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GDF High-pressure Plunger Pump Operation Manual


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


Zhejiang Botuolini Machinery Co., Ltd


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.


mark


2.1 Pay attention to safety


2.2 Please read carefully before operating


2.3 Danger Beware of electric shock


2.4 Danger Please use a protective mask


2.5 Danger Please use goggles


2.6 Danger Please wear protective gloves during operation


2.7 Danger Please wear insulated boots for operation


3. Safety


3.1 General Safety Instructions


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 Safety requirements for high-voltage components


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).


3.3 Operational Safety Guidelines


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 Operational safety precautions


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:


Model


flow rate


pressure


rotate speed


power


weight

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


7. Instructions for pump use


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.


7.1 Water temperature


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).


Follow these steps to start the pump:


Follow these steps to stop the pump:


1) Turn on the main water supply pipe switch M


1) Release the pressure regulator G to relieve pressure


2) Release the pressure regulator G to relieve pressure


2) Turn off pump D


3) Start the booster pump C


3) Turn off booster pump C


4) Start the water pump D and run it without pressure for a few minutes


4) Turn off the main water supply pipe switch M


5) Adjust the pressure regulator G to make the pump reach the required working pressure


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


10.1 Pre-Start Checks


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.
5. Confirm that the lubricating oil level has been in the correct position, and the oil quantity can be verified by the oil scale or the side oil level.

10.1.
6 As shown in Figure 10, when the pump is in the horizontal position, add oil until the oil is more than half of the oil level scale.


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.


Service intervals


parts and components


steps


Every weekday


filter


Check the filter element


Check the oil level and whether there is oil or water leakage


Every 50 hours worked


Coupling of pump to power unit (pulleys, belts, couplings, etc.)


examine


Check the mountings


Pipes and fittings


examine


Every 500 hours worked


Oil change


Every 1500 hours worked


Check valves, seals


Inspect every 500 hours if there is no damage


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


Manifest the phenomenon


Causes


Resolution


The pump vibrates


There is an abnormal noise in the pump


The tubing vibrates


The pressure is unstable


The water outlet is unstable


There is air in the pump or line


The pump runs no-load for a period of time to exhaust the air;


Dirty and clogged filters lead to insufficient water supply


Wash the filter


The inlet and outlet valves are jammed, not opened, severely worn, and the valve seat is damaged


Clean the water valve or replace it


The regulator is working abnormally


Check the regulator or replace it


The relief valve line is clogged


Check the tubing


2) There is no pressure or insufficient pressure in the water pump when working


Manifest the phenomenon


Causes


Resolution


The pump operates without water, without pressure, or with insufficient pressure


Insufficient water supply and failure of water supply pipes


Check whether the water supply line and filter are smooth, and whether the water supply valve is open


The speed of the water pump did not reach the required speed


Increase the rotational speed


The water seal is damaged and leaking


Replace the water seal


The plunger is damaged


Replace the plunger


Inlet and outlet check valves are worn out and cause internal leakage


Replace the check valve


Improper adjustment or damage to the regulator


Readjust or replace the regulator


Leaking or damaged relief valve


Check the relief valve or replace it


Nozzle orifice size, number of nozzles do not match, or wear increases


Reduce the number of nozzles or replace them


Water leakage and oil leakage observation hole at the bottom of the water pump


Manifest the phenomenon


Causes


Resolution


Leaking


The water seal is worn


1. Normal wear and tear


Replace the water seal


2. The water filtration accuracy does not meet the requirements


3. Lack of water dry operation


4. The inlet and outlet check valve is not opened due to scale bonding, and the operation is out of water


The plunger is damaged


1. Normal wear and tear


Replace the plunger


2. Lack of water produces high temperature during dry operation, and cracks occur when cold water comes into contact with it


Oil spills


The oil seal is damaged


1. Normal wear and tear


Replace the oil seal


2. The oil temperature is too high


3. After the water seal is worn, the high-pressure water jet damages the oil seal


4. The working environment is harsh, and impurities (such as fine sand) enter and bond to the plunger from the bottom leakage hole


The noise of the pump is worn by the rod and the noise of the gearbox


Manifest the phenomenon


Causes


Resolution


The noise of the pump is worn out by the rod


1. The water supply system sucks in air


Tighten the fitting at the water inlet


2. The spring of the check valve in and out of the water is damaged or broken


Replace the check valve


3. The check valve is blocked by foreign matter


Clean the check valve


4. Bearing wear


Replace the bearings


5. The inlet water temperature is too high


Reduce the inlet water temperature


The gearbox is noisy


1. Gear wear


Replace the gears


2. Bearing wear


Replace the bearings


The pump temperature is too high


Manifest the phenomenon


Causes


Resolution


The pump temperature is too high


1. The operating pressure of the pump is too high


Reduce the pressure to the rated pressure


2. The drive belt is too tight


Restore normal belt tension


3. The pulley and drive coupling are not calibrated


Recalibrate the pulley drive coupling


4. The lubricating oil has not been replaced for a long time, the lubricating oil is missing, and the lubricating oil model is wrong


Change the lubricating oil.


16. Exploded view and schedule


16.1 Exploded view


16.2 Schedules


serial number


name


quantity


serial number


name


quantity


serial number


name


quantity

1


Hexagon round head screws

8

23


GF water baffles

3

45


O-rings

2

2


Plugs

1

24


GDF ceramic tubes

3

46


GDF Inlet Check Valve Bonnet

1

3


O-rings

3

25


GF ceramic tube locking bolts

3

47


Hexagon round head screws

8

4


GF back cover

1

26


GF copper gaskets

3

48


Double-sided tooth pads

8

5


O-rings

1

27


GDF rear guide ring

3

49


Open retaining rings

6

6


GF crankcase

1

28


O-rings

3

50


O-rings

3

7


GF crankshaft

1

29


GDF sub-water seal

3

51


GDF outlet check valve assembly

3

8


Tapered roller bearings

2

30


GDF Support Rings

3

52


O-rings

3

9


GF adjustment gaskets

2

31


GDF main water seal pressure ring

3

53


Open retaining rings

3

10


O-rings

2

32


DS main water seal

6

54


GDF valve plug

3

11


GF protruding end flange

1

33


DS main water seal gasket

3

55


GDF outlet check valve bonnet

1

12


TC oil seals

1

34


DS main water seal spring

3

56


Hexagon round head screws

4

13


Hexagon round head screws

12

35


DS water-sealed spring seat

3

57


Double-sided tooth pads

8

14


Flat keys

1

36


Hexagon flat-end locking screws

2

58


Hexagon round head screws

8

15


GF linkage assembly

3

37


GDF pump heads

1

59


GF Eyebolts

1

16


Retaining rings for holes

6

38


GDF water inlet check valve cover

3

60


Hexagon round head screws

1

17


GF plunger pins

3

39


GDF water inlet check valve spring

3

61


GF left side cover

1

18


GF plunger rod

3

40


GDF inlet check valve disc

3

62


O-rings

1

19


GF square hole cover

6

41


Open retaining rings

6

63


GF side oil level

1

20


GF Round Hole Cover

6

42


O-rings

6

64


GF side oil level indication

1

21


TC4 oil seal

3

43


GDF inlet check seat

3

65


GF Oil Mark components

1

22


GF support frame

3

44


O-rings

3