KE Owner’s Manual • Installation • Use • Maintenance General Pump is a member of the Interpump Group 8
GENERAL PUMP INDEX A member of the Interpump Group KE SERIES 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3 3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3.2 High pressure system safety requirements . . . . . . . . . . . . . . . . .
GENERAL PUMP 1. INTRODUCTION A member of the Interpump Group 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.
GENERAL PUMP A member of the Interpump Group 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.
GENERAL PUMP 4. PUMP IDENTIFICATION KE SERIES A member of the Interpump Group Each pump is fitted with a rating plate (see Fig. 1) containing the following information: 2. 3. 4. 5. 6. 6. serial number pump model and version max RPM power absorbed max operating pressure (bar) 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.
GENERAL PUMP A member of the Interpump Group 7. GENERAL INFORMATION ABOUT PUMP USE KE SERIES 8. CONNECTIONS AND PLUGS 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.
GENERAL PUMP 9. PUMP INSTALLATION A member of the Interpump Group 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.
GENERAL PUMP A member of the Interpump Group 9.5 Filtration All pumps require a suitable filter. The filter should be installed as close as possible to the pump, should allow easy inspection and have the following characteristics: 1. The filter capacity must be at least 3 times the rated pump volume. 2. Filter port diameters must not be smaller than the pump inlet ports. 3. Filtration degree in between 50 and 80 mesh (360 200 microns).
GENERAL PUMP 9.7 Internal diameter of piping A member of the Interpump Group KE SERIES To determine the internal diameter of the piping, follow the following diagram. Example 1 (-----) With a flow of 150 l/m and a water speed of 0.45 m/sec, the diagram line joining the 2 scales intersects the central scale, indicating the diameters, at a value of 80mm. Example 2 ( ) With a flow of 70 l/min and a water speed of 5.
GENERAL PUMP A member of the Interpump Group 10. START UP AND RUNNING PROCEDURES 10.1 Before start up Before start up make sure that the following conditions have been complied with: 1. Suction line should be connected: the pump must never run dry. 2. Suction line must be perfectly airtight. 3. Any ON-OFF valve in between the pump and water source should be open and make sure the water gets into the pump freely. 4.
GENERAL PUMP KE SERIES A member of the Interpump Group 11. MAINTENANCE INSTRUCTIONS 11.1 Crank mechanism maintenance. Check oil level though the oil level indicator (1, Fig. 8) at least on a weekly basis.
GENERAL PUMP A member of the Interpump Group 11.1.1 Crank mechanism disassembling KE SERIES Do as follows: A) Drain the oil from the pump and remove: -shaft key -back cover -connecting rod cap -side covers. To do so, put 3 screws M6 x 50 wholly threaded into the holes drilled for that purpose. See fig 9. C) Before reassembling the side covers, check the seal lips for wear. If they need replacing, fit the new ring following the indications in Fig. 11.
GENERAL PUMP A member of the Interpump Group D) Install the connecting rod cap taking care the numbers match and tighten the relevant bolts in 3 different stages: KE SERIES 1. Approach torque 6 - 8 Nm 2. Presetting torque 25-28 Nm 3. Tightening torque 38 Nm Note: The screws must be greased on the thread and under the head. The rolling couple of the crankshaft (with connecting rods coupled) must not exceed 8 Nm. 11.1.
GENERAL PUMP A member of the Interpump Group The new roller bearings can be mounted at room temperature with a press; it is necessary to hold them on the side surface of the ring nuts with suitable rings. The driving operation can be facilitated by heating the parts at a temperature between 250-300oF, making sure that the KE SERIES E) Fit the shims under the sight glass cover tightening it on the crankcase with the screws, checking that the stall torque is between 4 Nm and 6 Nm.
GENERAL PUMP 11.2 Fluid end maintenance A member of the Interpump Group 11.2.1 Pump head The fluid end does not require periodical maintenance. Service operations are limited to the component inspection and/or replacement, when necessary. Valve Units: A) B) C) KE SERIES IMPORTANT NOTE: BEFORE REPOSITIONING THE VALVE UNITS AND O-RINGS CLEAN AND PERFECTLY DRY ALL VALVE HOUSINGS INSIDE THE FLUID END. Loosen the valve cover screws. Extract the valve plugs with an extractor or a M8 threaded rod.
GENERAL PUMP B) KE SERIES A member of the Interpump Group Remove the high pressure packings from the fluid end and the low pressure ones from their support by means of standard tools, taking great care not to damage the seats. Fig. 22 Take note of the correct order of the entire package components when dissassembling (Fig. 23): 1. Head ring 2. HP packing 3. “Restop” ring 4. Middle ring 5. LP packing 6. Back packing 7.
GENERAL PUMP A member of the Interpump Group 14. PUMP STOPPED FOR LONG TIME 12. SCREW CALIBRATION Before starting the pump for the very first time after a long period from the date of shipment check for the correct oil level, check the valves as indicated in chapter 11 and then comply with the starting procedures indicated in chapter 10.
GENERAL PUMP A member of the Interpump Group 16.
GENERAL PUMP Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part # Description F91847700 Roller bearing F70010022 F90391500 F70220081 F70220381 F70220581 F90074500 F70211801 F90387700 F70150122 F99185400 F90383300 F98209900 F98211500 F90160022 F90394400 F98200500 F99312300 F70020035 F91490000 F70150022 F90166800 F70030043 F70050015 F97742000 F90167700 F96709900 F70040009 F70040109 F70040209 F70040309 27 28 29 F70040409 F90367100 F70219566 F70120036 F70120136 F70120236
GENERAL PUMP A member of the Interpump Group 17. TROUBLE SHOOTING KE SERIES THE PUMP DOES NOT PRODUCE ANY NOISE: the pump is not primed and is running dry! - no water in the inlet line - the valves are blocked - the pressure line is closed and does not allow the air to get out the fluid end. INSUFFICIENT PUMP PRESSURE: - the nozzle is (or has become) too large.
GENERAL PUMP A member of the Interpump Group 18. MAINTENANCE TOOLS The pump maintenance can be carried out with simple tools for mounting and dismounting the components, but special tools can be made to facilitate the operations. The drawings here below will help the operator make tools if he choosed to. KE SERIES 18.2 Piston guide oil seal assembling 18.
GENERAL PUMP A member of the Interpump Group 19. MAINTENANCE LOG KE SERIES HOURS & DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT GP Companies, Inc. 1174 Northland Drive Mendota Heights, MN 55120 Phone:651.686.2199 Fax: 800.535.1745 www.generalpump.com email: sales@gpcompanies.com Ref 300614 Rev.
