
7
5. If the pressure regulator internal bypass valve is
worn, it will allow too much of the pump capacity to
be bypassed and recirculated back to the tank. By
examining the flow from this valve with the discharge
turned on, it can be determined whether or not the
valve is worn. If a heavy flow continues when the
discharge is turned on, it is usually a good indication
of a worn valve and should be replaced.
6. Worn plunger cups, valves or valve seats will cause a
severe drop in pump capacity pressure. Worn
plunger cups are detected by water leakage past
the cups and should be replaced immediately. Water
getting into the pump crankcase will cause severe
corrosion of the bearings. Worn valves can only
be detected by visual examination of each valve
assembly. Abrasive liquid will cause wire cuts which
begin as a very small groove, but increase rapidly
once the valve starts to leak through this groove. If
the valve plates are replaced as soon as they start to
show this cutting action, it will prevent the valve seat
from becoming cut in a similar manner.
7. Pump cylinder bodies withstand an extreme amount
of shock and pulsation while in operation, but if the
pump is allowed to freeze, by not being drained, the
freezing may crack the cylinder body walls in almost
any location. If the crack occurs on the suction valve
or cylinder portion of the body, it may allow a small
amount of air to enter on the suction stroke and
cause noisy operation or a decrease in pumping
capacity. If the crack develops in the walls between
the cylinder cavities or discharge valve cavity, it
may allow the water to flow from one cavity to the
adjacent cavity and cause uneven displacement.
8. The holes in the gun or nozzle discs are continually
subject to wear because of the high velocity of the
liquid through the holes. If the holes become worn,
they may allow a higher rate of discharge than the
pump is able to provide, then a drop in pressure will
be noticed. This can quickly be checked by reducing
the number of nozzles or guns while watching the
amount of overflow from the pressure regulator. If
there is considerable overflow, it is an indication that
the regulator valve is worn rather than the gun or
nozzle disc.
9. Suction surge arresters should be installed on the
suction line of reciprocating pumps, 1-1/2" or 2"
can be used. A standing height of 12"-15" will be
sufficient with the top end closed by an ordinary
pipe cap.
10. Water may accumulate in the pump crankcase from
two sources; leakage of the plunger cups or an
accumulation of condensation/moisture inside the
crankcase due to changes in weather or the repeated
heating and cooling of the pump. Pumps used
consistently, running for a considerable period of
time to heat the oil and other working parts, will not
normally accumulate water by condensation. Replace
the plunger cups as soon as they start to leak.
11. Worn connecting link bearings are caused by
unusual or adverse operating conditions and are
seriously affected by corrosion if water is present
in the crankcase. They will wear out from overheating
if adequate oil is not provided in the crankcase. It
is recommended to drain, clean and refill with new
oil prior to any storage period. Replace bearings as
soon as any damage is discovered to avoid possible
damage to crankshaft.
12. Low oil in the crankcase can quickly cause failure
of the pump's power end and result in extensive
repairs. Oil level should be checked periodically
during normal operation and during all
maintenance work.
13. A foaming mixture will sometimes have the same
effect as a small air leak in the suction line. This is
because various quantities of the foam are drawn
through the suction line into the pump disrupting the
normal flow of water.
14. Pressure regulators and unloading valves may
become sluggish in action due to the plunger sticking
or fitting too tightly in its cylinder. This may happen
by an accumulation of chemicals collecting in and
around the plunger or due to excessive corrosion of
the plunger parts. To check this condition, remove
and clean the plunger and cover the parts with a
waterproof grease before assembling.
15. The stuffing box nut on the unloading valve lifting
post should not be tightened to severely grip or
bind the packing on the post. Tighten this nut just
enough to prevent leakage and chatter. The pressure
regulator and unloading valves may chatter or
vibrate excessively due to an unstable operation
from nozzling in the high or low capacity range of the
regulator or unloader. The range should be at least
50% to 90% of pump capacity. With unloader valves,
nozzle capacity should be at least 20% and not
exceed 90% of pump capacity.
16. If foreign matter becomes lodged between the pump
valve and valve seat, a drastic drop in capacity and
considerable surge or pulsation will occur in the
discharge line. Examine each valve if this occurs.
17. When a pump is used for a long period of time, a
waterlogged discharge surge could cause pulsation
at the discharge. The suction should be opened into
the atmosphere to allow air to be drawn through the
pump to recharge the surge arrester. Do this with the
pressure release valve open so the pump operates at
no pressure.