Pratissoli KF Series User manual

Serie KF
KF - KFR
Manuale uso e manutenzione
Use and Maintenance Manual
Manuel d’utilisation et d’entretien
Betriebs- und Wartungsanleitung
Manual de Uso y mantenimiento
Manual de uso e manutenção
уководство по эксплуатации и техническому обслуживанию
使用和保养手册Kullanma ve bakım kılavuzu

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Contents
1 INTRODUCTION ....................................................................................................................................................................... 23
2 DESCRIPTION OF SYMBOLS .................................................................................................................................................... 23
3 SAFETY ..................................................................................................................................................................................... 23
3.1 General safety warnings.................................................................................................................................................................. 23
3.2 Essential safety in the high pressure system............................................................................................................................ 23
3.3 Safety during work............................................................................................................................................................................ 23
3.4 Rules of conduct for the use of lances........................................................................................................................................ 23
3.5 Safety during system maintenance............................................................................................................................................. 24
4 PUMP IDENTIFICATION ........................................................................................................................................................... 24
5 TECHNICAL CHARACTERISTICS .............................................................................................................................................. 24
6 DIMENSIONS AND WEIGHT..................................................................................................................................................... 25
7 OPERATING INSTRUCTIONS.................................................................................................................................................... 25
7.1 Water temperature............................................................................................................................................................................ 25
7.2 Maximum pressure and ow rate ................................................................................................................................................ 25
7.3 Minimum operating speed ............................................................................................................................................................ 25
7.4 Sound emission .................................................................................................................................................................................. 25
7.5 Vibration................................................................................................................................................................................................ 25
7.6 Brands and types of oils recommended.................................................................................................................................... 25
8 PORTS AND CONNECTIONS .................................................................................................................................................... 27
9 PUMP INSTALLATION .............................................................................................................................................................. 27
9.1 Installation............................................................................................................................................................................................ 27
9.2 Rotation direction.............................................................................................................................................................................. 27
9.3 Version change ................................................................................................................................................................................... 28
9.4 Hydraulic connections ..................................................................................................................................................................... 28
9.5 Pump supply........................................................................................................................................................................................ 28
9.6 Suction line .......................................................................................................................................................................................... 28
9.7 Filtration................................................................................................................................................................................................ 28
9.8 Outlet line............................................................................................................................................................................................. 29
9.9 Calculation of the internal diameter of the duct pipes........................................................................................................ 29
9.10 V-belt transmission............................................................................................................................................................................ 29
9.11 Transmission denition ................................................................................................................................................................... 30
9.12 Denition of static pull to apply on belts.................................................................................................................................. 32
9.13 Transmission of power from the second PTO.......................................................................................................................... 32
10 START-UP AND OPERATION .................................................................................................................................................... 33
10.1 Preliminary checks............................................................................................................................................................................. 33
10.2 Start-up.................................................................................................................................................................................................. 33
11 PREVENTIVE MAINTENANCE .................................................................................................................................................. 33
12 PUMP STORAGE ....................................................................................................................................................................... 33
12.1 Long-term inactivity ......................................................................................................................................................................... 33
12.2 Method for lling pump with anti-corrosion emulsion or anti-freeze solution.......................................................... 33
13 PRECAUTIONS AGAINST FROST.............................................................................................................................................. 34
14 WARRANTY CONDITIONS........................................................................................................................................................ 34
15 OPERATING FAULTS AND THEIR POSSIBLE CAUSES .............................................................................................................. 34
16 EXPLODED DRAWING AND PARTS LIST.................................................................................................................................. 35
17 FLUSHING CIRCUIT DIAGRAM OF USE.................................................................................................................................... 37
18 SPECIAL VERSIONS .................................................................................................................................................................. 38
18.1 KFR pump ............................................................................................................................................................................................. 38
18.1.1 Operating instructions ....................................................................................................................................................... 38
18.1.2 Water temperature .............................................................................................................................................................. 38
18.1.3 Maximum pressure and ow rate................................................................................................................................... 38
18.1.4 Minimum operating speed............................................................................................................................................... 38
18.1.5 Technical characteristics.................................................................................................................................................... 38
18.1.6 Dimensions and weight..................................................................................................................................................... 38
18.1.7 Exploded view....................................................................................................................................................................... 39
19 DECLARATION OF INCORPORATION ...................................................................................................................................... 41

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1 INTRODUCTION
This manual describes the instructions for use and
maintenance of the KF pump and should be carefully read and
understood before using the pump.
Proper pump operation and duration depend on the correct
use and maintenance.
Interpump Group disclaims any responsibility for damage
caused by negligence or failure to observe the standards
described in this manual.
Upon receipt, check that the pump is intact and complete.
Report any faults before installing and starting the pump.
2 DESCRIPTION OF SYMBOLS
Read the contents of this manual carefully before each
operation.
Warning Sign
Read the contents of this manual carefully before
each operation.
Danger Sign
Danger of electrocution.
Danger Sign
Wear a protective mask.
Danger Sign
Wear protective goggles.
Danger Sign
Put on protective gloves before each operation.
Danger Sign
Wear appropriate footwear.
Symbol for protection against explosion. This
denes special safety requirements for the use of
the pumps in areas identied in accordance with the
ATEX Directive.
When pumps are ordered in the ATEX
conguration because they are going to work
in areas with a potentially explosive atmosphere,
you must STRICTLY comply with the notes given
under the headings marked with this symbol
and the instructions in the supplementary
instructions manual “ATEX EXPLOSION
PROTECTION”.
3 SAFETY
3.1 General safety warnings
Improper use of pumps and high pressure systems as well as
non-compliance with installation and maintenance standards
can cause serious damage to people and/or property. Anyone
assembling or using high pressure systems must possess the
necessary competence to do so, knowing the characteristics
of the components to be assembled/used and taking all
the necessary precautions to ensure maximum safety in all
conditions of use. In the interest of safety, both for the Installer
and the Operator, no reasonably applicable precaution should
be omitted.
3.2 Essential safety in the high pressure system
1. The pressure line must always be provided with a safety
valve.
2. High pressure system components, particularly for systems
that operate primarily outside, must be adequately
protected from rain, frost and heat.
3. The electrical control system must be adequately
protected against sprays of water and must meet specic
regulations in force.
4. The high pressure pipes must be properly sized for
maximum operating pressure of the system and always
and only used within the operating pressure range
specied by the Manufacturer of the pipe itself. The same
rules should be observed for all other auxiliary systems
aected by high pressure.
5. The ends of high pressure pipes must be sheathed
and secured in a solid structure, to prevent dangerous
whiplash in case of bursting or broken connections.
6. Appropriate protective casing must be provided in pump
transmission systems (couplings, pulleys and belts,
auxiliary power outlets).
3.3 Safety during work
The room or area within which the high pressure system
operates must be clearly marked and prohibited to
unauthorized personnel and, wherever possible, segregated
or fenced to ensure restricted access. Personnel authorized
to access this area should rst be instructed how to operate
within this area and informed of the risks arising from high
pressure system defects or malfunctions.
Before starting the system, the Operator is required to verify
that:
1. The high pressure system is properly powered, see
chapter9 par.9.5.
2. The pump suction lters are perfectly clean; it is
appropriate to include a device indicating the clogging
level on all devices.
3. Electrical parts are adequately protected and in perfect
condition.
4. The high pressure pipes do not show signs of abrasion and
the ttings are in perfect order.
5. Attention: in relation to the application, use and
environmental conditions, during the operation the outer
surfaces of the pump may reach high temperatures.
Therefore we recommend to take precautions to avoid
contact with hot parts.
Any fault or reasonable doubt that may arise before or
during operation should be promptly reported and veried
by qualied personnel. In these cases, pressure should be
immediately cleared and the high pressure system stopped.
3.4 Rules of conduct for the use of lances
1. The operator must always place his safety and security
rst, as well as that of others that may be directly aected
by his/her actions, or any other assessments or interests.
The operator’s work must be dictated by common sense
and responsibility.

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2. The operator must always wear a helmet with a protective
visor, waterproof gear and wear boots that are appropriate
for use and can ensure a good grip on wet oors.
Note: appropriate clothing will protect against sprays of water
but not from direct impact with jets of water or very close sprays.
Additional protections may therefore be necessary in certain
circumstances.
3. It is good practice 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 operations.
4. The work area jet 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 always and only be pointed in the
direction of the work area, including during preliminary
tests or checks.
6. The operator must always pay attention to the trajectory
of debris removed by the water jet. Where necessary,
suitable guards must be provided by the Operator to
protect anything that could become accidentally exposed.
7. The operator should not be distracted for any reason
during work. Workers needing to access the operating area
must wait for the Operator to stop work on his/her own
initiative, after which they should immediately make their
presence known.
8. It is important for safety that all team members are always
fully aware of each other’s intentions 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. High pressure system maintenance 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 performed by trained and
authorized personnel.
3. Assembly and disassembly of the pump and the various
components must only be carried out by authorized
personnel, using appropriate equipment in order
to prevent damage to components, in particular to
connections.
4. Always only use original spare parts to ensure total
reliability and safety.
4 PUMP IDENTIFICATION
Each pump has its own Serial No. XX.XXX.XXX see point cand
an identication plate see point din Fig.1 which shows:
- Pump model and version
- Max revs
- Absorbed power HP - kW
- Pressure bar - P.S.I.
- Flow rate l/min - Rpm
Fig.1
For pumps ordered with the ATEX conguration.
Pos. eplate with specic ATEX marking for
explosion protection.
Pos. fplate for locating the grounding screw.
Model, version and serial number must always be
indicated when ordering spare parts
5 TECHNICAL CHARACTERISTICS
Model Rpm Flow rate Pressure Power
l/min Gpm bar psi kW HP
KF 28 1000 93 24.5 210 3045 37 50
KF 30 1000 106 28 200 2900 40 55
KF 32 1000 120 31.7 180 2610 41.2 56
KF 36
800 122 32.2 160 2300 37 50
900 137 36.2 140 2050 37 50
1000 153 40 130 1900 38.2 52
KF 40 900 170 45 110 1595 36 49

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6 DIMENSIONS AND WEIGHT
For Standard Version pump dimensions and weight, refer to Fig.2.
Dry weight 68 kg. Fig.2
7 OPERATING INSTRUCTIONS
The KF pump has been designed to operate in
environments with atmospheres that are not
potentially explosive, with ltered water (see
par.9.7) and at a maximum temperature of 40°C.
Other liquids can be used only upon formal approval
by the Technical or Customer Service Departments.
7.1 Water temperature
The maximum permissible water temperature
is 40°C. However, the pump can be used with
water up to a temperature of 60°C, but only for
short periods. In this case, it is best to consult the
Technical or Customer Service Departments.
7.2 Maximum pressure and ow rate
The rated specications stated in our catalog are the max.
that can be obtained by the pump. Independently of the
power used, the maximum pressure and rpm indicated on the
specication label can never be exceeded unless prior formal
authorization is given by our Technical or Customer Service
Departments.
7.3 Minimum operating speed
The minimum permissible speed for these types of pumps is
100rpm for non-continuous periods.
Any rotating speed other than that indicated in the
performance table (see chapter5) must be expressly
formally authorized by our Technical or Customer Service
Departments.
7.4 Sound emission
The sound pressure detection test was performed according
to Directive 2000/14 of the European Parliament and Council
(Machinery Directive) and EN-ISO 3744-1995 with class 1
instrumentation.
A nal detection of sound pressure must be performed on the
complete machine/system.
Should the operator be located at a distance of less than
1meter, he will have to use appropriate hearing protection
according to current regulations.
7.5 Vibration
The detection of this value shall be carried out only with the
pump set up on the plant and at the performance declared by
the customer.
Values must be in accordance with regulations.
7.6 Brands and types of oils recommended
The pump is supplied with oil suitable for room temperatures
from 0°C to 30°C.
Recommended types of oil are indicated in the table below,
these oils have additives to increase corrosion resistance and
fatigue resistance (DIN 51517 part 2).
Alternatively you can also use Automotive Gear SAE 85W-90
oil for gearing lubrication.
Manufacturer Lubricant
AGIP ACER220
Aral Degol BG 220
BP Energol HLP 220
CASTROL HYSPIN VG 220
CASTROL MAGNA 220
Falcon CL220
ELF POLYTELIS 220
REDUCTELF SP 220
NUTO 220
TERESSO 220
FINA CIRKAN 220
RENOLIN 212
RENOLIN DTA 220
Mobil DTE Oil BB
Shell Tellus Öl C 220

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Manufacturer Lubricant
Wintershall Ersolon 220
Wintershall Wiolan CN 220
RANDO HD 220
TOTAL Cortis 220
Check the oil level and top up if necessary
Using the oil dipstick pos.c, Fig.3.
The correct checking of the oil level is made with the pump
not running, at room temperature. The oil change must be
made with the pump at working temperature, removing: the
oil dipstick, pos.c, and then the plug pos.d, Fig.3.
The oil check and change must be carried out as indicated in
the table in chapter 11.
The quantity required is ~ 3.8 liters.
Set up the plant so that the oil temperature does
not exceed in any case 100°C (212°F) during pump
operation.
Use a temperature probe to be inserted into the oil
drain plug Pos. dFig. 3.
See “ATEX EXPLOSION PROTECTION”manual.
ATTENTION: Use only oil with a ash point higher
than 200°C.
Fig.3
In any case the oil must be changed at least once
a year, as it is degraded by oxidation.
For a room temperature other than between 0°C - 30°C,
follow the instructions in the following diagram, considering
that oil must have a minimum viscosity of 180 cSt.
Viscosity / Room Temperature diagram
mm2/s = cSt
Viscosity ν
Ambient temp. (°C)
The used oil must be poured unto a suitable container and consigned to an authorized recycling center.
Do not release used oil into the environment under any circumstances.

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8 PORTS AND CONNECTIONS
The KF series pumps (see Fig.4) are equipped with:
cNo. 2“IN“ inlet ports 1”Gas.
Line connection to any of the two ports is indierent for
proper pump functioning. The unused ports must be
hermetically closed.
dNo. 2“OUT“ outlet ports 1/2” Gas.
eNo. 3 service ports 1/4” Gas; usually used for the pressure
gauge.
Fig.4
9 PUMP INSTALLATION
9.1 Installation
The pump must be xed horizontally using the M16x1.5
threaded support feet. Tighten the screws with a torque of
210Nm.
The base must be perfectly at and rigid enough as not
to allow bending or misalignment on the pump coupling
axis/transmission due to torque transmitted during operation.
The unit cannot be xed rigidly to the oor but must
interposed with vibration dampers.
For special applications contact the Technical or Customer
Service Departments.
A lifting bracket is mounted on the pump for easy installation,
as per the gure below.
Should it be necessary to disassemble it, to avoid the entrance
of dirt in the front part of the casing, close the threaded hole
with the cap provided.
Earthing: the pump must be connected to an
earth conductor using the stainless steel M6 screw
and stainless steel serrated washer marked with a
YELLOW label. See “ATEX EXPLOSION PROTECTION”
manual.
Replace the oil lling hole closing service
plug (red) positioned on the rear casing cover.
Checkthe correct quantity with the oil dipstick.
The dipstick must always be accessible, also when
the unit is installed.
The pump shaft (PTO) must not be rigidly
connected to the drive unit.
The following types of transmission are
recommended:
- Hydraulics by ange, for proper application
consult with our Technical or Customer Service
Departments.
- V-belts.
- Universal joint (comply with the maximum
working angles recommended by the
manufacturer).
- Flexible coupling.
In all cases the transmission must be assembled
correctly to avoid incorrect or harsh operation of
the connection parts and to prevent excessive
wear, temperature rise and/or hazardous breakages
that may create potential sources of ignition and
explosion. See “ATEX EXPLOSION PROTECTION”
manual.
9.2 Rotation direction
The rotation direction is indicated by an arrow located on the
casing near the drive shaft.
From a position facing the pump head, the rotation direction
will be as in Fig.5.
LH SIDE
clockwise
RH SIDE
anticlockwise
Fig.5

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9.3 Version change
The pump version is dened as right when:
Observing the pump facing the head side, the pump shaft
must have a PTO shank on the right side.
The pump version is dened as left when:
Observing the pump facing the head side, the pump shaft
must have a PTO shank on the left side.
Note. The version shown in Fig.5 is right.
The version can only be modied by trained and
authorized personnel and carefully following the
instructions below:
1. Separate the hydraulic part from the mechanical
part as indicated in chapter2 par.2.2.1 of the
Repair manual.
2. Turn the mechanical part 180° and reposition
the rear casing cover in such a way that the
oil dipstick is turned upward. Reposition the
lifting bracket and relative hole closing plugs
in the upper part of the casing. Finally, properly
reposition the specication label in its housing
on the casing.
Make sure that the lower casing draining
holes in correspondence with the pistons are
open and not closed from the plastic plugs
provided for the previous version.
3. Unite the hydraulic part to the mechanical part
as indicated in chapter2 par.2.2.5 of the Repair
manual.
9.4 Hydraulic connections
In order to isolate the system from vibrations produced by
the pump, it is advisable to make the rst section of the duct
adjacent to the pump (both suction and outlet) with exible
piping. The suction hose must be suciently rigid to prevent
deformation due to the negative pressure exerted by the
action of the pump.
9.5 Pump supply
A positive head of at least 0.20 meters is required for the best
volumetric eciency.
For negative prevalence contact our Technical or
Customer Service Departments.
9.6 Suction line
For smooth operation of the pump, the suction line must have
the following characteristics:
1. Minimum internal diameter as indicated in the graph in
par.9.9 and in any case equal to or exceeding that of the
pump head.
Localized restrictions should be avoided along the
piping, as these can cause pressure drops resulting
in cavitation. Avoid 90° elbows, connections with
other piping, restrictions, reverse gradients, inverted
U-curves and Tee connections.
2. The layout must be such as to prevent cavitation
problems.
3. Completely airtight and constructed to ensure a perfectly
hermetic seal through time.
4. Prevent the pump from emptying when it is stopped,
including partial emptying.
5. Do not use 3 or 4-way hydraulic ttings, adapters, swivel
joints, etc. as they could jeopardize pump performance.
6. Do not install Venturi tubes or injectors for detergent
suction.
7. Avoid use of foot valves or other types of unidirectional
valves.
8. Do not recirculate the by-pass valve drain directly to the
suction line.
9. Provide for proper guards inside the tank to prevent that
water ow from the bypass and the tank supply line can
create vortexes or turbulence near the pump supply pipe
port.
10. Make sure the suction line is thoroughly clean inside
before connecting it to the pump.
9.7 Filtration
1 lter must be installed on the pump suction line, positioned as indicated in Fig.6 and Fig.6/a.
With a manually activated control valve
1 Filter 1
2 Plunger pump
3 Pressure gauge
4 Safety valve
5 Manual control valve
Inlet
Supply tank
Bypass
Fig.6

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With pneumatic control valve
1 Filter 1
2 Plunger pump
3 Pressure gauge
4 Safety valve
5 Pneumatic control valve
Inlet
Supply tank
Bypass
Fig.6/a
The lter, which is to be installed as close to the pump as
possible, must be easily inspectable and have the following
specications:
1. Minimum ow rate at least 3 times the nominal ow rate
of the pump.
2. Inlet/outlet port diameters no smaller than the inlet port
diameter of the pump.
3. Filtration grade between 200 and 360 µm.
For smooth pump operation, regular lter
cleaning is necessary, planned according to the
actual use of the pump in relation to the quality
of water used and actual clogging conditions.
9.8 Outlet line
For correct design of the outlet line comply with the following
installation prescriptions:
1. The internal diameter of the pipe must be sucient to
ensure correct uid velocity, see graph in par.9.9.
2. The rst section of the line connected to the pump outlet
must be a exible hose, in order to isolate vibration
produced by the pump from the rest of the system.
3. Use high pressure pipes and ttings to ensure high safety
margins in all operating conditions.
4. The outlet line must always be provided with a Max.
pressure valve.
5. Use pressure gauges capable of withstanding the
pulsating loads typical of plunger pumps.
6. During the design stage, keep in mind the line pressure
drops that lead to a pressure reduction at the user with
respect to the pressure measured on the pump.
7. For those applications where pulses produced by the
pump on the outlet line may prove harmful or unwanted,
install a pulsation dampener of sucient size.
9.9 Calculation of the internal diameter of the
duct pipes
To determine the internal diameter of the duct, refer to the
following diagram:
Suction duct
With a ow rate of ~ 170 l/min and a water velocity of
0.5m/sec. The graph line joining the two scales meets the
central scale showing the diameters, corresponding to a value
of ~ 80 mm.
Outlet duct
With a ow rate of ~ 170 l/min and a water velocity of
5.5m/sec. The graph line joining the two scales meets the
central scale showing the diameters, corresponding to a value
of ~ 30 mm.
Optimal speeds:
- Suction: ≤ 0.5 m/sec.
- Outlet: ≤ 5.5 m/sec.
The graph does not take into account pipe
resistance, valves, load loss produced by the length
of the ducts, the viscosity of the liquid pumped or
the temperature itself.
If necessary, contact our Technical or Customer
Service Departments.
9.10 V-belt transmission
The pump can be controlled by a V-belt system. For this
pump model, we recommend to use No. 4 XPB belts (16.5x13
serrated). Use an XPC prole only for long durations. Both the
characteristics and transmissible power of each belt can be
veried in the diagram in Fig.7, in relation to the number of
rpm normally declared by the manufacturer.
Minimum duct pulley diameter (on pump shaft): ≥250 mm.

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The radial load on the shaft must not exceed 7500N
(value necessary for Layout denition). The transmission is
considered adequate if the load is applied at a maximum
distance a=40 mm from the shaft shoulder (P.T.O) as shown in
Fig.10.
For dimensions diering from those specied
above, contact our Technical or Customer Service
Departments.
Fig.7
9.11 Transmission denition
To prevent irregular radial loads on the shaft and the relative
bearing, follow these directions:
a) Use pulleys with V-belts with the size of the groove
required/recommended by the manufacturer of belt used.
In the absence of directions, follow Fig.8 and the table in
Fig.9.
Single groove
Break
corners
Multiple groove
Fig.8

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Dimensions (in mm)
Belt section as per DIN symbol
DIN 7753 part 1 and B.S. 3790 symbol B.S./ISO
Belt section as per DIN symbol
DIN 2215 and B.S. 3790 symbol B.S./ISO
XPB/SPB
SPB
17
B
XPC/SPC
SPC
22
C
Pitch width bw14.0 19.0
Increased grooving width b1≈ α = 34° 18.9 26.3
α = 38° 19.5 27.3
c 8.0 12.0
Distance between grooving and 23 ± 0.4 31 ± 0.5
f 14.5 ± 0.8 20.0 ± 1.0
Increased grooving depth tmin 22.5 31.5
α 34° by primitive diameter dwfrom 140 to 190 from 224 to 315
38° narrow-section V-belts
DIN 7753 part 1 > 190 > 315
α 34° by primitive diameter dwfrom 112 to 190 from 180 to 315
38° classic section V-belts
DIN 2215 > 190 > 315
Tolerance for α = 34°-38° ± 1° ± 30’
Pulleys for b2 by grooving number z
b2 = (z-1) e + 2 f
1 29 40
2 52 71
3 75 102
4 98 133
5 121 164
6 144 195
7 167 226
8 190 257
9 213 288
10 236 319
11 259 350
12 282 381
Minimum pulley diameter must be respected.
Do not use laminated V-belts. Fig.9
b) Use high performance belts – for example XPB instead of
SPB – as a lower quantity of belts for the same transmitted
power may be necessary and a consequent shorter
resulting distance compared to the shaft shoulder (P.T.O)
“a”of Fig.10.
Shaft
shoulder
(P.T.O.)
Fig.10
c) Pull the belts according to manufacturer instructions.
Excessive pulling can cause reduced bearing life and wear
out the pulley prematurely. Pulling depends on dierent
variables as indicated in par.9.12.
d) Belt length has a natural tolerance ≥ ± 0.75%. For this
reason, the 2 belts must be purchased as a pair.
e) Follow the direction of the belt pull as shown in Fig.9 for
other needs, contact our Technical or Customer Service
Departments.
f) Take care of the alignment of the driving pulley and driven
pulley grooves.

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9.12 Denition of static pull to apply on belts
Static pull depends on:
a) The wheelbase between the two pulleys (belt length).
b) The load due to static pull of the belt.
c) The number of belts.
d) The winding angle of the smallest pulley.
e) Average speed.
f) Etc.
Values of the static pull to be applied can be obtained from
the diagram in Fig.11 for belts with a XPB prole in relation to
the wheelbase.
te = Belt bend mm
Lf= Wheelbase mm
Fig.11
Conclusion: with a wheelbase of 600 mm and with a
dynamometer, loading the belt branch with 75 N as indicated
in Fig.12, a“te”bend of approximately 10.8 mm is obtained.
Lf = Wheelbase
te = Belt bend
Fe = 75 N Dynamometer load
Fig.12
NOTE1.Unless otherwise stated by the supplier of the belts,
control of proper pull and its relative re-tensioning should be
performed after no less than 30 minutes of motion necessary
for the normal adjustment of the belts. Best performance and
durability will be achieved with proper tensioning.
NOTE2.In case of necessity or for routine maintenance, never
replace a single belt but the complete set.
9.13 Transmission of power from the second PTO
Upon request, KF series pumps can be supplied with an
auxiliary PTO on the opposite side to the drive (Transmission
of power from the second PTO).
Transmission can be carried out:
• By means of the V-belts.
• By means of the joint.
By means of the V-Belts, withdrawable Max Torque is:
65 Nm which corresponds to:
7 HP at 750 rpm;
7.4 HP at 800 rpm;
8.3 HP at 900 rpm;
9.3 HP at 1000 rpm;
11.1 HP at 1200 rpm.
By means of the joint, withdrawable Max Torque is:
130 Nm which corresponds to:
14 HP at 750 rpm;
14.8 HP at 800 rpm;
16.6 HP at 900 rpm;
18.6 HP at 1000 rpm;
22.2 HP at 1200 rpm.
By means of the V-belt, the transmission is
considered suitable if: belt pull is applied at a max
distance of 22 mm from the bend shaft shoulder
Fig.13. Min diameter of pulley to be used =
Ø100mm
With transmission by means of the joint, pay
particular attention to perfect alignment so that no
transverse forces are generated on the pump shaft.
Fig.13
For applications diering from those specied
above, contact our Technical or Customer Service
Departments.

ENGLISH
33
10 START-UP AND OPERATION
10.1 Preliminary checks
Before start-up, ensure that:
The suction line is connected and pressurized
(see par.9.4 - 9.5 - 9.6) the pump must never
rundry.
1. The suction line ensures a hermetic seal over time.
2. Any shut-o valves between the supply source and the
pump are fully open. The outlet line is free discharge,
topermit rapid expulsion of the air present in the pump
manifold and therefore facilitate fast priming.
3. All suction and outlet ttings and connections are
properly tightened.
4. The coupling tolerances on the pump/transmission axis
(half-joint misalignment, Cardan joint tilt, belt pulling,
etc.) remain within limits required by the transmission
manufacturer.
5. Oil in the pump casing is at level, veried with a dipstick
(Fig.14, pos.c) and exceptionally with a level indicator
(pos.Fig.14, d).
Fig.14
In case of prolonged storage or long-term
inactivity, check proper functioning of the
suction and outlet valves.
10.2 Start-up
1. At rst start-up, verify that the rotation direction and the
supply pressure are correct.
2. Start-up the pump without any load.
3. Check that the supply pressure is correct.
4. Check that the rotation rpm during operation does not
exceed the nominal rpm of the pump.
5. Let the pump run for a period of no less than 3 minutes,
before putting it under pressure.
6. Before each pump stop, reset pressure by means of the
control valve or with any relieving devices and reduce to a
minimum rpm (activation with combustion motors).
11 PREVENTIVE MAINTENANCE
For pump reliability and eciency, comply with maintenance
intervals as shown in the table of Fig.15.
PREVENTIVE MAINTENANCE
Every 500 hours Every 1000 hours
Check oil level Change oil
Check / Replace:
Valves
Valve seats
Valve springs
Valve guides
Check / Replace:
H.P. seals
L.P. seals
Fig.15
ATTENTION: Replace the bearings and the related
seal rings every 8000 hours of operation.
Perform periodical checks on cleaning and
maintenance on the pump. See“ATEX EXPLOSION
PROTECTION”manual.
12 PUMP STORAGE
12.1 Long-term inactivity
If the pump is started for the rst time after a long
period from the date of shipment, before operation
check the oil level, inspect the valves as specied
in chapter 11, then follow described start-up
procedures.
12.2 Method for lling pump with anti-corrosion
emulsion or anti-freeze solution
Method for lling pump with anti-corrosion emulsion or
anti-freeze solution using an external diaphragm pump based
on the layout shown in par.9.7, between pos.cand pos.dof
Fig.6 and Fig.6/a:
• In place of the service tank, use a suitable container
containing the solution to be pumped.
• Close the lter drainage, if open.
• Make sure that the hoses to be used are clean inside and
spread grease on their connections.
• Connect the high pressure exhaust pipe to the pump.
• Connect the suction pipe to the diaphragm pump.
• Connect the suction pipe between the pump head and
the diaphragm pump.
• Fill the service container with solution/emulsion.
• Insert the free ends of the suction pipes and the high
pressure exhaust pipe inside the container.
• Switch on the diaphragm pump.
• Pump the emulsion until it exits from the high pressure
exhaust pipe.
• Continue pumping for at least another minute.
• Stop the pump and remove the previously connected
pipes.
• Clean, grease and plug the connections on the pump
head.
The characteristics of the emulsion can be strengthened if
necessary by adding, for example, Shell Donax.

ENGLISH
34
13 PRECAUTIONS AGAINST FROST
Follow the instructions in Chapter 12 in areas and
times of the year at risk of frost (see par.12.2).
In the presence of ice, do not run the pump
for any reason until the circuit has been fully
defrosted, in order to avoid serious damage to
the pump.
14 WARRANTY CONDITIONS
The guarantee period and conditions are contained in the
purchase agreement.
The guarantee will in any case be invalidated if:
a) The pump is used for purposes other than the agreed
purposes.
b) The pump is driven by an electric motor or internal
combustion engine having performance values exceeding
those shown in the table.
c) The safety devices provided are uncalibrated or
disconnected.
d) The pump has been used with accessories or spare parts
not supplied by Interpump Group.
e) Damage has been caused by:
1) improper use
2) failure to follow maintenance instructions
3) any use dierent from that described in the operating
instructions
4) lack of sucient ow rate
5) defective installation
6) improper positioning or sizing of pipes
7) unauthorized design modications
8) cavitation.
15 OPERATING FAULTS AND THEIR
POSSIBLE CAUSES
The pump does not produce any noise upon
start-up:
- The pump is not primed and is running dry.
- No suction water.
- Valves are jammed.
- The outlet line is closed and does not allow the
release of air present in the pump manifold.
Pump pulsates irregularly:
- Air suction.
- Insucient supply.
- Bends, elbows, ttings on the suction line are
choking the passage of liquid.
- Suction lter is dirty or too small.
- The booster pump, where installed, is supplying
insucient pressure or ow rate.
- The pump is not primed due to insucient head
or the outlet is closed during priming.
- The pump is not primed due to valve jamming.
- Worn valves.
- Worn pressure seals.
- Imperfect functioning of the pressure control
valve.
- Problems on the transmission.
The pump does not supply the nominal ow rate/
excessive noise:
- Insucient supply (see various causes as above).
- Pump speed is below the rated speed.
- Excessive internal leakage of pressure control
valve.
- Worn valves.
- Excessive leakage from the pressure seals .
- Cavitation due to:
1) Improper sizing of suction ducts/undersized
diameters.
2) Insucient ow rate.
3) High water temperature.
The pressure supplied by the pump is insucient:
- The user ow (nozzle) is or has become greater
than the pump capacity.
- Insucient revolutions per minute.
- Excessive leakage from the pressure seals.
- Imperfect functioning of the pressure control
valve.
- Worn valves.
Pump overheats:
- The pump is working in overpressure conditions
or pump rpm is higher than the nominal value.
- Oil in the pump casing is not at level or not the
recommended type as detailed in chapter 7
(seepar.7.6).
- Excess belt tension or joint or pulley alignment is
incorrect.
- Excessive pump tilt during operation.
Vibrations or hammering on pipes:
- Air suction.
- Faulty operation of pressure control valve.
- Valves malfunction.
- Non-uniformity of transmission motion.

ENGLISH
35
16 EXPLODED DRAWING AND PARTS LIST

ENGLISH
36
.)
'
.)
'
.)
'
.)
'
.)
'
$
.,7 .,7 .,7 .,7 .,7
% &
'
.,7 .,7 .,7 .,7 .,7
(
&2'(
'(6&5,37,21
&2'(
&2'(
'(6&5,37,21
&2',&(
'(6&5,=,21(
&2',&(
&2',&(
'(6&5,=,21(
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  25'[1%56+ '     $/%(52$*20,7,&'372    7$3323(5)252'       63,1$&,/,1'5,&$'[ 
  9,7(6(55$**,2%,(//$       ',6335(6$',)25=$$86,/,$5,$    $/%(52$*20,7,&       526(77$'[[    /,1*8(77$[[       9,7(0[ 
  &23(5&+,2/$7(5$/(/$72372    '    $1(//25$''[[ '    %&'    9,7(0[    *5*8,'$3,6721(       /,1*8(77$[[ 
  $1(//2$55(672-       &23(5&+,2/$7(5$/(/$72372 
  *8,'$3,6721(       $1(//25$''[[ 
  63,12772'[       63,1$&,/,1'5,&$'[ 
  $1(//25$''[[ '       63,$/,9(//22/,2* 
  526(77$'[[    %&'    9,7(0[ 
 3,6721('[   &    &23(5&+,26&$72/$5,'87725( 
 3,6721('[   %    &86&,1(772$6)(5( 
 3,$721('[     3,*121(=5(/,&2,'$/(
 3,6721('[     3,*121(=5(/,&2,'$/(
 3,6721('[     3,*121(=5(/,&2,'$/(
  25'[1%56+ '       &86&,1(772$6)(5( 
  9,7(),66$**,23,6721(       9,7(0[    $1(//2$55(672'       521'(//$),66$**,2&2521$ 
 $1(//23(57(187$'     &2521$=5(/,&2,'$/(  $1(//23(57(187$'   (   &2521$=5(/,&2,'$/(
 $1(//23(57(187$'   (   &2521$=5(/,&2,'$/(  $1(//23(57(187$'      25'[1%56+   $1(//23(57(187$'      6&$72/$5,'87725( 
 $1(//27(1$/7'[[/3 $'      25'[1%56+   $1(//27(1$/7'[[/3 $'      7$332*[7(=,1&   $1(//27(1$/7'[[/3 $'      63,1$&,/,1'5,&$'[   $1(//27(1$/7'[[/3 $'   '    *8$51,=,21(6&$72/$5,'87725( 
 $1(//27(1$/7'[[/3 $'  68332572*8$51,=,21,'    9,7(0[ 
 68332572*8$51,=,21,'    $/%(52$*20,7,&+<36$(&   68332572*8$51,=,21,'    )/$1*,$02725(,'56$(&   68332572*8$51,=,21,'    7$3323(5)252'   68332572*8$51,=,21,'      $1(//23(5$/%(52'+<'53$&. 
  25'[1%56+ $'    9,7(0[&21,1&$92&203/(7$ 
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7(67$7$3(53,6721('
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
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.,75,&$0%,2±63$5(.,7
.LWEURQ]LQHELHOOH±&RQURGEXVKLQJNLW

7$332*[
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$1(//2$17,(67'[[

15
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
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5,'87725(±*($5%2;
 
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15
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326
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02725(,'56$(&±6$(&+<'502725'5,9(
$1(//27(1$/7'[[+3 $1(//25(6723'[[
&21)/$1*,$³$´±:,7+',5(&7'5,9()/$1*(
7(67$7$3(53,6721('137

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'(6&5,37,21
15
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.,7
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7$332*[137
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.,7
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7(67$7$3(53,6721('137 7(67$7$3(53,6721('137 7(67$7$3(53,6721('137

ENGLISH
37
17 FLUSHING CIRCUIT DIAGRAM OF USE
Adhere to the following values for proper system operation:
minimum circuit ow rate 4 l/min, maximum uid pressure 6 bar
Pump head Pump casing
Outlet
Inlet
Outlet
Inlet

ENGLISH
38
18 SPECIAL VERSIONS
The KF pump is also available in the special version:
• KFR
The following information is helpful in deciding how to
choose and use this version.
Unless specied otherwise, observe the above instructions for
the standard KF pump.
18.1 KFR pump
18.1.1 Operating instructions
The KFR series pump has been designed to operate
in environments with atmospheres that are not
potentially explosive and for using water rich in
particulate, therefore it is considered ideal for
systems with uid recirculation.
The durability of the piston seals is directly in
relation to the percentage of the presence of solids
in the uid as regards both their size and their
density.
For a long seal life we recommend a particulate
grain size of no more than 200 micron and 20% max.
in volume.
For more information and a general system layout,
see par.9.7.
18.1.2 Water temperature
The maximum permissible water temperature
is 40°C. However, the pump can be used with
water up to a temperature of 60°C, but only for
short periods. In this case, it is best to consult the
Technical or Customer Service Departments.
18.1.3 Maximum pressure and ow rate
The rated specications stated in our catalog are the
maximum that can be obtained by the pump. Independently
of the power used, the maximum pressure and rpm indicated
on the specication label can never be exceeded unless prior
formal authorization is given by our Technical or Customer
Service Departments.
18.1.4 Minimum operating speed
The minimum permissible speed of the crankshaft for these
types of pumps is 100 rpm; any rpm other than as shown in
the performance table (see par.18.1.5) must be expressly
formally authorized by our Technical or Customer Service
Departments.
18.1.5 Technical characteristics
Model Rpm Flow rate Pressure Power
l/min Gpm bar psi kW HP
KFR 28 1000 93 24.5 210 3045 37 50
KFR 30 1000 106 28 200 2900 40 55
KFR 32 1000 120 31.7 180 2610 41.2 56
KFR 36
800 122 32.2 160 2300 37 50
900 137 36.2 140 2050 37 50
1000 153 40 130 1900 38.2 52
KFR 40 900 170 45 110 1595 36 49
18.1.6 Dimensions and weight
For KFR version pump dimensions and weight, refer to Fig.16.
Dry weight 68 kg. Fig.16

ENGLISH
39
18.1.7 Exploded view

ENGLISH
40
.)5
'
.)5
'
.)5
'
.)5
'
.)5
'
$
.,7 .,7 .,7 .,7 .,7
%
&
'
.,7 .,7 .,7 .,7 .,7
(
&2'(
'(6&5,37,21
&2'(
&2'(
'(6&5,37,21
&2',&(
'(6&5,=,21(
&2',&(
&2',&(
'(6&5,=,21(
  &$57(53203$   $'   7$332&$57(5   $'  7(67$7$3(53,6721('137   &$338&&,27$332&$57(5   25'[1%56+.)5 $'  7(67$7$3(53,6721('137   $1(//25$''[[ '   $'  7(67$7$3(53,6721('137   67(/2*8,'$3,6721(    7(67$7$3(53,6721('137   %,(//$&203/(7$     7$332*[137 
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  25'[1%56+ '     63,1$&,/,1'5,&$'[    63,$/,9(//22/,2     ',6335(6$',)25=$$86,/,$5,$ 
 $1(//2'$55(672=- '   %    526(77$'[[ 
 $1(//2'$55(672=-$7(;      9,7(0[   &23(5&+,2/$7(5$/(/$7263,$   %&' 
 &23(5&+,2/$7(5$/(/$7263,$$7(;      9,7(0[ 
  25'[1%56+ '       &23(5&+,2/$7(5$/(/$72372 
 63(6625(',5$6$0(172PP      $1(//25$''[[   63(6625(',5$6$0(172PP      /,1*8(77$[[ 
  &23(5&+,2/$7(5$/(/$72372    '    63,1$&,/,1'5,&$'[    $1(//25$''[[ '       63,$/,9(//22/,2*    /,1*8(77$[[       9,7(0[ 
  $/%(52$*20,7,&    &    &23(5&+,26&$72/$5,'87725(    67$))$',62//(9$0(172       &86&,1(772$6)(5(    9,7(0[      3,*121(=5(/,&2,'$/(   *8,'$3,6721(      3,*121(=5(/,&2,'$/(   9,7(0[    3,*121(=5(/,&2,'$/(
  25'[1%56+ '     &86&,1(772$6)(5(    9,7(0[$7(;     9,7(0[    526(77$'[[$7(;     521'(//$),66$**,2&2521$ 
  25'[1%56+ %&'   $'  &2521$=5(/,&2,'$/(   $1(//2$17,(67'[[ '   $'  &2521$=5(/,&2,'$/(   7$3329$/92/(   $'  &2521$=5(/,&2,'$/(   &23(5&+,29$/92/(   $'   25'[1%56+ 
 02//$'P[.)5  $'   6&$72/$5,'87725( 
 02//$'P[.)5  $'   25'[1%56+ 
 02//$'P[.)5  $'   7$332*[7(=,1& 
 02//$'P[.)5  $'   63,1$&,/,1'5,&$'[ 
 $1(//23(502//$'  $'   *8$51,=,21(6&$72/$5,'87725( 
 $1(//23(502//$'  $'
 $1(//23(502//$'  $'   9,7(0[   $1(//23(502//$'  $'   $/%(52$*20,7,&+<36$(& 
 $1(//23(502//$'  $'   )/$1*,$02725(,'56$(& 
 $'   7$3323(5)252'   $'   $1(//23(5$/%(52'+<'53$&. 
     9,7(0[&21,1&$92&203/(7$ 
  '$'20[ 
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25'[1%56+.)5
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