DX-ZB2 Single cylinder reciprocating mode

hydraulic jet instruction manual

Beijing Dongxing jet Machinery Co., Ltd.

Beijing Lier High-Temperature Materials Co., Ltd.

1
 Content

I、 Overview …………………………………………………………1

II、 Device structure…………………………………………………1

1. Stirring structure …………………………………………1

2. Pumping structure ………………………………………2

3. Hydraulic structure ………………………………………2

4. Electrical structure…………………………………………2

III、 Device operation…………………………………………………5

1. Before starting preparation ………………………………5

2. Spray operation method …………………………………6

3. Cleaning device……………………………………………7

IV、 Fixing breakdown method（Appendix1）…………………8

V、 Normal injury detail explanation table（Appendix2）

VI、 Enclosed drawing

Hydraulic pressure system working theory

Electrical distribution cabinet panel layout drawing

Main circuit theory drawing

Device appearance drawing

2
 I. Overview
DX-ZB2 is single cylinder piston reciprocating medium package
jet machine，working principle of this machine：dry materials（1 ton
package）was passed the hopper to materials stirring system, defined
amount of water was added to become mixing mud then go into pumping
body，go through the pumping pipe to pumping gun，with repairing
middle package working line. Table 1 show the properties parameter of
DX-ZB2 middle package jet machine:

Highest Material Conveying Hopper

loading Motor power
pumping spray- distance（m）
Items pressure out rate capacity
Level Hydraulic Mixing
Vertical motor
（Mpa） （t/h） Horizontal （t） motor

Parameter 3 1.5-3 80 30 1.5 5.5 4.5

II. Device structure

Device includes of: hopper,stirring equipment, pumping device,
hydraulic system, electrical control system and conveying pipe, spraying
gun...
1.Stirring structure

Material was put into hooper, hopper and stirring device connect
together. Hopper and stirring are separated by butterfly valve. When
troubles happen with stirring device or maintenance, the butterfly valve
should be closed,then the stirring device will be withdrawn to repair.
Motor speed of stirring machine is 4KW/1440r.p.n be compared with 13
cycloidal gear reducer transmission. The water from water spraying pipe
on the stirring tank was mixed with defined materials by movement of
stirring vane to become mud form, that is flown into pumping body
through small hopper.

1
Starting and stopping of mixing device was controlled by pumping speed.
Spraying water pipe, magnetic valve and mixing machine on/off stage
are linked.
2. Pumping structure

Pumping structure includes of pump body, material transmitted

cylinder and hydraulic ram. There is a up/down ball inside the pump, the
material flow is controlled by movement of piston. Pumping body include
of 03 parts, which is connected by the bracing rod on both sides and is
fastened with a conical wedge,such is easy to take apart for maintenance.
Top of pump body is cabinet, when material is pressed into the cabinet,
gas inside cabinet will be compressed, which reduce intermittence of the
pump that make the pulsation of material inside pipeline。Pump cylinder
is inserted stiffness alloy layer with high wear resistance. There is a
cooling system on the cylinder, that cooling and cleaning the inner wall
of cylinder and piston, ensure pump can work normally.

3.Hydraulic system
Hydraulic system includes of electrical machine, oil pump, reversing
electromagnetic oil cylinder valve,electromagnetic overflow valve, speed
controlling valve, oil return filter, air, filter and water cooler.
Two ends of oil cylinder are equipped with sensors, when oil
cylinder moves to sensor positions, signal will be emitted to control the
cylinder change direction automatically. Movement speed of oil cylinder
is adjusted by the speed adjustable valve to achieve production process
requirements.
Oil pressure of hydraulic system can be adjusted according to
process requirements. When the oil pressure exceeds the set pressure,
system will automatically decompress to protect device working safely.
When the device open but hydraulic pressure cylinder stop,
electromagnetic overflow valve will active the unload stage. 。

4.Electric system

（1）Device overview

Electrical control device mainly include of operation of oil pump,

stirring machine, water valve and automatically
2
reciprocating cylinder and start control and operation of these four parts.

（2）Operation order of on/off device control

Operator need to follow the starting order of: oil pump-stirring
machine-water valve- oil cylinder and reverse stopping order.。If the oil
pump is started first, the oil cylinder starting operation is not valid. If the
oil cylinder is stopped first, the stop operation of the oil pump is invalid.

(3)Operation of oil pump and stirring machine

（3.1）When oil pump and stirring machine is in stop stage, "green
light on", in running stage, "red light on"
（3.2）At the stopping stage, press "Green start buttom" device
will start running, "red light on"
(3.3) At the running stage, press "Red stop buttom", device will
stop, "Green light on"
（3.4）The ac meter on the panel shows the running current of the oil
pump motor, at normal condition, the current of oil pump should be
lower than 12A, otherwise need to investigate intime.
(4)Water valve controlling operation.
（4.1）Water valve and stirring linkage control

Before starting stirring machine, if the water valve switch is at

"open" position, when start stirring machine, water valve will open
automatically, when stop stirring machine, water valve will stop
automatically.
（4.2）Water valve switch (on/off) controlling
Starting stirring machine first, then turn the water valve switch, control
water vale on/off

（5）Oil cylinder control operation

（5.1）Automatically reciprocating operation of oil cylinder

3
 （5.1-1）Press the "Green light starting button" of cylinder, the
"red forward or backward indicator light" on, when go to forward
or backward limited position, the "yellow forward or backward
indicator light" on, oil cylinder automatically reverse the
direction, operate in cycle.
（5.1-2）Press the "Red light stopping button" of cylinder, the "red

forward or backward indicator light" off, not same as the randomly

stop position, the "yellow forward or backward indicator light"
sometimes on/off.
（5.2）Oil cylinder inching operation

Inspection, adjustment, and breakdown maintenance should

be carried out before starting:
（5.2-1）Before "Yellow forward limited position indicator light"
of oil cylinder turn on, need to press "Blue light backward inching
button", when cylinder is backward, "Red backward indicator
light" on. When loosing "Blue light backward inching button", oil
cylinder stop automatically, "Red backward indicator light" off.
（5.2-2）In opposite, before "Yellow backward limited indicator
light" of cylinder turns on, need to press "Blue forward inching
button". When the cylinder is forward, "Red forward indicator
light" on. When loosing "Blue forward inching button", the cylinder
stop automatically, "Red forward indicator light" off.

（5.2-3）If both of "Yellow limited position indicator light" turn

off, can randomly choose forward or backward inching operation.
（5.2-4）In the inching progress, if keep pressing the "Blue light
inching button", cylinder will continuously operate, it will be
stopped automatically until reaching the limited position. It is
needed to loose the "Blue inching button" in this time.

4
（6）Safety precautions of electrical device
(6.1) When the device is operating, if there is any emergency trouble
happen that is needed to stop immediately, press "Emergency stop
button", the electrical control of total air switch turns off, device will be
stopped. After fixing the trouble, restore the "Emergency stop button"
first, then switch on the total air switch, if not, the air switch won't
operate.

（6.2）All the electrical equipments are not allowed to take along,

before maintenance checking the device, it must be isolated the primary
power source, and hang the "Don't switch on" tag.
（6.3）Regularly clean the device based on the actual situation, because
electrical control panel internal must be ventilated to cool the "DC
electrical source". If the dust is too much, it is easy to overheat, short
circuit will happen. Too much of dust amount will affect to the device
lifetimes.

（6.4）The indicator light appearance of the electrical control cabinet is

same but the voltage is different, in replacing procedure, it is needed to
refer the provided drawing and materials (documents).

III、 Device operation

1. The works before starting machine

(1)When place the device on the ground, ensure its stabilization.

(2)Check the oil level of hydraulic pressure tank, if the level of oil is
lower than lower critical point, it is needed to supplement, ensure
the oil level is more than 2/3 tank height.

(3)Regarding cleaning the material hopper, it should not have iron

type of sundries inside hopper.

(4)Check the water system to ensure the water flow of the hydraulic
station and mixing equipment.
Checkthepowersupplyvoltageiswithin380V±5%ornot.

5
 （6) Switch on the motor, observe whether the motor is working normally
and check whether the motor movement is correct by the oil pressure meter
ofhydraulicpressurestation.

(7) If the temperature is low, free running time should be longer start
pumpingnormallywhenoiltemperaturereaches15ºC.

(8）Pressure of cooling water should not lower than 4Mpa, its

temperature should not higher than 30ºC。Device should be stopped
when the temperature of hydraulic pressure oil higher than 70ºC.

（9）Don't adjust the hydraulic pressure system casually.

2. Spraying operation method

(1)Starting
（1.1）Open hopper discharge butterfly valve
（1.2）Open hopper pneumatic oscillator
（1.3）Open mixing system motor (open mixing system motor and
electromagnetic valve at the same time)
（1.4）Openthereciprocationpumpafterhopperstore1/3mud
materials.
（1.5）Takes the Jet gun place and open the compression air valve.
（1.6）Start spraying when the material was discharged

（2）Stoping

（2.1）Close the hopper oscillator.

（2.2）Close hopper butterfly valve.
（2.3）Observe the material output status from mixing system,
when the output material flow become thin, close the mixing system
motor. (water electromagnetic valve close automatically)

6
 （2.4）Close reciprocating pump when the nozzle is not normally
discharging
（3）Adjustment

（3.1）By adjusting the air pressure intensity of oscillator, the taken

down amount of other materials bin and mixing system will be
matched.
（3.2）Adjust the water flow by the water amount in material.
(Don't adjust after matching material and water)
（3.3）Adjust the air pressure of spray gun to achieve best spraying
effect
（3.4）Adjust speed control valve and shutoff valve of hydraulic
pressure system, using output material amount and oil cylinder
pressure to reach the spraying requirement.

3. Device cleaning

(1) Close butterfly valve of hopper

(2) Open the barrier of motor connected of mixing cabinet, pack

the material in the bag.
(3) Remove the stirring tank, and stirring shaft, clean second part
of material tank, open the hydraulic pressure station, start the
oil cylinder means piston rod go to front end.
（4）Remove the oblique wedge from the pump body, take down
pump body, clean pump body and other parts by water.
（5）Pump body parts, spraying tube and spraying gun must be
clean thoroughly. Don't leave any hardened materials inside, if there
is any hardened material was left inside, the tube will be jammed in
next time.

7
IV、Troubleshootingmethod（Appendix1）
Trouble Reason
Wrong rotation direction
No pressure in the Improper adjustment of
hydraulic system overflow valve
Not enough oil in oil tank,
pipe leakage
The oil cylinder end
Oil cylinder not sensor is damaged or
move to the end excessive
points
Ball valve of pump body
Not smoothly is stuck
discharge
Pipe is stuck
Hydraulic system
Low outlet pressure is low
pressure Cylinder piston is
damaged
Electrical control plug of
hydraulic valve is loose.
System doesn't Terminal cable of electrical
work normally cabinet is loose
The pump performance of
the material is poor
Water outlet is stuck
Mixing device is
abnormal Electromagnetic water
supply valve failured
Shooting method
Adjust connection line
Turn knob clockwise, increase pressure
Check oil level in oil tank, check pipe
for leakage points
Check the sensor damage
Distance between speed sensor and
emit signal ring is within 1-2mm
Take apart the pump body, clean ball
valve seat
Clean pipe (input/output material pipe)
Adjust the overflow of hydraulic
pressure station, increase pressure
Change the cylinder piston sealing ring
Fastening checking
Fastening checking
Adjust the material proportion, increase
pumping performance
Take apart the water spit, checking for
stuck material
Checking whether the electromagnetic
valve plug is loose
Change electromagnetic valve if it is
broken-down
8
 1250

16 20

Large hopper
3000

Butterfly valve

Dry material Auger motor

Stirring device conveying device
4Kw 1440R, P,M

Oil pumping motor

Pressure meter 5 5 Kw 1440R,P, M
Hydraulic
pressure cylinder Manifold block Hydraulic pressure station
Store tank

Small hopper

9 00
Pump body Cylinder direction Water cooling
change sensor machine
Material Conveying
Cylinder

2100

Design 2016 9 29 DX-ZB3 0Hydraulic pressure D r a w

No. LGB - 00
Drawing jet machine appearance
Checking drawing 共 张 Material Weight Peice No. Scale
Approve 北 京 东 兴 喷 射 第 张
Tracing
机 械 有 限 公 司 Device name
Proofing
 No. Name Installation position Spec / Model Remarks
1 Ball valve seat Pump body ZB3 0-1 Self-control part
2 Steel ball Valve seat 63 Standard part
3 Piston set Material piston cylinder ZB3 0-2 Self-control part
4 Forward piston sealing ring Material piston cylinder ZB3 0-3 Self-control part
5 Backward piston sealing rin Material piston cylinder Standard part
6 Bearing seat Auger tank front cover TY390208 Standard part
Pressure meter Hydraulic pressure station/ Standard part
7 store tank
M14 1 5
8 Limited tank Convey material auger tank ZB3 0-4 Self-control part
9 Membrane piece Pressure meter holder ZB3 0-5 Self-control part

10 O shape sealing ring Valve seat under part face 外 110 3 5 Standard part

11 O shape sealing ring Above/below pump body flange 外 135 5 7 Standard part
12 O shape sealing ring Oil cylinder connect part 外 20 3 1 Standard part
13 O shape sealing ring Pressure meter ending face 外 15 2 4 Standard part
14 O shape sealing ring Limited tank sealing 外 250 5 7 Standard part
15 O shape sealing ring Limited tank sealing 外 280 3 5 Standard part
Electromagnetic direction
16 O shape sealing ring changing valve ending face 外 12 2 0 Standard part
17 O shape sealing ring Manhole cover ending face 外 310 5 7 Standard part

18 O shape sealing ring Small hopper below flange 外 120 5 7 Standard part

Design
Draw No
Prepared by 王 晓 彬 2016 10 Easy damaged parts list
Check 共 张 Material Weight Piece No Scale
Approve 第 张
北 京 东 兴 喷 射
Tracing DX-ZB3 0hydraulic
机 械 有 限 公 司 Device name pressure jet machine
Proof
 8

7
9

Technical parameter

T1 T2
6 1 Pressure system： 3Mpa
2 System flow： 70L／min．

5
10
13 Y1 3 2 S- 4 (I MB 5) Motor（ 5 5Kw/1440r p m) 1 Installation type B 5 Bejiing Motor factory
12 25VQ-17 Oil pump 1 54ml/r 威 克 斯
4
11 11 KF-L8/14E Pressure meter switch 1 黎 明 液 压
10 L H G M 1 4 × 1 5 Shockproof pressure meter 1 Meter plate diameter 7 5 黎 明 液 压
9 Oil cylinder 1 80 45/270 非 标 定 制
3 T5 8 KGG12P3KP24V200Sn2CZL55 Position sensor 2 台湾明伟公司
12
Electromagnetic direction
7 4 W E 1 0 E 3 1 / C G 2 4 N 9 Z 5 L changing valve 1 北 液 华 德
6 2 F R M 1 0 - 2 0 / 5 0 Speed control valve 1 Max flow speed 5 0 L / m i n 北 液 华 德
2 Pilot-operated Pressure
13 5 DBW10B-1-50/200AG24NZ5L Relief Valve 1 Normal open 北 液 华 德
4 RF-160 5F Back oil strainer 1 黎 明 液 压
D 3 SL-415 Cooling machine 1 黎 明 液 压
1 2 Q U Q 2 - 1 0 × 1 Air filter 1 黎 明 液 压
1 YWZ-250T Oil thermalmeter 1 黎 明 液 压
Quantity Unit Net
No Code Name Material Remarks
weight weight
Design 王晓彬 2016 9 Draw
Hydraulic pressure 附图 1
Drawing theorical drawing No
Checking 共 张 材 料 重 量 件数 比例
Approve 第 张
北京东兴喷射机械
Tracing
有 限 公 司 设 备 名 称 DX-ZB3 0液 压 往 复 喷 射 机
Proof
 QFl Tundish spraying machine- Motor adjustment principle drawing

��--�E=l--+----,-----------------+�--------------------
N---------1---------l---l---l--------------�----+--1----+------------------r-----+-.-----
PB'---------l--l----------1---1---1---------------1------+--1----+---------------+-----+-1----
LC1 N
LC1 N

QF2 QF3 QF4

w N LIii N
Lal JCDJY

QF5 QF6
SBE D:SitlW Pl
11 12
HRl KM2 HR2
21
KMl HGl KM2 24V-1 24V+l
KMl KM2 HG2

�rr
13
KRl KR2
SBl SB3

24V- 24V+

Note:
1.When connect QF7 DC broken cable, please pay attention to the
polarity
tlbli Stirring manchine
5.5KW
Dongying Tundish spraying machine electromagnetic adjustment electrical schematic diagram -1
24V+ 24V-

----��
HYl
--�-���$
[1 Front limited position indicator
32
FU2 Front limited position

SQP1 HY2
Behind limited
34
12 position indicator
FU3 33
1-------t � ��

Behind limited position

L ___ -_- _ _J
· SQP2 ·

Dfl SBS SB6

35 36

Oil cylinder operation

IO

IO 12 [1
41 42 43

Forward operation
13

[1 12
45 46

Backward operation
14

[1 48 12

SB7
IO IS [1 16
51 52 53 54
-�!�
Forward start

SB8 16
55 56 12 57 IS
�ii!�
Backward start
IM2 SA
,J<.". lli
IlO
58
c/ 59

Water output valve

d
Dongying Tundish spraying machine electromagnetic control electrical schematic diagram -2

Forward output

Backward output

overflow output

Oil pump stop control

Forward operation indicator

Backward operation indicatior

Forward electromagnetic valve

Backward electromagnetic valve

overflow valve

Water valve
Dongying tundish spraying machine- schematic diagram of electrical cabinet panel

Oil pump electric current

Operation Operation Forward Front limited position

Stop Stop Backward Behind limited position

Start Start Start Front switch

Stop Stop Stop Behind switch

Oil pump Auger Oil cylinder operation Oil cylinder switch

Stop

Start

Water valve
Emergency stop
 Approach switch Approach switch

Stand by