Académique Documents
Professionnel Documents
Culture Documents
1.Power End 2
1Structure 2
2Mechanical principle 2
3Technical parameters 2
4 Announcements 2
5Maintenance 3
2. Fluid end 3
Use of Adhesives 3
Maintenance of valve 8
1.Daily 13
2.Every 50 Hours 14
Difficult problems solution 14
Storage and transportation
15 Unpacking and inspection
15 Company information and Pump assembly diagram
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Maintenance
1Power End
1) STRUCTURE
This power end is constituted by the Gear Box, crank shaft, gear shaft, slipper,
connecting rod assembly, pin shaft ,compulsory Lubrication parts and other major
parts
Body is box structure, made from high strength cast iron. Dustproof and
waterproof have been fully considered, On the case there is a vent cap, in order to
balance the air pressure inside and outside, screw down the vent cap ,there will be a
oil hole, Drive part installed in the cabinet, gear shaft and shaft assembly of
herringbone gear meshing, smooth transmission, low noise, Three sets of crankshaft
connecting rod mechanism drive the crosshead intermediate rod connection between
the plunger and doing reciprocating motion, drive end Lubricated by forced, the high
speed gear shaft drive oil pump to supply oil, bearing bush, bearings, rod pin Shaft,
crosshead guide, the kinematic pair lubrication fully, to reduce wear and prolong
service life.
2) WORKING PRINCIPLE
Gear shaft driven by a motor and mesh with herringbone gear which is install
on the crankshaft, Transfer the torque to the crankshaft. Crankshaft drive connecting
rod , crosshead, middle rod assembly, change the rotary motion to be linear
reciprocating motion, then finish complete condition requirements.
3) TECHNICAL PARAMETER
Input shaft revolutions 1 480 rmin
Output shaft revolutions 366 rmln
Input power 200 kW
4) ANNOUNCEMENTS
Before operating the pump, please read the instruction for use, it contains the
installation and use and safety
If operator don't follow the instruction to use, then plunger pump damage, the
company shall not be liable for any
Please in strict accordance with the instructions from the content of the
installation, maintenance and use
It is strictly prohibited to start the pump when no operator at the construction
site
When the pump working, operator cant close to the moving parts , also cant
remove any parts
Inside the gear box, lubricating oil should be prescribed brand and quantity to
injection
It is strictly prohibited to use new and old oil combination and different type oil
mixed, Lest reduce the performance of the lubricating oil
When the plunger pump oil is too low and pump has abnormal noise it should be
timely stop to check
When the environment temperature is lower than the 0, the pump should be
empty load operation for a period of time first ,Increase the pressure after the oil
temperature rise
Before you Start the pump , check the pump connecting rod is connected firm
After Start pump first inching to check is the pump rotation is correctly, it must
be consistent with the direction sign
When the pump is running, check if the oil pressure is normal or not
When the pump is running , the temperature of the lubricating oil must not to be
more than 78 , both sides of the bearing parts temperature is not more than fifty
degree
Pump in the stop before, should gradually reduce the pressure of work, in the
empty load condition parking
5MAINTANCE
Pump first running after fifty hours must be replaced the lubricating oil, Future
time replaced every 200 hours
Lubricating oil choose the vehicle gear oil 15 and a grade of 85 w / 90 GL4.5 ~
15 . Diesel engine oil :wz30cd
Lubricating oil must from oil hole injection (unload vent cap is the oil hole), oil
injection is about 18Liters
Before add Lubrication oil , it must go through 0.150mm filter, injection after
filter . To prevent debris into the crankcase body.
At any time to observe pump operation condition. Oil pressure remain in about
5Mpa. Lubrication system, filter should always clean screen pack, if the screen
damage must be replaced new filter.
Replace the lubrication when the oil is warm ,take away the dirty oil ,cleaning the
gear box before put in the clear oil
Keep an eye on each part of the pump joints connecting rod bolt status, to prevent
faults
2. Fluid end
Safety Note
1)During preparation process to ensure the electric power supply is in the closed
position before start the pump
2The pump is Ban to start when there is no supervisor stand by.
3) Pump not allowed to running over rate Max pressure
4) When operating pump there should be a pressure gauge
5) Fluid end should have two safety device
6)Dont install any valve between liquid outlet and safety valve(device).
The use steps of adhesive
Adhesive used for fixed hydraulic end some parts. The following is the manual before
use about adhesive preparation and use of steps, for adhesive for, stainless steel can be
considered as a kind of inert material. Stick before using, parts must be clean, it is
recommended to use detergent
1Preparing work before using ---cleaning
a. Paint detergent on the necessary parts
b Use a clean cloth to wipe cleanly before it comes to be dry, and clean the
pollutants in the hole by compressed air
c.or the next step before operation to ensure that all of the detergent has been
volatile, avoid dissolvent vestigital
2preparing work before Bonding ---painting
a . Ensure parts have been cleaned.
b. Put parts In the open air , daub adhesive on the touch contact place
c. After Solvent volatilization, ensure the surface is completely dry before next
step.
d. As soon as possible to install and prevent the secondary pollution
Instal
a. finish above steps, and then bonding
b. Drop a few binding agent on the connection part
c. Install immediately
d .Cleaning the left binding agent
Dismounting
Remove after heating
Maintenance of packing box and valve assembly
Note: this unit use tungsten carbide plunger. The material of the plunger is much
harder and a little crisp than other plunger. The plunger cannot afford local
(heterogeneous) load and impact load. So,use it carefully
Note: before loosen packing box, please Loosen the plunger and the middle pole
First . If you don't do it like this, Plunger will have bending stress, may lead to
plunger fracture.
Dismounting
1) Stretch out middle lever to make plunger inset packing box completely , loosen
plunger and intermediate billot connection
2) Use socket wrench unscrewing the four bolts of the stuffing box which need to
maintain
3) Screw down the top two bolt (E), and then put it aside. Remove method is very
simple, just use a special Wrench locks bolt and then turn on a few ring That's it
4) Loosen the two bottom bolt (E 1), but don't let them out of packing box fully
exit 1 l / 2"To 2 "distance, make the packing box (c) and the pressure plate (D) slide
toward the power end direction.
5) One hand holding the bottom two bolt (E1), the other hand holding tightly
handle of packing box, sliding to power end , until the bolt head touch with pump
head . Then there will have space to take out valve assembly (B) and packing box (c) .
6) Take out valve assembly (B), so that there have space to take out packing box
Note: there are three O ring (one in packing box, two in the pump head) in the
valve assembly Sometimes, 0 ring may loose, when you take out the valve
assembly please make sure it won't damage .
7) One hand hold the handle of packing box , another hand control plunger
backend (S) through out binder plate (D),and take away packing box (C).
Note: don't let the spring pressing sleeve slide out (K)
Note: the ring gasket (0 - 1) should take out with packing assembly together.
Remove packing and plunger
Put the packing assembly on a flat surface,take out plunger (s) and ring gasket (0, 1)
1) From backend of the packing box
2) Take out spring pressing sleeve (K) and spring (L)from front (see P 4)
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3) Use a plastic rod stroke surface of sealing and take out seal (N), baffle ring (0)
and sealing set (M). gently(see chart 5)
install the new packing and plunger
1) Clean inner packing box With a soft cloth packing box stand up.
Thoroughly clean all internal parts and components, and coated with a thin layer of
vegetable oil or similar products (non-oil products). Baffle ring (0) and seal (N) Need
lubrication
Note: remember to replace a complete sets of sealing ring (N) and baffle ring (0)
Note: in general, sealing set (M), spring (L) and spring pressing sleeve (K)
normally do not belong to wearing parts,
Can be reused.
2) Put new baffle ring (O) into the packing box, cross face toward the packing
box's backend. (see P 6)
6
3) Put In the new sealing ring (N) and sealing set (M). push down With plastic
rod. (see chart 7)
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3) Put spring (L) and spring pressing sleeve (K) in packing box. (see figure 8)
8
4) Check the surface of the plunger (S), see if there is much scratch or point, if
necessary change it.
Daub a layer of thin oil (non-oil) on the surface of the plunger
Set The ring gasket (0-1) around the plunger (S).
5) When spring pressing sleeve (K) install in packing box (C),put the rabbet side
down and on a clean surface. own weight of Packing box can compress the
pressure set and compression spring, packing box should be horizontal position
on the surface. (see figure 9)
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10) Cross the baffle ring (0), put the plunger into packing box (S). Allow plunger
bulge 2 "to 3" out of the packing box surface (see chart 1)
lO
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3) take out The drainage valve core from the body drainage hole (See p 13)
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5)Check into turn liquid valve and valve seat surface. If there is a scratch, it must
regrinding again, until can't see any scratch
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6) Check if the drain valve core guide surface have signs of wear.
7) To see if it is wearing Through the drain valve core (G) of the guide surface by
checking the valve plate (H) and valve body (F) inner hole
grinding
1)The drain valve core (G) vertical placed in pliers, clamping two bulge plane
of valve core . daub valve seat surfaceand drain valve seat surface with grinding
paste (220 coarse sand and fine sand grinding). (see figure 15)
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2)Put the valve body on the guide surface of drainage valve core install the inlet
valve and sealing surface with valve body then they contact together
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3) Use finger to press inlet valve and rotating back and forth, until the two
contact surfaces are present "grey", and can't see any Trace
4) Cleaning up all paste on the parts surface
Install
1) Clean and keep all parts dry
2) Clamp The drainage spool (G) with forceps and then put on the valve body
(F) and intake valve plate (H) (See P15)
3) Cleaning and daub lock nut (J) and drainage spool (G) of the thread.
4) use thread adhesive In the lock nut (J) of the internal thread and drainage
spool (G) of the outside thread . (see
"Maintenance - adhesive use step - etc)
5) The spring (I) installed in the intake valve
6) Immediately lock nut (J) screw to drainage spool (G), then use pliers and
fastening.
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7) Immediately wipe off excess adhesive parts, if possible, it's better to use
compressed air to clean up hole on the drainage spool
O ring
1) Check the O ring (Q, R, P) to see if there is a crack or wear, if it is necessary
change it.
2) Put O ring (Q, R, P) into the corresponding of the valve body
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3) Rotating drain valve (I) and intake valve (H), make sure that they can free
rotation (because excess adhesive can make These parts "stick" together).
4) Ensure that 0 ring (Q, R, P) installed in the valve assembly (B) at the right
position.
5) Make the valve assembly locate with pump head ,take care, don't let the
valve assembly tilt.
note: if the valve assembly is ok, valves can free rotation in the pump head
6) Install Valve assembly well, one hand holding the position of the
cylindrical body, another hand on back of packing box(D), and then Push toward the
pump head direction, seize the valve spool, to ensure the valve spool at the right
Position betwee pump head and packing box
Note: when Packing box(c) touch with valve assembly (B) , make sure the rabbet of
packing box and valve assembly's corresponding bulge part can just anastomosis.
7) Ensure that the four connecting bolt thread place and bolt head below are
already use release agent for lubrication processed.
8) Holding the Packing box (D), the top two root bolt screw into the pressure
plate until bolt head contact to pump head ,Fixed the packing box and valve assembly
in position.
9) Screw bottom two root bolt into the pressure plate until the bolt head touch the
pump head , slowly adjusting screw up the four pillars bolt,to ensure the packing box
and valve assembly in a straight line.
10) In order to make the connecting bolt and pump head keep complete touch,
valve assembly and packing box fixed in the right position, and must to screw the four
root bolt crossed, First to twist evenly fifty feet/one pound force respectively, and use
500 feet one pound of force to binding finally
Note: connection bolt (E, E 1) must use the right force 500 feet a pound to screw,
screw and bolt head must use Release agent or other appropriate bolt lubricant treated.
If not, there might be a dangerous situation.
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