General Pump VK Owner Manual

VK

8

Owner’s Manual

• Installation

• Use

• Maintenance

General Pump is a
member of the
Interpump Group

Ref 300837 Rev.B

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 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

VK SERIES

9. PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11

9.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 11

9.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 12

9.3 Version Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 17

9.12 Definition of static pull to apply on belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 18

10. START UP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

10.1 Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

10.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 20

10.3 Cooling circuit seal packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21

11. PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 21

12. PUMP STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

12.1 Inactivity for lengthy periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

12.2 Filling the pump with anti-corrosion emulsion or anti-freeze . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

12.2 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

13. PRECAUTIONS AGAINST FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

14. WARRANTY TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 22

15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 23

16. EXPLODED VIEWS AND PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 24

17. MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 26

Ref 300837 Rev.B

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06-12

GENERAL PUMP

A member of the Interpump Group

VK SERIES

1. INTRODUCTION

This manual describes the use and maintenance instructions of the VK 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

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GENERAL PUMP

A member of the Interpump Group

VK 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

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.

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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 accidentally 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

VK 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.

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GENERAL PUMP

5. TECHNICAL FEATURES

A member of the Interpump Group

VK SERIES

VK12

VK14

MODEL RPM

Version

without

reduction gear

Version

with reduction

gear

Version

without

reduction gear

Version

without

reduction gear

1200

1500

1800

2200

1200

1500

1800

2200

FLOW RATE PRESSURE POWER

GPM LPM PSI BAR HP kW

5.4 20.4 21750 1500 79 59

7.4 28 15950 1100 79 59

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GENERAL PUMP

A member of the Interpump Group

VK SERIES

6. DIMENSIONS AND WEIGHT

For dimensions and weight of reduction gear unit version, please refer to fig. 2.
For dimensions and weight of version without reduction gear unit, please refer to fig. 2a.

7. OPERATING INSTRUCTIONS

The VK pump was designed to operate with filtered water (see paragraph 9.7) and at maximum temperature

of 104oF (40oC).

Weight: 212 Lbs./96 Kg.

Weight: 135 Lbs./60 Kg.

fig. 2

fig. 2a

Other fluids may be used only upon the approval of The Customer Service Department .

7.1 WaterTemperature

The max water temperature is 104oF (40oC).However, it is possible to use the pump at temperatures of up

o

to 140

Department.

F (60oC) for short periods of time. In this case we advise consulting the Customer Service

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GENERAL PUMP

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.

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

VK 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 162.3 oz. (4.8
liters)for versions with a reduction gear in positions 1 and 4 (fig. 6). Said quantity will be slightly lower for positions
2 and 3. Quantity of oil for version withoug a reduction gear is 148.8 oz. (4.4 liters).

Ref 300837 Rev.B

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06-12