GDF High Pressure Piston Pump Instruction Manual
Zhejiang Botuolini Machinery Co., Ltd
directory
1. Note 2
2. Mark 2
3. Safety 3
3.1 General Safety Instructions3
3.2 Safety requirements for high-voltage components3
3.3 Operational Safety Guidelines3
3.4 Operational safety precautions3
3.5 Safety matters during maintenance4
4. The nameplate of the pump 4
5. Technical parameters 5
6. Installation size 5
7. Instructions for pump use 5
7.1 Water temperature 6
7.2 Maximum flow and pressure 6
7.3 Rotational speed and direction of rotation 6
7.4 Brands and types of lubricating oil6
8. Interfaces and connections 7
9. Install 7
9.1 Installation 7
9.2Direction of rotation 8
9.3 Pump rotation direction change 8
9.4 Pipeline connection 9
9.5 Water supply requirements 9
9.6 Pump water inlet connection mode and start and stop precautions 9
9.7 Drainage line 10
9.8 Determination of the inner diameter of the pipeline11
10. Start and run 12
10.1Pre-launch checks12
10.2 Startup 12
11. Maintenance precautions 12
12. Storage 13
12.1 Method of filling the pump with anti-corrosion emulsion or antifreeze using an external diaphragm pump 13
12.2 Hose 13
13. Prevention of freezing14
14. Warranty clause 14
15. Common fault phenomena and elimination methods 14
16. Exploded view, schedule 16
1. Description
1.1 This manual introduces the use and maintenance of GDF series high-pressure piston pumps, please read and understand the contents of this manual carefully before using the water pump.
1.2 The Company shall not be liable for any damage caused by improper use or negligence.
1.3 Correct use and maintenance are conducive to prolonging the service life of the pump.
1.4 To the extent permitted by law, the Company reserves the right of final interpretation of this Manual. If you encounter any problems, please contact us.
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3. Safety
Incorrect use or disregard of installation and maintenance guidelines can result in serious personal injury or property damage, and personnel using high-pressure pumping units must be trained and qualified to work. For the safety of the occupants, appropriate personal protective equipment (e.g., protective gloves, face shields, goggles, insulated boots, etc.) must be used and worn during maintenance and use.
3.2.1 Safety valves must be installed.
3.2.2 High-voltage components, especially exposed ones, should be protected from rain, frost and overheating.
3.2.3 The electrical part should be waterproof and comply with relevant specifications.
3.2.4 The outlet pipeline must be able to meet the maximum working pressure, and must be within the manufacturer's nominal pressure range, and this standard is applicable to other pressure components.
3.2.5 In order to prevent the rupture caused by the loss of force and torsion of the pipeline, the joint part must be fixed.
3.2.6 The pump transmission part should also strengthen safety protection (joints, safety belts, belts, pulleys).
The working area of the high-pressure pump must be cleaned and not accessible without permission, and if possible, a fence can be erected, and the personnel who are allowed to enter the work area must be trained and qualified. Check before start-up to make sure the water supply is connected and that the line is full of water.
3.3.1 The water supply pipeline is well sealed and cannot leak.
3.3.2 Confirm that the on/off valve between the water source and the pump has been opened, and the water can enter the pump smoothly, and adjust the pressure pipeline to the unloading mode to let the air in the pump discharge smoothly, so that the pump can start smoothly.
3.3.3 Confirm that all water supply pipes are tightly connected.
3.3.4 The high-pressure pipe does not appear particularly obvious wear, all pipe fittings are intact, before the operation, any abnormality must be reported in time, verified by a special person, in this case, the pressure in the pipeline must be released, and the high-pressure unit is shut down.
3.4.1 The operator should have the corresponding operating skills, use the equipment in strict accordance with the requirements, and put safety first.
3.4.2 The operator must wear goggles, helmets, waterproof clothing, protective gloves and insulated boots.
Note: Workwear will protect against splashing, but not for direct or close spraying, and in some cases further protection is required.
3.4.3 It is recommended to have at least two people to assist each other and even swap up during long periods of heavy work.
3.4.4 It is strictly forbidden to enter within the working range of jetting and flow jetting, and any objects that are dangerous or damaged due to the impact of high-pressure water column must be removed in this area.
3.4.5 Even during the initial test, the effluent must point to the work area.
3.4.6 When the high-pressure pump is running, it is strictly forbidden for other personnel to enter the work area without safety measures.
3.5 Safety matters during maintenance
3.5.1 The maintenance of the pump must be carried out within the period indicated by the manufacturer.
3.5.2 Maintenance must be performed by professional personnel.
3.5.3 The installation and disassembly of the pump must be operated by a special person with the correct tools to avoid damage to the parts.
3.5.4 Please use original parts.
4. The nameplate of the pump
The parameter nameplate is shown in Figure 1
The nameplate shown here contains important information for safe operation, and the plaque is attached to each pump (as shown in Figure 1).
A) Brand name E) Rated power (kW/hp)
B) Product model F) Rated flow rate (Lpm/gpm).
C) Product serial number G) Pressure rating (bar/psi).
D) Rated speed(r.p.m)
Note: When purchasing accessories, the model and specifications of the pump should be indicated.
5. Technical parameters
The parameters of each model in this series are as follows:
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L/min | gpm | bar | psi | MPa | r/min | hp | kW | kg | |
GDF18 | 30 | 8.1 | 600 | 8700 | 60 | 800 | 49 | 36 | 62.5 |
38 | 10.1 | 500 | 7250 | 50 | 1000 | 50 | 37 | 62.5 | |
GDF20 | 47 | 12.4 | 400 | 5800 | 40 | 1000 | 50 | 37 | 62.5 |
GDF22 | 45 | 12.0 | 400 | 5800 | 40 | 800 | 49 | 36 | 62.5 |
57 | 15.0 | 350 | 5075 | 35 | 1000 | 50 | 37 | 62.5 | |
GDF25 | 73 | 19.3 | 280 | 4060 | 28 | 1000 | 50 | 37 | 62.5 |
6. Installation size
The working medium of this series of high-pressure piston pumps is clean fresh water, and the maximum suitable water temperature is 40°C. If you need to pump other media liquids, please contact our company to obtain a suitable special piston pump.
The maximum inlet water temperature of the pump should not exceed 40°C, if it exceeds 40°C, please contact our company to obtain a piston pump for high temperature.
7.2 Maximum flow and pressure
The performance parameters indicated in Chapter 5 are formulated with reference to the limit parameters of the pump, and cannot exceed the rated power and pressure when used independently.
7.3 Speed and direction of rotation
7.3.1 The speed of the pump shall not exceed the rated speed specified on the corresponding nameplate, and the minimum allowable speed is: rated speed X 0.6
7.3.2 For the direction of rotation of the crankshaft of the pump, please refer to 9.2.
7.4 Brands and types of lubricating oil
The lubricating oil in the water pump is suitable for the ambient temperature range: 0°C~30°C. Choose from SAE 85W-90 or ISO VG 220 gear oils. The brand and model of oil can be referred to the figure below
7.4.1 When the water pump is shut down, check the oil level with an oil ruler after the oil is cooled, and also visually measure the amount of oil through the side oil level (position refer to Figure 10), If necessary, refill the lost lubricating oil.
7.4.2 If you want to replace the lubricating oil, after the pump is shut down, the oil temperature is still at the working temperature to replace it (pay attention to protection and avoid scalding), which is conducive to eliminating the wear and debris in the crankcase (remove the oil drain bolt and change the oil, position reference Figure 10).
7.4.3 The oil volume of this pump needs to be about 3.8 liters.
7.4.4 Regardless of the quality of the lubricating oil, the oil should be changed at least once a year (the workload is large, and it needs to be replaced after 500 hours).
7.4.5 With the change of room temperature (0-30 °C), the kinematic viscosity of oil will change accordingly, and the minimum should not be less than 180CST.
7.4.6 Waste oil must be collected in the correct container and disposed of in accordance with laws and regulations, and cannot be discarded at will.
8. Interfaces and connections
The interface of the pump (shown in Figure 4).
8.1 The pump has 2 water inlets and the threaded connection is: G1". The water inlet pipeline can be used to feed water in two ways, or it can be used to feed water in one way, and when using one inlet water, one of the inlets of the pump must be blocked to prevent the pump from sucking in air.
8.2 This pump has 2 outlets with a threaded connection: G1/2".
Installation
9.1 Installation
The pump must be mounted on a level, rigid and horizontally placed foundation, bolted to it. This reference must be flat and rigid enough to avoid deformation and misalignment caused by transmission torque.
The lifting rings on the pump are easy to install. The lifting eye is only suitable for lifting the pump itself, and no additional weight is allowed.
Once installed in place, replace the yellow oil plug on the back cover with an oil gauge.
The pump and the motor do not use a rigid coupling connection, and the following transmission types are recommended: flexible coupling, cardan shaft, pulley.
9.2 Direction of rotation
Run according to the correct direction of rotation indicated by the arrow, as shown in Figure 5, the correct direction of rotation of the pump is marked, from the direction of the pump head, the crank handle is on the left side, isRotate in a clockwise direction; The crank shank is on the right side and rotates in a counterclockwise direction.
(Note: From the direction of the pump head, it is to distinguish which side of the crankshaft is on, and the direction of rotation refers to the view from the outstretched end of the crankshaft.) )
9.3 Pump rotation direction change:
The change in the direction of rotation of the pump must be carried out by a professional according to the following steps.
9.3.1 Separate the pump head part from the crankshaft box part and remove the lifting ring.
9.3.2 After the crankcase part is rotated 180 degrees, remove the back cover and rotate 180 degrees to install, ensure that the oil scale is up, then install the lifting ring, and finally paste the nameplate on the crankcase.
9.3.3 Connect the pump head and the crankshaft box.
9.4 Pipeline connection
In order to isolate the impact of pump vibration on the high-pressure system, it is recommended to use hoses at least in the initial section of water supply and drainage, and pay attention to providing support protection for the water supply pipeline to prevent the water supply pipeline from collapsing when the pump is pumped.
9.5 Water Supply Requirements
The pump is installed as a positive suction water source, and a booster pump must be installed, and the flow rate of the booster pump must be twice the normal working flow rate of the high-pressure pump, and the operating pressure of the booster pump is 02~0.3MPa。
9.6 Pump inlet connection mode and start and stop precautions
9.6.1. Connect the booster pump (booster pump water supply).
Joints must be operated according to the recommended specifications.
1) The flow rate of the booster pump must be twice the normal working flow rate of the high-pressure pump, and the operating pressure must be 02~0.3MPa。
2) Take appropriate precautions during the connection of the water supply system.
Below is a simple diagram of the connection between a pump and a booster pump. See Figure 8
A) Water tank B) Inlet filter C) Booster pump
D) High pressure pump E) Pressure gauge F) Accumulator
G) Regulator H) Drain L) Nozzle
m) Main water supply main switch
9.6.2. Precautions for use
Before starting, the operator must carry out the necessary safety checks.
When the high-pressure pipeline leaks, stop the operation of the pump immediately and eliminate the cause of the leakage.
The pump should not be used beyond the standard parameters specified by the manufacturer.
If the system needs to be shut down when the ambient temperature is close to 0°C, continue to run the pump for 10 seconds (before stopping the system) after shutting down the inlet water to ensure that all the water in the pump and the entire pipeline is discharged from the drain pipe to prevent freezing in the pump.
9.6 3 The filter should be installed as close to the pump as possible, which can be easily inspected and has the following characteristics:
1) The filtration capacity is at least three times the flow rate of the pump.
2) The size of the interface of the filter must be smaller than the size of the inlet of the pump.
3) The filtration level range is 200~360um.
Due to the difference in water quality, filtration accuracy, and working time, please clean the filter regularly to protect the water pump.
9.6 4 booster pump water supply pump start and off (as shown in Figure 8).
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9.7 Drainage pipes
To ensure that the drain line is used correctly, please follow the following rules:
9.7.1 The inner diameter of the pipeline must be sufficient to ensure the appropriate flow rate. See Figure 9
9.7.2 The initial section of the drain pipe must be a flexible hose to isolate the vibration of the pump from other systems.
9.7.3 Use high-pressure pipes and components to ensure the safety of all operations.
9.7.4 At least one suitable pressure regulator or relief valve (safety valve) must be installed on the drain pipe.
9.7.5 Please use a glycerin pressure gauge because this gauge is suitable for shock loads.
9.7.6 When designing drainage pipelines, pay attention to the friction and damage of pipelines.
9.7.7 If required, an accumulator may be installed on the pressure line to attenuate the effect of the pump's pulsation.
9.8 Determination of the inner diameter of the pipeline
To determine the inner diameter of the pipe, follow Figure 9 below
For example:
Water supply pipes
The flow rate is 170L/min, and the water flow speed is 0.5m/s
The 170 L/min on the left side of the connection chart and 0.5 m/s on the right side of the connection chart, and the coordinate value in the middle is 80 mm, which is the inner diameter.
drainpipe
The flow rate is 170L/min and the water flow velocity is 5.5m/s
The 170 L/min on the left side of the joint chart and 5.5 m/s on the right side of the joint chart are connected with a coordinate value of 30 mm in the middle, which is the inner diameter.
Optimal flow rate
Water supply ≤ 0.5 m/s
Effluent ≤ 5.5 m/s
This chart does not take into account the resistance pressure drop of the tubing itself, the resistance pressure drop of the valve, the load loss of the tubing, or the viscosity of the liquid.
10. Start and run
Please ensure that the water supply pipe is connected and that the pipe is full of water, and do not run the pump without water inflow.
10.1.1 The water supply pipe is well sealed and cannot leak.
10.1.2 Confirm that the on/off valve between the water source and the pump has been opened, and the water can enter the pump smoothly, and adjust the pressure regulator valve on the outlet pipe to the unloading mode, so that the air in the pump can be discharged smoothly, so that the pump can start smoothly.
10.1.3 Confirm that all water supply/drainage connections are tightened.
10.1.4 The coaxiality of the coupling, the tension of the pulley and the inclination error of the power take-off shaft are in line with the standards of the supporting manufacturers.
10.1.
10.1.
10.2 Startup
If it is parked for a long time or restarted after maintenance, perform the following steps:
10.2.1 When starting for the first time, check whether the direction of rotation is correct.
10.2.2 Check whether the water supply is sufficient.
10.2.3 When there is no load, start the pump (that is, the pressure of the outlet pipeline is zero).
10.2.4 During operation, check the speed of the pump, and the speed cannot exceed the rated speed of the pump.
10.2.5 Before adjusting the outlet pressure, the pump must be allowed to run for at least 3 minutes.
10.2.6 Before stopping the pump, unload the pipeline pressure through the relief valve.
11. Maintenance precautions
Before any maintenance work can be carried out, all pressure is removed from the entire system circuit and all power is cut off to drive the pump.
After maintenance, check for tools, rags or other objects near running parts or danger zones before restarting the pump.
Replace excessively worn parts with genuine parts and use the lubricant recommended by the manufacturer.
Dispose of worn parts and lubricants in accordance with the relevant legal regulations.
Follow the manufacturer's instructions for routine maintenance to maintain pump performance and safety.
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12. Storage
12.1 Method of filling the pump with anti-corrosion emulsion or antifreeze using an external diaphragm pump (according to the layout provided in Figure 8).
A) Turn off the filter. (if it's open).
B) Make sure the coupling pipes are clean, greased and connect them to the high-pressure drain.
C) Fix the suction pipe to the diaphragm pump and connect it to the suction port of the pump.
D) Fill the container with preservative emulsion and antifreeze.
E) Insert the free end of the suction hose and the high-pressure drain into the container.
F) Start the diaphragm pump.
G) Suck up the preservative until the preservative/antifreeze flows out of the high-pressure water pipe.
H) Let the pump suck up the preservative/antifreeze for a few minutes. Adding "shell donax" to preservatives/antifreeze can enhance its performance.
I) Stop the pump, remove the tube from the suction coupling and plug the plug.
J) Remove the hose from the high-pressure drain, clean the drain and plug the connection and pipe.
12.2 Hoses
A) According to the procedure described earlier, dry the connection points with compressed air before lubricating and protecting the hose.
B) Fill with polyethylene.
C) Don't roll it too tightly and make sure it doesn't get folded.
13. Prevention of freezing
Refer to section 12.1 to prevent freezing according to different regions and times of the year.
In addition, the following methods can be applied to prevent freezing:
Compressed air is connected to the inlet of the pump to drain the water in the pump and the drain line.
When ice is formed, the pump should not be run for any reason until the line is completely thawed, which can prevent serious damage to the pump.
14. Warranty clause (check valves and high and low pressure seals for inlet and outlet are wearing parts and are not covered by warranty).
The warranty time and warranty terms are included in the purchase contract.
The warranty is not available in the following cases
A) The pump is not used for the agreed purpose of use B) Overloaded C) The safety equipment is not calibrated or installed.
D) The accessories and parts used in the pump are not original components.
E) Damage due to the following reasons:
(1) Incorrect use (2) Failure to follow maintenance guidelines (3) Failure to operate in accordance with the instruction manual (4) Insufficient water supply
(5) Wrong installation (6) Mismatched pipelines (7) Unauthorized disassembly (8) Cavitation phenomenon
15. Common fault phenomena and elimination methods
1) Pump vibration or shock
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2) There is no pressure or insufficient pressure in the water pump when working
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Water leakage and oil leakage observation hole at the bottom of the water pump
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The noise of the pump is worn by the rod and the noise of the gearbox
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The pump temperature is too high
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16. Exploded view and schedule
16.1 Exploded view
16.2 Schedules
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1 |
| 8 | 23 |
| 3 | 45 |
| 2 |
2 |
| 1 | 24 |
| 3 | 46 |
| 1 |
3 |
| 3 | 25 |
| 3 | 47 |
| 8 |
4 |
| 1 | 26 |
| 3 | 48 |
| 8 |
5 |
| 1 | 27 |
| 3 | 49 |
| 6 |
6 |
| 1 | 28 |
| 3 | 50 |
| 3 |
7 |
| 1 | 29 |
| 3 | 51 |
| 3 |
8 |
| 2 | 30 |
| 3 | 52 |
| 3 |
9 |
| 2 | 31 |
| 3 | 53 |
| 3 |
10 |
| 2 | 32 |
| 6 | 54 |
| 3 |
11 |
| 1 | 33 |
| 3 | 55 |
| 1 |
12 |
| 1 | 34 |
| 3 | 56 |
| 4 |
13 |
| 12 | 35 |
| 3 | 57 |
| 8 |
14 |
| 1 | 36 |
| 2 | 58 |
| 8 |
15 |
| 3 | 37 |
| 1 | 59 |
| 1 |
16 |
| 6 | 38 |
| 3 | 60 |
| 1 |
17 |
| 3 | 39 |
| 3 | 61 |
| 1 |
18 |
| 3 | 40 |
| 3 | 62 |
| 1 |
19 |
| 6 | 41 |
| 6 | 63 |
| 1 |
20 |
| 6 | 42 |
| 6 | 64 |
| 1 |
21 |
| 3 | 43 |
| 3 | 65 |
| 1 |
22 |
| 3 | 44 |
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