R E F E R E N C E ... Reference Manual and User’s Guide 1-800-888-1436 • gethurco.com www.GETHURCO.com

R E F E R E N C E  ... Reference Manual and User’s Guide 1-800-888-1436 • gethurco.com www.GETHURCO.com
REFERENCE MANUAL
TM
Reference Manual and User’s Guide
www.GETHURCO.com
1-800-888-1436
• gethurco.com • [email protected]
Welcome
Welcome
Thank you for purchasing Hurco’s Old Faithful Pumper hydrostatic test pump. Like its namesake, the
“Old Faithful” line of hydrostatic test pumps are engineered for reliability and durability, with low cost
maintenance and nearly “wear free” operation. Hurco revolutionized the manifold system back in the
1980’s when we first introduced our hydrostatic test pumps. The manifold system replaces many of the
traditional pipe fittings it would take to build the hydrostatic test pump. This eliminated as many as 21
potential leak points and made maintenance and repairs much easier.
Old Faithful Pumper:
• Available in two models. 10 GPM @ 500 PSI and 23 GPM @ 700 PSI, both featuring Hypro
Pumps.
• Capable of handling chlorine solutions up to 10%.
• Bypass relief valve take pressure off the pump during start up and safeguards against valve
seat sticking that could cause pump damage.
• Utilizes a damper diaphragm to help eliminate damage to the pump caused by pressure
spikes.
Hurco Technologies, Inc. would like to take this opportunity to welcome you as a new customer and
user of the Old Faithful Pumper. You have just purchased the best hydrostatic test pump available. The
Old Faithful Pumper is simple to use and will provide you with years of service.
This manual, along with the Hypro Medium or High Pressure Diaphragm Pumps manuals, will take you
through the step by step procedures for using the Old Faithful Pumper. We use simple to understand
instructions and photos to assist you in learning how to get the best results from your Old Faithful Pumper.
Please follow each step completely to insure maximum performance from your Old Faithful Pumper.
Your Old Faithfull Pumper will give you many years of service if you take care of it as you would any
expensive piece of equipment. The Old Faithful Pumper is rugged and built to last. It will withstand
the demands of your jobsite; however, is not abuse proof! Be sure to assign the use of your Old Faithful
Pumper to a competent worker who will take care of it.
In this manual, we will be giving you suggestions on basic line hydrostatic pressure testing activities.
As a general rule, these suggestions are based on testing that was done on the Old Faithful hydrostatic
test pump and methods commonly used in the field. Each community or engineering firm may have
their own requirements for hydrostatic pressure testing of their water lines. You should always follow
their instructions for testing. However, regardless of the instructions you are using, always keep in mind
safety. Hydrostatic testing can be extremely dangerous if it is done incorrectly.
If you have any questions regarding this manual or hydrostatic testing in general, please call and ask
for customer support at 1-800-888-1436.
Sincerely,
Lyndon J. Hurley
President, Hurco Technologies, Inc.
WARNING: Never do hydrostatic pressure testing or use the Old Faithful Pumper in temperatures
below 45° F. Call 1-800-888-1436 for more information.
www.GETHURCO.com
1
Welcome
Contents
Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydrostatic Pressure Testing Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Filling the Water Main Prior to Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting Your Old Faithful Pumper to the Water Main . . . . . . . . . . . . . . . . 5
Hydrostatic Testing the Water Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Determining Water Loss of Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance Instructions for Your Old Faithful Pumper . . . . . . . . . . . . . . . . . . 6
Parts Replacement and Miscellaneous Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Old Faithful Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2
1-800-888-1436
Important Safety Information
WARNING!
READ ALL OPERATING MANUALS
BEFORE OPERATION OF EQUIPMENT
GENERAL SAFETY INFORMATION
SAFETY FIRST!
Hydrostatic pressure testing of water mains can be extremely dangerous if not done properly. You must follow all the safety
guidelines and use common sense when operating a hydrostatic test pump. Never take chances; it could cost you your life!
•
WARNING: This pump is for pumping water only. Pumping other fluids can be dangerous causing personal injury and
will void all warranties.
•
ALWAYS wear protective clothing and safety glasses when operating machinery.
•
NEVER service or repair the Old Faithful Pumper while running. Allow engine to cool.
•
ALWAYS shut off engine and do not smoke when fueling the Old Faithful Pumper.
•
ALWAYS release all pressure within the pump before servicing any component.
•
NEVER operate a gasoline engine in an enclosed area. Be sure area is well ventilated.
•
NEVER pump at pressures higher than the maximum recommended pressures for the pump. (see Specifications in
Hypro Manual)
•
NEVER operate your Old Faithful Pumper in temperatures below 45° F. Doing so will damage the pump and can be
extremely dangerous, causing serious injury or death.
•
NEVER make a connection to your water main with old, worn or inferior parts. These parts can break under pressure
and cause serious injury or death.
•
ALWAYS secure all hoses and fittings. These fittings and hoses are under pressure and if there is a failure, they can
“whip,” causing serious injury or death.
•
ALWAYS wear protective clothing and eye protection. When working with chlorine, wear protective clothing as
recommended by the chlorine manufacturer.
•
Periodically inspect system components. Perform routine maintenance as required.
•
Refer to the Hypro Medium or High Pressure Diaphragm Pumps manuals for additional safety information.
WARNING: Your life depends on every move you make when hydrostatic testing. Don’t leave anything to chance. Check
every detail of your Old Faith Pumper and all connections before starting the engine.
www.GETHURCO.com
3
Operating Instructions
Hydrostatic Pressure Testing Steps
Hydrostatic pressure testing will help you quickly determine the quality of installation of your water mains. Done right,
hydrostatic pressure testing is fast and safe. Please take the time to completely read this manual and understand the steps for
safely testing your water mains.
TM
Operating Instructions
Old Faithful Pumper Operation Instructions
• Read Engine Manufacturers Owner’s manual
•
•
•
•
•
•
•
4
for operation. Check Oil and Gas levels in your
engine.
Refer to the Hypro Medium or High Pressure
Pumps manual for specific instructions for
pump operation. Check all fluid levels.
Connect the clear suction hose to the filter
assembly on the pump. Be sure to insert the
safety clip into the coupling.
Put the open end of the suction hose in to a
barrel full of water or if you have purchased
the optional water tank, connect the suction
hose from the tank to the filter assembly.
Again, insert the safety clip into the coupling.
CAUTION: DO NOT CONNECT THE SUCTION
HOSE TO A PRESSURE SOURCE OF WATER.
Doing so can cause damage to your test pump.
If you have purchased the optional water tank,
you can connect it to a pressure source of
water.
Refer to Operation Instructions in the
Hypro Manual, included with this manual,
for detailed instructions on setting the
control unit. Refer to instructions for the
9910-GS40GI Control Unit used on our
HTP10-500 pumps and the 9910-VDR50
Control Unit used on our HTP23-700 pump.
Before you start the engine, raise the pressure
release lever. This will take pressure off the
pump and make starting the engine easier.
Start the engine and let it run for about one
minute. Turn the engine off and recheck fluid
levels on the pump and the engine.
You are now ready to make a connection to
your water main.
Filling the water main prior to hydrostatic pressure
testing
1. Fill the water main following the recommendations
of the American Water Works Association (AWWA).
These recommendations can be purchased on
line at the AWWA website at www.awwa.org. Also,
refer to the pipe manufacturers recommendations.
Improper filling of the water main can cause
damage to the water main and can be a safety
hazard.
2. WARNING! It is important to get as much air out
of the water main prior to testing as is possible.
Air is a compressible gas and can turn your water
main into a potential “bomb” causing extensive
damage to the water main and injury or death
to workers in the area. If you are pressure
testing the water main and it is taking a lot of
water to bring the pressure up, abort the test
immediately and recheck the water main for
trapped air.
Note: Since water is nearly incompressible, it will not take
much water pumped from your Old Faithful Pumper to bring
water line pressure up to test pressure. For example, if you
had an 8 inch water main, 1,000 feet long and all of the air
was removed or purged from the water line, it would only
take about one cup of water to bring the pressure up to
150 PSI. WARNING;IF YOU ARE USING TOO MUCH WATER,
ABORT THE TEST IMMEDIATELY AND RECHECK THE
WATER MAIN FOR TRAPPED AIR.
1-800-888-1436
Operating Instructions
Connecting your Old Faithful Pumper to the water main
1. Read all warnings displayed on the Old Faithful
2.
3.
4.
5.
6.
7.
8.
Pumper before operation!
WARNING! Do not run your Old Faithful Pumper
in temperatures below 45° F.
WARNING! Inspect the supplied high pressure
hose for nicks, cuts or abrasions. If there are any
signs of wear, discard the hose immediately and
call Hurco to order a replacement parts or hoses.
Connect the supplied high pressure hose to the
pressure outlet on the front of the Old Faithful
Pumper. Insert the safety clip.
Determine where you will be making your
connection to the water main. Follow the American
Water Works Association (AWWA) recommendations
or the recommendations of your project engineer
or municipality.
This connection is critical. Do not leave anything
to chance. You must use high quality parts that are
in new condition and meet or exceed the pressure
maximum pressure- rating of your pump and have
been properly installed. The supplied high pressure
hose has a 1/2 inch male iron pipe thread fitting
on the end. You will need to build your connection
from this fitting. Use a high quality, high pressure,
pipe thread sealer on this fitting.
After you have made this connection to the water
main, secure the hose so it will not “whip” in the
event the connection you have made fails.
Recheck all connections and fittings. Be sure all
safety clips are in place and the high pressure hose
is properly secured to prevent “whipping”.
Hydrostatic Testing the Water Main
Now that you have properly made all connections to your
water main and have insured that the water main was
properly filled to eliminate trapped air, you are ready to start
your test. Follow these steps;
1. Read all warnings displayed on the Old Faithfull
Pumper before operation!
2. WARNING! Do not pressure test in temperatures
below 45° F.
3. Make sure your water source is full. (Do not connect
to a high pressure water source unless you are using
the Hurco optional float controlled reservoir.)
4. Raise the pressure release lever to relieve pressure
on the pump when starting the engine.
5. Start engine.
6. Be sure the relief or bleed off valve is in the closed
position.
7. Lower the pressure release lever into the locked
position on the appropriate number setting, (refer
to your Hypro manual).
8. Slowly open the high pressure valve on the front of
the Old Faithfull Pumper and allow the pressure to
build to the test pressure.
9. Once the desired pressure is achieved, slowly close
the high pressure valve. This will isolate the pressure
in the water main.
10. Raise the pressure release lever and turn off engine.
Determining Water Loss for Test Results
There are many methods to determine water loss. Using a
water meter would be one method. A simpler method to
measure water loss would be as follows;
1. Monitor pressure loss for the specified time
recommended by the engineer or municipality.
2. Note the pressure drop. For example, the test called
8.
for a 180 PSI test and during the test time period,
the pressure dropped to 140 PSI.
Now, with your Old Faithfull Pumper still connected
to the water main, repeat the instructions for
“Hydrostatic Testing the Water Main” on pages 7 and
8 in this manual.
Pump the pressure in the water main back to the
test pressure. In this example, 180 PSI.
Connect a short piece of garden hose to the relief
connection on the Old Faithful Pumper.
Put the hose into a clean barrel or 5 gallon bucket.
Slowly open the relief valve and allow water to
drain into barrel until the pressure reading on the
pressure gauge drops to the low pressure. In this
example that would be 140 PSI.
Measure water in barrel, this is your water loss.
www.GETHURCO.com
5
3.
4.
5.
6.
7.
Typical set-up for hydrostatic testing
WARNING: Do not use your Old Faithful Pumper in
temperatures below 45° F. Do not use worn or damaged
parts when making connection to water main. Be sure all air
is out of water main prior to testing.
Maintenance Instructions
Maintenance Instructions for your Old Faithful Pumper
Your Old Faithful Pumper will give you years of reliable
service if you follow these simple maintenance instructions.
1. Always refer to the detailed safety and maintenance
instructions in your Hypro manual.
2. After every use, flush the pump with a neutralizing
3.
4.
5.
solution for the liquid just pumped. For normal use,
a high quality anti-freeze will do the job. Brands
such as Prestone and Zerex contain cleaning and
lubrication agents as well as rust inhibitors. Flush
the pump for 4 or 5 minutes to thoroughly clean
the internal working parts of the pump. A simple
procedure would be to put the anti-freeze in a 5
gallon bucket, insert both the suction hose and the
pressure hose in the bucket and allow to circulate.
WARNING! Remember to secure the high pressure
hose so it does not “Whip”.
Your Old Faithfull pump came with oil in the pump
crankcase. It is recommended to change the oil
after 40 hours of break-in operation, and every
three months or 500 hours, whichever comes first.
Use high grade, non-detergent, SAE 30 weight oil.
To drain oil from the pump, remove the drain plug
and the sight glass cover and rotate the shaft until
the oil stops flowing out. To fill the pump with oil,
slowly pour oil into sight tube while turning the
pump shaft. Turning the pump shaft purges all the
air out of the crankcase. Always change oil when
replacing diaphragms.
For winter storage of if a freezing condition will be
encountered, flush the Old Faithfull Pumper with a
50/50 mixture of water and anti-freeze.
Gear Reduction Crankcase – Use 90W Gear Lube.
To properly fill, remove side level plug and the vent
plug. Fill until the gear lube is no higher than the
mark on the dipstick. Replace and tighten the side
level plug and the top vent plug.
Parts Replacement, Miscellaneous Repairs and
Troubleshooting
To replace the valves or diaphragms or to do any repairs to
your Old Faithful Test Pump, refer to the Hypro Medium or
High Pressure Diaphragm Pumps manuals.
Refer to the engine manufactures Operations Manuals for
specific information on routine maintenance and trouble
shooting.
6
1-800-888-1436
Parts Breakdown
Old Faithful Parts Breakdown
This parts breakdown is to help you identify any parts that may need to be replaced or repaired. For help repairing your Old
Faithful Hydrostatic Test Pumps or to order parts, call our office at 1-800-888-1436.
HTP10-500 Control Unit Parts
OUTLET SIDE - INLET SIDE
HTP10-500 CONTROL UNIT
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14A
14B
15
16
17
18
19
20
21
PART #
9910-320410
9910-320480
9910-320460
9910-320470
9910-320490
9910-320450
9910-320440
9910-110190
9910-230120
9910-320433
9910-320511
9910-390140
9910-620220
9910-KIT2497
9910-130491
9910-130171
9910-450110
4200-109
9910-180370
9910-320420
9910-110121
4200-111
DESCRIPTION
tension spring housing
pin
lever guide
pressure relief lever
locking clip
pressure adjustment nut
threaded guide
tension spring housing
tension spring seat
relief valve poppet retainer
gasket seal - o-ring
tension spring guide/seal
relief valve body
ball valve (vertical)
ball valve (horizontal)
plug
spring holder
pressure gauge
bolt
tension spring
relief valve seat
1/4” plug
# REQD
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
REF #
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
PART #
4200-112
9910-550350
4200-110
4200-124
4200-107
4200-118
4200-108
4200-106
3351-0014
3800-0041
3351-0024
1700-0057
4200-117
4200-114
4200-113
AC-1
KITS AVAILABLE
PART #
9910-KIT1757
9910-GS40GI
3350-0061P
www.GETHURCO.com
DESCRIPTION
3/8” plug
o-ring
90 degree elbow
hose
pressure manifold
hose bushing
45 degree elbow
filter manifold
filter body
strainer screen
filter clear bowl
filter gasket
1” straight fitting
1” compressor fitting
1/2” coupler
r-clip
DESCRIPTION
control unit kit
control unit assy
line strainer assy
# REQD
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
INCLUDES:
ref# 10, 11, 12, 16, 19, 20
ref# 1-23, except #22
ref# 30-33
7
Parts Breakdown
HTP10-500 Pump Assembly Parts
8
1-800-888-1436
Parts Breakdown
HTP10-500 Pump Assembly Parts
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
PART #
9910-629011
9910-620101
9910-620102
9910-320130
9910-620080
9910-620120
9910-620140
9910-620110
9910-580470
9910-380300
9910-380080
9910-160230
9910-580360
9910-1040180
9910-550131
9910-180150
9910-620030
9910-1409050
9910-130171
9910-111120
9910-620020
9910-620210
9910-620291
9910-620190
9910-390440
9910-550331
9910-550330
9910-180101
9910-550030
9910-550040
9910-550056
9910-620160
9910-550060
9910-620130
9910-620330
9910-620170
9910-620150
9910-180101
9910-650660
9910-650670
9910-650690
9910-622070
9910-550190
9910-629211
9910-650542
9910-180020
9910-390060
9910-621780
9910-390270
DESCRIPTION
pump body
head assembly right
head assembly left
nut
buna diaphragm
piston
connecting rod
piston sleeve
retainer ring
connecting rod pin
retainer ring
piston ring
retaining bolt
retaining washer
locknut
nut
o-ring
check valve assembly
drain plug
retainer ring
oil sealing cap
o-ring
retaining ring
ball bearing
nut
washer
stud
o-ring
oil sight glass
o-ring
cap for sight glass
spacer washer
roller bearings
seal
retainer ring
crankshaft
manifold
o-ring
damper body
damper diaphragm
clamp
accumulator manifold
accumulator diaphragm
accumulator head
o-ring
air valve
o-ring
bolt
nut
# REQD
1
1
1
8
2
2
2
2
2
2
4
2
2
2
2
2
4
4
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
8
2
KITS AVAILABLE
PART #
9910-KIT1916
9910-KIT2110
9910-KIT1724
9910-KIT1917
www.GETHURCO.com
DESCRIPTION
o-ring kit
diaphragm kit
diaphragm kit
valve repair kit
INCLUDES:
ref# 17, 22, 28, 30, 45, 47
ref# 5, 17, 43 (buna)
ref# 5, 17, 43
ref# 17, 18
9
Parts Breakdown
HTP10-500 Component Assembly Parts
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
10
PART #
4200-101
4200-102
4200-104
4200-105
9910-GS40GI
4200-309
4200-310
4200-303
4200-302
4200-301
4200-304
4200-119
4200-206
990-400
4200-129
902-105
DESCRIPTION
pump base
pump protection frame
Honda engine
pump D30-B
control unit
handles
handle grips
support foot
axle
test pump wheels
axle spacer
support bracket
frame plug
u bolt
u bolt
bolt
# REQD
1
1
1
1
1
2
2
2
2
2
2
1
4
1
1
4
REF #
17
18
19
20
21
22
23
24
25
26
27
28
PART #
903-103
901-106
901-102
903-021
902-020
903-020
901-001
902-001
903-001
901-020
4200-306
9910-651000
Not Pictured
Not Pictured
1-800-888-1436
DESCRIPTION
bolt
bolt
bolt
washer
washer
washer
1/4-20 nylock
5/15-18 nylock
3/8-16 nylock
washer
cotter pin
bolt
4200-125
4200-126
outlet hose
suction hose
# REQD
4
2
4
2
4
4
4
4
4
4
2
4
1
1
Parts Breakdown
HTP10-500 Gear Box Assembly Parts
REF #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
www.GETHURCO.com
PART #
9910-620561
9910-180030
9910-621000
9910-620990
9910-651620
9910-200231
9910-620470
9910-620950
9910-651000
9910-620960
2406-0023
9910-740290
9910-1140370
9910-621660
9910-621010
9910-320240
9910-961780
9910-320240
9910-961800
9910-961790
9910-881090
DESCRIPTION
o-ring
bolt
pump adapter flange
bearing
gear
lock washer
bolt
gasket
bolt
gearbox body
plug
o-ring
vent plug
pinion gear
bolt
retaining ring
bearing
retaining ring
seal
retaining ring
key
# REQD
1
1
1
1
1
6
3
1
4
1
2
2
1
1
4
2
1
2
1
1
1
11
Warranty Information
Limited Warranty
When used in accordance with instructions, HURCO Technologies, Inc. will replace to the original purchasers,
free of charge, any part or parts of the Old Faithful Test Pumps, excluding the engine and Hypro Pumps, found to
be defective in material or workmanship or both; this is the exclusive remedy. All transportation charges on parts
submitted for replacement under this Warranty must be borne by the purchaser. The engine and Hypro Pump
is warranted as outlined by each manufacturer’s separate, limited warranty only. This warranty does not cover
damage or loss to the Old Faithfull Hydrostatic pumps due to operating negligence, or due to accident or other
casualty. THERE IS NO OTHER EXPRESS WARRANTY OR IMPLIED WARRANTIES. THIS WARRANTY IS LIMITED TO
A PERIOD OF ONE YEAR FROM THE DATE OF PURCHASE AND TO THE EXTENT PERMITTED BY APPLICABLE LAW,
ANY AND ALL IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE HEREBY EXCLUDED, TO THE EXTENT PERMITTED BY LAW. IN NO EVENT SHALL WARRANTOR BE
LIABLE FOR DIRECT, INDIRECT, INCIDENTAL AND CONSEQUENTIAL DAMAGES RESULTING FROM ANY DEFECT IN
THE GOODS, TO THE EXTENT SUCH AVOIDANCE IS PERMITTED BY APPLICABLE LAW.
12
1-800-888-1436
Notes
NOTES
www.GETHURCO.com
13
1-800-888-1436 • gethurco.com • [email protected]
Rev: 8-9-2012
Part No. HTP-OM
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement