The following are common troubleshooting methods for quad parallel double plunger pumps:

1、 Insufficient flow or abnormal pressure

Phenomenon: The actual flow rate is lower than the set value, the system pressure fluctuates greatly, and may be accompanied by vibration, noise, or motor overload.

Reason: clogged inlet filter, deformed pipeline, or high medium viscosity; The clearance between the plunger and the cylinder body is too large (normally ≤ 0.05mm); Sealing failure or spring breakage of suction/discharge valves; Abnormal motor speed or high hydraulic oil temperature (recommended to be controlled at 40-60 ℃).

Exclusion method: Clean or replace the filter element, check the smoothness of the pipeline; Measure the clearance between the plunger and the cylinder body, and replace or repair it if it exceeds the limit; Disassemble and clean the valve seat, grind the sealing surface, and replace the failed spring; Detect voltage and speed, and add a cooler to control oil temperature.

2、 Leakage and pressure leakage

Phenomenon: Oil leakage in the pump body or pipeline, inability to maintain system pressure, and abnormal consumption of hydraulic oil.

Reason: Aging of plunger sealing ring and hardening of valve plate gasket; High pressure impact causes thread loosening; Fatigue cracks or corrosion in the cylinder body; Air mixed into the oil causes cavitation.

Exclusion method: Use fluororubber or polytetrafluoroethylene seals and install according to the standard compression capacity; Use a torque wrench to tighten again and install a locking nut; Using ultrasonic flaw detection to detect cracks, repairing or replacing the cylinder body locally; Exhaust before starting and check the sealing of the oil suction pipeline.

3、 Abnormal vibration and noise

Phenomenon: The pump body vibrates violently, accompanied by high-frequency whistling or metal impact sound, and the bearing temperature rises abnormally.

Reason: The plunger is stuck or the guide sleeve is worn, resulting in uneven force distribution; Wear of rolling bearings or contamination of lubricating grease; Loose anchor bolts or insufficient foundation rigidity; Oil precipitation bubbles cause cavitation noise.

Exclusion method: Repair or replace the guide sleeve, calibrate the consistency of the connecting rod length; Clean the bearing seat and replace it with a bearing of the same model, and add high-temperature resistant lithium grease; Strengthen the anchor bolts, add shock-absorbing pads or rebuild the concrete foundation; Raise the fuel tank level to ensure that the oil cleanliness is ≥ NAS level 8.

4、 Motor overload and electrical faults

Phenomenon: The current exceeds the limit and triggers the thermal relay to trip, causing the control system to alarm or command delay.

Reason: Foreign objects get stuck in the pump chamber or the plunger gets stuck; Power supply phase loss, low voltage, or incorrect parameters of the frequency converter; Pressure/flow sensor signal distortion; Shrinkage of the outlet pipeline or blockage of the filter element increases resistance.

Exclusion method: Manually rotate the disc to check for mechanical jamming and clean up foreign objects; Use a multimeter to check the three-phase balance and reset the parameters of the frequency converter; Compare and verify sensor data, replace faulty components; Preheat the oil to operating temperature and replace the high-precision filter element.

5、 Preventive maintenance strategy

Regular inspection: Check the wear status of seals, lubricating oil, and plungers every 500 hours of operation.

Oil management: Use anti-wear hydraulic oil, change the oil and clean the oil tank every 2000 hours.

Data monitoring: Establish pressure, flow, and vibration parameter files, and intervene in advance through trend analysis.

Standardized operation: Overloading operation is prohibited to avoid frequent starting and stopping that may cause impact.