Kärcher HAWK LEUCO TXT Series, Instruction Manual

Page 1: ... INSTRUCTIONS LEUCO S p A Via Colletta 20 42124 Reggio Emilia RE ITALY Tel 0522 923011 Fax 0522 923030 This manual and associated information can be downloaded from the website www hawkspumps com This manual is an integral part of the product and should always be made available to any persons using it ...

Page 2: ... 7 Pressurised liquids 10 3 SAFETY 10 3 1 General safety instructions 10 3 2 Residual risks 11 3 3 Personal protective equipment 12 3 4 Working safely 12 3 4 1 Safety when using the pump 12 3 4 2 Safety when using high pressure circuits 12 3 5 Safety during lifting and handling 13 3 5 1 Packing unpacking and transport 13 3 6 Safety during maintenance 14 3 7 Products used 14 3 8 Product labels 14 3...

Page 3: ...al maintenance 26 6 2 Removal of mechanical parts 27 6 3 Assembly of mechanical parts 28 6 4 Inspecting the bearings 28 6 5 Changing the bearing 29 6 6 Maintenance of the hydraulic part 29 6 6 1 Replacement of suction delivery valves 29 6 6 2 Replacement of the seals 30 6 6 3 Replacing the plungers 33 7 TROUBLESHOOTING 33 7 1 Problems and potential remedies 33 8 DISMANTLING AND DISPOSAL 34 9 SPARE...

Page 4: ...le of the high pressure positive displacement piston pumps to be observed by any persons involved in its assembly end user in order to prevent possible risks Operators and qualified technicians must read the instructions in this publication with due care before starting any operation on the equipment Contact LEUCO S p A for the necessary explanations if you have any doubts regarding the correct me...

Page 5: ...er of crushing the upper limbs when positioning or handling the pump MOVING MECHANICAL PARTS HAZARD Indicates a hazard due to the presence of moving parts such as drive shafts or reduction units SYMBOL MEANING COMMENT WARNING SAFETY INFORMATION A warning or note regarding key features or useful information Pay maximum attention to the text boxes indicated by these symbols REFERENCE Refer to the in...

Page 6: ...e returned freight paid for inspection repair or replacement by the manufacturer This limited warranty is the only form of valid guarantee and replaces any other form of explicit or implicit warranty including any guarantee of fitness for sale or any particular purpose The manufacturer refuses any such liability with this statement Faulty products will only be repaired or replaced according to the...

Page 7: ...wer consumption The volume is given in litres per minute and is directly proportional to the rotation speed The speed of rotation is given as revolutions per minute The pressure is given in bars and is the maximum pressure that the pump can reach The power consumption is shown in kW and is the absorption required to achieve the maximum flow rate and pressure indicated When coupled with an electric...

Page 8: ... TXT Series Doc code M I TXT 21 Rev 0 Page 8 of 35 2 1 Main parts A MANIFOLD HOUSING B PUMP BODY C OIL DIP STICK D CRANKSHAFT E CONNECTING ROD F PLUNGER relative parts G OIL LEVEL INDICATOR H DELIVERY LINE VALVE I SUCTION LINE VALVE More details on the parts can be found in the exploded views attached to this manual ATTACHMENT II C D A B E F G H I ...

Page 9: ... 1 1 4 74 5 TXT1817L 170 2465 180 47 55 1000 58 80 78 85 G 2 G 1 1 4 74 5 TXT2214R 140 2175 220 58 12 1000 59 20 79 39 G 2 G 1 1 4 74 5 TXT2214L 140 2175 220 58 12 1000 59 20 79 39 G 2 G 1 1 4 74 5 Detailed technical specifications for each range or series with the associated product versions are provided in ATTACHMENT II at the end of this document 2 2 Ambient conditions The local operating condi...

Page 10: ...il The lubricating transmission products contained in the pump body are used to safeguard correct pump operation by keeping the mechanical parts lubricated 3 SAFETY 3 1 General safety instructions Hawk pumps were designed to be safe to operate for the intended purposes provided they are run incorporated used and maintained according to the instructions in these operating and maintenance instructio...

Page 11: ...aintenance Make sure all the steps described in the section on maintenance are carried out regularly 3 2 Residual risks The pumps were designed and built in order to eliminate any risks associated with their operation The residual risks are described below a Crushing Handling and positioning the pump may bring the risk of crushing the upper limbs or hands or feet Pay particular attention when unde...

Page 12: ... training on the risks arising from high pressure system damages or defects Prior to starting up the system the operator or operators are required to check that the system has the correct power supply the electrical parts are correctly and adequately protected and work efficiently the high pressure hoses and hose fittings do not exhibit signs of abrasion or excessive wear Any defect damage or reas...

Page 13: ...ls can be safely undertaken Only authorised qualified personnel who have received specific training may perform unloading loading handling and lifting operations People who are not involved in the operations must keep at a safe distance during lifting and handling All equipment used for lifting and transport including accessories such as hooks ropes and chains must be of a suitable capacity and ch...

Page 14: ...rised to carry our maintenance repair work 3 7 Products used All the products used during normal operation including oils lubricants and cleaning products must be used as instructed in the safety notices provided by the manufacturer Use the oil already in the pump for the first 50 hours and then replace with SAE 10 40W oil as shown on the label The TXT pumps are already filled with SAE 10 40W oil ...

Page 15: ...rink attempting to treat sprains and or broken bones etc 3 9 2 Emergency Call To be sure of a successful outcome it is important to make sure the emergency services can reach the place of the event without delay So it is very important that the first aider who calls the emergency services gives the following information The address where the accident or medical emergency has taken place How many p...

Page 16: ... Do NOT use cotton wool alcohol or antibiotic powder to disinfect a wound Always remember to wear latex gloves to prevent contact with body fluids 4 INTENDED USE 4 1 Intended use Hawk pumps must not be used for any other purposes than those described in these instructions Complying with the terms of use repair and maintenance specified by the Manufacturer in strict accordance are an essential elem...

Page 17: ... purpose than those mentioned above 5 INSTALLATION AND ASSEMBLY Read this chapter with due care before starting to install the machine Failure to install the pumping system correctly can result in injury or damage to property it is important to follow all the points below General scheme A Tank or mains water supply B Shut off valve C Suction filter D Auxiliary pump E Suction pressure gauge F Deliv...

Page 18: ...ature and or excessive current absorption 5 1 1 Placing The pump must be placed horizontally using the M16 support feet provided The base used must be sufficiently flat and rigid so as to avoid bending and misalignment on the pump transmission axis due to the output torque transmitted during operation You might also require vibration dampers to be placed between the floor and the pump support The ...

Page 19: ...e evacuation of any air pockets It should be free from leaks and made to ensure tightness over time It should be as free as possible from 90 bends connections with other pipelines bottlenecks counterslopes inverted U shaped curves and T joints It should be designed in such a way as to prevent the circuit from emptying when the pump stops Avoid hydraulic type fittings Avoid the presence of Venturi ...

Page 20: ...e present Check that the speed does not exceed the value indicated on the nameplate Wait a few minutes before pressurizing the circuit making sure that the pump is sucking properly Before stopping the pump reset the pressure to zero by discharging the pressure regulating valve or using the circuit s discharge mechanisms where present If the pump is coupled to an endothermic motor bring the motor d...

Page 21: ...discharge line is an open drain type in order to ensure the speedy evacuation of air in the circuit thereby encouraging pump priming All fittings and connections are properly tightened The pump transmission alignment is properly aligned The oil level inside the crankcase is correct this can be checked by means of the dipstick found in the airtight stopper cap or by looking at the oil level indicat...

Page 22: ...diately below the next one in the example the value is circled in green This Manual remains the property of the Manufacturer it may not be reproduced or copied even partially Instructions Manual High pressure piston pumps GXT GXT HT GPX SERIES Doc code M I GXT 18 Rev 1 Page 22 of 35 NOZZLE TABLE the table below is an example of how to choose the nozzle correctly based on the pump s specifications ...

Page 23: ...Instruction Manual High pressure piston pumps TXT Series Doc code M I TXT 21 Rev 1 Page 23 of 35 This Manual remains the property of the Manufacturer it may not be reproduced or copied even partially ...

Page 24: ...This Manual remains the property of the Manufacturer it may not be reproduced or copied even partially Instruction Manual High pressure piston pumps TXT Series Doc code M I TXT 21 Rev 0 Page 24 of 35 ...

Page 25: ...This Manual remains the property of the Manufacturer it may not be reproduced or copied even partially Instruction Manual High pressure piston pumps TXT Series Doc code M I TXT 21 Rev 0 Page 25 of 35 ...

Page 26: ...by following the preventive maintenance schedule below CONTROL DAILY WEEKLY 50 H 500 H 1000 H CLEAN FILTERS X OIL LEVEL CONDITION X OIL WATER LEAKS X HYDRAULIC SYSTEM X 1St OIL CHANGE X CHANGE OIL X X REPLACE SEALS X REPLACE CHECK VALVES X Each maintenance schedule depends on the type of job that the pump is used for The operating cycle the temperature and the quality of the pumped liquid the type...

Page 27: ...unt of oil using the level indicator located on the rear of the pump body see section 2 1 letter G If necessary top up with oil as indicated in section 3 7 through the oil plug located in the upper part of the pump body see section 2 1 letter C Change the oil Put the machine where the pump is fitted on a perfectly level surface with the pump slightly warm Do not spill any oil Dispose of oil accord...

Page 28: ...ankcase the shaft should still be inserted on the side without the PTO supporting this with your hand Replace the oil seal if it is worn and then insert the two bearing housings in the crankcase holes remembering to check the wear rings are fitted Tighten the 6 screws by applying 20 Nm torque Replace the connecting rod feet taking care not to swap their positions and respecting the torque of 38 Nm...

Page 29: ...ent of a significant reduction in flow rate and therefore the maximum working pressure of the pump For routine maintenance intervals refer to chap 6 6 6 1 Replacement of suction delivery valves DISMANTLING To replace the suction delivery valves in the head proceed as follows Unscrew the 8 8 M12 screws securing the VAM covers suction and discharge and remove them Figure 4 Figure 5 Using a threaded ...

Page 30: ...0 of 35 Generously grease all VAM seats inside the header Figure 13 Insert the new VAMs Figure 14 Figure 15 Insert the VAM plugs Figure 16 Mount the 2 suction and discharge covers by screwing them on with a socket spanner Figure 18 Mount the 2 suction and discharge covers by screwing them on with a socket spanner Figure 19 figure 13 figure 14 figure 15 figure 16 figure 17 figure 18 figure 19 ...

Page 31: ... brass spacers Figure 23 Remove the cylinder head using a plastic hammer Figure 24 Use a crank to facilitate the removal of the gasket holder bushings pressers and anti extrusion rings Figure 25 Figure 26 Figure 27 Remove the crankcase spacer Figure 28 Remove the low pressure seal using a plastic tool to prevent damage to the brass seat Figure 31 If one or more bushings still have a presser and ex...

Page 32: ... gasket bushings inserting the pin into the hole of the spacer Figure 45 Insert the high pressure gasket pack into the piston in the following order anti extrusion E gasket F and plastic ring G Figure 46 Insert the piston scraper ring into the plastic bushing Figure 47 a The TXT2214 model on the other hand features a double gasket and V without piston ring Figure 47 b Insert the OR into the respec...

Page 33: ...be reproduced or copied even partially Instruction Manual High pressure piston pumps TXT Series Doc code M I TXT 21 Rev 0 Page 33 of 35 figure 46 figure 47 a figure 47 b figure 48 figure 49 figure 50 figure 51 figure 52 figure 53 figure 54 figure 55 figure 56 E F G ...

Page 34: ...e threaded rod Figure 60 Pre assemble the nut in the piston hole paying attention to the correct insertion of the O ring Figure 61 Finally tighten the piston nut to a torque of 20 Nm figure 57 figure 58 figure 59 figure 60 figure 61 figure 62 7 TROUBLESHOOTING 7 1 Problems and potential remedies Only authorised and qualified personnel may attempt troubleshooting This section suggests some solution...

Page 35: ...rature Reduce the water temperature Worn piston seals Replace the seals The pump is very noisy Worn bearings Replace the bearings High inlet water temperature Reduce the water temperature Pump motor coupling problems Check the status of the keys and the flexible coupling or the pulley Short piston seal life Cavitation or air in the system Check the state and size of the suction pipe and replace wi...

Page 36: ... lubricants into the environment Any non ferrous parts must be disposed of by an authorised company Any parts made of iron can be recycled or sold The manufacturer must be notified if the machine is decommissioned or sold The packing materials can be recycled Do not throw the packing materials away with normal household waste but send them for recycling The pump contains important raw materials th...