5.0HP High Pressure Diesel Pump

Transcription

1 Instruction Manual 5.0HP High Pressure Diesel Pump Model: YW50DHP WARNING! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. 1011

2 TABLE OF CONTENTS WARRANTY 2 INTRODUCTION.. 3 SPECIFICATIONS. 3 KNOW YOUR PRODUCT. 4 PACK CONTENTS. 7 DESCRIPTION OF SYMBOLS 7 GENERAL SAFETY INSTRUCTIONS. 8 ADDITIONAL SAFETY INSTRUCTIONS FOR PUMPS. 9 SET-UP & INSTALLATION OPERATION 12 MAINTENANCE 16 SPARE PARTS 18 TROUBLESHOOTING 19 1

3 WARRANTY YARDWORKS TWO YEARS LIMITED WARRANTY Your YARDWORKS product is covered for a period of 2 years from the ORIGINAL date of purchase and is intended for home use only. The warranty covers faulty parts or workmanship. The warranty is only made available by returning the product to your point of purchase with a confirmed cash register receipt. SHOULD YOU HAVE ANY QUESTIONS PRIOR TO RETURNING YOUR PRODUCT FOR WARRANTY OR REPAIR PLEASE TELEPHONE OUR CUSTOMER SERVICE HELPLINE: Australia New Zealand TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER AND DATE OF PURCHASE AVAILABLE. A CUSTOMER SERVICE REPRESENTATIVE WILL TAKE YOUR CALL AND ANSWER ANY QUESTIONS YOU MAY HAVE RELATING TO THE WARRANTY POLICY OR PROCEDURE. Yardworks Letcon Drive Bangholme, Victoria, Australia 2

4 INTRODUCTION Congratulations on purchasing the YARDWORKS 5.0HP Diesel High Pressure Water Pump. We aim to provide quality products at an affordable price. Before using, it is most important that you read and follow the instructions in this manual, even if you feel you are quite familiar with this type of product. This product has been designed for numerous water transfer applications. These include draining flooded laundries, bathrooms, basements or garages, emptying rainwater tanks, pools and spas, emptying garden ponds and transferring water for both domestic and agricultural irrigation. Motor Power: 5.0HP Engine Type: 4 Stroke, air-cooled Fuel Type: Diesel Fuel Tank Capacity: 3.5 Litres Engine Capacity: 296cc Engine Speed: 3600rpm Engine Oil Type: SAE 10W - 30 (Diesel Oil) Oil Tank Capacity: 1.1 Litre Max. Head: 55m Max. Lift: 6m Max. Flow Rate: 17,000 litres/hour Suction Inlet Size: 40mm (1 1 /2") Discharge Outlet Size: 2 x 25.4mm (1"), 1 x 40mm (1 1 /2") Weight: 50kg Height/head (m) SPECIFICATIONS ,000 6,000 9,000 12,000 15,000 18,000 21,000 24,000 Performance Curve 3 Flow Rate (l/hr)

5 KNOW YOUR PRODUCT 1. Priming Cap 2. Discharge Outlets 3. Suction Inlet 4. Pump Housing 5. Oil Fill Plug 6. Lockable Throttle Knob 7. Recoil Starter 8. Fuel Pipe 9. Fuel Tap 10. Fuel Cap WARNING! THIS PRODUCT IS NOT SUITABLE FOR USE WITH DRINKING(POTABLE) WATER. 4

6 11. Motor Housing 12. Air Filter 13. Exhaust 14. Decompression Lever KNOW YOUR PRODUCT (cont.)

7 KNOW YOUR PRODUCT (cont.) m Suction Hose x 25.4mm (1 ) Outlet Caps x 25.4mm (1 ) Collars x 25.4mm (1 ) Hose Adaptors x 25.4mm (1 ) Hose Clamps x 25.4mm (1 ) O-rings x 40mm (1 1 /2") Inlet/Outlet Cap x 40mm (1 1 /2") Collars x 40mm (1 1 /2") Hose Adaptors x 40mm (1 1 /2") Hose Clamps x 40mm (1 1 /2") O-rings x Filter x Double Open Spanner (10mm & 12mm) x Double Open Spanner (14mm & 17mm) x Screwdriver

8 PACKED CONTENTS Contents Included 1 x 5.0HP Diesel High Pressure Water Pump 1 x 5M suction hose 2 x 25.4mm (1 ) Outlet Caps 2 x 25.4mm (1 ) Collars 2 x 25.4mm (1 ) Hose Adaptors 3 x 25.4mm (1 ) Hose Clamps 4 x 25.4mm (1 ) O-rings 1 x 40mm (1 1 /2") Inlet/Outlet Cap 2 x 40mm (1 1 /2") Collars 2 x 40mm (1 1 /2") Hose Adaptors 3 x 40mm (1 1 /2") Hose Clamps 3 x 40mm (1 1 /2") O-rings 1 x Filter 1 x Double Open Spanner (10mm & 12mm) 1 x Double Open Spanner (14mm & 17mm) 1 x Screwdriver 1 x Instruction Manual DESCRIPTION OF SYMBOLS Hp Horse power Hz Hertz ~ Alternating current W Watts /min Revolutions or no No load speed reciprocation per minute l Litres kw kilowatt p/hr Per hour kpa Pressure rating (kilopascals) bar Pressure rating F Insulation class PVC Polyvinyl chloride IPX8 Ingress protection from water Regulator compliance mark Warning Read instruction manual 7

9 GENERAL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 1) WORK AREA a) Do not operate pump in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Engine may create sparks which may ignite the dust or fumes. b) Never run engine in an enclosed area. Exhaust gases contain deadly, poisonous carbon monoxide, which has no odor or taste. Exposure may cause loss of consciousness and may lead to death. c) Keep by-standers, children and visitors away while installing pump. Distractions can result in mistakes. d) Keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place flammable objects close to the engine. Procedure should be followed to prevent fire hazards and to provide adequate ventilation. 2) PERSONAL SAFETY a) Stay alert, watch what you are doing and use common sense when operating this pump. Do not attempt to use pump while tired or under the influence of drugs, alcohol or medications. A moment of inattention while operating power tools may result in serious personal injury. b) Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts. c) Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the pump in unexpected situations. d) Use safety equipment. Always wear eye protection. Dust mask, non-skid safety shoes and hard hat must be used for appropriate conditions. 3) PUMP USE AND CARE a) Store idle pump out of reach of children and other untrained persons. Pumps are dangerous in the hands of untrained users. b) Maintain pump. Keep hoses in proper operating condition. Properly maintained pumps are less likely to malfunction and cause injury. c) Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the pumps operation. If damaged, have the pump serviced before using. Accidents can be caused by poorly maintained pumps. d) Always shut off the engine, allow the engine to cool before performing any maintenance. Such preventative measures reduce the risk of starting the pump accidentally. e) Keep handles dry and clean; free from oil and grease. Allows for better control of the pump. 4) SERVICE a) Pump service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified repair personnel could result in injury. b) When servicing a pump, use only identical replacement parts. Follow instructions in the Maintenance Section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury and may void your warranty. 8

10 ADDITIONAL SAFETY INSTRUCTIONS FOR DIESEL PUMPS 1) Never refuel while engine is running or hot. Fuel spilled on a hot engine could result in a fire or explosion. 2) Use caution when handling diesel fuel. Refuel in well-ventilated area. Do not overfill fuel tank and do not spill fuel. Make sure tank cap is closed properly. Diesel fuel is extremely flammable and is explosive under certain conditions. 3) Never run the engine in an enclosed or confined area. Exhaust contains poisonous carbon monoxide gas; exposure may cause loss of consciousness and may lead to death. 4) Do not use to pump flammable or explosive liquids such as gasoline, fuel oil, kerosene, solvents or thinners. Pump should only be used with liquids compatible with pump component materials. Failure to follow to this warning can result in serious personal injury, death and/or property damage. 5) Pump must be located on a solid level surface. Pump could tip or fall causing serious injury. 6) Do not hold or suspend pump by means of a discharge pipe. Pipe could break or come loose. 7) Be careful not to touch the muffler while it is hot. To avoid severe burns or fire hazards, let the engine cool before transporting or storing it indoors. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Exhaust may contain chemicals that may cause cancer or reproductive harm. This appliance is not intended for use by people (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. Ensure the water pump is not running during the assembly process. Do not install or operate the water pump in an explosive environment or near flammable material. Do not operate the water pump without liquid. Do not run the water pump dry. WARNING! The water pump together with associated pipework operate under pressure. Do not disconnect water pump or pipework until internal pressure has been released. Failure to do this could result in personal injury and damage to property. WARNING! The muffler becomes very hot during operation and remains hot for a period of time after stopping the engine. Be careful not to touch the muffler or exhaust while it is hot. To avoid severe burns or fire hazards, let the engine cool before transporting or storing. WARNING! Do not use any other fuel other than diesel, doing so will result in damage to the motor. 9

11 SET-UP & INSTALLATION Positioning The Pump 1. Place the pump close to the water that is required to be pumped (Fig. 1). Note: Ensure the pump is no further than 5m away from the water's edge. 2. Fill the engine crank case with oil (not included). Note: SAE 10W-30 Diesel Oil (ONLY) is recommended, refer to the maintenance section for more information Fig. 1 Suction Inlet Connecting Hose or Pipe to the Suction Inlet Note: Keep all hoses short and as straight as possible, failure to do so may decrease the pressure pumps performance. Note: It is recommended that a filter (26) and check valve (not included) is installed at the end of the suction hose or pipe. This can prevent long priming periods and unnecessary damage to the pump as a result of stones and solid foreign materials entering. Note: Reinforced or ridge suction hoses are required on the suction line to prevent the pipe from collapsing due to pressure from suction. Caution: All connections must be air tight, failure to do so may result in an air leak which can prevent the pump from priming. It is recommended that a thread sealant (not included) and/or Teflon tape (not included) is used on threads to ensure a water tight seal and prevent any leakage. 1. Assemble the 40mm (1 1 /2") hose clamp (24) and filter (26) to the intake side of Fig. 2 the suction hose (Fig. 2). 2. Tighten the 40mm (1 1 /2") hose clamp (24) tightly ensuring it clamps the hose against the filter (26) (Fig. 2). 3. Assemble the 40mm (1 1 /2") hose adaptor (23) by inserting into the 40mm (1 1 /2") collar (Fig. 3). Note: Ensure the 40mm (1 1 /2") o-ring (25) is fitted into the 40mm (1 1 /2") collar, failure to do so may result in an air leak. Fig Assemble the 40mm (1 1 /2") hose clamp (24) and the assembled inlet adaptor to the outlet side of the suction hose (Fig. 4). Fig. 4 10

12 SET-UP & INSTALLATION (cont.) 5. Add thread sealant (not included) and/or Teflon tape (not included) on to the suction inlet (3). 6. Align and screw the collar of the assembled inlet adaptor onto the thread on the suction inlet (3) port of the pump (Fig. 5). Note: Ensure the collar is tightly fastened onto the suction inlet; failure to do so may result in an air leak. Fig. 5 Discharge Outlet Connecting Hose or Pipe to the Discharge outlet Note: Keep all hoses short and as straight as possible, failure to do so may decrease the pressure pumps performance. Caution: All connections require being air tight, failure to do so could result in an air leak which can prevent the pump from priming. It is recommended that a thread sealant (not included) and/or Teflon tape (not included) is applied to threads to ensure a water tight seal and prevent any leakage. 1. Assemble the 25.4mm (1") hose adaptor (18) by inserting into the 25.4mm (1") collar (17) as shown in (Fig. 6). Note: Ensure the 25.4mm (1") o-ring (20) is fitted into the 25.4mm (1") collar (17), failure to do so may result in an air leak. Fig Determine which discharge outlet (2) port will be used. Screw the outlet caps (16) onto 2 of the 3 discharge outlet (2) that are not going to be used. Note: Multiple outlets can be used to pump water simultaneously but this will result in lower pressure and flow rate. Note: If the unused discharge outlets are not blocked off this will result in water expelling out of the discharge outlet (2). 3. Add thread sealant (not included) and/or Teflon tape (not included) on to the discharge outlet (2). Fig Align and screw the collar of the assembled inlet adaptor onto the thread on the discharge outlet (2) port of the pump (Fig. 7). Note: Ensure the collar is tightly fastened onto the discharge outlet (2); failure to do so may result in an air leak. 11

13 SET-UP & INSTALLATION (cont.) Priming Priming the pump prepares the motor for safe operation. Caution: Do not run the pump dry, this may result damage to the pump. 1. Unscrew the priming cap (1) by turning anti-clockwise. Using a hose, fill the pump by pouring water into the priming plug hole (Fig. 8). 2. Ensure the pump and suction line are full. 3. Replace the priming cap (1) and ensure it is secure. 4. Fully open any shut off mechanisms (eg: spray nozzle, valves etc.) in the input and output hose or pipe so that the air can escape without obstruction. Fig. 8 OPERATION Pre Operation Inspections Environment Conditions The operation of a four-stroke diesel engine is affected by: 1. Temperature a. Working in low temperatures could lead to difficult cold starting. b. Working in very high temperatures could lead to difficult hot starting due to evaporation of the fuel. c. The correct oil must be used according to the operating temperatures. 2. Altitude a. The higher the altitude (above sea level), the lower the pressure and flow rate will be. b. When there is a considerable increase in altitude, the load on the machine should be reduced and heavy work load avoided. 12

14 OPERATION (cont.) Fuel inspection WARNING! Be sure to stop the engine before re-fueling. WARNING! Do not over fill the fuel tank. WARNING! Do not smoke while re-fueling. Good quality fuel is a major factor for engine reliability. 1. Only use high quality diesel. 2. Use clean, fresh fuel; purchase fuel in quantities that can be used every 30 days, to prevent gum or foaming inside the container and/or fuel tank. 3. Do not add oil or any kind of fuel additive. Engine oil inspection 1. The high pressure pump is shipped without oil. Before starting ensure an oil inspection is conducted. Always use high quality oils, select their viscosity grade according to the operating temperatures. Note: It is recommended that SAE-10W-30 (diesel oil only) oils are used at temperatures from 5 to 35ºC and synthetic oils 5W-30 (diesel oil only) is used for temperatures -5 to 5ºC. 2. To change or top up the oil in the engine refer to the maintenance section of this instruction manual. Air Filter The air filter must always be in perfect working order, to prevent debris and dust from being sucked into the engine and reducing the efficiency and life of the machine. 1 Always keep the air filter free of debris and in perfect working order. 2. If necessary, replace the filter with an original spare part. An incompatible filter can impair the efficiency and life of the engine. 3. Never start the engine without the filter assembled. 4. To change the air filter refer to the maintenance section of this instruction manual. 13

15 OPERATION (cont.) Starting the Engine WARNING! Before starting please ensure all inspections stated above have been made. WARNING! Exhaust gas contains poisonous carbon monoxide. Never use the machine in poorly ventilated locations. Doing so may result in carbon monoxide poisoning. WARNING! Do not touch muffler and muffler cover while the machine is running or hot. 14

16 OPERATION (cont.) Note: The decompression lever (14) will automatically reset. Note: If motor does not start repeat steps 4 to 6, if the motor still fails to start refer to the trouble shooting section of the manual (page 18). 7. Once the motor has started move the lockable throttle knob (6) to the center throttle position (in the middle of the STOP and START position (Fig. 9) and let the engine idle no load for 3 minutes. 8. The lockable throttle knob (6) can now be adjusted to obtain the desired pressure at the discharge outlet (2). Adjusting the Throttle The throttle is used to regulate the RPM of the engine, which also controls the water flow out of the discharge outlet (2). 1. To increase the speed of the engine and water flow, loosen the lockable throttle knob (6) and push down to the START position and re-tighten the lockable throttle knob (6) (Fig. 10). 2. To decrease the speed of the engine and water flow, loosen the lockable throttle knob (6) and move the throttle up to the STOP position and re-tighten the lockable throttle knob (6). Fig. 9 Fig. 10 Stopping the Engine 1. Decrease the speed of the engine and water flow by moving the throttle up towards the STOP position and allow idling for 2 minutes. 2. Then move the throttle to the STOP position and rotate the fuel tap (9) to the anti-clockwise closed/shut "S" position (Fig. 11). Fig. 11 Caution: Suddenly stopping the engine will cause an abnormal increase of temperature which could result in damage to the engine. 15

17 MAINTENANCE Storing the Pump Before storing the pump, it is recommended to empty the pump body of any water. Turn the drain screw (a) anti-clockwise with the 14mm spanner (28) and remove from the pump body. This will drain any excess water. Replace the drain screw (a) (Fig. 12). a Fig. 12 Changing the Oil Note: After the first 20 hours of use the engine oil needs to be replaced, and then every 100 hours after that. The high pressure pump is shipped without oil. Before starting ensure an oil inspection is conducted. Always use high quality oils, choosing their viscosity grade according to the operating temperatures. Note: It is recommended that SAE-10W-30 (diesel fuel only) oils are used at temperatures from 5 to 35ºC and synthetic oils 5W-30 (diesel fuel only) is used for temperatures -5 to 5ºC. 1. Place the high pressure pump on a level surface. 2. Clean around the oil fillers. Fig Remove the oil cap fill plug (5) from either the left or right side of the engine (Fig. 13) and clean the dip stick and re-insert without screwing down. 4. Remove the dipstick and ensure the oil lays between the min and max marks (Fig. 14). 5. Fill the engine with SAE 10W-30 oil up to the max level of the oil gauge. Note: Ensure the engine is not over filled with oil. 6. Re-tighten both the left and right oil fill plug (5). min max Fig. 14 Replacing the Air Filter 1. Remove the cover by unscrewing and removing the wingnut (g), washer (h) and cover (i) (Fig. 15). 2. Remove and inspect the filter (j). It must be intact and clean. If not either clean or replace the filter. 3. Replace the filter (j), filter cover (i), washer (h) and wingnut (g). Fig

18 MAINTENANCE (cont.) Cleaning the Pump Body Use a moist cloth to wipe down the pump housing (4). Allow to dry thoroughly before storing in a dry location that is protected from bad weather conditions. If the pump is not going to be used for a long period of time, it is advisable to rinse with water. Ensure the pump is completely dry before storing. Checking the Bolts Regularly check all the bolts on the diesel engine and pump body to ensure all bolts are adequately tightened. Purging the Fuel System of Air In some cases air may develop in the fuel lines restricting the fuel from entering the injector. To bleed air from the fuel system follow the below instructions. Caution: Ensure the throttle is in the off position before purging the fuel system of air. 1. Remove the fuel injection pipe using a 17mm open ended spanner by rotating Fig. 16 the nut in an anti-clock wise direction (towards the exhaust) and pulling out the pipe from the injector (Fig. 16). 2. Open the fuel tap (9) by rotating in a clock wise direction to the O position (Fig. 17). 3. Press the decompression lever (14) down. 4. Firmly grasp the recoil starter (7) handle and pull slowly until the compression position has been reached and then let the handle return to the original position. 5. Repeat steps 3 and 4 above until a steady stream flows from the fuel pipe. 6. Refit the fuel pipe into the injector and re-tighten the nut to secure the pipe into the injector. Fig

19 MAINTENANCE (cont.) Recommended Check & Maintenance Chart Item Time Every operation / daily After 20 hours or 1 month Inspect and tighten all nuts and bolts After 100 hours or 3 months After 300 hours or 6 months After 1000 hours or yearly Engine Oil Oil Filer Air Filter Fuel Tank Fuel Filter Nozzle Injection pump Fuel lines (top up if required and check for leaks) (only required after first 20 hours / 1 month of use) (Frequency depends on pump location. i.e. High dust environment every 10 Hrs) (change if neccesary) Adjust inlet and exhaust valves Grind inlet and exhaust valve holders Change piston rings Check accumulator fluid Check Change Clean (required after first 20 hours / 1 month of use) * To be performed by qualified service centre * * SPARE PARTS Limited spare parts are available subject to availability. Please contact your local Bunnings Special Orders Desk to order the required spare parts. Most common spare parts listed below Spare Part Part No. Air Filter SPYW50DHP-0708 Fuel Tank Filter SPYW50DHP-1022 Fuel Tank Cap SPYW50DHP-1023 Recoil Starter SPYW50DHP

20 TROUBLE SHOOTING Symptom Possible Cause Corrective Action Unit runs but delivers little or no water Leak in suction hose or piping Clogged suction strainer Water level below pump intake Pump not primed Water level more than maximum lift of 6m Tighten suction hoses and use thread sealer. Clear debris from suction strainer Lower suction hose into water Turn engine off & fill the pump housing with water Move pump closer to water level and increase discharge line length if necessary Unit will not start No fuel Fill engine fuel tank. Refer to engine operating instructions Unit starts but runs and performs poorly Oil level too low Air-filter clogged Temperature to hot or cold for the oil being used Air Filter clogged Engine or carburetor difficulties Fill with correct oil per operating instructions Check, clean or replace filter as required Refer to the maintenance section for the correct oil to be used and replace if required Check, clean or replace filter as required Contact YARDWORKS customer service 19