HF Owner Manual
Contents
1. Owner s Manual e Installation e Use e Maintenance HF SERIES INDEX 1 A 3 lt lt gt oS 10 11 12 13 14 15 17 18 19 20 INTRODUCTION uu e dk n aa ui SE oos nie ai Page 3 SYMBOL DESCRIPTIONS SS SS ES SS ees Page 3 SAFETY ereere OE OE ME OE EE Sess N OE N EE Page 3 3 1 General safety Warnings Page 3 3 2 High pressure unit safety requirements SS SS SS ss es es eee Page 3 3 3 Safety of operation 22 504 adm Eb EK AAN BEERS PER BAR HR BA BR d Page 4 3 4 General procedures for high pressure lance gun operation Page 4 3 5 Safety of maintenance naana EE SE EE eee es Page 4 PUMP IDENTIFICATION cc eee Page 5 TECHNICAL FEATURES 2222932 2 99 92432 59 91 WEJAA 99 V 9 9 25 5 DO RED ESE Page 5 DIMENSIONS AND WEIGHT 0 00 00 ccc ee Page 5 GENERAL INFORMATION ABOUT SPECIFIC PUMP USE Page 6 J Water temperature nc actetedadeseaedaewdaeSetadadecud eed RR R3 BR ER Page 6 7 2 Maximum flow and a pus sa ska EE REED HEDE HAAR ee Page 6 FI Lowest operating KP eis ie ceed een dan hehehe UR SES ep ha ee GEN Page 6 CONNECTION AND PLUGS SS SS SE SE SE ne Page 6 PUMP INSTALLATION SS ESE SE SE SE SE ees Page 7 S T POSITORBIFIO EE Geo OE HOES EO OE EE OO NS AE EE Page 7 9 2 Direction of rotation 224424445544 EH SEA REEDE AUS BES RES EN e EA Noe len GR RE Page 9 3 Water connections vececcahedeeerenedeeteied bs use miu2. 2 The Operator should wear suitable waterproof protective clothing having regard to the type of work being undertaken The clothing set should include adequate hand protection suitable boots able to ensure proper grip on wet floors helmet provided with full face shield waterproof garment providing full cover to the Operator including his arms As most water jets produce noise levels in excess of HF SERIES 90 dB A suitable ear protection is advised NOTE it must be emphasized that whereas protective clothing provides adequate protection against spray and flying particles it does not constitute complete protection protection against the direct impact of the water jet Additional protections in the form of suitable metal shields or barriers may be necessary for certain jetting operation 3 In most jetting operations it is an accepted practice to employ a team of Operators consisting of two members at least in order to provide mutual assistance in case of need and to rotate their duties in case of long and heavy work While the first Operator holds the gun the second Operator attends the pump unit keeping close watch on the first Operator for signs of difficulty or fatigue and watching the surrounding area for intrusion by other persons or unsafe situations If required he will shut off the pressure unit until it is safe to continue 4 The area in which the work is to proceed should be clear of loose items and debris
3. Example 1 With a flow of 150 l min 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 80 mm Example 2 With a flow of 70 l min and a water speed 5 5 m sec The diagram line joining the 2 scales intersects the central scale indicating the diameters at a value of 16 mm Optimal speeds suction 0 5 m sec delivery 5 m sec i d mm DN A Cm o E 2 a N a 5 e o amp linea di mandata The diagram does not take into consideration the pipe and valve resistance drop in pressure due to the pipe length the viscosity of the pumped fluid its temperature etc If necessary contact our technical department 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 2 3 Suction line should be connected the pump must never run dry Suction line must be perfectly air tight Any ON OFF valve in between the pump and water source should be open and make sure the water gets into the pump freely Set the pressure line in dump mode in order to let the air in the pump get out easily thus facilitating the pump priming Make sure all suction delivery line connections are fully tightened Joint alignment belt tightening and PTO shaft inclination tolerances sho
4. O RINGS CLEAN AND PERFECTLY DRY ALL VALVE HOUSINGS INSIDE THE FLUID END d tia ker 1 ES B Remove the high pressure packings from the fluid end and the low pressure ones from their support see arrows Fig 23 by means of standard tools taking great care not to damage the seats See Fig 25 id Fi Ip M D To reassemble the valves proceed the other way around and tighten the cover screws with a torque wrench Table on page 18 contains the screw tightening torque values and Fig 28 page 17 indicates the sequence GENERAL PUMP A member of the Interpump Group Take note of the correct order of the entire package components when disassembling Fig 26 1 Head ring 2 HP packing 3 Restop ring 4 Middle ring o LP packing 6 Back packing 7 Elastic ring 8 O ring When reassembling make sure of the correct order of the components Packing set HF 22 25 version Fig 26 G7 n i E set HF 18 version Fig 27 EISA ra C Reassembling In order to carry out the replacement more easily apply a very small quantity of silicone grease on the pressure packing lips and their seats in the fluid end This operation will also help the sealing lips settle on the plunger HF SERIES Fit the fluid end back in place and tighten the bolts with a torque wrench set for the value indicated in the table on page 18 and in the sequence indicated here below LTL a WA
5. e mE i ed Page 9 4 Suction line cratere N DE OES EE N SIRE E ES PIRE OE Page 7 Seoda e e fics oc see es eee a ee ee eee eee OE ME eee ede RUSSES Page 8 9 6 Delivery time 2c 2 46 68 ROER MAR 40685 SA a PEGS Eo Oh Gee Od Are EER BE Page 8 9 7 Internal Diameter of Hose 0 0 ces Page 9 START UP AND RUNNING PROCEDURES Page 10 10 1 Before start up cirio la UR d haere ee eee Page 10 102 SAUNG N GE N RA Titta Page 10 MAINTENANCE INSTRUCTIONS SS SS SS SS SS SS SE ee ee Page 11 11 1 Crank mechanism maintenance ESE SS cee eee ee Page 11 11 2 Fluid end maintenance SE SEE EE ss eens Page 15 TORQUE SPECIFICATIONS leere Page 18 MAINTENANCE TOOLS SS SS SS rn Page 18 PUMP STOPPED FOR LONG TIME SS SS SS SS SS SE Se ee Page 19 PRECAUTIONS AGAINST FREEZING SS SES SS SS Se ee Page 19 EXPLODED VIEWS AND PARTS SS SS SE SS SS SS es Page 20 TROUBLE SHOOTING iss Soo hie ESE es REST die tee DR E E Page 22 MAINTENANCE TOOLS SS SS SS SS eee Page 23 MAINTENANCE LOG SS SS SS ee eens Page 24 GENERAL PUMP A member of the Interpump Group 1 INTRODUCTION 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 your HF high pressure plunger pump is correctly installed and
6. ie F ed N SA IN IN T OO 11 2 3 Plunger To replace the plunger if necessary do as follows A Loosen and remove the plunger screws as indicated in Fig 29 When aisseeembling the pumping unit the O rings should always be replaced B Fit back the replaced components inverting the order Use a torque wrench set for the values indicated in the table on page 18 GENERAL PUMP A member of the Interpump Group HF SERIES 11 2 4 Fluid End In order to mount the fluid end on the pump proceed as follows A Fit the packing supports back in place in the crankcase B Fit the pressure packings back in place in the pump head C Using two stud bolts min length 200 mm and the central plunger as a guide carefully slide to head in position against the crankcase D Tighten the head bolts with a torque wrench set as indicated in the chart to the right 12 TORQUE SPECIFICATIONS The following table contains the screw a tightening torque values to be set by means of a torque wrench only DESCRIPTION Ft Lbs Rear cover Screws Plunger Bolts Connecting Rod Screws Valve Plate EE Screws Fluid End Bolts Auxiliary Plug The conrod screws must be tightened as indicated in point D page 13 The valve plate must be tightened following the sequence indicated in fig 28 The fluid end screws must be tightened in 2 stages following the sequence indicated in fig 24 First stage 20 N m Secon
7. see Fig crankshaft without key it is necessary to push 10 that must be turned towards the operator so the the unit piston guide connecting rod backward crankshaft can be easily extracted NOTE to extract the piston guide it is necessary to remove the cramic plunger and wiper first C Disassemble the crankshaft oil seals and the piston guides using standard tools GENERAL PUMP A member of the Interpump Group HF SERIES 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 12 RING POSITON ON FIRST ASSEMBLING RING POSITON WITH WORN SHAFT Fig 12 NOTE Should the shaft show diameter wear in the seal position it is possible to avoid grinding it by fitting the seal further as indicated in Fig 12 Before installing the cover sight glass side check the shim rings have been placed To help the covers fit on the crankcase you can use 3 screws M6 x 40 and then finish screwing them with the original bolts M16 x 18 D Install the connecting rod cap taking care the numbers match and tighten the relevant bolts in 3 different stages 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 E Fit the back cover putting the dipstick hole upward 11 1 3 Disassembling Reassembling of the bearings and shims The type of bea
8. to prevent tripping and slipping hazards 5 The water jet should be directed only and always against the workpiece even during preliminary operating tests prior to starting work 6 Where applicable proper side shields should be suitable placed to safeguard personnel and equipment against contact with grit or particles removed by the water jet 7 On no account must the Operator be distracted during operation until the jet has been stopped Personnel having reason to enter the water jetting area should wait until the jet is stopped and his presence known 8 Each team member must always be aware of the actions and intentions of other team members in order to prevent any dangerous misunderstanding occurring during jetting operation 9 The pump unit should not be started and brought up to pressure unless each team member is in his designated position the nozzle directed to the workpiece and the lance or gun securely held 3 5 Safety of maintenance Apart from the working pressure regulation no attempt should be made to adjust any nut hose fitting etc while that part of the system is under pressure The pump should be stopped and any pressure in the line released prior to making any adjustments 1 The high pressure water unit should be maintained in accordance with the Manufacturer s instructions 2 The unit should be maintained only by competent personnel 3 Service and maintenance should be carried out with proper to
9. 18 F If the torque is correct connect the rods to the crankshaft otherwise calculate the shims again as per point C HF SERIES 11 2 Fluid end maintenance A Loosen the valve cover screws not shown B Extract the valve plugs with an extractor or a M8 11 2 1 Pump head threaded rod see Fig 19 The pump head does not require periodic maintenance C Extract the valve unit with the same tool Service operations are limited to the component inspections and or replacement when necessary Valve units L D Extract the valve spacer using an extractor or a M16 threaded rod see Fig 20 E Extract the suction valve unit by using an extractor or a M8 threaded rod see Fig 21 The valve units are contained in the head and mounted in a vertical position For proper inspection they should be taken out Proceed as follows HF SERIES Valve components of each valve are pressed together 11 2 2 Seals and therefore they can be easily replaced and installed back in place by means of simple tools see Fig 22 The replacement of the seals is necessary when water drips throught the holes provided underneath the Check the components for wear and replace if necessary crankcase For replacement do as follows Replace all o rings of the valve units and valve plugs at each inspection A Remove the fluid end by loosening the 8 bolts see Fig 24 IMPORTANT NOTE BEFORE REPOSITIONING THE VALVE UNITS AND
10. Delivery Kit F36205066 HF18A Suction Delivery Valve Plate F36203966 HF22A 25A Suction Delivery Valve Plate 7 F36204366 Valve Seat Delivery 48 F90385100 O ring 21 89 x 2 62 51 F90S17900 Backup ring 6 314x355x18 5 F90385600 O ring 23 47 x 2 62 HF18A 4 90515500 HF18A Back up ring 023 9 x 28 x 2 3 90517700 HF22A 25A Back up Ring 30 x 34 x 1 5 36204966 HF18A Valve Seat Suction 6204266 HF22A 25A Valve Seat Suction 0357600 O ring 6 75 x 1 78 7 98197200 Plug G 1 8 x 8 8 36713901 Valve Assembly Delivery rserissoi HEZ2A zSA Valve Assembly Sueion 3 60 E10067720 Fydrauie Motor Fene SSCS Cer ressoseoo Screw toe Mex ss UNI TE 4 71223074 Lifting Eyebolt 1 2 dk 39 40 A AJ AP A O T mim W mim 6 mim e a F2022 HF22A amp HF25A F2023 HF18A 22A amp 25A F2031 HF18A F2024 HF18A F2026 HF22A F2028 HF25A Items Included 44 46 53 54 56 65 44 45 46 47 48 49 in Kit 59 59 58 Number of 44 46 53 54 55 65 32 34 32 34 32 34 35 36 35 36 35 36 A member of the Interpump Group GENERAL PUMP 18 TROUBLE SHOOTING D 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 THE PUMP KNOCKS Air sucti
11. d Stage 80 N m 13 MAINTENANCE TOOLS Standard tools are required for the pump maintenance but to facilitate the mounting and dismounting operations of some pump components you will find the drawings to make some tools on page 23 GENERAL PUMP A member of the Interpump Group HF SERIES 14 PUMP STOPPED FOR LONG TIME 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 When a long inactivity is scheduled drain the entire suction and delivery line and then run the pump dry only for a few seconds in order to drain out the water collected inside the fluid end 15 PRECAUTIONS AGAINST FREEZING Where and when there is a risk of freezing the following pracautions should be taken After use drain the entire suction and delivery lines filter included by means of discharging devices provided and positioned specifically for this purpose along the lowest point of the lines Run the pump only for a few seconds in order to drain the water collected inside the fluid end Or when applicable Add a recommended amount of anti freeze into the water tank and run the pump until the anti freeze works all through the system If a pump is frozen or appears frozen ON NO ACCOUNT SHOULD THE PUMP BE OPERATED until the entire system has been
12. 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 adeguately protected against rain frost and heat 3 Electric components and wiring should be provided with an adeguate 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 GENERAL PUMP A member of the Interpump Group A 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 fail
13. ected with other pipelines 5 It must be positioned in such a way to prevent the pipe emptying after the pump stops 6 Do not use high pressure hydraulic fittings like 909 elbows high pressure adaptors high pressure 3 or 4 way nipples and so on 7 Do not install any kind of detergent infector along the suction line 8 Do not install standing valves check valves or other GENERAL PUMP A member of the Interpump Group kind of one way valves 9 n the case of a feed tank make sure that dimensions of the tank and the water minimun level do not give rise to turbulence at the tank outlet port which in turn might create cavitation in the pump 10 Do not connect the by pass line from the valve directly to the pump suction line 11 Connect the bypass line from the valve directly to the feed tank and make sure that both the bypass and tank feeding flows could not give rise to turbulence at the tank outlet port which in turn might create cavitation at the pump Proper baffle plates should be provided inside the tank 12 Before connecting the suction line to the pump inlet port make sure the pipe is perfectly clean 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 should be at least three times the rated pump volume 2 Filter port diameters should not be smaller t
14. ged at least once a year since oxidation deteriorates it A member of the Interpump Group HF SERIES List of recommended oils BRAND TYPE GENERAL PUMP SERIES220 Bp ENERGOLHIP220 Mineral or synthetic oils can be used but they must be chosen according to the working environment temperature Here below is a diagram indicating viscosity according to room temperature GENERAL PUMP RECOMMENDS USING SAE 50W Oil grade SAE for engine oil Recommended according to the room temperature indicated in Celsius degrees 30 25 20 18 10 10 415 420 425 430 435 40 HF SERIES 11 1 1 Crank mechanism disassembling 11 1 2 Crank mechanism reassembling Do as follows After washing the crankcase reassemble the power end A Drain the oil from the pump and remove sedelose shait key back cover connecting rod cap side covers To do so use 3 screws M6 x 50 wholly threaded putting them into the holes drilled for that purpose See Fig 9 A Fit the piston guide seals into their seat thoroughly making sure they are correctly positioned B Introduce the unit piston guide connecting rod into their seats To facilitate the tightening of the B Push the piston guides and connecting rods forward connecting rod cap position the connecting rod SO you can remove the pump crankshaft from the SO you can easily read the number To install the side On the crankshaft you will find marks
15. han the pump inlet ports 3 Filtration degree in between 50 and 80 mesh 360 to 200 microns IMPORTANT NOTE In order to properly safeguard the pump it is very important to plan cleaning of the filter with a frequency depending on the water quality filtration degree and number of hours of each application It is recommended to use filters with a clogging signaling device 9 6 Delivery line For a correct delivery line comply with the following instructions 1 The first length of delivery hose should be flexible in order to isolate the pump vibrations from the rest of the system 2 Use only high pressure hoses and fittings able to guarantee the largest possible safety margins in any working conditions 3 A suitable relief valve should be installed in the delivery line 4 Use glycerine filled pressure gauges as the most suitable for pulsating loads o When designing the delivery line take into proper account the unavoidable drop in pressure due to its length and size 6 If necessary the effects of the pump pulsations can be reduced by installing a proper pulsation dampener in the pressure line HF SERIES NO 90 ELBOW ic T CONNECTIONS DIAMETER REDUCTION l COUNTER SLOPE I BY PASS BACK TO THE INLET LINE NEGATIVE SUCTION HEAD BAFFLE PLATE BY PASS LINE HF SERIES 9 7 Internal Diameter of Piping To determine the internal diameter of the piping follow the following diagram
16. maintained it will give trouble free operation for a long time Themanufacturer declines all responsibility for damages arising from the misuse and non observance of the instructions indicated in this manual On receiving the pump please check that it is conplete and in good state Should you find anything out of order please contact General Pump before installing and starting the pump 2 SYMBOL DESCRIPTIONS Warning Potential Danger Read carefully and understand the manual before operating the pump Danger Electrocution Danger Danger Wear protective mask Danger Wear goggles Danger Wear protective gloves Danger Wear protective boots HF SERIES 3 SAFETY 3 1 General warnings for safe operation The misuse of a high pressure water unit and the non observance of the pump installation and maintenance instructions may cause serious damages and or injuries to people or properties or both Any Manufacturer Operator requested to assemble use a high pressure water unit should be competent to do so should have the necessary knowledge on every high pressure component installed in the unit and on the precautions to be taken in order to guarantee the largest safety margins during operation No precaution so far as is reasonably practical should be left out in the interest of safety both from the Manufacturer and the Operator 3 2 High pressure unit safety requirements 1 A safety valve should be installed in any
17. n the catalog and on the rating plate refer to the maximum performance of the pump The use of the pump below the rated performances does not allow the drop in power absorbed to be balanced by altering the pressure or volume of the pump above its maximum value unless especially authorized by our technical department 7 3 Lowest operating RPM The lowest operating speed for all HF s all versions is 500 RPM on crankshaft GENERAL PUMP A member of the Interpump Group 9 PUMP INSTALLATION 9 1 Positioning The pump must be installed on a rigid and perfectly flat and horizontal base by means of the proper four M16 x 1 5 threaded feet The base should be rigid enough to avoid any misalignment or flexing on the pump transmission cou pling axis due to the torque involved during operation The unit should not be rigidly fixed on the floor but be installed upon vibration dampeners For special applications contact our technical department An eye bolt is provided on top of the crankcase for easy handling of the pump see picture below The eye bolt can be replaced with a plastic cap see below in order to protect the thread in the crankcase The plastic cap is provided with the pump The oil plug must absolutely be replaced by the oil stick and the oil level checked Make sure that you can easily reach the oil stick even after the unit has been assembled Never use rigid coupling on the shaft The following transmission ty
18. ng from the 2 shaft ends by means of a standard pin extractor or similar tool See Fig 15 16 The new roller bearings can be mounted at room temp erature 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 250 300 F making sure that the ring nuts are fitted in their seats NOTE Take care not to invert the components of the 2 bearings outer ring nut of bearing 1 instead of the one of bearing 2 To maintain the right axial load the shim package has to be calculated again as follows A Install the crankshaft into the crankcase making sure that the PTO end comes out on the correct side B Fit the motor side flange on the crankcase with special attention to the seal lip as indicated on point 11 1 2 C Position the sight glass side flange using the 3 screws M6 x 18 until the crankshaft cannot be turned by hand freely D By means of a thickness gauge see Fig 11 determine the shim package as indicated in the table below Meoswe Shin ype Pieces _ CI I Fomor 020 i 3 Fiom 02110030 or 2 Fiom ostto035 os 1 21 LL MN WE WEE ME 0 35 0 35 Fit the shims under the sight glass side cover gp it on the crankcase with the screws and check that the stall torque is between 4 Nm and 6Nm n N NI gt a f Fig
19. ols in order to prevent any damage on high pressure connections and fittings 4 Use of other than original spare parts is strictly forbidden HF SERIES 4 PUMP IDENTIFICATION Each pump is fitted with a rating plate see Fig 1 containing the following information Serial number Pump model and version Max RPM Power absorbed Max flow rate l min and pressure bar pr pigs po M 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 2 TECHNICAL FEATURES Rowmw pressure Power MODEL ou m pm www Lm ow e sam 6 DIMENSIONS AND WEIGHT VA b e Weight 132 Ib HF SERIES 7 GENERAL INFORMATION ABOUT PUMP 8 CONNECTIONS AND PLUGS USE AN The HF pump has been designed to pump fresh filtered 360 micron max water at room temperature 400 C max 7 1 Water temperature Water temperature is critical for the pump life the higher it is the more likely it is to create cavitation resulting in premature seal and valve failures For such conditions use HT series HF pumps are provided with Fig 3 pps 1 2 inlet ports IN 1 NPT Either inlet port can be used the one not used must be hermetically plugged 7 2 Pump performances 2 2 outlet ports OUT 3 4 NPT The performance data indicated i
20. on Insufficient feeding bends elbows and fittings along the suction line throttle the amount of water which passed through too small inlet filter dirty inlet filter the feeding pump where provided is not of the suitable type or provides insufficient pressure or volume The pump is not primed due to insufficient feeding or the delivery line is closed during start up The pump is not primed because some valves are stuck i e pump inactivity for long time Jammed or worn out valves Worn out pressure packings The pressure regulating valve does not work properly Clearance in the drive system RPM are higher than rated THE PUMP DOES NOT DELIVER THE RATED VOLUME Insufficient feeding due to the cause listed above RPM are less than rated Excessive amount of water by passed by the pressure regulating valve Worn out valves Excessive leakage packings from pressure HF SERIES INSUFFICIENT PUMP PRESSURE The nozzle is or has become too large RPM are less than rated Excessive leakage packings Excessive amount of water by passed by the pressure regulating valve or faulty valve operation Worn out valves from pressure EXCESSIVE WATER LEAKAGE FROM THE PUMP Pressure packing are excessively worn out due to normal wear or excessive cavitation Worn out plungers OVERHEATED PUMP The direction of rotation is not correct P
21. pes are suggested Hydraulic by means of a flange Pulleys Cardan joint within the max working angles indicated by the manufacturer HF SERIES 9 2 Direction of rotation An arrow situated on the crankcase near the shaft indicates the correct direction of rotation Fig 4 shows the direction of rotation looking at the pump from the fluid end side LEFT SIDE clockwise RIGHT SIDE Anti clockwise 9 3 Water connections In order to isolate the high pressure equipment from the pump vibrations it is suggested where applicable to use flexible hoses for both suction and delivery lines at least for the first length The flexible suction hose must be rigid enough to prevent it from collapsing during the suction stroke when a partial vacuum may occur 9 4 Suction line The pump life is considerable influenced by the effective ness of the suction line which must have the following characteristics 1 The internal diameter of the suction line should be at least 30 mm see the diagram on point 9 7 in any point possibly larger depending on the drop in pressure due to the length and shape of the line 2 It should be as straight as possible minimizing changes in size and direction and positioned in such a way to allow air pockets and bubbles to escape 3 It should be perfectly airtight 4 It should be completely free from 900 elbows diameter reductions counter slopes T connections and and should not be conn
22. rings conical roller ensures there is no end float on the crankshaft the shims are to be determined to reach that purpose To disassemble reassemble and if required replace them it is absolutely necessary to do as indicated below Disassembling reassembling of the crankshaft without replacing the roller bearings After removing the side covers as indicated on point 11 11 1 check the rollers and reces for wear if they are in good state accurately clean the components with suitable degreaser and grease them again evenly with oil same as the pump oil The same shims can be used again taking care to fit them under the sight glass cover After installing the complete unit sight glass side flange crankshaft engine side flange check that the rolling couple with connecting rods free is at least 4 Nm max Nm To position the two side covers on the crankcase you can use 3 screws M6 x 40 first and then the original screws to fix them The rolling couple of the crankshaft with connecting rods coupled must not exceed 8 Nm Screw M6x40 To position the cover GENERAL PUMP A member of the Interpump Group HF SERIES 11 1 4 Disassembling reassembling of the crankshaft with replacement of the bearings After disassembling the side covers as indicated in point 11 1 1 remove the outer ring nut of the bearings from their covers and the inner ring nut together with the remaining part of the beari
23. thawed out HF SERIES 17 EXPLODED VIEW AND PARTS LIST 30 31 32 33 34 35 3637 GENERAL PUMP A member of the Interpump Group Kem Part Descripton jar 4 For stimo _ __ OO aaaer Sm oz __ jrrzzoser Sam os __ 6 rrznsor ortevermdcaor Ef TT 8 rrnsorz2 oi Level Indicator Bearing CoverSide 9 F99166700 Screw TGEMEX 18 UNI 5931 E Plug G1 2 x 13 Nickel 76 ross13800 ComecingRodScew 5 22 Feo0sos00 Rms g20UN743 5 rro Pumenaz2 rr4209 Pumgera25 arme ewe Re 022 Farao eene Ring 225 F9o2ri900 Packing gz2LR prae Pacme g25 LP E Frt2isiv0 Packing Suppo 22 E F71215270 Packing Suppo 025 E _ Feoersooo rese aa E roozraso reso 028 E F9o272500 Packing gz2HP E Feo274900 Packing 25HP E Forest RomRme02 WEN GE IE RomRme025 Hol F71120136 Wanifoid for Plunger 22 6 TT F71120236 Wanifoid for Plunger 28 6 TT OO F71124136 Wanifoid for Plunger 22 NPT TT Frrt24236 Wanifola for Plunger 25 NPT TT REPAIR KITS HF SERIES Part Description Screw TCEI M12 x 150 UNI 5931 Valve Cover 41 F99485000 Screw TCEI M14 x 40 UNI5931 42 Back up Ring OR 40 9 x 45 x 5 43 Valve Plug A Suction Delivery Valve Guide 5 Valve Spring
24. uld remain within the values indicated by the transmission Manufacturer Make sure the oil level is correct using the dipstick position 1 Fig 7 and the oil sight glass position 2 figure 7 10 1 2 HF SERIES When starting the pump up for the first time check check for proper direction of rotation Pump and motor engine must start offload set the regulating valve to zero or set the pressure line in dump mode by means of proper dumping devices During operation check that the rotating speed does not exceed the rated value Before putting the pump under pressure let it run for at least 3 minutes Before stopping the pump release the pressure from the system by operating the dump device or by releasing the regulating valve and reduce RPM to a minimum diesel applications 2 Starting up Note in case of feeding by a centrifugal pump make sure that the plunger pump starts only when the correct inlet pressure is provided GENERAL PUMP 11 MAINTENANCE INSTRUCTIONS 11 1 Crank mechanism maintenance Check oil level at least on a weekly basis Fig 8 Fig 8 If necessary add the missing oil through the oil plug position 1 Fig 8 Check oil level when the pump is at room temperature When changing the oil removing the plug position 3 Fig 8 the pump should be at its work ing temperature Change oil every 1000 working hours oil pump capacity is 2 litres In any case the oil should be chan
25. ump is overloaded pressure or RPM over the rated values The oil level is too low or the oil is not of a Suitable type or fully used Water in the oil Excessive belt tension or incorrect alignment of the joint where provided Excessive inclination of the pump during operation PIPE VIBRATIONS OR KNOCKING Air suction The pressure regulating valve does not work properly The by pass line is undersized Jammed up valves Drive transmission motion is irregular HF SERIES 19 MAINTENANCE TOOLS 19 2 Piston guide oil seal assembling The pump maintenance can be carried out with simple tools for mounting and dismounting but tools can be made to facilitate these operations The drawings here below will help the operator make tool if he wants to 19 1 Assembling crankshaft oil seal 60 D 45 D 52 REPAIR KITS HF SERIES MAINTENANCE LOG HOURS amp DATE OIL CHANGE GREASE PACKING REPLACEMENT PLUNGER REPLACEMENT VALVE REPLACEMENT GENERAL PUMP GP Companies Inc 1174 Northland Drive Mendota Heights MN 55120 Phone 651 686 2199 Fax 800 535 1745 Ref 300622 Rev F www generalpump com email sales gpcompanies com 03 11
26. ures 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 ds 3 4 General procedures for high pressure gun lance operation 1 The Operator should take reasonable care for the safety of himself and of other persons who may be affected by his acts or omission at work His actions should always be governed by his good sense and responsibility
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