Hypro 5200 Series Manuals

Installation, Operation, Repair and Parts Manual Description Form L-0225P 10-05 1. Warning: Do not pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in explosive atmospheres. The pump should be used only with liquids compatible with the pump component materials. Failure to follow this warning can result in personal injury and/or property damage and will void the product warranty. 2. Be sure all exposed moving parts such as shafts,couplers and adapters are properly shielded or guarded and that all coupling devices are securely attached before applying power. 3. Pumps mounted directly on to PTO shaft or other power shaft must be prevented from rotating with the power shaft by use of a torque arm. Pump must float freely on the power shaft and must not be tied rigidly to equipment on which it is mounted. 4. Do Not Exceed recommended speed, pressure and temperature for pump and equipment being used. 5. Before Servicing, disconnect all power, make sure all pressure in the system is relieved, drain all liquids from the system and flush. 6. Secure the discharge lines before starting the pump. An unsecured line may whip, causing personal injury and/or property damage. 7. Check hose for weak or worn condition before each use. Make certain that all connections are tight and secure. 8. Periodically inspect the pump and the system components. Perform routine maintenance as required (see Maintenance section). 9. Protect pump from freezing conditions by draining liquid and pumping rust inhibiting antifreeze solution through the system, coating the pump interior. 10. Use only pipe, hose and fittings rated for the maximum psi rating of the pump. 11. Do not use these pumps for pumping water or other liquids for human or animal consumption. Safety Information Series 5200 Big Twin® Piston Pumps The Hypro Series 5200 Big Twin® piston pump is suitable for applications in high pressure washers for industrial and agricultural cleaning needs. It is also useful as a sprayer pump to apply a wide range of chemicals. The Series 5200 is constructed of cast iron body and cylinder heads, unitized stainless steel valve assemblies and double row ball bearing supported crankshaft. Three cup materials are available to meet specific pumping needs. They are: Leather–for pumping aromatic solvents and other chemicals damaging to rubber. Fabric–for pumping most insecticides, herbicides and fertilizers. Buna-N Rubber–for pumping soap and detergent solutions and some fertilizers. Two crankshaft options are available—1" solid shaft for belt and pulley or flexible coupling drive, or 1-3/8" hollow shaft for direct mounting onto a 6-spline 540 rpm PTO shaft. SERIES 5200C Cast Iron Big Twin Piston Pump Max. Flow Rate: .....6 gpm (5206) @ 600 rpm 10 gpm (5210) Max. Pressure: ...................................400 psi Max. Speed: ...........................800 rpm (5206) 600 rpm (5210) Ports: ....................................... 3/4" NPT inlet 3/4" NPT outlet Shaft: ..................................................1" solid 1-3/8" hollow shaft -2- Drive Source Installation This manual will cover the installation of the basic drive configurations available for the Hypro Big Twin Piston pumps. Consult the manufacturer of your motor or engine for additional information. Read all instructions and general safety information before attempting to install or operate the pump. Belt/Pulley Drive Installation Mounting Belts and Pulleys Mount pulleys as close to pump and motor engine shaft bearings as possible. Check alignment with a straight edge as shown in Fig. 1. Make sure that belt has proper tension. (Too much tension will cause bearing wear; too little will cause slippage.) See Fig. 2. Check with belt and pulley sources for specific recommendation. To figure proper diameter of pump pulley, multiply the motor/engine rpm by the diameter of the motor/engine pulley and divide that figure by desired pump speed. Pump = Motor RPM x Motor Pulley Size Pulley Size Desired Pump Speed Refer to the pump performance chart on Page 5 to determine the desired speed to obtain the desired maximum flow. NOTE: Shaft rotation can be either clockwise or counter clockwise. 1 Direct Drive - Flexible Coupling Installation 3 Four points of contact indicate alignment. NOTE: Pump may be mounted in other orientations with respect to the motor or engine 4 Caution: For safety, always install a shield over rotating shafts and couplings Caution: For safety, always install a shield over rotating shafts and couplings First, slide coupling ends onto motor/engine and pump shafts as far as possible (Fig 3). Mount motor/engine and pump onto base, shimming pump or power unit so that shafts are aligned. Leave enough space between ends of shafts to allow coupling disc to be inserted. When alignment is made, slide coupling ends over coupling disc. Leave clearance between coupling ends and center disc. Tighten screws in both coupling ends. For electric motor drive, use couplings rated at least twice the horsepower required to operate pump. For gas engine drive, select couplings rated at three times the required pump horsepower. Hollow shaft models may be mounted directly onto power shaft — motor or engine shaft, truck or tractor PTO shaft. Important: When direct mounting a hollow shaft pump, Do Not rigidly mount the pump base. The pump must be allowed to “float”. Secure a torque arm with a chain or flexible fastener to the frame or base, directly below and in-line with the pump. This prevents the pump from rotating with the shaft. Always check to see if the pump will turn by hand to ensure that the pump rotates freely. Do Not apply power to a pump where the shaft doesn't rotate freely. Direct Drive - Hollow Shaft Installation 2 Push the belt midway between the pulleys, check the deflection (d) and adjust: d = 0.016 x L L d Caution: For safety, always install a shield over rotating shafts and belts. -3- System Installation 5 Series 5200 Pump Hook-Up for Pressure Washing Series 5200 Pump Hook-Up to Boom for Chemical Spraying Piston Pump Installation Accessories should be installed with solid piping and be mounted as close to the pump as possible. Hose must be used right after accessories. NOTE: If remaining installation is solid piping, a two to four foot length of hose must be installed between accessories and solid piping. Hose Selection of the right size and type of hose is vital to good performance. Be sure to hook up to proper ports on pump (note markings “IN” and “OUT” on pump castings). Suction Hose Always use genuine suction hose of at least the same inside diameter as pump ports. Hose should have some elasticity, but not overly soft so that it collapses. Use 3/4" (ID) hose or larger for a Series 5200 pump. If suction hose is over 6 feet long on Series 5200 use next larger size hose. Keep suction hose as short as possible and restrictions such as elbows, check valves, etc. at a minimum. Discharge Hose High pressure pumps require the use of special high pressure discharge hose (2 rayon braid or equivalent). Use a hose rated at least 50% greater than the highest operating pressure required of pump. Example: If required pump pressure is 200 psi, use discharge hose rated at minimum of 300 psi working pressure. Unloader or Relief Valve The unloader or relief valve has a very important safety function in your piston pump hook-up. The valve protects the pump by unloading or bypassing the pump’s flow when gun is shut off or discharge is otherwise blocked. Strainers Use a suction line strainer with an open screen area of at least 3 to 5 times the suction port area. For example, an area of approximately 2-1/3 to 4 square inches for a 1" suction port. Be sure the screen is suitable for the liquid being pumped. Keep filter clean. A clogged strainer will cause cavitation, which usually leads to a poor performance, wear and failure of pump parts. Vacuum Gauge (Optional) Pump should not be subjected to high suction line vacuums. To check on this, install a vacuum gauge at pump inlet. Generally, it should not read over 5 inches of mercury. Suction Line Shut-Off This suction line accessory allows the pump to be removed for service without draining the tank. Be sure valve is open before starting pump. Surge Tank or Pulsation Dampener This device absorbs the shock and smooths out the pump discharge pulsations, providing smoother operation. A charge of 50% of operating pressure is normally optimum. Note: A surge tank or pulsation dampener is required on Series 5210 and optional on Series 5206. Pressure Gauge/Dampener Use gauge capable of reading double the pump working pressure. Use a filled gauge or a gauge dampener to protect the gauge needle against pressure surges to provide easier reading and longer life. Spray Gun Use a Model No. 3381-0010 spray gun or a 3381-0013 Turbo 400 spray gun with the correct nozzle. For 5206 models use a 3385-3000 nozzle and for the 5210 models use a 3385-4000 to obtain a maximum pressure of 400 psi. Note: A pulsation dampener such as our Model No. 3375-0017, 3375-0015 or surge tank Model No. 3375-0003 must be installed on the outlet side for optimum performance and maximum life. For the proper operation of some unloader valves, it may be necessary to install a pulsation dampener downstream from the unloader valve; however, for optimum system dampening, it may be installed upstream from the unloader valve provided that the unloader valve will still function properly. -4- Operation Priming If liquid is below level of pump, some means should be provided in installation to prime pump — such as a Riser Pipe. If there is a suction lift use a Foot Valve or Check Valve to hold prime. In general, keep suction lift to minimum and avoid unnecessary bends in suction line. Before starting pump, make sure air bleeder valve or spray gun is open — or unloader/relief valve is adjusted to its lowest pressure. After starting pump, open and close gun several times if necessary to aid priming the pump. If pump does not prime within a few seconds, stop motor and inspect installation for suction line leaks or obstructions. Make sure that strainer is not clogged. Be sure that suction line is not obstructed, kinked or blocked. If pump is to operate hours at a time, check frequently for: 1. Adequate liquid supply. Pump must not run dry for more than 30 seconds. 2. Temperature rise. Overheating is harmful to bearings and piston cups. Care of Pump Your pump will last longer and give best performance when properly taken care of. Proper pump care depends a lot on the liquid being pumped and when the pump will be used again. Generally, after each use, flush pump with a neutralizing solution for the liquid just pumped. Follow with a clear water rinse. This is especially important for corrosive chemicals. Then flush out pump with a 50% solution of automotive radiator anti-freeze (ethylene glycol type such as Prestone, Zerex, etc.) containing a rust inhibitor...or use a commercial rust-inhibitor such as Fluid Film. While this flushing is not absolutely necessary for short periods of idleness (as over night) it is good practice to clean the pump after each use to prevent deposits from forming and damaging the pump. The antifreeze not only coats the interior of the pump with an inhibitor, but acts as a lubricant as well, keeping the valves from sticking and protecting against any remaining moisture freezing in cold weather. For infrequent use and before long periods of storage, drain pump thoroughly. Open any drain plugs, remove suction hose from liquid and run pump “dry” from 0 to 30 seconds (not longer). Flush with a 50% solution of anti-freeze and water. Then, plug both ports to keep out air until pump is used again. Lubrication Use a small push-type grease gun to lubricate Hypro Series 5200 Piston Pumps. Do not use airpowered or hand lever operated grease guns as they develop too much pressure and may cause damage to the sealed cam bearing. Lubricate a minimum every 100 hours or when bearing appears to need grease. Use Moly-Lithium No. 2 wheel bearing grease. Exception: In applications where FDA approval is required, use one of these greases: Chevron FM#2, Mobile FM#2 Keystone (Penwalt Corp.) Nevastane SP Medium. Do not under-grease or premature bearing failure may result. Do not grease excessively. Remove (do not WASH out) any excess grease from pump cavity to prevent grease build-up. Ref. Description Part No. A Internal External Pliers 3010-0084 B Valve Seat Extractor 3010-0130 C Valve Cage Extractor 3010-0052 D Wire Brush 3010-0066 E Wire Brush Holder 3010-0067 F Allen Wrench 3020-0009 G Allen Wrench 3020-0008 H Sleeve Extractor 3010-0064 Tool Box (Not Shown) 3010-0168 Repair Instructions Recommended Repair Tools For Hypro Big Twin Piston Pumps C H D E B A F G 6