable doubt that may arise before or during operation should be promptly reported and verified by
competent personnel. In these cases, pressure should immediately be released and the high pressure system 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 and 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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GENERAL PUMP
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. It is generally best to organize personnel into teams of at least two people capable of giving mutual and immediate
assistance in case of necessity and of taking turns during long and demanding operation.
4. Access to the work area that is within the water jets’ range must be absolutely prohibited to and free from objects
that, inadvertently under a pressure jet, can be damaged and or create dangerous situations.
5. The water jet must only and always be directed in the direction of the work area, including during testing or
preliminary tests or checks..
6. The Operator must always pay attention to the trajectory of the debris removed by the water jet. If necessary,
suitable guards must be provided by the Operator to protect anything that may be accidentally exposed.
7. The Operator should not be distracted for any reason during operation. Workers needing to access the operating
area must wait for the Operator to stop work, and then immediately make their presence known.
8. For safety reasons, it is important that each member of the team is fully aware of the intentions and actions of
other team members in order to avoid dangerous misunderstandings.
9. The high pressure system must not be started up and run under pressure without all team members in position
and without the Operator having already directed his/her lance toward the work area.
3.5 Safety During System Maintenance
1. The pressure system meintenance must be carried out in the time intervals set by the manufacturer who is
responsible for the whole group according to law.
2. Maintenance should always be carried out by trained and authorized personnel.
3. Assembly and disassembly of the pump and its various components must be performed exclusively by authorized
personnel, using appropriate equipment in order to avoid damage to components and connections.
4. Always use original spare parts to ensure total reliability and safety.
A member of the Interpump Group
KT SERIES
4. PUMP IDENTIFICATION
Each pump has a specific label which contains:
Pump model and version
Serial Number
Flow Rate - GPM
Pressure - PSI
Power - Hp-kW
Maximum RPM
Pump model, version and serial number must always
be specified when ordering spare parts.
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GENERAL PUMP
5. TECHNICAL FEATURES
A member of the Interpump Group
KT SERIES
MODEL RPM
KT16A 1750 7.1 27.4 7,250 500 35.6 26.2
KT18A 1750 9.2 34.7 5,800 400 36.1 26.5
KT20A 1750 11.4 42.9 4,650 320 35.6 26.2
KT22A 1750 13.7 51.9 3,630 250 33.7 24.8
KT24A 1750 16.4 61.7 2,900 200 32.1 23.6
KT28A 1750 22.2 84.0 2,540 175 38.2 28.0
KT30A 1750 25.4 96.4 2,175 140 35.1 25.8
KT32A 1750 29.1 110.0 1,750 150 35.4 26.0
KT36A 1580 33.1 125.4 1,813 125 40.7 29.9
FLOW RATE PRESSURE POWER
GPM l/min PSI Bar Hp kW
KT40A 1450 37.5 142.1 1,450 100 36.9 27.1
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GENERAL PUMP
6. DIMENSIONS AND WEIGHT
For dimensions and weight of KT16A, KT18A, KT20A, KT22A, please refer to fig. 2.
A member of the Interpump Group
KT SERIES
For dimensions and weight of KT24A, KT28A, KT30K, KT32A, KT36A, KT40A pumps, please refer to fig. 2a.
fig. 2
fig. 2a
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GENERAL PUMP
A member of the Interpump Group
KT SERIES
7. OPERATING INSTRUCTIONS
The KT pump was designed to operate with filtered water (see paragraph 9.7), in environments that are not
potentially explosive and at maximum temperature of 1040F (400C).
Other fluids may be used only upon the approval of The Customer Service Department .
7.1 WaterTemperature
The max water temperature is 1040F (400C).However, it is possible to use the pump at temperatures of up
0
to 140
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.
F (600C) for short periods of time. In this case we advise consulting the Customer Service
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.
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.
Check the oil level by using the oil level dipstick (1), fig. 3.
Refill if necessary to top off level. Correct oil level
inspection is done with the pump at room temperature; oil
is changed with the pump at working temperature, by
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
Hyspin VG 220, Magna
POLYTELIS 220
220
removing the oil dipstick (2), fig 3, and then the drain plug
(3), fig. 3.
Checking and changing oil is to be carried out as indicated
in the table in fig. 14,Chapter 11. The amount required is
304 oz. (2 liters).
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GENERAL PUMP
In any case, oil must be changed at least once a year since it may deteriorate by oxidation.
For room temperatures that differ from that mentioned earlier, 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
KT SERIES
VISCOSITY/ROOM TEMPERATURE DIAGRAM
Exhausted oil must be collected in an appropriate recipient and disposed of in appropriate
locations. In absolutely no case may it be dispersed into the environment.
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GENERAL PUMP
A member of the Interpump Group
KT SERIES
8. PORTS AND CONNECTIONS
KT Series pumps are equipped with (see fig. 4):
1. 2 inlet ports “IN”, 1” NPT (KT16A, KT18A, KT20A, KT22A).
2 inlet ports “IN”, 1-1/4” NPT (KT24A, KT28A, KT30A, KT36A, KT36A, KT40A).
Line connection to any of the two ports is indifferent for proper pump functioning. The unused ports must be sealed off.
2. 2 outlet ports “OUT”, 1/2” NPT-F (KT16A, KT18A, KT20A, KT22A).
2 outlet ports “OUT”, 1” NPT-F (KT24A, KT28A, KT30A, KT36A, KT36A, KT40A).
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