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Operation Manual

70

PROBLEM 

POSSIBLE CAUSE

REMEDY

Insufficient water 
lubrication

Needle valves not properly adjusted Adjust the needle valves

Air in the system

Open the manifold drain with 
pump on

Plugged lines

Remove debris from lubrication 
lines

Leakage from 
pump
manifold uni-valve
leakage holes

Damaged valve seal

Replace seals

Leakage from 
discharge fitting 
leakage holes

Damaged fittings or seals

Replace the fittings and/or seals

Pump oil leaking 
from breather

Check oil level

Add oill as necessary

Verify use of proper oil type

See “Oil Specifications” on page 
62

Water in pump oil

Cross head oil seal leak

Replace seal

Cold oil

Continue to run until oil temp in-
creases to adequate temperature

Engine will not 
return to idle when 
control gun dump-
ing

Excessive hose back pressure

Reduce hose string length

Throttle control piston sticking

Repair throttle control unit

Engine will not 
increase in speed 
when control gun 
first closes

Engine idle speed too low

Increase idle speed

Large gun nozzle

Decrease nozzle size

Insufficient water
lubrication

Needle valves not properly adjusted Adjust the needle valves

Air in the system

Open the manifold drain with 
pump on

Plugged lines

Remove debris from lubrication 
lines

Poor packing life

Hot water

125°F max

Insufficient water flow

Adjust water flow

Dirty water

Clean/replace filter

Scored/pitted plunger

Replace plunger

Gland nut loose

Tighten nut

Содержание 3000 series

Страница 1: ...OPERATION MANUAL Bareshaft Pump...

Страница 2: ...ii Visual Safety System...

Страница 3: ...to another language Every reasonable effort has been made to ensure that the data given in this document is accurate however the information figures illustrations tables specifications and schematics...

Страница 4: ...re disks etc 4 Failures resulting from the machine being operated in a manner or for a purpose not recommended by Jetstream including failures or malfunctions resulting from corrosion misapplication o...

Страница 5: ...imum Pressure Required 3 Be Prepared 3 Performing Maintenance or Repairs 3 Freezing Conditions 3 Store Components Properly 3 COMPONENT IDENTIFICATION 5 UNx Pump 5 Manifold 5 Manifold Drain Valve 5 Wat...

Страница 6: ...eam Pumps 21 Secondary Filter 40k Operation Only 22 Filter Cartridge Replacement 23 Switch Adjustment 23 Uni Valve Life 23 PRESSURE CONVERSION 25 Converting a Pump 25 40K Hose Connections 32 SERVICE 3...

Страница 7: ...Bareshaft Pump vii TROUBLESHOOTING 69 TRAINING 71 Safety Training 71 New Start up Training 71 FS Solutions Training 71 Additional Training Opportunities 71 INDEX IND 1...

Страница 8: ...Operation Manual viii...

Страница 9: ...definitions of the signal words before oper ating or working on the unit Danger is used to indicate the presence of a hazard which WILL cause severe physical injury or death if proper precautions are...

Страница 10: ...r 15 000 psi 1000 bar and lower pressures use at least four wraps of Teflon tape on male pipe NPT threads for sealing purposes Do not allow any tape to overlap the end of the fitting Tape fragments ma...

Страница 11: ...system should be avoided if possible Components with a lower pressure rating can be overlooked and explode if vigilance is not maintained Keep equipment pres sure rating and warning tags intact Be Pre...

Страница 12: ...Operation Manual 4...

Страница 13: ...s are available at the following website http www waterblast com Service_and_Support Resourc es Download_Literature aspx Manifold The manifold houses many of the components that make up the fluid end...

Страница 14: ...asses the valve will drain from the bypass drain throughout operation The proper use of the bypass valve is to install the correct size nozzle in the system so that the bypass valve can be closed duri...

Страница 15: ...er becomes plugged and flow is insufficient the switch will cause the engine to shut off Emergency Stop will be displayed on the control panel A drain valve is located on the filter cover that allows...

Страница 16: ...e with no additional ttings elbows espe cially important with gravity fed setup If bends are required it is best to bend the hose without the use of elbows The plunger packing is lubricated with the s...

Страница 17: ...pply pressure of 75 psi Lubrication The powerend is lubricated with 12 gallons of ISO 320 gear oil Only the following brands are allowed Aral Motanol HP 320 Mobil DTE Oil AA 320 BP Energol CS 320 Shel...

Страница 18: ...rotates and pulls the crosshead backwards through the suction stroke the force between the connecting rod journal bearing and the crankshaft decreases greatly This reduction in force and the rotation...

Страница 19: ...quick disconnect coupling is an important means of protecting the manifold from wear at the high pressure discharge hose connection port If the internal threads on the manifold become worn or damaged...

Страница 20: ...ng on the manifold along with a hose safety check 7 Open the bypass valve by turning the knob fully counter clockwise until the O ring is visible where the knob enters the valve body or four full turn...

Страница 21: ...about 30 seconds Note A substantial amount of thrust may occur at the discharge end while flushing 6 Decrease flow to the hose by fully opening counter clockwise the bypass valve Some water will conti...

Страница 22: ...that you can keep your fingers on it for 10 seconds If there is no water flow or the temperature is too hot or if steam is visible the needle valves need to be adjusted 4 Adjust the needle valves Fig...

Страница 23: ...ating in cold temperatures allow ample time for the pump oil to warm before raising system pressure ATTENTION If new packing was installed or if operating the pump for the first time the pump packing...

Страница 24: ...ng boxes for excess temperatures Stuffing boxes and gland nuts should only be slightly warm to the touch when the pump is running at the rated operating pressure Hot stuffing boxes and gland nuts may...

Страница 25: ...1 the outer O rings Figure 13 on the valves have failed Note The larger O ring will leak to the rect angular weep hole Monitor the manifold for leakage during operation If leakage occurs immediately r...

Страница 26: ...Operation Manual 18...

Страница 27: ...Inspection Inspect the seals for damage and the valve seats for deposits jet ting or other damage Refer to Valve Inspec tion on page 50 2 Inspect Pump Breather Remove the breath er and inspect for dir...

Страница 28: ...ld 6 Pour a glycol based anti freeze solution into the funnel Figure 15 Approximately 0 5 gal 2 L of anti freeze is required 7 Before starting the engine check the area in the path of the discharge fi...

Страница 29: ...d Compatibility with Jetstream Pumps Jetstream pumps are designed and built primari ly for pumping water at various pressure ratings Jetstream does not have a compatible uids list at this time The use...

Страница 30: ...n the filter housing will trip and the engine will shut off to protect the unit from damage Replace the dirty filter cartridge if this occurs ATTENTION Extended operation with a dirty filter will lead...

Страница 31: ...e hours of operation are ac cumulated on the filter cartridge When the pressure on the filter gauge has dropped ap proximately 7 to 10 psi 0 48 to 0 69 bar with the unit operating at the same rpm as e...

Страница 32: ...Operation Manual 24...

Страница 33: ...procedure to convert a pump to a different pressure 1 Relieve pressure from the pump shut off the engine and disengage the clutch 2 Turn off the water supply drain the water tank 3 Remove the two bolt...

Страница 34: ...d mounting studs Figure 25 into the two open holes to allow for easier installation of the new manifold Note Manifold mounting studs can be pur chased from Jetstream 4200 3600 p n 54261 3000 p n 56742...

Страница 35: ...uffing box 12 Remove the two bolts that secure each plung er coupling Figure 28 to the plungers and remove the three couplings Note The coupling halves are matched and must be kept together CAUTION Us...

Страница 36: ...plunger coupling Figure 30 on each plunger and secure with the two bolts Tighten the bolts to 20 ft lb 27 N m 17 Ensure the gland nuts are tight Use the pump wrench and a 5 lb 2 kg hammer to tighten...

Страница 37: ...the ends since it will be supporting the weight of the manifold block This centered position of the manifold will also ensure proper operation of the valves and seals at all pressures a Remove two ma...

Страница 38: ...trunnions up or down until the manifold bolts thread in and out easily 22 Install the manifold bolts Figure 36 in the open holes and hand tighten 23 Remove the manifold mounting studs Figure 36 24 Ins...

Страница 39: ...n New Pack ing on page 16 ATTENTION If converting to a 40K fluid end the secondary filter must be plumbed for operation Refer to 40K Hose Connections When converting to 40K a charge pump is re quired...

Страница 40: ...condary filter inlet coupling Figure 43 5 Install the charge pump supply hose on the secondary filter inlet coupling CAUTION When flushing the system before operation purge the secondary filter of air...

Страница 41: ...the gland nut holes 3 Use a 5 lb 2 kg hammer to hit the wrench in the direction to tighten the gland nuts Hit the wrench about three times using moderate force This will supply sufficient torque on t...

Страница 42: ...off the water supply and drain the water tank 3 Open the rod box cover 4 Disconnect the water lubrication lines if equipped 5 Position the plunger to be serviced so that it is at bottom dead center p...

Страница 43: ...ure the plung er coupling Figure 50 to the plunger and remove the coupling Push the plunger into the stuffing box for clearance 8 Remove the gland nut and plunger from the stuffing box It may require...

Страница 44: ...nspect Note The guide bushing may be stuck and require some force to remove Use a tool in the cutout Figure 53 to push the bushing out Use caution to avoid damaging the gland nut Figure 52 Guide Bushi...

Страница 45: ...tion listed in the 40K Guide Bushing Replacement Table below replace the bushing If the bushing shows scoring or if the edge is chipped re place the bushing 40K Guide Bushing Replacement Diameter Flui...

Страница 46: ...Orient the packing as shown in Figure 54 for 15K 20K and Figure 55 for 40K 4 Lubricate the gland nut with anti seize com pound Apply the compound to the threads and on the small face that contacts the...

Страница 47: ...install the coupling bolts Figure 60 Tighten the bolts to 20 ft lb 27 N m 7 Use the pump wrench and a 5 lb 2 kg ham mer to tighten the gland nuts to approximately 250 ft lb 338 N m Hit the wrench abo...

Страница 48: ...lines from the stuffing box fittings 5 Remove the manifold bolts Figure 64 Ensure the hinge rod Figure 65 is installed before removing the bolts Note The pump wrench can be used with a hammer to remov...

Страница 49: ...inger and gently pull the seal out Figure 67 2 Wipe the seal retaining area and inspect 3 Apply O ring lubricant to the entire area of the new seal 4 With the sealing lip facing away from the stuff in...

Страница 50: ...ighten in a criss cross sequence starting with the center bolts Figure 69 Proper torque is 350 ft lb 470 N m 5 Connect the water lubrication lines Figure 70 to the stuffing boxes and close the rod box...

Страница 51: ...and backup rings Note Note the orientation of the seals for installation 3 Use a small screwdriver to depress the spring retainer Use another screwdriver to remove the retaining ring Insert the blade...

Страница 52: ...ewdriver until the spring releases from the groove Note 3015 valves are equipped with a retaining ring to secure the discharge spring Figure 77 7 Remove the discharge valve and discharge spring 8 Insp...

Страница 53: ...p Ring 3 O Ring 4 Suction Valve 5 Discharge Valve Body 6 O Ring 7 Backup Ring 8 O Ring 9 Discharge Valve 10 Discharge Valve Spring 11 Retaining Ring 3015 Valves Only 12 Suction Valve Spring 13 Spring...

Страница 54: ...ion the suction valve in the valve body Figure 79 4 Insert the suction valve spring and spring retainer into the valve body Ensure the ledge the retaining ring sits on is positioned properly Figure 80...

Страница 55: ...e taining ring Insert the blade under the slit and rotate the ring out of the groove Figure 82 Use caution to prevent bending or distorting the ring 3 Use the screwdriver to remove the ring seal Figur...

Страница 56: ...Figure 84 6 Remove the valve spring and valve spring retainer 7 Remove the suction and discharge valves Figure 85 8 Inspect the valves Refer to Valve Inspection on page 50 for inspection criteria Figu...

Страница 57: ...sembly Note the chamfer on the inside diameter of the backup ring Orient the back up ring so the chamfer faces the valve body and the flat side of the ring faces the cup seal Install the cup seal and...

Страница 58: ...y by disengaging sur faces Rotate the parts in the opposite direction approximately 90 degrees Do this a few times during lapping This will ensure that the lapping compound distributes evenly along th...

Страница 59: ...ing 4 Inspect the diffuser Figure 96 for jetting dam age Replace if damage is extensive 5 Push the new cartridge into the housing until it snaps into place 6 Install the cartridge housing back onto th...

Страница 60: ...tion for purposes of checking the oil stop the pump wait 1 2 minutes and check the sight gauge As long as oil is visible in the gauge the oil level is acceptable If oil needs to be added add 80W 90 de...

Страница 61: ...listed below 3 Install an extension hose pipe to extend the drain past the trailer frame if desired 4 Open the ball valve to drain the oil 5 After the oil has drained from the case close the ball valv...

Страница 62: ...two capscrews that secure the plunger coupling Figure 100 to the plunger and remove the coupling Rotate the pump until the pony rod is fully retracted Note The coupling halves are a machined pair Keep...

Страница 63: ...e O ring and seals 14 Repeat for the remaining crosshead seals if necessary Installation 1 Place the seal plate in a hydraulic or arbor press with the inboard side facing up Place the red outboard sea...

Страница 64: ...and pressure only Do not hammer the plate into place The plates must be flush with the frame 9 Using a 1 4 hex drive tighten the set screw that secures the plate to 15 in lb 1694 mN m inside the acces...

Страница 65: ...te the pump by pulling on the belts Figure 110 to gain access to the capscrews as needed 4 Once the capscrews are removed remove each rod cap from the crankshaft Observe the stamp marks on the top of...

Страница 66: ...l a small strip of plasti gauge onto the end cap bearing Figure 113 3 Position the end cap with capscrews back onto the matching connecting rod 4 Screw in the capscrews by hand and then tighten to the...

Страница 67: ...bearing inner diameter only Figure 115 2 Slide the bearing Figure 116 into the con necting rod from below the crankshaft journal 3 Apply oil to the inner surface of the cap end bearing 4 Properly ori...

Страница 68: ...the bearings were properly installed If the crankshaft does not spin freely remove the journal bearings and replace with another set 9 Repeat the previous steps for installation of the remaining jour...

Страница 69: ...rometer to measure the outer diam eter of the pin in three places and record the measurements 2 Add the three measurements and divide by 3 to get the average diameter 3 Use an inside micrometer to mea...

Страница 70: ...of the crossheads pins and connecting rods for any signs of damage Replace any suspect or damaged parts 3 Inspect the long bore oil passage through the length of the connecting rod Use a wire or a lon...

Страница 71: ...cover Figure 126 and dis connect the wiring Unscrew the conduit fitting from the switch housing and lay the conduit and wiring aside 5 Remove the belts 6 Use a marker to mark the location of the pump...

Страница 72: ...ware 6 Install the belts onto the pulleys Adjust the belt tension per manufacturer specifications 7 Install the belt guard 8 If equipped with a secondary filter insert the switch wiring into the switc...

Страница 73: ...washers that secure the rear cover Figure 133 and belt guard to the power frame Remove the cover guard and gasket 6 Pull the three connecting rod crosshead assemblies towards the fluid end as far as p...

Страница 74: ...If the bear ings turn blue or black they are overheated 2 When ready slide the bearings onto each end of the crankshaft until they are fully seated Figure 134 3 Verify that the bearing turns on the s...

Страница 75: ...hit either end of the crankshaft to seat it in the bearing bore Ensure the outer bearing race Figure 138 is inside the power frame case 11 Tap in the bearing race on the opposite end of the crankshaf...

Страница 76: ...packs within 0 010 in 0 254 mm of each other 17 Install the remaining capscrews onto the inboard and outboard side plates Tighten the capscrews to 50 ft lb 68 N m 18 Oil the bearings and install the c...

Страница 77: ...l tank unplug vent Leaking pump valves Repair or replace valves Broken pump valve springs Replace springs Worn pump plunger packing Replace packing Belts slipping Increase belt tension Dirty filter ba...

Страница 78: ...il seal leak Replace seal Cold oil Continue to run until oil temp in creases to adequate temperature Engine will not return to idle when control gun dump ing Excessive hose back pressure Reduce hose s...

Страница 79: ...sted the Shipping Manager contacts the new owner to arrange for the unit s arrival to the right place at the right time 2 Training All new waterblasters include personal training by the Right Start Te...

Страница 80: ...Operation Manual 72...

Страница 81: ...5 40K Hose Connections 32 Converting a Pump 25 Manifold Trunnion Adjustment 29 S SERVICE 33 Fluid End 33 15K 20K Uni Valve Service 43 Assembly 46 Disassembly 43 40K Face Seal Replacement 41 Installati...

Страница 82: ...erforming Maintenance Or Repairs 3 Purge The System 3 Read Instructions 2 Rupture Discs 2 Slowly Increase pressure 3 Store Components Properly 3 Test The system 3 Tighten Connections 2 Use The minimum...

Страница 83: ......

Страница 84: ...47 0660 Highland IN 219 924 3180 Lakewood WA 253 584 0653 Long Beach CA 866 515 9891 New Brunswick NJ 732 448 7830 Midland TX 432 563 4450 Streator IL 815 672 6028 LaPorte TX 281 674 8668 Williston ND...

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