Maintenance and repair methods for ATOS piston pumps
$277.02
ATOS piston pumps are divided into two types: pressure-fed and self-priming. Pressure-fed hydraulic pumps mostly use pressurized oil tanks, and some pumps have a built-in replenishing pump that supplies pressurized oil to the pump inlet. Self-priming hydraulic pumps have strong self-priming capabilities and require no external oil supply. With pressurized hydraulic tanks, after each machine start-up, the hydraulic tank must reach the required pressure before operation. Starting the machine when the hydraulic tank pressure is insufficient can cause the slip plate inside the pump to detach, resulting in abnormal wear of the return plate and pressure plate within the pump body.
Brand
ATOS/Italian Atos
Application Areas
Chemical, Petroleum, Energy, Electrical, General
ATOS Hydraulic Pumps, ATOS Piston Pumps, ATOS Gear Pumps, ATOS Vane Pumps, ATOS Cylinders, ATOS Relief Valves
ATOS Piston Pump Maintenance and Repair Methods
As follows:
The Italian ATOS piston pump uses a supplementary oil pump for oil supply. After 3000 hours of use, operators should check the piston pump 1-2 times daily, checking if the hydraulic pump's operating sound is normal. If a decrease in hydraulic cylinder speed or stalling is observed, the supplementary oil pump should be disassembled and inspected to check for scratches on the impeller edges and excessive clearance in the internal gear pump. For self-priming piston pumps, the hydraulic oil level in the tank must not be lower than the lower limit of the oil level gauge; a sufficient quantity of hydraulic oil must be maintained. The higher the cleanliness of the hydraulic oil, the longer the service life of the hydraulic pump. The most critical component of the Italian ATOS piston pump is the bearing. If the bearing has clearance, the normal clearance of the three pairs of friction surfaces inside the hydraulic pump cannot be guaranteed. This also damages the hydrostatic support oil film thickness of each friction surface, reducing the service life of the piston pump bearing. According to data provided by the hydraulic pump manufacturer, the average service life of a bearing is 10,000 hours; exceeding this value requires replacement. Without professional testing equipment, the clearance of a disassembled bearing cannot be detected; it can only be visually inspected. If scratches or discoloration are found on the roller surface, the bearing must be replaced.
When replacing bearings in an Italian ATOS piston pump, pay attention to the letters and model number of the original bearing. Piston pump bearings are mostly high-load-capacity bearings; it is best to purchase products from the original manufacturer and of the original specifications. If replacing with a different brand, consult an experienced bearing specialist to refer to a table for the correct replacement, in order to maintain the bearing's precision grade and load capacity.
The service life of an Italian ATOS piston pump is related to routine maintenance, the quantity and quality of the hydraulic oil, and the cleanliness of the oil. Avoiding wear caused by particles in the oil on the piston pump's friction pairs is also an effective way to extend the piston pump's lifespan. When replacing parts during maintenance, original manufacturer parts should be used whenever possible. These parts are sometimes more expensive than imitations, but their quality and stability are better. Purchasing cheaper imitations may seem like a short-term saving, but it introduces hidden dangers and could cause greater damage to the piston pump.
The Italian ATOS piston pump's distributor plate comes in two forms: flat and spherical. For spherical distributors, shallow scratches on the cylinder block's distributor surface can be repaired by grinding. For deeper grooves on the cylinder block's distributor surface, surface engineering techniques should be used to fill the grooves before grinding. Blind grinding should be avoided to prevent thinning of the copper layer or oil leakage through the steel base. Italian ATOS piston pumps can also be powered by frequency converters. Engineers at Shanghai Zhengyi point out that in actual production, piston pumps typically operate by regulating their working state through pressure or flow rate. When the actual pressure exceeds the required pressure, an overflow valve is used to regulate the pressure, maintaining a stable operating pressure by releasing the excess. Meanwhile, the motor runs continuously at full speed, resulting in constant power consumption.
When the Italian ATOS piston pump uses overflow to regulate pressure and flow, some excess pressure overflows back into the original system, causing wasted power and low efficiency. However, with the Chuangjie energy-saving frequency converter, the overflow valve can be permanently closed, and the frequency converter automatically adjusts the operating pressure to maintain stability and track the equipment's pressure. This achieves automated control and saves energy. The biggest advantage of this regulation method is its ability to reduce the piston pump's operating energy consumption, achieving energy savings of over 30%.
