HPP CLW66 High Pressure Pumps Instruction Manual

HPP CLW66 High Pressure Pumps

Specifications :

• Product: High-pressure pump
• Recommended Usage: Water pumping at high pressure in washing machines (pressure washers, bin washers, street cleaners, etc.)
• Safety Features: Maximum pressure valve

Product Information

The high-pressure pump is designed for pumping water at high pressure in various machines such as pressure washers, bin washers, and street cleaners. It comes with safety features including a maximum pressure valve to ensure safe operation.

Product Usage Instructions

1. Assembly and Maintenance:
   Refer to the assembly, usage, and maintenance instructions provided in the manual. Follow the guidelines carefully to ensure proper functioning of the pump.

2. Symbols:

   • Attention Symbol: Follow the prescribed instructions and indications.
   • Warning Symbol: Follow the specified instructions.

3. Component Identification:
   Refer to the identification chart in the manual for component details such as suction connection, pump head, oil level indicator, identification plate, oil cap with vent, pump housing, discharge connection, pump shaft, etc.

4. Safety Devices:
   The pump may include a maximum pressure valve as a safety accessory. Do not tamper with the valve settings; consult a specialized technician for adjustments or maintenance.

5. Preliminary Steps:
   Check the oil level when the pump is stationary and cooled down. Ensure it is at the midpoint of the oil level indicator. Refer to the specific oil type mentioned in the series manual fo  top-ups.

6. Water Connection:
   Connect the pump to a water source following the guidelines provided in the manual of the machine incorporating the pump. Flush with clean water for a few minutes before operation.

7. High-Pressure Operation:

   • Adjust the pressure setting by rotating the pressure regulation knob counterclockwise.
   • Start the pump and let it run at zero pressure for a few minutes to stabilize.

Frequently Asked Questions (FAQ):

• Q: What should I do if the oil level is low?
  A: Refer to the specific oil type mentioned in the series manual and top up accordingly following the instructions provided.

• Q: Can I adjust the maximum pressure valve settings?
  A: It is recommended to consult a specialized technician for any adjustments or maintenance related to the maximum pressure valve to ensure safe operation.

HIGH PRESSURE PUMPS

WARNING. Read the instructions before using and assembling

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

FOREWORD

• This manual is intended for both the end user and the Skilled Technician and contains the pump operation and maintenance instructions.
  This manual is completed by another, dedicated to the Skilled Technician only and specific for each series of pumps, which provides instructions for the correct integration of the pump in the end machine and for special maintenance, also including exploded diagrams, overall dimensions, technical data, detail specifications, etc..

By Skilled Technician is meant:

• the Manufacturer of the machine (e.g., high pressure cleaner, bin washer, road sweeper) in which the pump is integrated (from now on, when reference is made to “machine in which the pump is integrated”, this may also refer to “system in which the pump is integrated”, such as, for example, in the case of a pumping station);
• a person, normally belonging to the after-sales centre, specifically trained and authorised to perform special maintenance jobs and repairs on the pump and on the machine in which this is integrated. It should be remembered that jobs on the electrical parts must be performed by a Skilled Technician who is also a Professional Electrician, meaning a person professionally qualified and trained to check, install and repair electrical apparatus in a “workmanlike” manner and in accordance with the laws applicable in the country where the machine integrating the pump is installed.

GENERAL INFORMATION

• Carefully read the pump manuals and that of the machine in which the pump is integrated: carefully comply with the instructions contained in them. Special care must be given to reading the parts of the text marked by the symbol:
  WARNING inasmuch as these contain important safety instructions concerning pump operation.

The Manufacturer disclaims all liability relating to damage caused by:

• failure to abide by the contents of the pump manuals and the manual of the machine in which the pump is integrated;
• the pump being used in ways other than those indicated in the “INTENDED USE” paragraph;
• the pump being used in ways contrary to applicable laws on safety and prevention of work accidents;
• tampering with the safety and max operating pressure limitation devices;
• incorrect assembly and installation;
• incorrect maintenance;
• changes made or jobs done on the pump without the permission of the Manufacturer;
• use of non-original spare parts or which are not suitable for the pump model;
• repairs not performed by a Skilled Technician.

USING AND LOOKING AFTER THE MANUALS

WARNING

• The pump manuals complete that of the machine in which the pump is integrated: read all the manuals carefully.
• The manuals must be deemed an integral part of the pump and must be looked after for future reference and kept in a protected place where they can easily be referred to in case of need.
• The manuals contain safety precautions for the operator and those surrounding him/her and for the protection of the environment.
• In case of deterioration or loss, a new copy must be requested from the Manufacturer or from a Skilled Technician.
• In the event of the machine in which the pump is integrated being transferred to another user, please also include the relevant manuals.
• The Manufacturer reserves the right to make all the amendments required to update and correct these publications without prior notice.

SYMBOLS

The symbol:

• WARNING marking certain parts of the text indicates a likely chance of injury to persons unless the relative prescriptions and indications are followed.

• The symbol:
  CAUTION marking certain parts of the text indicates the possibility of damaging the pump unless the relative instructions are followed.

• The symbol: (→MS) indicates that reference must be made to the manual of the specific series of pumps.

IDENTIFICATION OF COMPONENTS

Refer to Figure 1 at the beginning of the manual.

1. Suction fitting
2. Pump head
3. Threaded fastening plate
4. Reduction gear (if fitted)
5. Delivery fitting6. Oil level indicator
6. Identification plate
7.  Oil cap with vent
8. Pump crankcase
9.  Pump shaft

PUMP IDENTIFICATION PLATE

WARNING

• Should the identification plate deteriorate during use, contact the Manufacturer or a Skilled Technician to have it restored.
• The identification plate (7) shows : the pump model, the serial number, the maximum rotation speed, the maximum pressure, the maximum flow rate, the maximum power input, the oil type and its quantity in volume. It is located on the pump crankcase (9).

SAFETY DEVICES

WARNING

• The machine integrating the pump must always feature at least the safety devices mentioned below.
• In case of the pressure relief valve tripping frequently, immediately stop using the machine integrating the pump and have it checked by a Skilled Technician.
• Pressure unloader/regulation valve.
• Available as an optional accessory depending on the pump model.
• This valve, suitably set by the Manufacturer, allows regulating the operating pressure and permits the pumped fluid to flow back towards the bypass duct, thus preventing the accumulation of dangerous pressures when the delivery line is closed or when attempts are made to set pressure values above the maximum ones allowed.
• Pressure relief valve
• Available as an optional accessory depending on the pump model.
• This valve is suitably calibrated by the Manufacturer. It releases any overpressures in case of a fault occurring in the pressure adjustment system

WARNING

• The pressure unloader/regulation valve and the pressure relief valve are either calibrated by the pump Manufacturer or by the Manufacturer of the machine integrating the pump.
• Never try and adjust the pressure unloader/regulation valve to alter its setting: only adjust this by means of the relevant knob. Never change the calibration of the pressure relief valve.

INTENDED USE

WARNING

• The pump must not be run by itself. It is only meant to be integrated in a machine.
• The pump must only be integrated in machines used for the following purposes:
  • pumping of water at high pressure in washing machines (high pressure cleaners, bin washers, road sweepers, etc.);
  • pumping water for non-edible use.
• The pump must not be integrated in machines for pumping:
  • unfiltered water or with impurities;
  • detergents, paints and chemical substances, both pure and in aqueous solution;
  •  seawater or water with high salt concentration;
  • fuels and lubricants of all kinds and types;
  • inflammable liquids or liquefied gases;
  • edible liquids;
  • solvents and thinners of all kinds and types;
  • water with temperatures and pressures outside the range designed for the specific series of pumps (→MS);
  • water taken from tanks with negative head;
  • liquids containing granules or solid parts in suspension.
• The pump must not be integrated in machines designed to wash: people, animals, energized electrical apparatus, delicate objects, the pump itself or the machine in which it is integrated.
• The pump is not suitable for being integrated in machines designed to operate in environments with special conditions such as, for example, corrosive or explosive atmospheres.
• For integration in machines designed to operate on board vehicles, ships or planes, contact the Manufacturer’s Technical After-Sales Service, inasmuch as additional requirements may be necessary. All other uses are to be deemed incorrect.
  The Manufacturer disclaims all liability for any damage deriving from incorrect or erroneous uses.

PRELIMINARY ACTIVITIES

WARNING

• The pump cannot be operated unless the machine in which it is integrated conforms to the safety requirements laid down by European directives. Such conformity is indicated by markings  and by the declaration of conformity of the Manufacturer of the machine in which the pump is integrated.

• Before starting the pump, carefully read the instructions in its manuals and in the manual of the machine in which the pump is integrated. In particular, make sure you have correctly understood how the pump and the machine in which it is integrated work as regards liquid on/off operations.

• Perform the preliminary operations indicated by the Manufacturer of the machine in which the pump is integrated.

• Make sure all deliveries are off or connected to accessories that have been turned off (e.g., closed spray gun).

• Make sure that the moving parts of the pump are suitably protected and that they are not accessible to unauthorised persons.

• Do not use the pump (and therefore the machine in which it is integrated) in the event of:

• the safety devices being damaged;

• its having suffered heavy knocks;

• evident oil leaks;

• evident leaks of pumped liquid.
  In such cases, have the pump and the machine in which it is integrated checked by a Skilled Technician.

• Have a Skilled Technician perform the inspections required by special maintenance.

• Wear clothing and personal protective equipment able to provide adequate protection from any high-pressure jets and chemical products used.

CAUTION

• In case of operation at very low temperatures, make sure there is no ice inside the pump and pipes.
• Perform the checks required by routine maintenance, with special reference to those relating to the oil.
• The standard oil provided with the pump is suitable for operation at room temperatures between 5°C/41°F and 30°C/86°F. If the pump is required to operate at different ambient temperatures contact a Skilled Technician to change the oil. In any case the maximum ambient temperature allowed for pump operation is 65°C/149°F.

Carry out the preliminary activities indicated in the manual of the machine in which the pump is integrated; unless otherwise indicated, with respect to the pump, always remember the following.

• With the pump off and completely cooled down, make sure the oil level is at mid-point of the oil level indicator (6).
  To make any top-ups, refer to the lubricant shown in the specific manual of the series (→MS).

• Refer to the operation and maintenance manual of the machine in which the pump is integrated and make sure:

  • the suction filter is clean;
  • the suction and delivery circuits are in good conditions;
  • the pump has primed correctly.

CHECKING AND CONNECTING UP TO WATER MAINS

WARNING

• Also follow the instructions contained in the manual of the machine in which the pump is integrated.
• Follow the water mains connection instructions applicable in the country where the machine in which the pump is integrated is installed.

CAUTION

• Follow the water mains connection instructions shown in the “INTENDED USE” paragraph and in  the specific manual of the series (→MS), with special reference to the priming depth and supply pressure and temperature: in case of any doubts, contact a Skilled Technician.
• The pump suction unit must always be equipped with a suitably-sized filter: frequently make sure this is clean in accordance with the blockage times tied to the specific operating conditions of each application.
•  Never operate the pump:
  • without water supply;
  • with salt water or water containing impurities: if this occurs, have it operate for a few minutes with clean water.

STANDARD OPERATION (HIGH PRESSURE)

WARNING

• Also follow the instructions contained in the manual of the machine in which the pump is integrated with special reference to the parts relating to the safety precautions, any use of personal protective equipment (protective eyewear, gloves, etc.) and handling.
• Before starting up the pump carefully read the instructions contained in its manuals and in the manual in which the pump is integrated. In particular, make sure you have fully understood how the pump and the machine in which it is integrated work as regards liquid on/off operations.
• The pump and the machine in which it is integrated are not intended to be used by people (including children) with reduced physical, sensorial or mental capacities, or who lack the experience and expertise, unless they are able to benefit, through the intermediation of a person responsible for their safety, from supervision or instructions concerning the use of the pump and of the machine in which it is integrated.
• Children must be supervised to make sure they do not play with the pump and with the machine in which it is integrated.
• Special care must be taken when using the pump in environments where there are moving vehicles which could crush or damage any: delivery pipe, spray gun and lance.
• Before using the pump, put on individual protective gear and devices to ensure adequate protection from wrong manoeuvres with the jet of fluid under pressure.
• WARNING. Do not use the pump or the machine in which it is integrated near people if these are not wearing personal protective equipment.
• WARNING. Do not direct high-pressure jets against yourself or other people to clean clothes or footwear.
• WARNING. High-pressure jets can be hazardous if incorrectly used. High-pressure jets must not be directed against people, energized electrical appliances or the pump itself or the machine in which it is integrated.
• Never run the machine in which the pump is integrated in closed premises, if this is driven by an internal combustion engine.
• WARNING. Explosion risk – Do not spray inflammable liquids.
• Keep clear of moving parts of the pump and of the machine in which it is integrated, even if these are adequately protected.
• Do not remove the guards of the moving parts.
• Do not touch pipes containing liquids under pressure.
• Do not perform maintenance operations on the pump and on the machine in which it is integrated if this is operating.
• Read the “intended use” paragraph carefully.
• Do not modify in any way the installation conditions of the pump. In particular, do not modify the fastening, the hydraulic connections and the guards.
• Do not open any taps on the pump unless these are connected to an accessory that prevents the accidental escape of the pumped liquid.
• Do not deactivate or tamper with the controls and the safety devices and the pressure unloader/regulation valve.
  The connection of the machine in which the pump is integrated to the power mains must be made by a Professional Electrician in accordance with the regulations applicable in the country of use.

During operation :

• always keep an eye on the pump and the machine in which it is integrated and out of the reach of children; in particular, be very careful when using near nurseries, clinics and old-people’s homes, in case of children, elderly people or disabled people without supervision;
• do not direct high-pressure jets against materials containing asbestos or other substances harmful for the health;
• do not cover the pump and the machine in which it is integrated and do not place them where ventilation is prevented (remember this above all when using the machine in closed environments);
• grip any spray gun used tightly because when the lever is operated a reaction force of the high-pressure jet is produced;
• when not in operation and before doing any jobs, perform the operations described in the “stop” paragraph;
• operating pressure must never exceed the maximum value set for the pump, as shown in the technical data plate;
• use adequate personal protective equipment to safeguard against noise emissions (e.g., ear muffs).

Perform the steps relating to the high-pressure operation indicated in the manual relating to the machine in which the pump is integrated; unless otherwise indicated, in relation to the pump, the following should be remembered.

• Reset the delivery pressure, turning the pressure unloader/regulation valve in a suitable way. This condition usually occurs by fully turning the pressure unloader/regulation valve knob counter-clockwise.
• Start the pump and leave it at reset pressure for a few minutes so as to allow the oil to reach the correct viscosity and complete pump priming.
• Set the required pressure value gradually. This is usually possible by adjusting the pressure unloader/regulation valve knob. When this is turned clockwise, pressure increases, when turned counter-clockwise, pressure drops.

WARNING
Never touch the pressure unloader/regulation valve so as not to alter its setting: only adjust this valve by means of the special knob.

CAUTION

• During the first hours of operation, it is best to check the oil level and, if necessary, top up the level, following the instructions in the “PRELIMINARY ACTIvITIES” paragraph.
• Do not operate the pump if it is too noisy and/or oil is dripping from it: in this case have it checked by a Skilled Technician.
• IMPORTANT NOTE.
• During operation, the pressure seals allow a certain quantity of water to seep through (from a special groove located between the head and the crankcase), as shown in the specific manual of the series (→MS). Such seeping is perfectly normal and allows the lubrication of the seals themselves.

STOPPING OPERATION
By closing the delivery line, the pump switches to bypass operation and remains in this condition until the delivery line is opened again.

STOPPING, CLEANING AND DECOMMISSIONING

•   WARNING
• Follow the instructions regarding stopping, cleaning and decommissioning contained in the manual of the machine in which the pump is integrated.

STOPPING

• WARNING

• Always make sure that, once stop operations have been performed, no part of the pump and of the machine in which it is integrated is moving and no pipes contain liquid under pressure.
  Always remember in particular to disconnect the power supply, for example:

  • to disconnect the plug from the socket (electric motors);
  • to disconnect the sparking plug contact (petrol engines);
  • to remove the ignition key (diesel engines).

• Perform the stop operations contained in the manual of the machine in which the pump is integrated; unless otherwise indicated, in relation to the pump, remember the following.

  • Reset the delivery pressure as described at a) of the “STANDARD OPERATION (HIGH PRESSURE)” paragraph.
  • Stop the pump and the machine in which it is integrated.
  • Wait for the pump and the machine in which it is integrated to cool down.

WARNING

• Once the pump and the machine in which it is integrated have cooled down, be careful:
• not to leave them unattended in the presence of children, elderly people or disabled persons without supervision;
• to arrange them in a stable position without any risk of falling;
• not to put them in contact or in the immediate vicinity of inflammable materials.

CLEANING AND DECOMMISSIONING

WARNING

• WARNING. All cleaning jobs must only be performed after carrying out the operations described in the “stop” paragraph, meaning without any moving parts, no pipe full of liquid under pressure and only after complete cooling. In particular, always remember to disconnect the power supply.
• Any cleaning jobs must be performed in conditions of total stability.
• To clean, do not use thinners or solvents.

CAUTION

• The pump must be protected against freezing.
• In very cold environments, to prevent the ice from forming inside, after use, always empty out all the pumped liquid.
• In case of ice, do not operate the pump.
• Failure to abide by these instructions can cause serious damage to the pump.
• During storage, protect the pump from dirt and dust.
• In case the pump is not required to operate for over two months, the pump must be completely filled with oil.

After a long time without operating (over six months), contact a Skilled Technician to:

• change the pump oil;
• inspect the suction/delivery valves;
•  check the efficiency of the seals.

MAINTENANCE

WARNING

• Follow the maintenance instructions contained in the manual of the machine in which the pump  is integrated.
• All maintenance jobs must only be performed after carrying out the operations described in the “stop” paragraph, meaning without any moving parts, no pipe full of liquid under pressure and only after complete cooling.
• In particular, always remember to disconnect the power supply.
• Any maintenance jobs must be performed in conditions of total stability.
• WARNING. To ensure the safety of the pump, only use original spare parts supplied by the Manufacturer or approved by it.

ROUTINE MAINTENANCE

Perform the routine maintenance jobs shown in the manual of the machine in which the pump is integrated; unless otherwise indicated, in relation to the pump, remember the following.

• Check oil level and conditions according to instructions in “P RELIMINARY Activities ” paragraph.
• Check and if necessary clean the suction filter.

Every 50 hours|

• Check the integrity of the suction and delivery circuit.
• Lubrication of the high-pressure seals on pump models featuring specific lubricator.
• Check the fastening of the pump to the motor to which it is coupled and/or to the structure of the machine in which it is integrated.
• In the event of such fastening being precarious, do not use the machine and contact a Skilled Technician (1).

(1) Checks must be made more frequently if the pump operates where there are strong vibrations.

SPECIAL MAINTENANCE

WARNING
Special maintenance jobs must only be performed by a Skilled Technician.

Perform the special maintenance jobs shown in the manual of the machine in which the pump is integrated; unless otherwise indicated, in relation to the pump, remember the following.

• Check the tightness of the pump screws (1).
• Check oil level (2).
• Check the pressure unloader/regulation valve and the pressure relief valve.

Every 1000 hours.|

• Check the tightness of the pump screws (1).
• Oil change (2).
• Check/replace oil seal rings (3).
• Check/replace whole seal pack.
• Check/replace suction/delivery valves.
• Check/replace pumping unit.

1. Checks should be made more frequently if the pump operates where there are strong vibrations.
2. The oil should be replaced at least once a year.
3. The oil seal rings are best replaced at least once every three years.

CAUTION
The data shown on the chart are approximate. More frequent jobs may be necessary in case of particularly heavy-duty use.

DISMANTLING AND DISPOSAL
Only qualified persons must be allowed to dismantle the pump and this operation must be performed in compliance with the laws applicable in the country where the machine in which it is integrated has been installed.

TROUBLESHOOTING

WARNING

• Also follow the instructions contained in the manual of the machine in which the pump is integrated.
• Before doing any jobs, perform the operations described in the “stop” paragraph. In the event of not being able to restore the correct operation of the pump with the aid of the information contained on the following table, contact a Skilled Technician.

circuit.
Suction circuit with choke points.| Check the suction circuit (especially make sure the suction filter is clean).
The pump fails to reach max pressure.| Pressure unloader/regulation valve knob not tightened enough.| Turn the knob clockwise until required pressure is reached.
Not enough water supply.| Make sure the suction flow rate is in compliance with the pump maximum rate shown in the technical data plate.
Suction circuit with choke points.| Check the suction circuit (especially make sure the suction filter is clean).
Unsuitable conditions of use of the accessory (e.g., nozzle worn, etc.)| Restore the correct use of the accessory.
Irregular pressure and flow rate (pulsating).| Air suction.| Check the integrity of the suction circuit.
Suction filter dirty.| Clean the filter.
Not enough water supply.| Make sure the suction flow rate is in compliance with the pump maximum rate shown in the technical data plate.
The pump has not completed priming.| Comply with the indications of the “S TANDARD O PERATION ( HIGH PRESSURE )” paragraph.
Accessory clogged (e.g. clogged nozzle).| Restore the correct use of the accessory.
Too much noise.| Suction circuit with choke points.| Check the suction circuit (especially make sure the suction filter is clean).
Water supply temperature too high.| Keep to the instructions indicated in the “I NTENDED USE ” paragraph and in the specific manual of the series ( → MS ).

P.T.C. Srl – via Mantegna, 4 – 42048 Rubiera (RE) – ITALY Tel.+39 0522/626477

• Email: service@ptcitaliana.com
• Website: www.ptcitaliana.com
• 1610 1425 00 A – 03/2023 – REV. 02

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