In this article my goal is to help you keep your pumps running well to minimizing downtime. That means more money in your pocket.
I have traveled all over North America and am always surprised at how many pumps I have come across that don’t run properly. These pumps are costly and when they don’t work there is a direct impact on productivity.
In this article my goal is to help you keep your pumps running well to minimizing downtime. That means more money in your pocket.
Below you will see that I focus on two of the most popular pumps used in the Hydrovac industry. 1. Cat pumps and 2. Prattazzoli pumps. I have also added some Terry’s tips. I hope this information helps minimize your downtime.
PREVENTIVE MAINTENANCE
For pump reliability and efficiency, comply with maintenance intervals to the manufacture’s specs.
Every day
Check oil level
Clean inline water supply filters
Every 500 hours
Check oil level
Check Valves
Check valve seats
Check springs
Check Valve guides
Check H.P. seals
Check L.P. seals
Every 1000 hours
Change oil
Check or Replace: Valves, Valve seats, Valve springs, Valve guides, H.P. seals, L.P. seals
Troubleshooting the most common problems
Pump pulsates irregularly:
Air suction
Insufficient supply
Bends, elbows, fittings on the suction line are choking the passage of liquid
Suction filter is dirty or too small
The booster pump, if installed, is supplying insufficient pressure or flow rate
The pump is not primed due to insufficient head or the outlet is closed during priming
The pump is not primed due to valve jamming
Worn valves
Worn pressure seals
Faulty pressure control valve
Problems with the transmission
Pump does not make any noise upon start-up:
The pump is not primed and is running dry
No suction water
Valves are jammed
The outlet line is closed and does not allow the release of air present in the pump manifold
Pump pulsates irregularly:
Air suction
Insufficient supply
Bends, elbows, fittings on the suction line are choking the passage of liquid
Suction filter is dirty or too small
The booster pump, where installed, is supplying insufficient pressure or flow rate
The pump is not primed due to insufficient head or the outlet is closed during priming
The pump is not primed due to valve jamming
Worn valves
Worn pressure seals
Imperfect functioning of the pressure control valve
Problems on the transmission
Reduced flow or excessive noise:
Insufficient supply (see various causes as above)
Pump speed is below the rated speed
Excessive internal leakage of pressure control valve
Worn valves
Excessive leakage from the pressure seals
Cavitation due to:
Improper sizing of suction ducts/undersized diameters
Insufficient flow rate
High water temperature
Insufficient Pressure:
The user flow (nozzle) is or has become greater than the pump capacity
Abnormal revolutions per minute. – Excessive leakage from the pressure seals
Imperfect functioning of the pressure control valve
Worn valves. Pump overheats:
The pump is working in over pressure conditions or pump rpm is higher than the nominal value
Oil in the pump casing is not at level or not the recommended type
Excess belt tension or joint or pulley alignment is incorrect
Excessive pump tilt during operation
Vibrations or hammering on pipes:
Air suction
Faulty operation of pressure control valve
Valves malfunction
Non-uniformity of transmission motion
PRATISSOLI PUMPS
Oil must be changed at least once a year, as it is degraded by oxidation
For a room temperature other than between 0 °C – 30 °C, follow the instructions, considering that oil must have a minimum viscosity of 180 cSt
The pump is supplied with oil suitable for room temperatures from 0 °C to 30 °C. Recommended types of oil are indicated in the table below, these oils have additives to increase corrosion resistance and fatigue resistance. Alternatively, you can also use Automotive Gear SAE 85W-90 oil for gearing lubrication.
PREVENTIVE MAINTENANCE
Every 500 hours
Check oil level
Every 1000 hours
Change oil
Check / Replace:
Valves
Valve seats
Valve springs
Valve guides
P. seals
P. seals
Brands and types of oils recommended:
AGIP ACER220
Aral Degol BG 220
BP Energol HLP 220
CASTROL HYSPIN VG 220 CASTROL MAGNA 220
Falcon CL220
ELF POLYTELIS 220 REDUCTELF SP 220
NUTO 220 TERESSO 220
FINA CIRKAN 220
RENOLIN 212 RENOLIN DTA 220
Mobil DTE Oil BB
Shell Tellus Öl C 220
Wintershall Ersolon 220
Wintershall Wiolan CN 220
RANDO HD 220
TOTAL Cortis 220
Check the oil level and top off if necessary, using the oil dipstick. The correct checking of the oil level is made with the pump not running, at room temperature. The oil change must be made with the pump at working temperature. The quantity required is ~ 3.8 liters.
CAT PUMPS
Pump and System Preventive Maintenance Guidelines
Many application factors determine proper pump maintenance intervals. Variation in duty cycle, operating performance, fluid temperature, fluid type, inlet conditions and application environment can affect maintenance schedules. Every application should be evaluated and serviced based on its own requirements.
Water leaks or loss of system performance can be an indicator of seal wear. Seal wear has many causes, including contaminated liquid or high-temperature/run dry operation. If the low-pressure seals show wear, the high-pressure seals most likely are in a similar condition. It is a good practice to replace both low and high pressure seals and inspect plungers when leaks are present.
Cat Pumps recommends using our custom-blend premium grade hydraulic oil formulated to meet Cat Pumps specifications. For best results, perform an initial oil change after the first 50 hours of operation and every 500 hours thereafter. If other oil is used, oil change should be performed every 300 hours of operation.
If system performance degrades or changes, check seals and valves immediately. Service as required to restore system performance. Depending upon operating conditions, maintenance intervals for seals kits range between 1,500 and 8,000 hours.
Pump valves typically require changing every other seal change. Depending upon operating conditions, maintenance intervals for valve kits range between 3,000 and 16,000 hours.
Doing simple routine maintenance and paying attention to your equipment is always affordable. Not doing so is costly.