Minor repair (1) Check the fastening bolts of the ministries;
(2) Check, clean or replace the one-way valve seat, diaphragm, stopper and so on;
(3) Check and adjust the plunger seal, depending on the situation to replace the packing and plunger;
(4) Check the cleaning charge valve, safety valve, adjust the set pressure;
(5) Check the quality of lubricating oil, fuel, depending on circumstances, to supplement or replace;
(6) check the motor coupling on the situation, replace the skeleton oil seal.
(1) Including minor repairs (2) Complete disassembly and cleaning of parts (3) Check the wear status and clearance of bearing bush, pin, crosshead, needle bearing, N shaft, worm gear and worm;
(4) Check the bearing conditions;
(5) check and repair the plunger and scraper ring;
(6) check the worm shaft conditions;
(7) the body to find out again;
(8) Check and repair the motor and electrical installations;
(9) Exterior painting anti-corrosion.
Fourth, the maintenance steps and quality standards 1, remove the import and export pipe flange and valve seat bolts, you can turn out the valve sleeve, valve ball limit tablets, valve ball, valve seat;
2, remove the cylinder head fastening bolts, you can remove the cylinder head, diaphragm, limit plate;
3, the plunger moved to the front dead center, the plunger screwed out from the crosshead, loosen the packing compression nut can be moved out of the plunger;
4, remove the diaphragm hydraulic cylinder and the base connection bolts, you can remove the hydraulic cylinder, under normal circumstances, this cylinder are not removed;
5, loosen gland bolts gland, you can remove the packing, ring and plunger sleeve;
6, release the scraper gland bolts, you can remove the scraper ring;
7, let go of the transmission body oil, remove the back of the plexiglass plate;
8, Remove the motor, remove the coupling, unscrew the bearing cap compression nut, the bearing cap, bearings, worm and oil sucker out from the transmission box;
9, contact the instrumentation workers, remove the travel adjustment motor wiring, open the adjustment cover, remove the adjustment box compression nut, rotate the adjustment dial, the adjustment screw and the adjustment box removed from the sleeve, and then the sleeve Remove from the transmission body;
10, Remove the bracket compression nut, the bracket removed from the transmission box body, open the transmission case cover, remove the crosshead pin and ten Chi head from the box 11, gently pull up the needle roller seat Note: the ruler may leave the needle in the connecting rod to prevent the needle from falling into the gear box when the needle holder is up), and then carefully detect the needle roller one by one, which can not be omitted;
12, a person gently remove the connecting rod together with the eccentric block (note that only in a suitable location can be removed);
13, pull up the N axis, you can remove the connecting rod, eccentric block sets;
14, loosen the N-axis hex bolts, remove the bearing gland, remove the lock nut, you can remove the bearing, bearing housing;
15, when the need to replace the worm shaft bearings or worm gear when the force can be pulled up the worm, if the match is too tight and can not pull out, remove the foot of the box body, the box upside down and disassembled Gland diaphragm, knock out with a copper rod;
16, according to the demolition of the reverse order of assembly, and meet the following requirements:
(1) seat and valve ball anastomosis width of 0.25-2.0MM, and anastomosis should not have rust, pitting and other defects, check the valve ball tightly on the valve seat, backlit check whether there is anastomotic Bright, if you can see the light between the two, you can use machining or centering percussion method combined with repair; when not repaired, you should replace the valve seat;
(2) seat and valve sleeve assembly, pay attention to adjust the gasket between the two sealing surface to the middle of the limit can not move up and down the limit, and can not be crushed as the best;
(3) check the diaphragm limit plate should be burr, solid particles exist, the entire concave smooth and flat, all through holes should be clean, no dirt obstruction, diaphragm should be smooth, no permanent deformation, good elasticity;
(4) Plunger and packing with the mating surface roughness of Ra1.6, no signs of tingling, outside the park in the premise of ensuring the surface roughness, the size of the outer garden is not critical, the packing should be tried on the plunger before loading , Can not be too long or too short, and the packing inner ring and plunger, outer ring and stuffing box should be close fit, when not up to requirements, you can use a hammer percussion filler: to achieve the required width or thickness, when the head does not When disassembling, but only just replace the packing, as long as the packing compression nut loose, the cup disassembly compressed air forced into the oil hole of the oil cup, you can stuffing stuffing out from the stuffing box;
(5) After packing is fully loaded, it should not be pressed immediately, but after the pump is started, a proper amount of oil should be pressed out of the packing and then the packing should be slowly pressed inwards to achieve the requirement of no leakage;
(6) There should be no scratches, bumps, burrs and other defects on the journal of the worm shaft: the circularity of the journal is 0.02MM, the straightness of the worm is 0.04mm / m, and the journal roughness at the bearing is Ra0. 8, the installation of oil seal at the journal roughness Ra1.6, keyway wear, the structure and strength of the case, the keyway in the original position 120K another keyway, the shaft serious wear or crack can not continue to use.
(7) Rolling bearings A, removable roller bearings should use special tools, no direct beat;
B, the installation of bearings should be used oil bath assembly method, the oil temperature shall not exceed 120 ℃;
C, bearing inner and outer ring raceway, the rolling body has pitting, rust, cracks or excessive loosening of the roller should be replaced;
D, bearing into the journal, the inner surface of the inner ring must be close to the shoulder with 0.05MM feeler inspection, shall not be passed;
(8) Skeleton Seal If the aging, deformation, wear and damage should be replaced, check the tightness of the inlaid spring in the oil seal before assembly, and apply grease. Pay attention to the positive and negative direction during installation.
(9) Worm, worm wheel A, worm wheel, worm tooth surface shall not have cracks, burrs, serious scratches;
B, worm gear, the top of the worm should be 0.2-0.3M (M is the modulus);
C, Worm wheel, worm should be properly meshed, meshing contact area along the tooth height of not less than 60%, not less than 65% along the tooth length, the correct position of the joint should be close to the worm outlet, not left and right;
D, worm gear, worm meshing side of the gap should be 0.13-0.26MM, side clearance available plug meter method, pressure lead measurement;
E, worm, worm center distance limit deviation does not exceed 0.09MM, available mandrel method of measurement;
F, Worm Gear Festival Teeth thickness wear the maximum allowable value of 0.24Mn (Mn is the normal modulus);
G, worm gear ring radial Park beating should be less than 0.07MM; H, worm, worm gear assembly should be flexible, the worm torque in any position should be basically the same;
I, connecting rod with the size of the needle and the needle and the crosshead pin with H6 / m6, roughness Ra1.6, small tile gap allows 0.04-0.09MM, large tiles allow 0.1-0.2MM: Color method to check the bearing Of the contact area, should not be less than 2 points / CM2 and uniform distribution, the size of the tile may not have cracks, trachoma, damage, porosity, lubrication;
J, needle roller surface should be smooth, no rust, pitting and other signs, if worn should be replaced, needle roller seat surface roughness Ra0.8, shall not damage, pitting, cavitation and other phenomena, the size should be consistent with the pattern Claim;
K, eccentric block, N axis with the roughness Ra1.6, may not have pitting, cavitation, wear signs, the eccentric angle between the two should be the same, the assembly should slide up and down, flexible rotation, no symptoms of card shade, the relevant Shall comply with the requirements of the drawings, N axis of the rolling bearing assembly should be flexible rotation, no movement, the outer ring without bearing phenomenon;
L, crosshead outside the park surface roughness Ra1.6, no brushed, wear signs, no cracks, trachoma, slag, begging holes and other defects, crosshead and plunger connection should be reliable, there is loose phenomenon;
M, the assembly should be adjusted between the sleeve and the box gasket, the worm should be made to rotate flexible thrust bearing clearance up and down more than 0.05MM: After assembly, the car should be easy, no heavy feeling, the device is running, Adjust the trip up and down should be easy, no obstruction or severity.
Fifth, test and acceptance 1, remove all tools and debris around the pump base;
2, check the oil level before the test is within the prescribed range;
3, check the ministries connecting bolts are fastened;
4, crank two weeks, pay attention to whether there is no sound in the pump, crank is light;
5, open the inlet valve, exhaust valve, exhaust gas pump, connect the power, start equipment;
6, at a lower stroke, hand-push the filling valve spool, the air discharge chamber until no bubbles discharge;
7, according to the need, slowly add the trip to the right place;
8, test must meet the following requirements:
(1) lubrication of all equipment is good;
(2) ministries do not run, run, drip, leak phenomenon;
(3) stroke adjustment is normal, fill valve work properly, the outlet pressure reaches the set value;
(4) No abnormal sound during operation
(5) 2-3 hours continuous running test time, the performance of the design capacity to meet or meet production needs.
9, overhaul quality to meet the standards of this procedure, test to meet the requirements, complete records, accurate, according to the provisions of the acceptance procedures, handed over to production use.
Schedule I
Common failures and treatment methods phenomenon, possible causes, treatment methods, completely liquid
1, Suction pipe blockage 2, Suction pipe leakage 3, Coupling not connected 4, Imported valve does not open 5, Diaphragm damage or failure 6, Due to solid particles, the pump check valve is normally open
1, cleaning, clear the suction pipe 2, to eliminate leakage 3, connected to the coupling 4, open the valve 5, replace the diaphragm 6, open the pump head, cleaning the check valve drain enough.
1, the import and export of one-way valve seat wear 2, packing wear 3, filling the gas cavity 4, the motor speed is low 5, filling the oil chamber too much or too little fuel
1, replace the valve seat 2, replace the filler 3, artificial oil, exhaust 4, check the power supply system 5, the fill valve artificial oil or discharge oil discharge pressure instability.
1, Suction or discharge pipeline blocked 2, diaphragm limit plate or drain at the Department of leakage 3, safety valve or fill valve action failure 4, the media have gas 5, one-way valve seat wear or dirt.
1, check and clear the pipeline 2, tighten the bolts at the junction 3, according to the safety charge valve group to adjust the way debugging 4, to strengthen the process control to eliminate gas 5, clean or replace the valve seat measurement accuracy is not enough.
1, gas filled in the cavity 2, the safety valve or fill valve action failure 3, the diaphragm aging or permanent deformation 4, the motor speed is unstable 5, the plunger seal packing leakage.
1, artificial oil, exhaust 2, readjustment 3, replace the diaphragm 4, check the power supply system 5, adjust or replace the impact of the operation of the ring.
1, transmission loose or severe wear 2, suction pipe leakage 3, the diaphragm cavity oil overload 4, there is gas inside the medium.
1, Tighten the bolts or replace the new parts 2, Eliminate the leakage point 3, Light pressure valve manually fill oil 4, Exhaust gas transmission medium pollution oil.
1, diaphragm rupture 1, replace the diaphragm.
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