Installation and Maintenance Precautions for KAYABA 2P-3146 Hydraulic Pump
Installation Precautions
Foundation and Mounting:
- The hydraulic pump can be mounted using a base plate or flange. The pump and the driving machine should share the same foundation, and both the flange and foundation should have sufficient rigidity.
- For piston pumps with a flow rate greater than or equal to 160L/min, it is not recommended to mount them directly on the oil tank.
Installation Location:
- The hyd pump should be installed in a well-ventilated, dry area, away from vibrations. Ensure that the installation site has structural strength and stable foundation support.
Pipeline Connection:
- The inlet, outlet, and rotation direction of the hyd pump must comply with the requirements indicated on the pump. Reversing the connections is not allowed.
- The suction and return ports of the hydraulic pump must be at least 200mm below the lowest oil level in the oil tank. Specifically, no oil filter should be installed in the suction pipeline of a piston pump. The shut-off valve on the suction pipeline should have a larger diameter than the suction pipeline, and the length of the suction pipe should be less than 2500mm with no more than two bends.
- The return pipe should extend below the oil tank's liquid level to prevent oil splashing and the formation of bubbles. The return pipe should be cut at a 45° angle toward the oil tank wall.
Coupling Installation:
- The hydraulic pump is generally not designed to bear radial loads, so an elastic coupling is commonly used for direct drive by an electric motor. The motor and pump shaft should be highly concentric, with the misalignment not exceeding 0.1mm, and the tilt angle should not be greater than 1° to avoid additional load on the pump shaft and noise generation.
- Do not install the coupling by striking, as this may damage the pump rotor.
Initial Operation:
- Before the hyd pump starts, ensure that the return port is filled with clean hydraulic oil to ensure proper lubrication of the bearings and friction parts, preventing damage from running dry.
- Do not start the system at full speed. The motor should be started several times in an unloaded state to expel air from the pipeline. After 1-2 minutes of unloaded operation without abnormalities, gradually load the system.
Maintenance Precautions
Regular Inspections:
- Check for oil leaks, especially at critical points such as seals and joints.
- Start the hydro pump and listen for abnormal noises. Unusual noises may indicate component wear or looseness.
- Use an infrared thermometer to check the temperature of various components. High temperatures could indicate potential system malfunctions.
- Remove and clean or replace the filter to ensure it meets cleanliness standards.
Cleaning:
- Use appropriate cleaning agents based on the material of the hydro pump and follow the instructions for proper use.
- During cleaning, avoid letting the pump come into contact with other objects to prevent damage.
- After cleaning, place the hydro pump in a ventilated, dry area to air dry.
Lubrication:
- Use the correct lubricant based on the type and operating conditions of the hyd pump, and add it according to the specifications.
- Regularly check the lubricant level and add or replace oil as necessary.
- Ensure that the correct lubrication points are serviced.
Oil Management:
- Hydraulic oil must be clean and free from mechanical impurities and corrosive substances. In systems without filters in the suction pipeline, use a filter truck (with filtration accuracy below 25μm) to add oil to the tank.
- Oil viscosity varies with temperature. As the temperature rises, viscosity decreases. Therefore, maintain the oil temperature below 60°C. It is recommended to use L-HM32 or L-HM46 anti-wear hydraulic oil (GB11118.1—94).
- The normal operating oil temperature for the hydraulic pump is between 15 and 65°C, with the pump casing temperature typically 10-20°C higher than the oil temperature at the inlet of the tank. The maximum pump casing temperature should not exceed 75-85°C when the oil temperature in the tank reaches 65°C.
Long-Term Storage:
- If the pump is not in use for an extended period, drain the oil, fill it with a low-acid value oil, apply anti-rust oil to exposed machined surfaces, and seal all oil ports with screw plugs to prevent contaminants from entering.
By following these installation and maintenance precautions, you can ensure the normal operation of the 2P-3146 hydraulic pump, extend its service life, and reduce the incidence of faults.
