How to Install and Maintain an Industrial Hose Pump

Proper installation and regular maintenance are essential for achieving long-term reliable performance from industrial hose pumps. Although hose pumps are designed for harsh working conditions, factors such as incorrect installation, unsuitable operating parameters, and improper maintenance may affect hose service life and system efficiency.

This guide from Shaanxi Hono Electronic Technology Co., Ltd. provides practical recommendations for hose pump installation, operation inspection, hose replacement, lubrication, and troubleshooting. By following professional maintenance practices, users can reduce unexpected downtime, extend hose life, and ensure stable performance in demanding applications such as slurry transfer, sludge dewatering, chemical handling, and wastewater treatment.

1. Installation

1.1 Unpacking & Inspection

Upon receiving the pump, follow the instructions printed on the packaging crate. Perform visual inspection to check for transit damage. If any damage is found, contact Shaanxi Hono Electronic Technology Co., Ltd. promptly.

1.2 Installation

Check the following points before pump installation:

1. The pump is delivered with a base plate pre-drilled with six mounting holes. It must be securely fixed onto a rigid foundation. The foundation gradient shall not exceed 5 mm per meter, and firm anchoring is mandatory.
2. The pump requires no priming before startup. Therefore, it can be installed above the liquid level without auxiliary pipelines or startup accessories; however, the vertical height difference should not exceed 5 meters. For high-viscosity media with abundant solid particles, high sedimentation tendency and poor flowability, the pump shall generally be installed below the liquid surface.
3. Sufficient clearance shall be reserved around the pump to facilitate maintenance. If adequate space cannot be guaranteed, relocate the pump to a suitable position.
4. Ensure adequate ventilation in the installation area to dissipate heat generated by the pump. Maintain clearance behind the motor fan shroud to avoid blocking air intake.

1.3 Piping Requirements

1.3.1 Suction Line

A. The inner diameter of connecting piping must be larger than the inner diameter of the pump hose. Keep the piping as short and straight as possible to minimize pressure loss on the suction side.

B. Install a flexible or rigid spool piece (approx. 80–100 cm) between the pump discharge flange and pipeline to facilitate hose replacement.

C. Fit a valve on the suction line, especially when the pump operates under loaded conditions.

D. Limit the number of pipe elbows and select elbows with the largest feasible dimensions.

E. Ensure connecting pipelines can withstand the pump's working pressure.

F. Install a filter at the pump inlet if the conveyed medium contains sharp or oversized solid particles.

1.3.2 Discharge Line

A. The inner diameter of connecting piping must be larger than the inner diameter of the pump hose. For long pipelines transporting high-viscosity, poorly flowable media, the discharge pipe diameter shall be 1.2–1.3 times the hose inner diameter.

B. Keep the piping as short and straight as possible to reduce discharge-side pressure loss.

C. Limit the number of pipe elbows and select elbows with the largest feasible dimensions.

D. Reserve installation space for a pulsation dampener (see figure below).

E. If a valve is installed on the discharge line, fit a pressure gauge or overpressure protection gauge to prevent potential damage to the pump and piping assembly.

F. Pump inlet and outlet are arranged on the same side and interchangeable. Users may swap inlet and outlet according to on-site piping layout.

Reserve adequate space during pump layout planning for hose replacement and potential pulsation dampener installation.

The reserved distance (L = 1.5 m–2 m) is required for hose removal.

1.4 Pump Lifting

The hose pump is equipped with three lifting lugs, fixed on the upper section of the motor, gear reducer and pump housing respectively. Comply with the requirements below during lifting:

Use qualified lifting slings / straps to hoist the complete pump set via lifting lugs and auxiliary supports on the gearbox and motor.

Take the pump's center of gravity into consideration. The pump head side of the motor-driven pump tends to tilt during hoisting. Ensure all personnel maintain a safe distance to avoid personal injury.

tips:

1.It is forbidden to lift the pump by any method other than the dedicated lifting lugs;

2.Never lift the pump through pump openings or support brackets.

1.5 Pump Startup

① Wire the motor in compliance with local codes and regulations. The motor shall be fitted with forward/reverse jog buttons for maintenance, hose replacement and self-cleaning operations. All electrical work must be completed by qualified personnel. (See figure below)

② Connect pipelines to pump inlet and outlet, and confirm all inlet & outlet valves are fully open.

③ Carry out jog test prior to formal startup. Check rotation direction via the sight glass. Formal startup is only permitted after confirming correct rotation direction.

2. Routine Maintenance of Hose Pump

2.1 Hose Replacement & Adjustment

WARNING! Check the following items before hose replacement:

a. Hose replacement must be performed by experienced personnel familiar with this operation manual.

b. Cut off power supply first, and close inlet and outlet valves to minimize material loss.

c. Always wear workwear and required protective equipment as specified for the conveyed medium.

d. Comply with all safety and environmental regulations governing the handled medium.

① For hose replacement: Loosen and remove hose clamps at both ends; loosen the eyebolt on one side and pull the pipe fitting out of the hose. Jog the motor to push the old hose out of the pump housing (see figure). Insert the new hose between pump housing and rollers from the side where the spool piece was removed; jog the motor to feed the hose into position. Refit the eyebolt and hose clamps to finish replacement.

NOTICE: Ensure the hose is tightly attached against the pump housing during installation. Confirm proper fitting before commissioning.

② After approximately 200 operating hours, rotate the hose by 90°. For single-hose pumps, besides rotational adjustment, the hose may also be shifted axially forward and backward to change compression points and extend hose service life.

2.2 Roller Adjustment

Rollers are pre-adjusted and tested at factory acceptance. If medium cannot be drawn in or the flow rate fails to meet specification under rated pressure after long-term operation, adjust the roller eccentricity offset following the steps below:

① Remove the acrylic covers over circular openings on both sides of pump housing and the rectangular acrylic cover at pump discharge end. Rotate rotor rollers to the position between circular openings, aligning bolts directly facing the openings. Measure dimension L1. Loosen bolts on both sides with a socket wrench. Insert a round bar or tool into the hole on the eccentric shaft (marked in red in attached drawing). The eccentric shaft can rotate clockwise (green arrow) or counterclockwise (red arrow). Rotate the eccentric shaft clockwise first and measure L1:

If L1 increases: adjust counterclockwise until L1 reaches minimum value;

If L1 decreases: continue adjusting in this direction to minimum L1.

The smaller L1 value, the tighter the hose compression. Replace the hose if flow still fails to reach standard after L1 is adjusted to minimum.

NOTICE: Adjust both rollers simultaneously when modifying eccentric offset.

Maximum clearance point shown in drawing: eccentric shaft positioned for maximum L1, minimum hose compression.

Minimum clearance point shown in drawing: eccentric shaft positioned for minimum L1, maximum hose compression.

② For newly replaced hoses, the clearance L1 between roller and housing shall be: Hose wall thickness × 2 − 2 mm.

When hose wall thickness decreases due to wear, resulting in insufficient pressure and flow, adjust the clearance appropriately.

2.3 Lubrication & Maintenance

① Inject grease into side guide rollers regularly via grease nipples (refer to structural drawing for location). Grease grade: High-temperature lithium base grease GB/T 5671-1995, once per week, to maintain good lubrication. Check tightness of side guide rollers during greasing. Tighten loose rollers with needle-nose pliers. If abnormal noise persists after adjustment, bearing wear inside side guide rollers is suspected; replace bearings or complete side guide roller assembly.

② Lubricate rotor bearings (see structural drawing) every two months with the same grease as side guide rollers.

③ Drain original oil and refill with ISO VG220 gear oil after initial running-in period for new gear reducers.

④ Inspect rotor roller bearings monthly for seizure or excessive clearance; replace worn components timely if abnormal conditions are found.

⑤ Accurately measure hose wall thickness before each hose replacement, and adjust roller clearance according to the dimension of new hose.

⑥ Inspect pump housing weekly for metallic debris. Remove debris immediately to avoid damage to other components.

⑦ When conveying corrosive or high-value media, accurately evaluate hose service life to prevent contamination and economic loss. For continuous operation, replace hose every month; for intermittent operation, replace hose every two months.

⑧ After the new pump runs for 10 days, shut down the pump and loosen pipe fittings while the hose remains hot. Allow natural hose elongation then retighten fittings. Repeat this operation after two months.

⑨ All inlet and outlet valves must remain fully open during pump operation. Closed valves will cause hose rupture, motor burnout and other failures.

⑩ The hose can be cleaned without disassembly. Use clean water or compatible cleaning fluid (verify chemical compatibility with hose material). If conveyed medium forms hard sediment, flush the hose thoroughly with clean water before shutdown to prevent solid buildup inside the hose.

3. Troubleshooting

4. Methods to Extend Hose Service Life

4.1 Select Proper Hose Material Based on Conveyed Medium

Hose material is a critical factor determining service life. Media under different working conditions vary in corrosion resistance, temperature tolerance and abrasion characteristics. Our company can recommend suitable hose materials according to the properties of the actual conveyed medium.

4.2 Avoid Operation Beyond Rated Pressure

• Select hoses with appropriate pressure rating for on-site working conditions
• Prevent frequent overpressure operation
• Monitor operating status in real time via pressure sensors

4.3 Maintain Proper Lubrication

• Regularly inspect lubricant condition
• Ensure sufficient lubricant supply
• Replenish or replace lubricant in a timely manner based on operating hours

4.4 Optimize Installation Method and Operating Conditions

Precautions during installation:

• Prevent external tension or torsion on the hose
• Guarantee unobstructed suction pipeline to reduce extra resistance
• Avoid frequent startup and shutdown cycles
• Adjust pump speed reasonably in accordance with medium characteristics

4.5 Conduct Regular Inspection and Timely Hose Replacement

Implement a periodic inspection schedule:

• Check whether cracks appear on the outer surface of the hose
• Check for abnormal swelling or deformation
• Check for flow reduction or abnormal pressure fluctuations
• Check for discoloration or leakage of lubricant

5. Hono Technical Support

Shaanxi Hono Electronic Technology Co., Ltd. offers professional installation guidance, maintenance services and customized hose pump solutions.