I. Lubrication System Maintenance: Protecting the Transmission Core
1. Lubricant Selection and Replacement
- Lubricant Requirements:
- Gearboxes require black gear oil (e.g., SYB1103-62S standard).
- Transmission boxes recommend Grade 30 mechanical oil (GB443-89).
- Plunger guide rails may use Grade 10 or 20 machine oil.
- Replacement Intervals:
- Initial Use: Replace after 30–50 hours of operation to remove metal debris from the break-in period.
- Routine: Replace every 500 hours thereafter; reduce to 300 hours in dusty environments or under high-frequency use.
- Oil Level Control:
- Transmission box oil levels should slightly exceed the crosshead guide surface.
- Gearbox oil should remain at the center mark of the oil gauge-overfilling causes overheating and leaks.
2. Key Component Lubrication Adjustments
- Worm Gear Clearance: Regularly check axial clearance (0.04–0.07mm for worms; 0.05–0.10mm for worm wheels). Adjust via end-cover shims if beyond tolerance to prevent accelerated wear.
- Plunger Seals: Minor leakage is acceptable (≈20 drops/minute). Excessive leakage requires replacing oil-soaked leather gaskets.
II. Working Medium Management: Preventing Clogs and Corrosion
- Medium Cleanliness: Media (water or oil) in the water tank must be filtered through a 100-mesh/inch filter to prevent impurities from clogging suction pipes or valves.
- Freeze and Corrosion Prevention:
- Below 0°C, use antifreeze (recommend denatured alcohol), with ratios adjusted for ambient temperature.
- For prolonged downtime, drain media and flush pipelines with rust-preventive oil or diesel fuel. Apply antirust grease to exposed metal surfaces.
- Prohibited Media: Avoid acids, alkalis, or corrosive liquids to prevent seal degradation and cylinder rust.
III. Critical Component Inspection: Preventing Failures
1. Seals and Connection Points
- Daily checks for leaks at pump bodies, pipelines, and joints-especially at water collectors and safety valve connections.
- Pressure gauges must be sealed with copper gaskets and calibrated periodically to ensure accuracy.
2. Valves and Filters
- Safety Valves: Never misuse as relief valves. Lock adjustment nuts after tuning.
- Suction Filters: Clean monthly; clogging reduces water intake and causes pressure instability.
3. Electrical Safety
- Ensure reliable grounding of power cables to prevent electrocution in humid environments.
IV. Long-Term Storage: Preventing Damage from Inactivity
1. Internal Rust Prevention: After draining media, circulate diesel fuel through pipelines until discharge is impurity-free.
2. External Protection: Clean the housing, apply lithium-based grease to transmission parts, and cover the entire unit with a dustproof shroud in a dry environment.
V. Fault Alerts and Rapid Response
Routine maintenance prevents 90% of common failures, such as:
- Failure to Build Pressure: Check for clogged filters, exposed suction ports, or stuck check valves (clean valve cores).
- Pressure Fluctuations: Inspect pipeline air leaks, unsealed outlet valves, or damaged pressure gauges.
- Abnormal Noise: Replace damaged bearings; adjust bushing clearance for seized plungers.
Maintenance Records: Log oil types, replacement times, and component status after each service to build a health profile for predictive maintenance scheduling.
Conclusion: Maintenance as Productivity
Stable operation of electric pressure test pumps hinges on the principle of "prevention > repair." Standardizing lubrication, media control, and component monitoring prevents unexpected downtime (e.g., valve jams, pressure failures) and extends equipment life by 5+ years. Integrating these protocols into daily practice ensures both testing safety and operational efficiency.
Technical standards referenced:
- Lubrication: GB443-89, SYB1103-62S
- Safety: Technical Documents from the Electric Pressure Test Pump Joint Design Group
This structured maintenance strategy empowers equipment managers to slash failure rates and boost testing efficiency. Customize checklists using the equipment manual for precise management.