Production Standard and Maintenance Manual for DHB High Pressure Diesel Ignition

1、 Production standards

1. Material selection and process requirements

The core components of DHB high-pressure diesel ignition pump need to be made of materials that prevent wear and tear. For example, key parts such as the pump body, gears, and bearings should be made of stainless steel or alloy steel, and operate stably for a long time in high temperature, high pressure, and corrosive media environments. The gear surface needs to undergo precision grinding treatment to reduce meshing noise and improve transmission speed. For bearing materials, it is recommended to use composite materials, which are made of steel plates as the matrix, sintered copper mesh as the intermediate layer, and plastic filled with tetrafluoroethylene for the friction surface. They have mechanical, low friction coefficient, and low noise characteristics, and can be used in oil-free or low oil lubrication conditions.

2. Structural specifications

The pump body needs to fully consider the correctness of the internal flow channel, avoid right angle turns or sudden expansion and contraction, in order to reduce the cavitation noise caused by fluid turbulence. The perpendicularity error between the gear end face and the hole axis line needs to be controlled within a small range to determine the mutual position accuracy of the two shafts after assembly. The gap between the front and rear end caps needs to be determined through precision machining to prevent increased internal leakage due to excessive gap or mechanical friction caused by insufficient gap. In addition, the input shaft end needs to be heat-treated with and to prevent fracture from occurring.

3. Sealing and leakage control

The sealing performance directly affects the service life of the pump. Choose the sealing method based on the characteristics of the conveying medium: if the medium contains a lot of impurities, it is recommended to use packing sealing for easy maintenance; If the medium is clean, mechanical seals can be used to reduce leakage; If the medium is corrosive, PTFE packing seal should be used. During assembly, the sealing surface should be flat to avoid leakage caused by tilting.

4. Performance parameter matching

The DHB high-pressure diesel ignition pump needs to be matched with pressure and flow range according to the application scenario. For example, boiler ignition systems typically require the pump body to have a stable high-pressure output capability to determine the fuel atomization effect. At the same time, the temperature and viscosity characteristics of the fuel need to be considered, and the pump should operate stably within the specified delivery temperature to avoid increased vibration or noise caused by high viscosity.

2、 Maintenance Manual

1. Daily inspection and maintenance

Oil management: Regularly check the level of the fuel tank to ensure sufficient oil. Regularly filter or replace hydraulic oil according to the working environment to prevent impurities from entering the system. If the oil shows emulsification or deterioration, it needs to be replaced immediately.

Leakage inspection: Check the pump body, pipelines, and joints daily for leaks, and pay attention to the sealing parts near high-temperature components. When a leak is discovered, it is necessary to promptly tighten or replace the sealing components.

Noise and vibration monitoring: During operation, it is necessary to monitor the pump body noise. If there are abnormal vibrations or intermittent sounds, it may be caused by high viscosity of the medium or component wear. It is necessary to adjust the medium temperature or replace worn parts in a timely manner.

2. Regular maintenance items

Filter cleaning and replacement: Regularly clean or replace the fuel filter according to the frequency of use. When cleaning, it is necessary to rinse the inside of the filter element with clean diesel. If the filter element is damaged, it should be replaced immediately.

Bearing lubrication: Regularly replace the bearing lubricating oil and ensure sufficient lubrication. When not in use for a long time, it is necessary to clean the bearings and apply rust proof grease to prevent rusting.

Performance testing: Regularly record the inlet and outlet pressure, flow rate, and other parameters of the pump, and compare them with the initial data. If performance degradation is found, it is necessary to check the gear clearance, sealing status, or whether the internal flow channel is blocked.

3. Long term suspension management

Evacuation and Cleaning: Before stopping, it is necessary to drain the remaining oil in the pump and clean the external soil and oil stains. If the oil storage tank is located underground, a bottom valve should be installed and the pipeline should be kept full of oil to prevent cavitation.

Rust prevention treatment: Remove rust from cast iron parts such as bottom valves and bends, and apply anti rust paint. The belt driven pump needs to clean the belt and store it properly.

Component inspection: Check the wear of components such as ball bearings, impellers, and pump shafts, and repair or replace them as needed. Screws need to be cleaned and coated with protective grease to prevent rusting.

4. Emergency handling of faults

Abnormal startup: If the pump cannot be started, check the power connection, oil circuit switch, and battery status. After manually turning the coupling to confirm there is no blockage, restart it.

Insufficient pressure: If the inlet and outlet pressure is lower than the rated value, it is necessary to check whether the gear clearance is too large, whether the seal is leaking, or whether the internal flow channel is blocked.

Overheating phenomenon: If the temperature of the pump body is too high during operation, it may be caused by insufficient lubrication or damaged bearings. It is necessary to immediately stop the machine for inspection and replenish lubricating oil or replace the bearings.