General Pump SM Owner Manual

SM
Owner’s Manual
• Installation
• Use
• Maintenance
General Pump is a member of the Interpump Group
Ref 300893 Rev.A
06-12
GENERAL PUMP
INDEX
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
2. DESCRIPTION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3
3. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.2 High pressure unit safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.3 Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.4 General procedures for using nozzles and lances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 4
3.5 Safety during unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
4. PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5
5. TECHNICAL CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 6
6. DIMENSIONS AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.1 Water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.2 Maximum flow and pressure rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.3 Minimum RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 7
7.4 Recommended lubricant types and manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 8
8. PORTS AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
8.1 Linings/Nose Cones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 10
A member of the Interpump Group
SM SERIES
9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
9.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11
9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
9.3 Version Change and reduction gear positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12
9.4 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.5 Pump power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.6 Inlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 13
9.7 Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
9.8 Outlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 14
9.9 Internal diameter of hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 15
9.10 V-belt transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
9.11 Transmission of power from the second PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 16
10. START UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
10.1 Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17
10.3 Cooling circuit seal packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
11. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18
12. PUMP STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
12.1 Inactivity for lengthy periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
12.2 Filling the pump with anti-corrosion emulsion or anti-freeze . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
12.3 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
13. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
14. WARRANTY TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 19
15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20
16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21
17. REPAIR KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 23
17. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24
Ref 300893 Rev.A
06-12
Page 2
GENERAL PUMP
A member of the Interpump Group
SM SERIES
1. INTRODUCTION
This manual describes the use and maintenance instructions of the SM pump, and should be carefully read and understood before using the pump.
Correct use and adequate maintenance will guarantee the pumps trouble-free operation for a long time. General Pump declines any responsibility for damage caused by misuse or the non-observance of the instructions indicated in this manual.
Upon receiving the pump, check that it is complete and in perfect condition. Should anything be found out of order, please contact us before installing and starting the pump.
2. SYMBOL DESCRIPTIONS
Warning
Potential Danger
Read carefully and understand the manual before operating the pump
Danger
High Voltage
Danger
Wear protective mask
Danger
Wear goggles
Danger
Wear protective gloves
Danger
Wear protective boots
Ref 300893 Rev.A
06-12
Page 3
GENERAL PUMP
A member of the Interpump Group
SM SERIES
3. SAFETY
3.1 General Safety Indications
Improper use of pumps and high pressure systems, and/or failure to observe the installation and maintenance instructions may cause serious injury to people and/or damage to property. Anyone assembling or using high pressure systems must possess the necessary competence to do so, should be aware of the characteristics of the components assembled/used, and must take all precautions necessary to ensure maximum safety in any operating condition. In the interest of safety, both for the Installer and the Operator, no reasonably applicable precaution should be omitted.
3.2 High pressure unit safety requirements
1. The pressure line must always be equipped with a safety valve.
2. High pressure system components, in particular for those units working outside, must be adequately protected against rain, frost and heat.
3. The electrical control system must be adequately protected from water spray, and must comply with the specific regulations in force.
4. High pressure hoses must be properly sized for maximum operating pressure of the system and always and only used within the operating pressure range specified by the hose manufacturer. The same rules should be observed for all other auxiliary systems affected by high pressure.
5. The ends of high pressure hoses must be sheathed and secured to a solid structure to prevent dangerous whiplash in case of bursting or broken connections.
6. Appropriate safety guards must be provided for the pump transmission systems (couplings, pulleys and belts, auxiliary drives).
3.3 Safety During Operation
The working area of a high pressure system must be clearly marked. Access must be prohibited to un-authorized personnel and, wherever possible, the area should restricted or fenced. The personnel authorized to access this area should first be trained, and informed about the risks that may arise from failures or malfunctions of the high pressure unit.
Before starting the unit, the operator must verify that:
1. The high pressure system is properly fed by a minimum pressure of 75-100 PSI (5-7 Bar), metered in the head flange.
2. The pump intake filters are perfectly clean; we recommend the use of a device that indicates the filters clogging level.
3. Electrical parts are adequately protected and in perfect condition.
4. The high pressure hoses do not show evident signs of abrasion, and that fittings are in perfect shape.
Any fault or reasonable doubt that may arise before or during operation should be promptly reported and verified by competent personnel. In these cases, pressure should immediately be released and the high pressure system stopped.
3.4 General Procedures For Using Lances/Nozzles
1. The Operator must always place his own and other worker’s safety before any other interest; his and should always be governed by good sense and responsibility.
2. The Operator must always wear a helmet with a protective visor, waterproof clothing, and appropriate boots capable of guaranteeing grip on wet pavement.
Ref 300893 Rev.A
06-12
Page 4
GENERAL PUMP
Note: appropriate clothing will effectively protect against water spray, but it may not offer adequate protection against the direct impact of water jets or sprays from a close distance. Some circumstances may require further protection.
3. It is generally best to organize personnel into teams of at least two people capable of giving mutual and immediate assistance in case of necessity and of taking turns during long and demanding operation.
4. Access to the work area that is within the water jets’ range must be absolutely prohibited to and free from objects that, inadvertently under a pressure jet, can be damaged and or create dangerous situations.
5. The water jet must only and always be directed in the direction of the work area, including during testing or preliminary tests or checks..
6. The Operator must always pay attention to the trajectory of the debris removed by the water jet. If necessary, suitable guards must be provided by the Operator to protect anything that may be accentally exposed.
7. The Operator should not be distracted for any reason during operation. Workers needing to access the operating area must wait for the Operator to stop work, and then immediately make their presence known.
8. For safety reasons, it is important that each member of the team is fully aware of the intentions and actions of other team members in order to avoid dangerous misunderstandings.
9. The high pressure system must not be started up and run under pressure without all team members in position and without the Operator having already directed his/her lance toward the work area.
3.5 Safety During System Maintenance
1. The pressure system 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 carried out by trained and authorized personnel.
3. Assembly and disassembly of the pump and its various components must be performed exclusively by authorized
personnel, using appropriate equipment in order to avoid damage to components and connections.
4. Always use original spare parts to ensure total reliability and safety.
A member of the Interpump Group
SM SERIES
4. PUMP IDENTIFICATION
Each pump has a specific label which contains:
Pump model and version Serial Number Maximum RPM Power - Hp-kW Pressure - PSI Flow Rate - GPM
Pump model, version and serial number must always be specified when ordering spare parts.
Ref 300893 Rev.A
06-12
Page 5
GENERAL PUMP
5. TECHNICAL FEATURES
A member of the Interpump Group
SM SERIES
MODEL RPM
1500 6.9 26 21750 1500 101 74
SM14
SM16
SM18
1800 6.9 26 21750 1500 101 74
2200 6.9 26 18850 1300 101 74
1500 9.0 34 17400 1200 106 78
1800 9.0 34 17400 1200 106 78
2200 9.0 34 17400 1200 106 78
1500 11.4 43 13050 900 101 74
1800 11.4 43 13050 900 101 74
2200 11.4 43 13050 900 101 74
FLOW RATE PRESSURE POWER
GPM l/min PSI Bar Hp kW
SM20
SM22
SM24
1500 14.0 53 10875 750 103 76
1800 14.0 53 10875 750 103 76
2200 14.0 53 10875 750 103 76
1500 16.9 64 8700 600 100 73.5
1800 16.9 64 8700 600 100 73.5
2200 17.2 65 8700 600 101 74
1500 20.1 76 7250 500 99 73
1800 20.1 76 7250 500 99 73
2200 20.3 77 7250 500 100 73.5
Ref 300893 Rev.A
06-12
Page 6
GENERAL PUMP
A member of the Interpump Group
6. DIMENSIONS AND WEIGHT
For dimensions and weight, please refer to fig. 2.
SM SERIES
Weight: 573 Lbs./260 Kg.
fig. 2
7. INFORMATION ABOUT PUMP USE
The SM pump was designed to operate with filtered water (see paragraph 9.7) and at
maximum temperature of 104oF (40oC).
Other fluids may be used only upon the approval of The Customer Service Department .
7.1 WaterTemperature
The max water temperature is 85oF (30oC).
7.2 Max Flow Rate and Pressure Values
The performance values indicated in the catalog refer to the maximum performance of the pump. Regardless of the power used, pressure and maximum RPM values indicated on the plate may not be exceeded unless expressly authorized by the
Customer Service Department.
7.3 Lowest RPM
Any RPM value different from what is indicated in the performance table (see chapter 5) must be explicitly authorized by the Customer Service Department.
Ref 300893 Rev.A
06-12
Page 7
GENERAL PUMP
7.4
Recommended Lubricant Oil Types & Manufacturers
The pump is delivered with lubricant oil compliant with room temperatures ranging between 32oand 89.6oF (0oand 30oC ). Some recommended lubricant types are indicated in the table below; these lubricants are treated with additives in order to increase corrosion protection and resistance to fatigue. As an alternative, Automotive SAE 85W-90 gearing lubricants may also be used.
A member of the Interpump Group
BRAND TYPE
GENERAL PUMP SERIES 220
ARAL Aral Degol BG220
BP ENERGOL HLP 220
CASTROL
ELF
ESSO NUTO 220
FINA Cirkan 220
FUCHS RENOLIN 220
MOBIL DTE OIL BB
SHELL TELLUS C 220
TEXACO RANDO HD 220
TOTAL CORTIS 220
Hyspin VG 220, Magna
POLYTELIS 220
SM SERIES
220
Check the oil level with the oil level lights located on the sides (1, fig. 3). If necessary, top off via the oil plug (3, fig. 3).
To correctly check the oil level the pump must be at ambient temperature. To change the oil the pump must be at operating temperature, and is done by removing the plug (2, fig. 3).
Checking and changing the oil must be done as shown in Chapter 11. The quantity necessary is 304 oz. (9 liters).
Ref 300792 Rev.C
06-12
Page 8
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