3NJ

3NJ Series

Slurry high pressure pump for detergent

Operation Instruction

Ningbo He Li Pump Co. Ltd.
 Catalogue

Chapter 1 Overview ------------------------------------------------------------------- 2

Chapter 2 Model preparation ------------------------------------------------------- 2
Chapter 3 Main parameter and specification of the pump ------------------ 3
Chapter 4 Structure and basic working principle of the pump ------------- 3
Chapter 5 Disassembly and assembly of main parts ------------------------ 6
Chapter 6 Pump foundation and installation ----------------------------------- 9
Chapter 7 Start and stop of the pump and precautions -------------------- 10
Chapter 8 Inspection in the process of pump operation -------------------- 11
Chapter 9 Maintenance of the pump --------------------------------------------- 12
Chapter 10 Failure and troubleshooting ----------------------------------------- 14
Chapter 11 Pump range ------------------------------------------------------------- 15
Chapter 12 Special tools list -------------------------------------------------------- 15

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Chapter 1 Overview
3NJ Series slurry high pressure pump for detergent is according to requirement on

detergent process flow; it is specialized in transportation slurry to the spray drying tower.

This series pump is horizontal type three-plunger single-effect reciprocation pump;

transportation flow is 1~25m3/h, discharge pressure is 6.5~8MPa, medium concentration

is 60~70%, medium max temperature is 90. Annual production capacity of single pump

can reach 5000~100000 ton detergent.

3NJ Series high pressure pump is consists of motor, coupling, reducer, power end,

lubrication system, fluid end, voltage regulator and etc. The above parts are installed on

the common base so that easy to transportation and installation.

This series pump is of the advantages such as advanced design, novel structure, smooth

operation, safe and reliable seal, long use life of the quick-wear parts and high volume

efficiency.

Chapter 2 Model preparation

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Chapter 3 Main parameter and specification of the pump
Model 3NJ100-10/8

Conveying medium detergent powder slurry

Medium temperature 80

Inlet pressure MPa

Outlet pressure MPa 8.0

Flow m3/h 10

Plunger diameter mm 100

Plunger stroke mm

Reciprocating times min

Model

Motor Power KW 30

Voltage V 380V

reducer Model

Speed ratio

lubricating oil brand and No. 68# machine oil or 11# supercharger oil

Lubrication lubricating oil dosage Kg

lubricating oil pressure MPa

lubricating oil pump type

Liquid inlet pipe diameter mm

Liquid outlet pipe diameter mm

Dimension(length* width*height) mm

Chapter 4 Structure and basic working principle of the pump

4.1 structure and feature of the pump

4.1.1. Motor is the power equipment of the pump. It is equipped with frequency converter

(or directly use electromagnetic speed regulating asynchronous motor) which is for

adjusting pump speed in order to adjust the conveying slurry flow.

4.1.2. The coupling adopts pin coupling with elastic sleeves which is for buffering,

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damping, no need lubrication and can compensate two axes relative displacement.

4.1.3. Reducer adopts hard tooth surface cylinder gear speed reducer which is of high

bearing capacity. It is of these advantages such as small volume, light weight, high

bearing capacity, long use life, high efficiency and low noise.

4.1.4. Power end: (see structure chart of the power end)

Power end is crankshaft connecting rod system, through computer optimization design,

makes specific pressure value and stress value of every stressed part of the component

decrease to a smaller value thereby raise the reliability of the pump operation.

4.1.4.1. Gray casting body is box-type structure. Bottom of the crankshaft end in the body

is designed as oil pool for storing lubrication oil. Oil level of the lubrication oil displays at

the oil pointer; normal oil level should at the midline of the oil pointer.

4.1.4.2. Crankshaft is made of 42CrMo alloy steel; the connecting rod is steel casting; it

adopts forced lubrication way pump, it has oil duct in the connecting rod of the crankshaft.

4.1.4.3. Among 3NJ Series pumps, the pump of the plunger force more than 5 ton adopts

forced lubrication way. Lubrication oil needed for the connecting rod tile and every part of

the crosshead, passing through oil filter and oil duct in the connecting rod of the

crankshaft, is conveyed by specialized oil supply pump to each frictional parts for

lubrication. Bearing at both ends of the crankshaft uses splash lubrication. Design a small

oil pool in the body above the crosshead guide hole; aim at the centre above the

crosshead guide hole and drill a hole. The lubrication oil which comes when the circular

crank of the crankshaft is rotating is guided into oil pool by oil wiper, through the hole can

lubricate the crosshead and the pin.

4.1.4.4. Connecting rod tile adopts 08 plastic alloy thin wall bearing bush. Small end of the

connecting rod is equipped with bronze bushing.

4.1.4.5.The pump which adopts splash lubrication way, its crosshead and crosshead pin

are full floating structure. The pump which adopts forced lubrication way, its crosshead

and crosshead pin are half floating structure; i.e. crosshead and crosshead pin is

interference fit; connecting rod bushing and crosshead pin is movable fit. Crosshead pin is

installed to the crosshead with the snap spring stuck on both ends to prevent the

crosshead pin out.

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4.1.4.6. During reciprocating motion of centre pole, 2 skeleton-type rubber oil seals in the

seal box seal up the power end to prevent the lubrication come out.

4.1.4.7. In the oil pool there is equipped with magnetic rod for cleaning the metal impurity

in the lubrication oil.

4.1.4.8. The oil level gauge and temperature control gauge installed on the pump are

connected with electric cabinet. When lubrication oil level is below lower limit and oil

temperature is higher than specified value, the oil level gauge and the temperature control

gauge will work and the pump will stop running. The pump which adopts forced lubrication

is equipped with lubrication oil cooler, oil filter rod and oil pressure controller; adjust the

lubrication oil pressure to be 0.3~0.4MPa and start lubrication oil pump, when lubrication

oil pressure reach the required value, the yellow pressure indicator on the electric cabinet

lights up, otherwise the 3NJseries pump can not be started. During the pump running, if

lubrication oil pressure drops to below required value, the electric cabinet secondary

circuit is off, the pump will stop running.

4.1.5 Fluid end: (see fluid end structure chart)

Ladder type hydraulic cylinder made of stainless steel in the fluid end is of strong

anticorrosion performance, easy for disassembly and assembly and easy maintenance.

Ball valve in the fluid end is continuously rotating when moving; there is no suitable place

for adhesive solid particle on the ball making the ball valve has good leakproofness

towards the mixed solid particle thus to ensure the pump has high volume efficiency.

Plunger seal adopts main and sub double seal; between the main seal and the sub seal

there equipped with flusher, the flushing water can both completely eradicate slurry

crystallization and carry off the heat produced by friction of plunger and packing thus

increase the reliability and the using life of the plunger seal.

4.1.6. A long cylindrical stabilizer is installed on the discharge pipe of the pump, which can

reduce volatility of pulse and flow of the discharge pressure to ensure even conveying of

the slurry.

4.2. Basic working principles

Motor, through coupling and reducer, drives the crankshaft to rotate; crankshaft drives

connecting rod, crosshead, centre rod and plunger to do reciprocating motion. When

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plunger moves backward, liquid inlet valve opens and the liquid enters the pump till the

plunger moves to the last position (crankshaft rotates 180 ) then the liquid stop entering.

When plunger moves forward, the liquid in the pump valve box is extruded, the pressure

rises, the liquid inlet valve stops, supplementary prefabricated of the discharge valve

opens, and the liquid is discharged.

Chapter 5 Disassembly and assembly of main parts

5.1. Disassembly of connecting rod, crosshead, crankshaft and etc.: (see chart1-1)

5.1.1

Remove cover (1, 2, 3) and remove seal box and oil seal (4, 5); twist off centre pole (6),

twist off connecting rod bolt (7); take out connecting pole cover from A direction, push

connecting rod body (9) and crosshead (10) meantime forward B direction till take out the

crosshead connecting rod body from the B direction.

5.1.2

Remove the clamp spring which blocks the crosshead pin by spring forceps and take out

crosshead pin (11). The pump which adopts forced lubrication, due to the interference fit

between the crosshead and the crosshead pin, when disassembly should use jack to push

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out the crosshead. (see chart 1-2)

5.1.3

After remove belt guard, belt, large pulley and large pulley taper sleeve, later remove

bearing covers at both crankshaft ends, by now the crankshaft can be drawn out from

either side.

5.1.4

Assembly sequence of crankshaft, crosshead, crosshead pin and connecting rod is

contrary to the disassembly sequence of them. But before assembly must repair the burr

of the parts and wash it clean. When assembly, add moderate lubrication oil to every

friction parts. When finishes inner body assembly, should immediately cover the plate and

the back plate to prevent dirt.

crosshead pin Supporting structure

crosshead Lifting jack

connecting rod

Parallels (outer Diameter is less than crosshead pin)

Parallels (hole is greater than crosshead pin)

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5.2 . Disassembly of liquid charge valve and liquid discharge valve (see chart 1-3)

5.2.1. First dismantle flange on the pump body and valve limited block (3,7); use clip ball

machine to take out valve ball (9), then use specialized tool to take out valve seat.

5.2.2. Assembly sequence of liquid charge valve and liquid discharge valve is contrary to

the disassembly sequence of them. But before assembly must repair the burr of the parts

and wash it clean and add moderate lubrication oil.

5.3. Disassembly of plunger and seal

5.3.1. Dismantle wash pipe components (2) on the seal body (1).

5.3.2. Loose the threaded connection between the plunger and the centre pole.

5.3.3. Use tool to dismantle socket head cap screw.

5.3.4. Use lifting hook to lift the seal body (1); take it out from the location hole of the body.

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5.3.5. First dismantle plunger and regulating nut, then use specialized tool (dismantle seal

ejector rod) to dismantle in sequence back guide sleeve, packing, wash ring packing and

front guide sleeve.

5.4. Assembly of plunger seal

5.4.1. Before assembly repair the burr of the parts and wash it clean

5.4.2. Use ejector rod for the seal to put in sequence front guide sleeve, packing (main

seal), wash ring, packing (sub seal) and back guide ring into the seal body and install

adjusting nut then install plunger and at last tighten up the thread of the plunger and the

centre pole.

5.5 .Fit clearance of main parts of the power end

No. Parts Fit clearance Remark

1 Axial clearance between bearing seat cover and main bearing

2 Radial clearance between crankshaft and connecting rod bearing shell

3 Axial clearance between crankshaft and connecting rod big end

4 Radial clearance between connecting rod shaft sleeve and crosshead pin

5 Radial clearance between crosshead and crosshead guide hole

Chapter 6 Pump foundation and installation

6.1. Foundation: see the anchor size chart in the general drawing.

Depth of the foundation is designed by the user according to local geological condition.

6.2 .Installation

6.2.1. Before pump is in place, should check the relative distance of the preformed hole of

foundation bolt on the foundation. Level the foundation and use leveling instrument to

measure its levelness.

6.2.2. Besides the anchor bolt hole, set wedge parallels; then put the pump on the

parallels, penetrate the anchor bolt, irrigate concrete, after conserve for 5~7 days remove

the parallels, then use leveling instrument to level in longitudinal and transverse way on

the pump upside; when the levelness meets the requirement tighten up the anchor bolt.

6.2.3. Installation of liquid charge pipeline and liquid discharge pipeline of the pump

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should be straight as far as possible in order not to increase resistance to the pump and

additional stress. After pipeline is installed, use high pressure water and compressed air to

blow and wash then come into use.

6.2.4. Connect the circuit of the lubrication oil pump.

6.2.5. Flushing pipe and water inlet and outlet pipe of the cooler, the user decides the

connecting way by himself.

6.2.6. When finishes pump installation, check if the screw of the every parts of the pump is

loose; clean the pump inside and outside and add enough lubrication oil of the specific

brand and No.; then check if the motor and the circuit is good in order to make preparation

for the start.

Chapter 7 Start and stop of the pump and precautions

7.1 Start procedure

7.1.1. Check if every connecting parts and screw are loose.

7.1.2. Check the quality of lubrication oil and the oil level height.

7.1.3. Check if the motor and its wiring are correct, tight and in good condition.

7.1.4. Drive with hand the motor end coupling to make it rotate over 40 circles; motion

mechanism can not have obstacles.

7.1.5. Open valves on the liquid charge pipe and discharge pipe and the by-pass valve on

the liquid discharge pipe.

7.1.6. Open valves on flushing pipe component.

7.1.7. Make sure the pump is trouble-free, and then switch on the motor power to make

the pump start up under no load.

7.1.8. When the pump reaches rated speed, close by-pass valve; the pump can change

over to on-load running.

7.2. Stop procedure

7.2.1 Open by-pass valve of the liquid discharge pipe, open valve of the liquid charge

pipe for the clean water; make the pump run under no load to wash clean the slurry in the

pump thoroughly.

7.2.2 Shut off the motor power.

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7.2.3 Close valves on the liquid charge pipe and discharge pipe and the by-pass valve.

7.3 Precautions

7.3.1 When stop the pump, must wash lean the slurry inside the pump.

7.3.2 It is never allowed to start pump without liquid in the pump body.

7.3.3 It is strictly prohibited to start pump when liquid charge pipe and discharge pipe

and the by-pass valve are closed.

7.3.4 New pump or the overhauled pump must have 2-hours idle running and then have

load running. During load running, it is suggested to do successive pressurization every

30 minutes according to one quarter of the rated pressure. During pressurization, if there

is abnormal situation, should immediately stop pump and inspect to find out the cause;

after troubleshooting then go on running. If no condition for successive pressurization, can

also directly boost to rated pressure, but the pump idle running time should over 4 hours.

7.3.5 In the process of load running, the instantaneous maximum pressure can not be

over as 110% as the rated pressure.

7.3.6 When pump is running, it is strictly prohibited to do any repair work to prevent

accident.

Chapter 8 Inspection in the process of pump operation

8.1 Check if the sound of the power end is regular; lubrication oil should be within the

prescribed scope.

8.2 Check temperature of every parts should be normal, temperature of every axle

should not over 75, temperature of the motor should not over 70, temperature of

plunger and the friction place should not over 75.

8.3 Check if the lubrication oil pump works fine; lubrication oil pressure should more than

0.2MPa.

8.4 Check the pump outlet pressure and its displacement should meet the requirement.

8.5 Check working situation of liquid charge valve and liquid discharge valve; should

have no abnormal noise.

8.6 Adjusting nut on the seal should be checked often, be sure not to be loose. When

plunger is working, if there is large amount liquid leakage, should stop pump and tighten

adjusting nut pr replace seal ring.

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8.7 Check if every part screw and every flange nut is loose and tighten it.

8.8 Check if water inflow and outflow in the components of the flushing pipe is normal.

Chapter 9 Maintenance of the pump

9.1 Lubrication oil of the power end adopts 68# or 11# diesel oil.

9.2 New pump or overhauled pump, the oil change is 500 hours for the first time, later is

every 3000 hours of running or change lubrication oil according to quality.

9.3 Wash regularly oil filter rod, cooler and magnetic bar.

9.4 Check regularly and adjust the release pressure of safety valve; it should be

1.08~1.1 times of the rated working pressure

9.5 Check regularly the accuracy of the pressure gauge.

9.6 Check regularly the tightness of the belt.

9.7 Replace damaged quick-wear part.

9.8 Adjust each clearance, check and screw up each screw.

9.9 Pump which should stop using for long time, should wash with clean water and

empty the liquid in the pump; dismantle all valves and coat it with lubrication oil; and do

anti-corrosion maintenance to the whole pump.

9.10 If start the pump which is parked a long time, should do overall overhaul

maintenance otherwise can not start using.

9.11 Pump overhaul period is tentative as 12000 hours.

Chapter 10 Failure and troubleshooting

No. Failure Cause Troubleshooting
1 Knock noise at 1. connecting rod bolt is loose 1. screw up connecting
motion part 2. big wear gap of connecting rod rod bolt
bearing shell 2. replace connecting rod
3. other part of motion part is loose bearing shell
3. adjust the loose part
2 Excess 1. bearing assembly bad clearance 1. reassemble, adjust
temperature of 2. dirt enters bearing clearance
rolling bearing 3. poor lubrication 2. remove dirt
4. bearing has fatigue etch or 3. improve lubrication
damage 4. replace bearing
3 Abnormal 1. check if oil filter rod works normal 1. wash or replace
lubrication oil 2. check each clearance of 2. adjust clearance or

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 pressure lubrication oil pump replace part
3. check if lubrication oil passage is 3. wash oil passage,
unblocked replace lubrication oil
4 Excess 1. motion part bad assembly 1. reassemble
temperature of 2. poor lubrication 2. improve lubrication
lubrication oil
5 Sharp swing of 1. energy accumulator failure 1. repair or replace
pressure gauge 2. leak of liquid charge and 2. replace damaged valve
at pump outlet discharge valve 3. replace seal ring
3. leak of seal of liquid charge and
discharge valve
6 Leakage at 1. flange nut is loose 1. screw up nut
pump flange 2. seal ring damaged 2. replace seal ring
7 Violent vibration 1. there is air in the pump body 1. discharge the air in the
of liquid charge 2. leak of liquid charge and pump
and discharge discharge valves 2. sharpen and replace
pipe of the 3. damage of seal ring of liquid valve
pump charge and discharge valve 3. replace seal ring
4. liquid charge and discharge pipe 4. strengthen the pipeline
is impending
8 Uneven knock 1. flange nut on the pump body is 1. screw up flange nut
noise in liquid loose 2. repair valve seat and
charge and 2. damage of valve seat and valve valve spool
discharge valve spool
cavity
9 Serious leak at 1. adjusting nut of the plunger seal is 1. adjust tightness of
plunger seal too loose adjusting nut
2. serious wear of seal ring 2. replace seal ring
3. medium not clean, dirt in the seal 3. remove dirt in pipe and
pump
10 Be short of Motor power shortage Overhaul or replace motor
pump power

Chapter 11 Pump range

No. Name Quantity Remarks
1 Pump 1 Power end, fluid end
2 Base 1 Random
3 Coupling 2 Random
4 Reducer 1 Random
5 Motor 1 Random
6 Energy accumulator 1 Supply according to contract
7 Pressure gauge 1 Container
8 Special tool 1 set Container
9 Electric cabinet 1 Supply according to contract

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Chapter 12 Special tools list
No. Name Quantity Usage
1 Ball clamp (food box) 1 set Lift ball valve
2 Valve seat puller 1 set Dismantle liquid charge/ discharge valve
seats
3 Regulating stem 1 Adjust tightness of screw cap
4 Seal ejector rod 1 Dismantle packing seal guide sleeve
5 Seal guide tube 1 Assemble seal guide sleeve
6 internal hexagonal wrench Disassemble and assemble seal body

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