VARISCO J2 180 User manual

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PUMPING AND ENERGY SOLUTIONS
PUMP
USER
MANUAL

Petrol engine pump on the frame
Technical specification:
Intended use Drainage water pumping
Make / Type Varisco / J2 - 180
Maximal flow 51 m3 / h, see curve
Maximal head 48 mwc, see curve
Maximal suction lift 8m
Suction connection 2’’
Discharge connection 2’’
Free passage Up to 15mm
Dimensions L x W x H 860mm x 710mm x 1140mm
Weight 126kg
Engine Petrol engine
Engine brand / Type Kohler / CH440
Engine power / rpm 10,4 kW / 3600 rpm
Fuel tank 7,7 liter
Maximal fuel consumption 2,5 l/h
Maximal working time with full revs 3h
GPS Not equipped

J2 180

Contents
1 Description, application and working principles............................................3
1.1 Description..................................................................................................3
1.2 Construction ...............................................................................................4
2 Specification and dimensions..........................................................................5
3 Performance and curve.....................................................................................6
4 Safety instruction..............................................................................................7
5 Transportation and lifting.................................................................................9
6 Pipework and installation...............................................................................11
6.1 Pipework....................................................................................................11
7 Symbols ...........................................................................................................12
8 Preparation for starting...................................................................................13
8.1 CHECKING THE SEAL..............................................................................13
8.2 Pumps with type TW or T4W mechanical seals .....................................13
8.3 Pumps with type T mechanical seals......................................................13
8.4 Filling the pump casing............................................................................14
8.5 Check fuel in fuel tank..............................................................................14
8.6 Check oil level in engine..........................................................................14
8.7 Checking safety and environmental risks ..............................................15
8.8 Checking visual inspection......................................................................15
8.9 Priming ......................................................................................................15
9 Starting.............................................................................................................16
10 Stopping .......................................................................................................18
11 Draining the pump when there is danger of freezing................................19
12 Troubleshooting...........................................................................................20

1 Description, application and working principles
1.1 Description
WARNING: This manual is intended to give Important Information that must be followed
during Storage, Transportation, Installation, Operation and Maintenance of the Pump-Set.
We therefore recommend that this manual is read carefully before the Pump-Set is put into
operation. To prevent damage being caused by inappropriate or incorrect use, or by being
used outside the normal operating parameters of the Pump-set, the Instructions in this
manual must be followed. Failure to do so may lead to damage to or premature failure of the
Pump-set and may cause Injury. Any such actions will invalidate the warranty.
Centrifugal pump mod. J2-180 is basically a pump driven by a petrol engine, featuring an open vane
impeller to allow it to handle even liquids containing solids. This pump can also operate satisfactorily
with liquids containing dissolved gases or air. It is suitable for handling liquids of viscosity up to 50 cSt,
containing solids in suspension, and can be used in industry, civil engineering, shipbuilding, wastewater
treatment, construction and agriculture. It must not be used in a potentially explosive atmosphere.
Always quote the pump type printed on the relevant nameplate, or the serial number, when
ordering/making enquiries etc.
Self-priming principle
The air (yellow arrows) is drawn into the pump due to the negative pressure created by the moving
impeller and is emulsified with the liquid (blue arrows) contained in the pump casing. The air-liquid
emulsion is forced into the priming chamber where the lighter air is separated and leaves through the
discharge pipe; the heavier liquid drops back down into circulation. Once all of the air has beenexpelled
from the suction pipe, the pump is primed and works like a normal centrifugal pump. The pump can
also work with an air-liquid mixture

1.2 Construction
Main pump elements:
1 –Lifting hook, 2 –Air filter. 3 –Petrol tank. 4 –Port with quick coupling delivery pipe, 5 –
Exhaust silencer, 6 –Port with quick coupler, suction pipe, 7 –Pump unit, 8 –Moving handle, 9
–Frame, 10 –Tyre

2 Specification and dimensions
J2 180
Max capacity
51m3/h
Max head
48m
Solids handling
15mm
Weight
126kg
Connection ports
2” DN50
Dimensions LxWxH
860x710x1140
Petrol engine
Kohler CH440
Displacement
429 cm3
Starting
Pull start
Power
10,4 kW
Nominal speed
3600 rpm
Fuel tank capacity
7.7 l
Cooling
Air

3 Performance and curve

4 Safety instruction
This manual contains warning and safety symbols. Do not ignore the instructions. They are
provided for the benefit of your health and safety and to prevent damage to the environment and
the pump unit.
DANGER
When the danger symbol with the text DANGER is shown, it is accompanied by
information that is of great importance for the safety of everyone concerned.
Ignoring the information can result in injury (possibly severe) or evendeath.
WARNING
When the warning symbol with the text WARNING is shown, it is accompanied by
information that is of great importance for everyone concerned with the pump
unit. Ignoring the information can result in injury or damage (possibly severe) to
the pump
unit.
The pump unit conforms to the European Machinery Directive. However, this does not exclude
the possibility of accidents if used incorrectly.
Use of the pump for an application and/or deployment of the pump in an environment other than
defined at the time of purchase is strictly prohibited and can result in a hazardous situation.
This is particularly true for corrosive, toxic or other hazardous liquids. The pump unit may only be
installed, operated and maintained by persons who have received appropriate training and are
aware of the associated dangers.
The installer, operator and maintenance personnel must comply with the local safety regulations.
The company management is responsible for ensuring that all work is performed by qualified
personnel in a safe manner. It is not permitted to make changes to the pump unit without written
permission from Varisco.
If any changes are made to the pump without the written permission of Varisco, Varisco disclaims
all liability. Hearing protection must be worn if the noise emission level exceeds 85 dB(A).
Ensure that hot/cold and rotating parts of the pump are shielded adequately to prevent
unintentional contact.
It is not permitted to start the pump if such guards are missing or damaged.
The company management must ensure that everyone who works with/on the pump unit is aware
of the type of liquid that is being pumped. These persons must know what measures are to be
taken in the event of leakage.
Dispose of any liquids that have leaked, in a responsible manner. Observe local regulations
Never allow the pump unit to run with a blocked discharge line. The heat build-up could lead to
an explosion
WARNING
Only appropriate fire extinguishers (e.g. carbon dioxide) are to be used in case
of fire or any other situation where open flames appear inside or outside the
equipment. It is strictly prohibited to use water to put out the flames

Lift the pump by the upper prat of the handle only
Use overalls and insulating shoes made according to specific safety
regulation
Wear safety eyewear
Wear safety gloves
Wear safety earmuffs
Wear hard hats
Do not go near hot surfaces (motor and vacuum pump)
Keep away from moving parts (belts etc.)

5 Transportation and lifting
“Transport” refers to the phase when the equipment is transferred from the manufacturing site to that
where it shall be used.
The electrical equipment is supplied mechanically fastened to the structure of its relative machine; refer
to the specific Use and Maintenance Manual for the methods of transport and handling.
Any kind of impact and stress to the components must be avoided when the electrical equipment is
transported and handled. Particular attention must be paid to:
•ensure the doors or access hatches are closed properly and secured;
•protect the equipment from all kinds of possible impact and stress according to the type of
transport.
The following precautions must always be complied with when transporting and handling the
goods:
•do not stand beneath suspended loads and keep at a safe distance from the area in which the
load is handled;
•if the load must be guided while being raised, do not use your hands or feet. Suitable equipment
must be used that allow the personnel to maintain a safe distance from the load being lifted.
WARNING
Use certified lifting equipment with an adequate lifting capacity and always lift from
directly above. Lifting from an angle can lead to dangerous situations.
Lifting work may only be performed by appropriately authorized personnel.
Because many different versions of the pump unit are available, only general
instructions are provided. See the specification sheet for the particular pump unit
for the weight and dimensions.
WARNING
Prevent particularly violent knocks during transport by paying attention to the overall
dimensions of the goods and fastening the load so as to prevent it from tipping over

6 Pipework and installation
6.1 Pipework
Clean pipework thoroughly before connecting it to the pump. Suction pipes must have the same
diameter as the pump’s suction port (for larger diameters, seek VARISCO Spa’s advice). Where
possible, avoid curves, elbows or constrictions liable to limit the flow of liquid to the pump.
Install the pump as near to the liquid to be pumped as possible. Where possible, try to reduce the
length of the suction pipe.
Suction pipe connections must be completely airtight: check pipe threads, flange gaskets, quick
couplings etc.

7 Symbols
On the pump engine can find symbols. Symbol descriptions are explained under.

8 Preparation for starting
WARNING
If the pump is equipped with a vacuum pump, the pump does not have to be filled
with the pumped liquid.
DANGER
Before operating the pump, check that all parts of the system have been correctly
installed and that all safety devices are operative.
8.1 CHECKING THE SEAL
Before starting the pump, check the type of mechanical seal shown on the pump name plate.
8.2 Pumps with type TW or T4W mechanical seals
Type TW and T4W mechanical seals are filled with grease during assembly. They do not require
maintenance during the first 500 hours of operation of the pump
8.3 Pumps with type T mechanical seals
Type T mechanical seals are oil lubricated. Check the oil level in the oiler; if it is low, top up with engine
lubricating oil

8.4 Filling the pump casing
Fill the pump casing completely with the liquid to be pumped through the opening on the top of the
casing (1). When the pump is stopped, the casing does not empty and therefore it is not necessary to
refill it.
8.5 Check fuel in fuel tank
WARNING
Always check fuel level in fuel tank. Don’t start the pump when fuel is running low.
In this case air can get in fuel system.
WARNING
Filling up the fuel, engine MUST be switched off.
8.6 Check oil level in engine
WARNING
Hot oil and components can cause personal injury. Do not allow hot oil or hot
components to contact the skin.
Note
Perform this maintenance engine must be stopped
1. Remove engine level dipstick (1) level must be above MIN level mark
2. If necessary to fill some oil, fill it through oil dipstick hole(1).

8.7 Checking safety and environmental risks
THE FOLLOWING ACTIONS ARE STRICTLY FORBIDDEN:
•Using the pumps in a potentially explosive atmosphere.
•Carrying out maintenance with the engine running.
•Climbing on top of the engine-driven pump to perform work of any kind.
•Working on the pump when it is connected to an active remote control.
•Before starting the trailer-mounted pump, make sure the wheels are suitably locked.
•Do not use the engine-driven pump indoors.
8.8 Checking visual inspection
•Check pump of any leakage
•Check of any cracks
•Check if not missing or damaged parts
•Suction and discharge ports are not damaged
•etc
8.9 Priming
Attention: if the pump does not prime, do not operate it for more than 2 minutes to avoid
overheating the liquid and damaging the seal. If the pump does not prime, read paragraph
Engine driven pumps should be brought up gradually to running speed. Never change the accelerator
limit stop: at speeds higher than that for which the engine is set, the pump would absorb more power
than the engine can supply.
Never exceed the maximum speed shown on the pump name plate.
When the pump has primed:
1. Check the shaft seal for leaks.
2. Check that the current absorbed by the motor does not exceed the rated value shown on the
name plate.
3. If the pump does not seem to be operating normally, it must be stopped and the cause found
in troubleshooting section.

9 Starting
1. Check the pump type (type plate) and the characteristics of the pump unit, such as: rpm, operating
pressure, power consumption, operating temperature, direction of rotation, NPSH, etc.
2. Check whether the pump unit is placed in accordance with the instructions. Pay particular attention
to the area around the pump unit. Make sure the pump unit can draw adequate fresh air.
3. Check whether the prescribed safety provisions are in place.
4. Connect the hoses
5. Perform preparation for starting
6. Turn the engine start-Stop switch to position “ON”(1)
7. Push throttle lever to “Turtle” position (2)
8. Open fuel lever (3)
9. If engine is cold, close choke lever (4)
10. Pull starter handle (5).
11. When motor is started open choke lever (4). Engine pick up nominal speed and start running
smoothly.

WARNING
If vibration occurs during starting, stop the pump immediately and eliminate the
cause before starting again.
WARNING
If the pump vacuum lift is set too high, cavitation in the pump set is possible and this can
be recognized by High levels of vibration, a crackling noise in the pump, decreased
capacity and pressure. If this condition is allowed to persist for long periods it will cause
damage the pump set. Continued running of the pump set in this condition will invalidate
the warranty
WARNING
Pump not allowed operate without pumping liquid more then 2 minutes. Its can
damage mechanical seal.