Fault Analysis and Troubleshooting Solutions for Pneumatic High-pressure Pumps
Fault Analysis and Troubleshooting Solutions for Pneumatic High-pressure PumpsI. Complete Pump Failure to Start with Zero Movement1. Air Supply Failures (Most Common)Fault Phenomenon: No exhaust from the reversing valve and the pump body remains completely stationaryRoot Causes:1. Insufficient air compressor pressure (air supply pressure <0.4MPa); pipeline air leakage; pressure relief valve adjusted to zero2. Clogged air supply filter with water vapor and impurities blocking the air circuit3. Unopened air supply switch or detached quick connectorSolutions: Raise air supply pressure to 0.5~0.7MPa; clean filter elements; inspect sealing of air pipe connectors2. Pneumatic Reversing Valve FailuresPhenomenon: Normal air supply, yet the pump fails to reciprocate with air discharging only from one sideRoot Causes:1. Worn or stuck internal sealing rings of the reversing valve, with impurities jamming the valve spool2. Worn or broken reversing sensing thimble that cannot trigger valve reversalSolutions: Disassemble and clean the reversing valve; replace O-rings and thimbles; apply special pneumatic grease3. Piston Seizure (Pneumatic Drive Piston)Phenomenon: The pump rod cannot be pushed by hand and no impact occurs during air intakeRoot Causes: Long-term lack of water vapor lubrication, dust entering the cylinder, and expansion locking of piston sealing ringsSolutions: Disassemble the cylinder and polish the cylinder barrel; replace piston oil seals; install an oil-water separator on the air supply lineII. Pump Reciprocates Fails to Build Pressure with Slow Pressure Rise### 1. Hydraulic Check Valve Leakage (Core High-pressure Fault)Phenomenon: Normal reciprocation under no load; operation halts once pressure reaches a certain value with rapid pressure drop during pressure holdingRoot Causes: Worn steel balls and valve seats of oil inlet/outlet check valves, impurities trapped on sealing surfaces, and fatigued softened springsSolutions: Disassemble the check valve and grind valve seats; replace steel balls and springs; filter hydraulic oil2. Damaged High/Low-pressure Piston SealsPhenomenon: Faster pump reciprocation, loud noise, and pressure failing to reach the rated valueRoot Causes: Aging or scratched high-pressure sealing rings, sealing wear caused by impurities in hydraulic oil, and accelerated aging from excessive oil temperatureSolutions: Fully replace all high-pressure oil seals; refill clean hydraulic oil; control oil temperature at ≤60℃3. Insufficient Oil Suction and Air Entrainment during Oil IntakePhenomenon: Pump vibration, abnormal noise, and severe pressure fluctuationRoot Causes:1. Excessively low oil level in the oil tank with the oil suction pipe exposed above the liquid surface2. Clogged oil suction filter or leaking oil suction pipe allowing air to mix into the oil circuit3. Stuck oil suction check valve obstructing oil supplySolutions: Refill oil to the standard liquid level; fasten oil suction pipelines; clean the oil suction filter4. Load Leakage (External Oil Circuit)Phenomenon: The pump can build pressure, yet pressure continuously drops after tools are shut offRoot Causes: Leaking high-pressure tubing connectors and damaged internal seals of oil cylinders/toolsTroubleshooting Method: Close the ball valve at the pump oil outlet for independent pressure holding test to distinguish internal pump leakage from external system leakageIII. Frequent Pump Reciprocation, Idle Pumping and Severe Impact- Excessively high sensitivity of the reversing valve causing continuous reciprocation upon slight pressure drop Solution: Adjust the reversing throttle screw to reduce reversing speed- No accumulator installed in the system; minor load leakage leads to uninterrupted pressure compensation by the pump Solution: Install a high-pressure accumulator to reduce losses from idle pumping- Worn buffer rubber pad of the pneumatic piston causing loud banging against the cylinder head Solution: Replace the buffer pad and adjust air supply pressure to a reasonable rangeIV. Severe Pump Vibration, Abnormal Noise and Heavy Shaking- Air entrainment during oil suction: Leaking tubing and low oil level generate bubble impact from oil cavitation- Broken check valve springs and bouncing steel balls create metal clanging noise- Insufficient internal cylinder lubrication leads to abnormal dry grinding noise- Loose fixed base causes overall pump resonanceSolutions: Bleed air and replenish oil, replace valve components, add atomized lubricating oil to the air supply, and fasten mounting boltsV. Failed Pressure Holding with Rapid Pressure Drop during StabilizationTwo categories for quick differentiation:1. Internal Pump Leakage: Pressure still drops when blocking the oil outlet and conducting independent pressure holding testFault Points: Oil inlet/outlet check valves and high-pressure piston seals2. External System Leakage: The pump maintains normal pressure alone, yet pressure drops once connected to oil cylinders/toolsFault Points: High-pressure connectors, oil cylinder oil seals and internal seals of hydraulic toolsVI. Unstable Reciprocation Speed and Fluctuating Output Force of the Pump- Severe air supply pressure fluctuation (frequent start-stop of air compressors and insufficient pipeline partial pressure)- Partially stuck reversing valve spool hindering smooth reversal- Abnormal hydraulic oil viscosity (solidification at low temperatures and thinning at high temperatures)- Partially clogged oil suction filter leading to intermittent oil supplyVII. Oil Leakage Faults (Divided into Pneumatic Side and High-pressure Hydraulic Side)- Air and oil leakage at both cylinder ends: Damaged O-rings of the pneumatic piston- Oil seepage at the piston rod in the middle of the pump: Worn main rod dust seals and guide oil seals- Oil seepage at the high-pressure oil outlet: Damaged sealing gaskets of high-pressure plugs and connectors- Oil seepage at the bottom of the oil tank: Aging shell sealing gasketsVIII. Unique Faults under Low/High Temperature ConditionsLow Temperature (Below 0℃)Thickened hydraulic oil, stuck reversing valve spools and hardened sealing rings result in weak pump startupCountermeasures: Replace low-temperature special hydraulic oil and preheat equipment in the workshopHigh TemperatureSoftened and expanded sealing components, oil sludge generated from oil oxidation clogs valve assemblies and causes pressure attenuation IX. Rapid Fault Troubleshooting Procedure (Practical Operation Sequence)1. Inspect air supply: Pressure, oil-water separator and air pipe leakage2. Observe pump reciprocation: No movement → inspect reversing valve/cylinder; movement without pressure → inspect check valves/high-pressure seals3. Isolation Judgment: Close the oil outlet ball valve to test independent pump pressure holding and distinguish internal/external leakage4. Check hydraulic oil: Oil level, cleanliness and air bubble presence5. Disassemble valve assemblies: Clean check valves and reversing valves, replace worn sealing componentsX. Daily Preventive Maintenance to Reduce Failures1. Mandatory air supply combination unit: Filter + pressure reducing valve + oil mist separator triple unit, drain water daily2. Replace hydraulic oil regularly and clean the oil suction filter monthly3. Prolonged pressure holding above rated pressure is prohibited to avoid rapid seal aging4. Apply pneumatic grease before long-term shutdown to prevent valve spool rust5. Inspect high-pressure pipelines regularly to eliminate risks of pipe burst and leakageAir-Driven High Pressure Pump/AHP2500 DetailGas Fuel Injector Test Unit / VPU 500 GI
Gas Fuel Injector Test Unit / VPU 500 GIEngine Type:ME-GIThe VPU 500 GI is a gas-powered gas valve test rig suitable for testing gas fuel injectors on two-stroke engines.This test rig is suitable for MAN GI engines.The VPU 500 GI is a pneumatic/hydraulic gas fuel injector test rig for GI engines. The VPU 500 GI gas fuel injector test rig features a robust design and is suitable for testing gas injectors, window valves, and pressure relief valves using 300 bar or 400 bar nitrogen. It features five stations for testing window valve seals, block valve seals, gas channel relief valve seals, bleed valve seals, and closed non-return valve seals.Features of VPU500-GI：Gas leak detection: detect gas leaks and detect if gas is leakingSimulated booster: provides the pressure required for test gas injectionSafety Valves and Sensors: Guarantees safe testing conditions by continuously monitoring system pressure and performance. DetailHydraulic Jack
Hydraulic Jack Test of 2200 Bar Hydraulic JackApplicable engine type：S65ME-C, G70ME-C, K80ME-C, S80ME-C, G80ME-C, K90ME-C, S90ME-C, G95ME-C, K98ME-C, K98ME.1. Safety measures In case of malfunctioning hydraulic jacks or hoses 1.1 Always keep clear of area above the pressurized hydraulic jack during use. Broken studs or malfunctioning jack can eject! 1.2 Bursting hydraulic hose can eject oil into the skin! Always inspect the hose assembly before use. Defective or damaged hose assemblies must be replaced and discarded!1.3 Verify correct engagement of couplings before applying hydraulic pressure1.4 Leaking hydraulic oil can pose a risk in case of skin contact. Always use goggles and oil resistant gloves when working with hydraulic oil. DetailFUEL VALVE TEST DEVICE HDFD1100 COMMON FAULTS AND TROUBBLES HOOTING
FUEL VALVE TEST DEVICE COMMON FAULTS AND TROUBBLES HOOTING Model:HDFD11001. Unable to build pressure:1.1 Check whether the fixing screw nut of the fuel valve is tightened (tighten the nut).1.2. Check whether the test hydraulic oil meets the hydraulic oil specified in this manual (replace the specified oil).1.3. Check whether the hydraulic oil filter in the oil tank is cleaned at the specified time (replace and clean the oil filter).1.4. Check whether the oil level in the oil tank is too low (increase the test oil).2. The fuel valve test device does not work: 2.1. Check whether the air pipe connecting the device is unobstructed (replace the joint and air pipe). 2.2. Check whether there is air pressure in the air pressure regulating valve (3) and the input air meter (6) (replace the air pressure regulating valve). 3. Pressure leakage: 3.1. Check whether there is leakage at the joints inside the test bench (tighten the joints). 3.2. Check whether the return oil valve is leaking (grind the return oil valve stem, replace the return oil valve). 3.3. Check the high-pressure oil pump input and output connectors for oil return (disassemble and clean or replace both connectors).4. Pressure gauge does not return to zero at zero pressure:After the pressure on the test bench is completely released, adjust the "0-adj" knob on the rear of the digital display to zero.Turn clockwise to increase, counterclockwise to decrease. (If there is no response, replace the pressure gauge and pressure sensor).5. Digital display does not display:5.1. Check the digital display power input terminals (terminals 1 and 2 are 110VAC; terminals 1 and 3 are 220VAC. Consult the ship's electrical engineer to determine which input terminal to use based on the ship's conditions).5.2. Check the input terminals for power. If there is power but no display, replace the digital display.6. Digital display displays garbled data:If garbled data persists after replacing the pressure sensor, replace the digital display. DetailAHP2500 pneumatic high-pressure pump
AHP2500 pneumatic high-pressure pumpAHP2500 pneumatic high-pressure pump is a hydraulic power equipment with excellent performance and wide application.From the perspective of characteristics, it has a good performance. First of all, the output pressure is high, up to 2250bar (input air pressure 8.0bar), which can easily cope with various work scenarios that require ultra-high pressure. Secondly, it has a fast working speed, about 450 cycles/minute (input air pressure 8.0bar), which can efficiently complete the work task and greatly save time. Furthermore, it is gas-driven and equipped with a sealing device to separate the gas compression cylinder from the air-driven cylinder. Moreover, a stainless steel seismic-resistant pressure gauge with a range of 0-250MPa is used to accurately display the pressure data. In addition, this pump is light in weight, only 24 kilograms.These characteristics bring many advantages. The high output pressure allows it to provide powerful ultra-high pressure hydraulic power for hydraulic tools such as cylinder head bolt tensioners and crosshead bolt tensioners, and easily realize interference fit disassembly and assembly, hydraulic bolt tensioning and other operations. The fast working speed improves the overall work efficiency, reduces the waiting time of equipment, and improves production progress. The gas-driven method makes it have excellent safety performance, without the danger of generating heat, sparks, and sparks. It is particularly suitable for some occasions with high requirements for fire and explosion prevention. At the same time, it is oil-free and avoids the problem of oil pollution. The stainless steel seismic-resistant pressure gauge ensures the accuracy and stability of the pressure display, allowing operators to grasp the pressure situation in real time to ensure safe and accurate work. The light size and weight mean that it can be more conveniently applied to various working environments, and it is very convenient to install and move, with higher flexibility.For users, the AHP2500 pneumatic high-pressure pump can bring great benefits. In the work of ship main engine hanging cylinder maintenance, it can efficiently complete the task, help the staff to carry out maintenance operations quickly and smoothly, ensure the normal operation of the ship, reduce the downtime of the ship for maintenance, and reduce operating costs. Its excellent safety performance allows users to use it without worrying about safety hazards such as fire and explosion, providing more reliable protection for the workplace. Accurate pressure display and stable performance help users to control the operation process more accurately, ensure work quality, and reduce equipment damage or work errors caused by improper pressure control. In addition, due to its low maintenance cost, it can also save users a lot of maintenance costs and time, further improving its use value. Choosing AHP2500 pneumatic high pressure pump means choosing an efficient, safe and reliable working partner, which will bring more convenience and value to your work. DetailFuel Valve Testing Device
Research Report on Fuel Valve Testing DeviceAbstractThis report focuses on the fuel valve testing device. It presents an in - depth analysis of its design, working principles, functions, and application scenarios. The purpose is to provide a comprehensive understanding of this crucial testing equipment in the field of fuel systems.IntroductionFuel valves play a vital role in the proper operation of various fuel - powered systems, such as engines in automobiles, aircraft, and industrial machinery. Ensuring the quality and performance of fuel valves is of utmost importance. A fuel valve testing device is developed to meet this need, which can accurately evaluate the functionality and reliability of fuel valves under different conditions.Design of the Fuel Valve Testing Device• Mechanical Structure: The device consists of a solid and stable frame that can firmly hold the fuel valve during the testing process. It also includes a series of connecting parts and fixtures to ensure proper alignment and connection with the valve.• Fluid System: A precisely designed fluid system is incorporated. It has the ability to supply fuel or a simulated fluid with specific pressure, flow rate, and temperature characteristics. This system can mimic the actual working conditions of the fuel valve in the real - world environment.• Measurement and Control System: The testing device is equipped with various sensors to measure parameters such as pressure, flow rate, opening and closing time of the fuel valve. A control unit is used to adjust and monitor these parameters, enabling precise control of the testing process.Working Principles of the Testing Device• Pressure Testing: The device can apply different levels of pressure to the fuel valve to check its sealing performance. By measuring the pressure change within the system and observing any leakage, the integrity of the valve can be evaluated.• Flow Rate Testing: The fluid system provides a controlled flow of fluid through the fuel valve. The flow rate sensors measure the actual flow passing through the valve under different pressure differences. This helps to determine if the valve can regulate the flow as designed.• Opening and Closing Characteristics Testing: The control system can actuate the fuel valve to open and close repeatedly. The time taken for opening and closing, as well as the smoothness of the operation, are monitored and analyzed to assess the mechanical performance of the valve.Functions of the Fuel Valve Testing Device• Quality Assurance: It enables manufacturers to ensure that each fuel valve produced meets the required quality standards before being installed in the final product. This reduces the risk of faulty valves causing problems in the overall system.• Research and Development: Researchers can use the testing device to study the performance of new - designed fuel valves, make improvements, and optimize their design based on the test results.• Maintenance and Troubleshooting: In the maintenance process of existing fuel systems, the device can be used to diagnose problems with fuel valves. By comparing the test results with the normal performance parameters, technicians can quickly identify and repair faulty valves.Application Scenarios• Automotive Industry: In automobile manufacturing plants, the fuel valve testing device is used to test fuel injection valves and other relevant valves in the fuel supply system of engines. This ensures the efficient and reliable operation of the vehicle's fuel system.• Aerospace Industry: For aircraft engines, the high - precision fuel valve testing device is essential. Given the critical nature of aircraft operation, any malfunction in the fuel valve can have serious consequences. The device is used to rigorously test fuel valves to meet the strict safety and performance requirements of the aerospace industry.• Industrial Machinery: In industrial applications where fuel - powered engines or burners are used, the fuel valve testing device helps to maintain the proper operation of the fuel supply system. This improves the overall efficiency and reduces downtime of the industrial equipment.ConclusionThe fuel valve testing device is an indispensable tool in the fuel system industry. Its advanced design, accurate working principles, and diverse functions make it possible to ensure the quality and performance of fuel valves in various applications. With continuous development and improvement, it will play an even more significant role in the future to meet the increasingly stringent requirements of different industries. DetailHydraulic cylinder
Hydraulic cylinderHydraulic cylinder is a commonly used hydraulic transmission device widely used in industrial and mechanical equipment. It is a device that generates force and movement through the pressure of hydraulic oil, and has the advantage of providing powerful and smooth movement.The hydraulic cylinder is composed of cylinder barrel, piston, seal, spring and oil inlet. During operation, hydraulic oil enters the cylinder through the oil inlet, causing pressure inside the cylinder to push the piston to generate force and movement. The function of the seal is to prevent hydraulic oil leakage and ensure the normal operation of the hydraulic cylinder.There are many types of hydraulic cylinders, including single-acting hydraulic cylinders, double-acting hydraulic cylinders and multi-stage hydraulic cylinders. Single-acting hydraulic cylinders can only achieve one-way movement, that is, they can only have thrust in one direction; double-acting hydraulic cylinders can achieve two-way movement, that is, they can have forward and reverse thrust; multi-stage hydraulic cylinders can achieve More force and travel.The working principle of a hydraulic cylinder is to use the pressure of hydraulic oil to transmit force and movement. When hydraulic oil enters the cylinder, since the liquid is incompressible, the hydraulic oil will generate a certain pressure in the cylinder. Due to the area difference on the piston, according to Pascal's law, the pressure of the hydraulic oil will generate a thrust, DetailContact information for AHP-3500High Pressure Pump Unit
Contact information for AHP-3500High Pressure Pump UnitAILESEN (CHANGZHOU) POWER TECHNOLOGY CO., LTD The company's main activities are the development, manufacturing, sales, sales and maintenance of pneumatic/hydraulic fuel injection valves and fuel pump test equipment and hydraulic power units for 2 and 4-stroke diesel enginesContact information for AHP-3500High Pressure Pump UnitEmail: ailesen@163.netwhatsapp:+86 13815036227If necessary, please send us an email DetailContact information for AHP-3500High Pressure Pump Unit
Contact information for AHP-3500High Pressure Pump UnitAILESEN (CHANGZHOU) POWER TECHNOLOGY CO., LTD The company's main activities are the development, manufacturing, sales, sales and maintenance of pneumatic/hydraulic fuel injection valves and fuel pump test equipment and hydraulic power units for 2 and 4-stroke diesel enginesContact information for AHP-3500High Pressure Pump UnitEmail: ailesen@163.netwhatsapp:+86 13815036227If necessary, please send us an email DetailMarine High-Pressure Pump Unit:AHP2500
Marine High-Pressure Pump Unit:AHP2500 Marine High-Pressure Pump Unit: The Best Hydraulic Solution for Marine Diesel Engine MaintenanceIntroduction:Marine high-pressure pump units are essential hydraulic pumps designed specifically for the maintenance of marine diesel engines. With their advanced technology and reliable performance, these units ensure the smooth and efficient operation of marine vessels. 1. Superior Performance and Efficiency:Marine high-pressure pump units are renowned for their exceptional performance and efficiency. These units are equipped with cutting-edge technology that allows them to deliver high-pressure hydraulic power, enabling effective maintenance and repair of marine diesel engines. With their precise control and smooth operation, these pump units ensure seamless power transmission, thereby maximizing the overall efficiency of marine engines.2. Robust Construction and Reliability:Built to withstand the harsh marine environment, marine high-pressure pump units are designed with durability in mind. They feature robust construction, corrosion-resistant materials, and sealed components, making them highly reliable even in extreme conditions. These units can operate continuously for extended periods without any compromise in their performance or reliability, ensuring uninterrupted hydraulic power for marine engine maintenance tasks.3. Versatility and Adaptability:Marine high-pressure pump units are versatile and can be customized to suit various marine engine maintenance requirements. They can be integrated with different types of marine diesel engines, offering compatibility and seamless operation. These units can efficiently handle hydraulic tasks such as pressure testing, making them indispensable tools in any marine engineering or maintenance workshop.4. Safety Features:Safety is of utmost importance in marine engine maintenance, and marine high-pressure pump units prioritize this aspect. These units are equipped with advanced safety features such as pressure relief valves, pressure sewhatsapp:+86 13815036227 Detail
Ai Lesen (ChangZhou) Power Technology Co., Ltd.
Contact: Shen Yu
E-mail: ailesen@163.net
Contact: +8613815036227
Address: AILESEN(CHANGZHOU)POWER TECHNOLOGY CO.,LTD
