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PRESSURE WASHER PUMP
USER MANUAL
MODEL:KPD2110G/KBD2815G
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MODEL:KPD2110G/KBD2815G
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PRESSURE WASHER
PUMP
KPD2110G
KBD2815G
GENERAL INEORMATLON
Purpose of the manual
The manufacturer has provided this manual to provide the operating
instructions and the criteria to be complied with when installing,using and
maintaining the pump identified by the designation on the cover.
The manufacturer supplies the original instructions in the English
language.
The manufacturer may supply the original instructions in other languages
in response to statutory or commercial requirements.
If the pump is sold,the seller must pass on this manual to the new owner
along with the appliance.
The instructions are intended for the skilled,suitably trained operators who
carry out the installation and routine maintenance procedures.
Refer to the table of contents for rapid access to the topics covered.
The manufacturer reserves the right to amend the manual without notice
unless the amendments refer to the pump's level of safety.
The purchaser must ensure that the installation is designed in accordance
with the instructions in this manual,statutory requirements,and the relevant
national and local regulations.
The technical instructions in this"Use and Installation Manual"are the
property of the manufacturer and must be treated as confidential.
There may be differences between the illustrations and the pump's actual
conformation,but any such differences will not affect the clarity of the
instructions. If in doubt,request the necessary explanations from the
manufacturer.
The symbols shown and described below are used to identify safety risks
orimportant information.
Danger-Warning
Identifies information or procedures the failure to comply with which may
constitute a serious threat to health and safety.
Caution
Identifies information or procedures the failure to comply with which may
constitute a threat to health and safety or cause damage.
Information
Identifies useful and important information or procedures that should be
borne in mind.
Pump and manufacturer identification
Data plate
The data plate shown here,containing essential information for safe
operation, is affixed to every pump.
A)L/min/GPM
B)MPa/psi
C)RPM
D)Kw
GENERAL INEORMATION
After-Sales service procedures
To request after-sales service(in the event of a pump malfunction or
failure,etc.), contact your nearest service centre or the manufacturer.
When requesting after-sales services,always state the pump's data plate
data and the type of problem.
Disclaimer
The manufacturer accepts no liability arising from:
- Incorrect installation;
- Improper use of the pump;
- Failure to service the pump;
- Unauthorised modifications and/or repairs;
- Use of non-original spare parts,or parts not specifically intended for
the model.
Annexed documentation
The following documentation is issued to the Customer together with this
manual:
- Declaration of incorporation
Glossary
Purchaser: Individual,organization or company which has purchased the
pump and intends to use it for the intended purposes.
Routine maintenance: All operations required to keep the pump in good
working order to ensure a longer working life and maintain compliance with
safety requirements.The manufacturer describes the maintenance
procedures and intervals in this"Use and Installation Manual".
Repairs: All operations performed to conserve the pump's efficiency and
operating characteristics.These procedures,required in the event of an
unexpected malfunction,must only be carried out by a skilled technician.
The information for the use of skilled repair technicians only is provided in
the"Repairs Manual".
Operator: An authorized person having the prerequisites,skills and
information needed for the use of the pump or the machine or plant on
which the pump is installed,and for routine maintenance procedures.
Installer: Authorized technician having the prerequisites and the specific
skills required for the tasks involved in the installation of the pump and/or
similar machinery and for the performance of the routine maintenance
operations in conditions of safety,independently and without risk.
Training: A phase necessary to transfer to the operators the knowledge
needed for the correct,risk-free performance of operations.
TECHNICAL INEORMATION
General description
The pump is designed and constructed to pump and compress liquids at
high pressure in industrial applications.The pumping action is provided by
a series of pistons connected to the drive shaft by connecting-rods.
When in operation,the pistons perform an axial stroke inside the head,
where the intake and delivery ducts are fitted with valves that allow the
liquid to pass in one direction only.
Main components
A). Head
B). Pump body
C). Crankshaft
D). Intake valve
E). Delivery valve
F). Guide
G). Seal
H). Piston
Intended uses
The pump is designed and built for incorporation in machinery and
plants(machinery for washing raw materials,fnished products,etc.).
The pump must be used in a manner appropriate to its technical
data(see"Technical Data"),and must not be modified or improperly used.
Misuses
Do not put the pump into service until the plant or machinery in which it is
incorporated has been declared compliant with the relevant nationaland
local legal requirements.
Do not use the pump in a potentially explosive atmosphere.
Do not use the pump for flammable,toxic or corrosive liquids,or those with
unsuitable density.Do not take in liquids at temperatures higher than those
specifed in the technical data.
Do not use the pump for the supply of drinking water.
Do not use the pump on products for human consumption.
Do not use the pump on pharmaceutical products.
Residual risks
Even if the safety regulations and information provided in the manual are
complied with,the residual risk described below is still present during the
use of the pump.
- Thermal hazard: Depending on the temperature of the liquid pumped,the
pump may reach high temperatures when in operation.The designer of the
installation must therefore bear this in mind and provide the appropriate
measures and warning signs for staff.
TECHNICAL INEORMATION
Technical Data
The technical and performance data are stated on the cover.
The pump's intake circuit must include a filter having a capacity at least
twice the pump's delivery rate, which must not cause restrictions or head
losses. The recommended degree of filtration is 50-80 mesh.Maximum
intake vacuum-0.25 bar, measured at the pump intake.
Overall dimensions
The illustrations showing the overall dimensions are provided in the
annexes.
Environmental operating limits
The pump operates correctly at an ambient temperature between 10 and
35°C, with a relative humidity of 80%.
Note: To match engines with different power, the factory set pressure will be
less than the rated maximum pressure. Just adjust the pressure limiting
valve if you need to increase the pressure.
Product Specifications and Packing List
Model
KPD2110G
KBD2815G
Working Pressure
3200 PSI
4000 PSI
Gun Closing Pressure
3700 PSI
4400 PSI
Factory set pressure
2500-2600 PSI
3500-3600 PSI
Matching Horsepower
6.5-7/HP
13-15/HP
Maximum Flow
2.5 GPM
4.0 GPM
Adaptive Model
208~230CC
420~460cc
Packing List
1 x Pressure Washer Pump；1 x Siphon；4 x Bolts；
1 x Vent Plug；1 x Shaft Key；4 x Flat Pads
4 x Spring Washers；1 x Manual
SAFETY INEORMATION
General safety rules
Most workplace accidents and injuries are caused by carelessness and
failure to comply with common sense and safety rules.
In most cases,accidents can be avoided by predicting their possible
causes and proceeding with the necessary care and attention.
A careful operator who follows the rules is the best guarantee against
accidents.
Before installing and using the pump,the operators and other staff must
read and understand the instructions in the manual provided and the
details of the installation design.
Do not tamper with,disarm or bypass the safety devices as this may cause
serious threats to health and safety. Do not release pollutants into the
environment.
Dispose of waste in accordance with statutory requirements.
Before performing any procedure,adopt appropriate safety measures in
accordance with the relevant statutory occupational safety requirements
and comply with the safety regulations in the manual.
HANDLING AND TRANSPORT INSTRUCTIONS
Safety recommendations for handling and lifting
Before starting the operations, organize the intended working area so that
the materials can be lifted and handled in safety.
Unloading, loading, handling and lifting operations must be carried out by
skilled,authorized, and specifically trained staff.
During lifting and handling operations, the people not involved in the
operations must remain at a safe distance.
For lifting, use hooks and ropes which are free from damage and appropriate
for the load to be lifted.
Packaging description and unpacking
The packaging normally consists of a cardboard box for easy, safe transport.
Depending on the quantity of goods to be shipped and the place of destination,
packages may be fixed on a pallet for easier lifting and handling.
Check the weight of the item on the transport documents to allow the use of
suitable lifting equipment.
When unpacking, check that all components are present and intact. If items are
missing or damaged, contact the dealer or manufacturer to agree on the
procedures to be followed.
The packaging material must be disposed of appropriately in accordance with the
relevant statutory requirements.
Transport
The pump may be shipped by a variety of means of transport(road, rail,sea or air)
depending on its destination. Secure the packaging firmly to the vehicle during
transport to prevent random movement.
Storage
In the event of a lengthy period out of use, place the pump(in its packaging if
possible or otherwise protected) under cover, protected from the weather.
Do not store in places where the ambient conditions might impair the pump's
operating condition over time.
NSTALLATION INSTRUCTIONS
Safety recommendations forinstallation
Take all possible precautions to allow the pump to be installed in a safe,
risk-free manner.
All installation phases must be taken into consideration when designing the
machinery or plant in which the pump is to be installed.
The design must consider all mounting points, the means of transmission
of the energy sources, and the protective and safety devices required by
the relevant regulations to prevent the risk of injury.
Installation
The mechanical connection between the pump and the motive power
source may be made by means of a pulley and belt, or a flexible coupling,
or through a direct flanged connection to the motive power source.
The crankshaft may turn in either direction.
The water supply connection can be made equally well to the intakes on
the right or left of the pump(see diagram). Only connect the pump to
filtered, clean water sources.
Unscrew the plugs fitted on the various ports in the factory by the
manufacturer, and screw the plugs onto the ports not used, depending on
connection requirements.
Replace the oil plug (A), used for shipment with the breather plug
(B)supplied.
A) Temporary oil plug
B) Oil plug with breather
C) Intake port
D) Delivery port
Mounting the pump
The pump must be installed on a horizontal surface with no flexible
components between it and the mounting surface.
The illustration shows the maximum permitted pump installation angle
beyond which proper lubrication of the crank mechanism is not ensured.
Secure the pump with screws of suitable diameter and length, fixing them
through the holes provided in the pump body.
INSTALLATLON INSTRUCTIONS
General guidelines on water supply connection
The pump's water supply connection can be made in one of the ways listed
below.
Connection to the mains water supply.
Connection to a tank(gravity-feed).
Connection to an external pump(force-feed).
The following requirements must be met for all types of connection.
1) The pump must be supplied by means of a crush-proof hose of suitable
diameter for the pump's intake connection(see "Technical Data").
2) There must be no restrictions or kinks in the hose.
3) A suitable filter must be installed at the pump intake(see "Technical
Data").
4) All connections between the unions and the intake line must be sealed
to prevent the pump from sucking in the air.
5) The connections and pipes must be suitable for the operating pressure
and the pump delivery rate, and must comply with the relevant
regulations.
6) To ensure operating safety install a relief valve(by-pass valve) suitable
for the pump's technical data and with a suitable setting downstream of
the pump.
7) The relief valve dump line must never be connected to the pump intake
line.
8) Install a pressure damper downstream of the pump to minimise the
water hammer effect in the delivery pipeline.
Connection to the mains water supply
The connection must comply with the recommendations provided.
1) The mains water system must have a flow rate twice the pump's rated
delivery rate and a pressure of 2-3 bar.
2) Adopt all the precautions described in the“General Guidelines on Water
Connections" section.
The following is a simplified illustration of the layout for connection of the
pump to the mains water supply.
A) Mains water supply
B) Intake filter
C) High pressure pump
D) Pressure gauge
E) Pressure damper
F) Relief valve (by-pass valve)
G) Dump pipeline
H) Nozzle
I ) Shut-off valve
INSTALLATLON INSTRUCTIONS
Connection to a tank(gravity-feed)
The connection must comply with the recommendations provided.
1) The pump must be installed in a position below the tank intake (with a
positive head).
2) The tank must have baffles to prevent water splashes and its capacity
must be at least 10 times greater than the pump's rated displacement.
3) The vacuum measured directly at the pump intake port must not exceed
0.1 bar and the water temperature must not be above 30℃ .
4) Adopt all the precautions described in the"General Guidelines on Water
Connections" section. The following is a simplified illustration of the
layout for the connection of the pump to a tank.
A) Tank
B) Intake filter
C) High pressure pump
D) Pressure gauge
E) Pressure damper
F) Relief valve(by-pass valve)
G) Dump pipeline
H) Nozzle
I) Shut-off valve
Connection to an auxiliary pump (force-feed)
The connection must comply with the recommendations provided.
1) The auxiliary pump must have a flow rate twice the high
pressure pump's rated delivery rate and an operating pressure of
2-3 bar.
2) Adopt all the precautions described in the“General Guidelines on Water
Connections" section.
The following is a simplified illustration of the layout for connection of the
pump to an auxiliary pump.
A) Tank
B) Intake filter
C) Auxiliary pump
D) High pressure pump
E) Pressure gauge
F) Pressure damper
G) Relief valve (by-pass valve)
H) Dump pipeline
I) Nozzle
J) Shut-off valve
INSTRUCTIONS FOR USE
Safety recommendations for use
Before start-up,the operator must perform the necessary safety
checks.
In the event of leaks from the pressurised pipes,stop the pump at
once and remove the cause of the leak.Do not operate the pump
above the limits set by the manufacturer to increase its performance.
lf the system is to be shut down with ambient temperatures close to
0℃, run the pump without water for 10 seconds with the end of the
delivery pipeline open to empty the system and pump of water and
prevent ice from forming.
Starting and stopping the pump when supplied by the mains water
system
To start the pump,proceed as described below.
1)Open the shut-off valve (I) .
2)Open the by-pass valve (F) to depressurise the delivery pipeline.
3)Start the pump and run it for a few minutes with no pressure.
4)Adjust the by-pass valve (F) to obtain the pump's operating pressure.
To stop the pump,proceed as described below.
1)Open the by-pass valve (F) to discharge the pressure.
2)Stop the pump.
3)Close the shut-off valve (I) .
Starting and stopping the pump when supplied by gravity-feed
To start the pump,proceed as described below.
1)Open the shut-off valve (I) .
2)Open the by-pass valve (F) to depressurise the delivery pipeline.
3)Start the pump and run it for a few minutes with no pressure.
4)Adjust the by-pass valve (F) to obtain the pump's operating pressure.
To stop the pump,proceed as described below.
1)Open the by-pass valve (F) to discharge the pressure.
2)Stop the pump.
3)Close the shut-off valve (I) .
INSTRUCTIONS FOR USE
Starting and stopping the pump when supplied by an auxiliary pump
To start the pump,proceed as described below.
1)Open the shut-off valve (J) .
2)Open the by-pass valve (G) to depressurise the delivery pipeline.
3)Start the auxiliary pump (C) .
4)Start the pump (D) and run it for a few minutes with no pressure.
5)Adjust the by-pass valve (G) to obtain the pump's operating pressure.
To stop the pump,proceed as described
below.
1)Open the by-pass valve (G) to discharge the pressure.
2)Stop the pump (D) .
3)Stop the auxiliary pump (C) .
4)Close the shut-off valve (J) .
MAINTENANCEIN STRUCTIONS
Safety recommendations for maintenance
Before doing any maintenance work, depressurise the water system
and isolate the pump from all energy sources.
When the jobs are done, before restarting the pump, check that no
tools, rags or other materials have been left close to moving parts or
in hazardous zones.
Replace any excessively worn components with original parts and
use the lubricants recommended by the manufacturer.
Dispose of the worn-out components and lubricants in accordance
with the relevant statutory requirements.
Carry out the routine maintenance procedures specifed by the
manufacturer to keep the pump safe and performing well.
Scheduled Service Table
Every working day
Filter
Inspect filter
cartridge
See"Inspecting the flter"
Pump
Oil level check
See"Checking the oil
leve!"
Every 50 working
hours
Connection of pump to
power source
(pulley,belt,coupling)
Inspection
Pump
Inspect
mounting
See"Inspecting thepump
mounting"
Pipes and connections
Inspection
See"Inspecting
theconnections and
pipes"
Pump
Oil change(1)
See"Changing the oil"
Pump
Oil change
See"Changing the oil"
Every 500 working
hours or every
year
Pump gaskets
Replacement
Contact an authorised
service centre
Every 1000
working hours
Valves
Replacement
Contact an authorised
service centre
Filter
Inspect filter
cartridge
See"Inspecting the flter"
(1) This interval refers to the first oil change only
MAINTENANCEIN STRUCTIONS
Table of lubricants
The pump is delivered complete with oil, with the characteristics stated on
the data plate.
When changing the oil, use an oil suitable for the conditions in the
operating environment (see recommendations provided in the annexes
and see"Environmental operating limits").
The correct lubricating oil viscosity depends on the external temperature.
Use the graph to select the degree of viscosity best suited to the
temperatures of use.
MAINTENANCEIN STRUCTIONS
Inspecting the pump mounting
Check that the pump's fixing screws have not become loose.
If necessary, tighten them with the driving torque stated in the installation
design.
Inspecting the connections and pipes
- Inspect the connections forleaks.
Leaks can normally be dealt with by tightening the connections properly.
If leaks from the intake pipeline connections are noticed, the seals must be
repaired.
- Inspect the hoses.
lf the pipes show signs of aging, breakage, swelling, rubbing, etc., they
must be replaced.
Inspecting the Filter
- Inspect the filter cartridge.
If the flter cartridge is fouled or damaged, refer to the filter manufacturer's
instructions for details on how to restore the filter cartridge to its original
filtering condition.
Checking the oil level
- Check the oil with the pump leveland cold.
- Check the amount of oil through the level gauge (A).
- If necessary, top up with oil with the characteristics specifed in
the "Lubricants table".
To top up with oil proceed as described below.
1) Unscrew the plug(B) and pour oil in until it is halfway up the level gauge
(A).
2) Screw on the plug (B).
Changing the oil
Position the machine in which the pump is incorporated perfectly
level, with the pump slightly warm.
Do not release oilinto the environment.
Dispose of spent oilin accordance with statutory requirements.
To change the oil, proceed as described below.
1) Position a receptacle of suitable capacity to collect the spent oil.
2) Unscrew the drain plug (A)and allow all the oil to flow out.
3) Screw on the drain plug( A).
4) Unscrew the filler plug (B).
5) Pour in the fresh oil through the fller hole until the correct
level is reached (see "Checking the oil level").
6) Screw on the fller plug( B).
MAINTENANCEIN STRUCTIONS
Lengthy pump lay-offs
If the pump is to be unused fora long time, proceed as described below.
1) Run the pump with clean water for a few minutes.
2) Operate the pump without water for 10 seconds with the end of the
delivery pipeline open to empty the pump and the delivery circuit and
prevent scaling.
3) Flush the pump with water and solvents authorized by the relevant laws.
4) Dry the pump with a pressurized air jet.
5) Protect the pump from the weather.
Putting the pump back into service
Before putting the pump back into service after a long period out of use,
check the oil level and the tightness of the mounting screws.
Scrapping the pump
The pump must be scrapped by skilled staff, in compliance with the
statutory requirements on occupational safety.
The dismantled components must be sorted by the type of materials from
which they are made. Do not dump pollutants such as seals and lubricants
into the environment.
Dispose of them in accordance with statutory requirements with regard to
waste disposal and recycling.
TRQUBLE SHQOTING
The information provided is intended to provide guidance on how to deal
with malfunctions that may occur during use.
Some of these procedures may be carried out by skilled staff, while others
have to be performed at specialized service centres since they require the
use of specific equipment as well as detailed knowledge of repair
operations.
Problem
Cause
Remedy
Pump does not
reach the
specified pressures
Pump sucking air
Restore the tightness of the
intake line
Intake flow rate insufficient
Increase the size of the intake
pipelines
Remove any kinks from the pipes
Increase the filter capacity or
clean the filter cartridge
Increase the rpm to the rated
speed
Worn intake and delivery valves
Replace the valves (1)
By-pass valve seat worn
Replace the valve
Worn gaskets
Replace the gaskets(1)
Unsuitable, worn nozzle
Replace nozzle
lrregular variations
in pressure
Worn intake and delivery valves
Replace the valves (1)
Valves blocked by dirt
Clean the valves(1)
Air being sucked into system
Restore the tightness of the intake
pipeline connections
Worn gaskets
Replace the gaskets(1)
Vibrations on pipes
Valves jammed
Replace the valves(1)
By-pass valve malfunction
Replace the by-pass valve
By-pass valve dump line too small
Increase size of by-pass valve
dump line
Pressure damper flat
Restore pressure damper to
correct inflation pressure
Pump sucking air
Restore the tightness of the
intake line
Pressure drop
Nozzle worn
Replace nozzle
Worn intake and/or delivery valves
Replace the valves(1)
Valves blocked by dirt
Clean the valves(1)
By-pass valve seat worn
Replace the valve
Worn gaskets
Replace the gaskets (1)
(1) Operations that must be carried out at an authorized service centre
TRQUBLE SHQOTING
Problem
Cause
Remedy
Pump noisy
Air being sucked into
system
Restore the tightness of the
intake pipeline connections
Intake and/or delivery
valve springs broken
or collapsed
Replace the valves(1)
Valves blocked by dirt
Clean the valves(1)
Worn bearings
Replace the bearings(1)
Intake liquid
temperature too high
Reduce liquid temperature
Pump overheating
High pump operating
pressure
Reduce the pressure to the
rated values
Drive belts too taut
Restore correct belt tension
Pulley or drive
coupling
alignment poor
Restore the correct
alignment
Water in oil
Guide piston gaskets
worn
Replace the gaskets(1)
High humidity
percentage in air
Change the oil twice as often
(than stated in"Routine
Maintenance"table)
Worn gaskets
Replace the gaskets(1)
Oil leaks from dump lines
underneath the pump
Worn gaskets
Replace the gaskets(1)
Worn pistons
Replace the pistons(1)
Oil leaks from dump lines
underneath the pump
Guide piston gaskets
worn
Replace the gaskets(1)
(1)Operations that must be carried out at an authorized service centre
*There are any minor changes to the numbers included in the user
manual without prior notice.
Manufacturer: ZHEJIANG KUHONG MACHINERY
TECHNOLOGYCO.,Ltd
Address：Building 1,No.1958,Haifeng Road,JijuDistrict,Taizhou
City,Zhejiang Province,China
Made In China
