General Pump HF Owner Manual
H
8
H
F
F
Owner’s Manual
• Installation
• Use
• Maintenance
General Pump is a
member of the
Interpump Group
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. SYMBOL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.1 General safety warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.2 High pressure unit safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3.3 Safety of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.4 General procedures for high pressure lance/gun operation . . . . . . . . . . . . . . .Page 4
3.5 Safety of maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
5. TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
7. GENERAL INFORMATION ABOUT SPECIFIC PUMP USE . . . . . . . . . . . . . . . . .Page 6
7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.2 Maximum flow and pressure ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
7.3 Lowest operating RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
A member of the Interpump Group
HF SERIES
8. CONNECTION AND PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.1 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.3 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.4 Suction line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
9.5 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.6 Delivery time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
9.7 Internal Diameter of Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 9
10. START UP AND RUNNING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
10.1 Before start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
11. MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
11.1 Crank mechanism maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
11.2 Fluid end maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15
12. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
13. MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
14. PUMP STOPPED FOR LONG TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
15. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
17. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20
18. TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22
19. MAINTENANCE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 23
20. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
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GENERAL PUMP
A member of the Interpump Group
HF SERIES
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
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
3. SAFETY
3.1 General warnings for safe operation
The misuse of a high pressure water unit and the nonobservance 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 delivery line
and should be sized to discharge or by-pass the
entire pump flow rate
2. High pressure unit components, with particular regard
for those units working outside, should be adequately
protected against rain, frost and heat.
3. Electric components and wiring should be provided
with an adequate degree of protection, able to protect
them against spray coming from any direction. They
should also be suitable for working in a wet
environment.
4. High pressure hoses and any other accessory under
pressure should be sized in accordance with the
maximum unit working pressure and must always
work within the safety margins indicated by the hose/
accessory Manufacturer.
5. High pressure hose ends should be fastened to a
steady object in order to prevent them from
dangerous sweeping around, should they burst or
come off their end fittings.
6. Proper safety guards should be provided to
adequately cover transmission joints, pulleys, belts or
auxiliary drives.
Danger
Wear protective gloves
Danger
Wear protective boots
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GENERAL PUMP
3.3 Safety of operation
The access into the area when a high pressure unit is
working should be strictly prohibited to unauthorized
personnel. The area should be suitably enclosed and its
perimeter, so far as is reasonably practical, cordoned
off and proper warning notices displayed in prominent
positions.
Personnel authorized to enter that area should have been
previously trained to do so and informed of the risks
arising from failures, misuse and any foreseeable
circumstance which may occur during operation. Before
starting the pump unit and bringing it up to pressure the
Operator is requested to carry out the following checks:
1. Make sure that a correct water supply to the pump
is provided.
2. Make sure that water inlet filters are properly clean.
3. Electrical components and wiring, with special
emphasis on connections, junction boxes, switches
and supply cables should be free from external
damage (i.e. exposed and broken wires) and
adequately protected against water.
4. High pressure hose should not show apparent
external wear and the fittings at both ends should be
free from signs of erosion or corrosion.
5. Make sure that all fluids (lubricating oil for pump and
engine, cooling water, hydraulic fluids) are at proper
levels and in good condition.
6. Make sure the safety guards are in good condition.
The work should stop immediately and the pressure must
be released in the event that leakage becomes apparent
or if any person becomes aware of an change in condition
or any hazard existing or being introduced. Any failure
must be promptly reported and then checked personnel.
3.4 General procedures for 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.
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
A member of the Interpump Group
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 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 tools in order to prevent any damage on high
pressure connections and fittings.
4. Use of other than original spare parts is strictly
forbidden.
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GENERAL PUMP
A member of the Interpump Group
4. PUMP IDENTIFICATION
Each pump is fitted with a rating plate (see Fig. 1)
containing the following information:
2. Serial number
3. Pump model and version
4. Max RPM
5. Power absorbed
6. Max flow rate (l/min) and pressure (bar)
Pump model, pump version and serial number should
be specified when ordering spare parts. Should the pump
be modified (i.e by changing the original version) than
any change should be mentioned on the rating plate for
future reference.
5. TECHNICAL FEATURES
FLOW RATE PRESSURE POWER
MODEL RPM
GPM l/min PSI Bar Hp kW
HF SERIES
HF18A 1000 10.08 38 7250 500 50 37.0
HF18A 800 8.06 30 8700 600 48 35.3
HF20A 1000 12.4 47 5800 400 50 37.0
HF22A 800 12.05 45 5800 400 50 37.0
HF22A 1000 15.0 57 5000 350 50 37.0
HF25A 1000 19.44 74 4060 280 53 39
6. DIMENSIONS AND WEIGHT
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GENERAL PUMP
A member of the Interpump Group
HF SERIES
7. GENERAL INFORMATION ABOUT PUMP
USE
The HF pump has been designed to pump fresh filtered
(360 micron max) water at room temperature (400C 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
pumps.
7.2 Pump performances
The performance data indicated in 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.
8. CONNECTIONS AND PLUGS
HF pumps are provided with (Fig. 3):
1 - 2 inlet ports IN Ø 1” NPT
Either inlet port can be used; the one not used must
be hermetically plugged.
2 - 2 outlet ports OUT Ø 3/4” NPT
7.3 Lowest operating RPM
The lowest operating speed for all HF’s (all versions)
is 500 RPM (on crankshaft).
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GENERAL PUMP
A member of the Interpump Group
HF SERIES
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 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. 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 types are suggested:
- Hydraulic by means of a flange
- Pulleys
- Cardan joint (within the max working angles indicated
by the manufacturer).
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.
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 effectiveness 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 90o elbows, diameter
reductions, counter slopes, “T” connections and and
should not be connected 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 90
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
o
Page 7
GENERAL PUMP
kind of one-way valves.
9. In 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 than the
pump inlet ports.
3. Filtration degree in between 50 and 80 mesh (360
to 200 microns).
A member of the Interpump Group
HF SERIES
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.
5. 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.
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