KCB gear pump (kcb stainless steel gear pump) common fault elimination：

At present, KCB gear pump (kcb stainless steel gear pump) is widely used in dump trucks and engineering machinery operating mechanisms. The common faults and troubleshooting methods are described below for reference.
1. Causes and elimination of vibration and noise
(1) Inhaling air
The pump body of the 1KCB gear oil pump is in direct contact with the two end caps. If the flatness of the contact surface does not meet the specified requirements, the pump can easily draw in air during operation; likewise, between the end cap and the gland of the pump Also for direct contact, the air is also easy to invade; if the gland is a plastic product, it will be deformed due to damage or deformation due to temperature changes, and the air will enter the air. The way to eliminate this kind of failure is: when the flatness of the pump body or the pump cover does not meet the specified requirements, it can be ground back and forth on the flat plate with gold steel sand in a figure-eight line, or it can be ground on a surface grinding machine. The flatness is not more than 5μm, and the verticality of the plane and the hole needs to be ensured; for the leakage of the pump cover and the gland, an adhesive such as epoxy resin can be used for sealing.

2 The pump shaft is generally sealed with a skeleton oil seal. If the spring of the clamping lip is detached, or the oil is packaged backwards, or the lip is pulled or aged, the rear end of the oil seal is often under negative pressure and the air is taken in. Generally, the new oil seal can be replaced.
3 The oil in the fuel tank is not enough, or the suction pipe port is not inserted below the oil surface, the pump will take in the air. At this time, the oil should be replenished to the oil mark line; if the oil return pipe is exposed to the oil surface, sometimes it will be The instantaneous negative pressure in the system causes the air to back into the system, so the return pipe should generally be inserted below the oil level.
The installation position of the 4KCB gear pump (kcb stainless steel gear pump) is too high from the oil level, especially when the pump speed is reduced, because the pump suction chamber does not have the necessary vacuum to cause insufficient oil absorption to draw in air. At this time, the relative height of the pump and the oil surface should be adjusted to meet the specified requirements.
5 The oil suction filter is blocked by dirt or its capacity is too small, resulting in increased suction resistance and intake of air. In addition, the larger diameter of the inlet and outlet ports may also bring in air. At this time, the oil filter can be cleaned, or an oil filter with a larger capacity and an appropriate diameter of the inlet and outlet can be selected. In this way, it not only prevents the inhalation of air, but also prevents noise.
(2) Mechanical reasons
1 The connection between the pump and the coupling generates vibration and noise due to irregular requirements. The coupling should be adjusted as required.
2 Noise is generated due to dirt and oil entering the pump causing wear and tear on components such as gears. The oil should be replaced, the filter should be reinforced, and the pump should be disassembled; the gears with severe wear must be repaired or replaced.
3 Damage or wear of the pump parts will cause vibration and noise: if the tooth shape error or the weekly error is large, the two gears have poor contact, the tooth surface roughness is high, the length of the common normal line is too poor, the back side gap is too small, and the two meshing gears The contact area is not in the indexing circle position or the like. At this point, the gear can be replaced or the gear pair can be ground. At the same time, the bearing needle holder damage, the long shaft journal and the needle wear, etc., can cause the bearing to rotate poorly and produce mechanical noise. At this time, the gear pump needs to be dismantled and the needle bearing replaced.
The axial assembly clearance of the 4 KCB gear pump (kcb stainless steel gear pump) is too small; the sliding joint between the gear end face and the front and rear end caps cannot be carefully removed due to the burrs of the gear before assembly, so that the joint is pulled during operation, so that The leakage is large, causing the output flow to decrease; the dirt enters the pump and wedges into the gap between the gear end face and the front and rear end caps to pull the mating surface, causing the high and low pressure chambers to communicate due to the radial strained groove, so that the output The flow rate is reduced. The above measures should be used to repair the above conditions. Disassemble the gear pump, appropriately increase the axial clearance, that is, the end face of the grinding gear; use a surface grinder to smooth the front and rear cover end faces and the gear end faces, and remove the burrs on the gear teeth (cannot be chamfered); The depth dimension of the unloading groove on the end face of the end cap may vary, and the width should be appropriately increased.
(3) Other reasons
High viscosity of the oil also produces noise, and it is necessary to use an oil of appropriate viscosity.

2, KCB gear pump (kcb stainless steel gear pump) output flow is insufficient
1 The high oil temperature will lower its viscosity and increase the internal leakage, which will reduce the pump output flow. Measures should be taken to determine the cause; for medium and high pressure gear pumps, the seal should be inspected for damage.
2 If the viscosity of the selected oil is too high or too low, the output flow of the pump will be reduced, and oil with acceptable viscosity should be used.
3KCB gear pump can not be reversed. If the pump body is installed, it will cause the oil pressure chamber and the oil suction chamber to be short-circuited locally, so that the flow rate can be reduced or even oil can not be sucked. At this point, the steering of the pump should be checked.
4 The engine speed is not enough, causing the flow to decrease. The cause should be identified and excluded.

3, poor rotation
1 Axial clearance or radial clearance is too small. Re-adjust
2 There is dirt in the pump. Disintegrate to remove foreign objects.
3 assembly is wrong. The machining reference surface of the two pin holes of the gear pump is not the assembly reference surface. If the pin is driven in first, and then the screw is tightened, the pump will not move. The correct way is to tighten the screw while turning the gear pump, and finally drill the pin hole and drive the pin.
4 The pump has poor coaxiality with the engine coupling. The coaxiality should be within 0.1mm.
5 The parts inside the pump are not demagnetized. All parts must be demagnetized before assembly.
6 The needle roller sleeve is unqualified or the needle is broken. Repair or replace.
7 The working oil outlet is blocked. Remove foreign objects.

4, fever
1 The causes of the poor rotation of the gear pump can cause the gear pump to heat up. The elimination method can also be implemented with reference to it.
2 oil viscosity is too high or too low. Re-select oil.
3 Side plates, bushings and gear end faces are severely rubbed. Repair or replace.
4 The ambient temperature is high, the volume of the fuel tank is small, and the heat dissipation is poor, which will cause the pump to heat up. Should be handled separately.
5. Repair of main parts of KCB gear oil pump (kcb stainless steel gear pump)
(1) gear
1 Tooth shape repair: remove the strained or multi-angled parts with fine sand cloth or oil stone, then change the gear meshing surface and properly research it, and finally clean it; the severe wear can be observed with the naked eye. Parts should be replaced.
2 Face repair: the end face of the gear wears due to the relative rotation of the bearing seat or the front and rear covers. When it is light, it will take up the line. The burr marks can be ground and polished by grinding method. When the wear is serious, the gear should be placed on the surface grinder. Grinding. It should be noted that the two gears must be placed on a surface grinder for grinding. The purpose is to ensure that the difference between the thickness of the two gears is within 5 μm. At the same time, the perpendicularity of the end faces and the holes and the parallelism of the two end faces must be 5 μm. Within the scope, use the oil stone to make the sharp edge blunt, but do not chamfer, so that there is no burr, flashing edge.
3 When the meshing surface of the gear wears, the application of the oil stone removes the burr generated by the wear; at the same time, the gear meshing orientation is changed, so that the tooth surface which is not engaged with the meshing work is engaged, so that the original working performance can be ensured. It can also extend the working life of the gear.
(2) KCB gear oil pump (kcb stainless steel gear pump) pump body
The wear of the pump body is mainly on the side where the inner cavity is in contact with the circle of the gear, and occurs mostly on the oil suction side. If the pump body is symmetrical, the pump body can be turned over 180 degrees before use; if the pump body is asymmetric, the plated bronze alloy process or brush plating method should be used to repair the wear parts of the pump body cavity.
(3) bearing race
The wear of the bearing race is generally on the end face that is in contact with the gear and the inner bore that is in contact with the needle roller. When the end face is worn or the wire is pulled up, the four bearing races can be placed on the surface grinder, and the roughened end faces are grounded on the basis of the side not in contact with the gears, and the precision should be within the range of 10 μm. The bearing races are generally less worn and can be ground if the wear is severe; or the hole diameter is appropriately increased and the needle roller is re-selected; or the bearing race is replaced.
(4) long and short axes
The failure of the long and short shafts is mainly caused by the contact with the needle bearing. If the wear is slight, a buff finish (and a new needle bearing) can be used; if the wear is severe or broken, it needs to be repaired by chrome plating or reworked. When reworking, the requirements of the parallelism and symmetry of the keyway on the long and short axes should be satisfied; the matching clearance between the flat key and the gear keyway installed on the shaft should not be too large; the shaft must not be in the gear bore. Radial oscillation is generated; the coaxiality of the journal and the mating surface of the mounting gear portion shall not exceed 10 μm, and the coaxiality of the journals at both ends shall not exceed 20-30 μm.KCB gear pump (kcb stainless steel gear pump) common fault elimination

At present, KCB gear pump (kcb stainless steel gear pump) is widely used in dump trucks and engineering machinery operating mechanisms. The common faults and troubleshooting methods are described below for reference.
1. Causes and elimination of vibration and noise
(1) Inhaling air
The pump body of the 1KCB gear pump is in direct contact with the two end caps. If the flatness of the contact surface does not meet the specified requirements, the pump can easily draw in air during operation; likewise, between the end cap and the gland of the pump Also for direct contact, the air is also easy to invade; if the gland is a plastic product, it will be deformed due to damage or deformation due to temperature changes, and the air will enter the air. The way to eliminate this kind of failure is: when the flatness of the pump body or the pump cover does not meet the specified requirements, it can be ground back and forth on the flat plate with gold steel sand in a figure-eight line, or it can be ground on a surface grinding machine. The flatness is not more than 5μm, and the verticality of the plane and the hole needs to be ensured; for the leakage of the pump cover and the gland, an adhesive such as epoxy resin can be used for sealing.
2 The pump shaft is generally sealed with a skeleton oil seal. If the spring of the clamping lip is detached, or the oil is packaged backwards, or the lip is pulled or aged, the rear end of the oil seal is often under negative pressure and the air is taken in. Generally, the new oil seal can be replaced.
3 The oil in the fuel tank is not enough, or the suction pipe port is not inserted below the oil surface, the pump will take in the air. At this time, the oil should be replenished to the oil mark line; if the oil return pipe is exposed to the oil surface, sometimes it will be The instantaneous negative pressure in the system causes the air to back into the system, so the return pipe should generally be inserted below the oil level.
The installation position of the 4KCB gear pump (kcb stainless steel gear pump) is too high from the oil level, especially when the pump speed is reduced, because the pump suction chamber does not have the necessary vacuum to cause insufficient oil absorption to draw in air. At this time, the relative height of the pump and the oil surface should be adjusted to meet the specified requirements.
5 The oil suction filter is blocked by dirt or its capacity is too small, resulting in increased suction resistance and intake of air. In addition, the larger diameter of the inlet and outlet ports may also bring in air. At this time, the oil filter can be cleaned, or an oil filter with a larger capacity and an appropriate diameter of the inlet and outlet can be selected. In this way, it not only prevents the inhalation of air, but also prevents noise.
(2) Mechanical reasons
1 The connection between the pump and the coupling generates vibration and noise due to irregular requirements. The coupling should be adjusted as required.
2 Noise is generated due to dirt and oil entering the pump causing wear and tear on components such as gears. The oil should be replaced, the filter should be reinforced, and the pump should be disassembled; the gears with severe wear must be repaired or replaced.
3 Damage or wear of the pump parts will cause vibration and noise: if the tooth shape error or the weekly error is large, the two gears have poor contact, the tooth surface roughness is high, the length of the common normal line is too poor, the back side gap is too small, and the two meshing gears The contact area is not in the indexing circle position or the like. At this point, the gear can be replaced or the gear pair can be ground. At the same time, the bearing needle holder damage, the long shaft journal and the needle wear, etc., can cause the bearing to rotate poorly and produce mechanical noise. At this time, the gear pump needs to be dismantled and the needle bearing replaced.
The axial assembly clearance of the 4KCB gear pump (kcb stainless steel gear pump) is too small; the sliding joint between the gear end face and the front and rear end caps cannot be carefully removed due to the burrs of the gear before assembly, so that the joint is pulled during operation, so that The leakage is large, causing the output flow to decrease; the dirt enters the pump and wedges into the gap between the gear end face and the front and rear end caps to pull the mating surface, causing the high and low pressure chambers to communicate due to the radial strained groove, so that the output The flow rate is reduced. The above measures should be used to repair the above conditions. Disassemble the gear pump, appropriately increase the axial clearance, that is, the end face of the grinding gear; use a surface grinder to smooth the front and rear cover end faces and the gear end faces, and remove the burrs on the gear teeth (cannot be chamfered); The depth dimension of the unloading groove on the end face of the end cap may vary, and the width should be appropriately increased.
(3) Other reasons
High viscosity of the oil also produces noise, and it is necessary to use an oil of appropriate viscosity.
2, KCB gear pump (kcb stainless steel gear pump) output flow is insufficient
1 The high oil temperature will lower its viscosity and increase the internal leakage, which will reduce the pump output flow. Measures should be taken to determine the cause; for medium and high pressure gear pumps, the seal should be inspected for damage.
2 If the viscosity of the selected oil is too high or too low, the output flow of the pump will be reduced, and oil with acceptable viscosity should be used.
3KCB gear pump can not be reversed. If the pump body is installed, it will cause the oil pressure chamber and the oil suction chamber to be short-circuited locally, so that the flow rate can be reduced or even oil can not be sucked. At this point, the steering of the pump should be checked.
4 The engine speed is not enough, causing the flow to decrease. The cause should be identified and excluded.
3, poor rotation
1 Axial clearance or radial clearance is too small. Re-adjust
2 There is dirt in the pump. Disintegrate to remove foreign objects.
3 assembly is wrong. The machining reference surface of the two pin holes of the gear pump is not the assembly reference surface. If the pin is driven in first, and then the screw is tightened, the pump will not move. The correct way is to tighten the screw while turning the gear pump, and finally drill the pin hole and drive the pin.
4 The pump has poor coaxiality with the engine coupling. The coaxiality should be within 0.1mm.
5 The parts inside the pump are not demagnetized. All parts must be demagnetized before assembly.
6 The needle roller sleeve is unqualified or the needle is broken. Repair or replace.
7 The working oil outlet is blocked. Remove foreign objects.
4, fever
1 The causes of the poor rotation of the gear pump can cause the gear pump to heat up. The elimination method can also be implemented with reference to it.
2 oil viscosity is too high or too low. Re-select oil.
3 Side plates, bushings and gear end faces are severely rubbed. Repair or replace.
4 The ambient temperature is high, the volume of the fuel tank is small, and the heat dissipation is poor, which will cause the pump to heat up. Should be handled separately.
5. Repair of main parts of KCB gear pump (kcb stainless steel gear pump)
(1) gear
1 Tooth shape repair: remove the strained or multi-angled parts with fine sand cloth or oil stone, then change the gear meshing surface and properly research it, and finally clean it; the severe wear can be observed with the naked eye. Parts should be replaced.
2 Face repair: the end face of the gear wears due to the relative rotation of the bearing seat or the front and rear covers. When it is light, it will take up the line. The burr marks can be ground and polished by grinding method. When the wear is serious, the gear should be placed on the surface grinder. Grinding. It should be noted that the two gears must be placed on a surface grinder for grinding. The purpose is to ensure that the difference between the thickness of the two gears is within 5 μm. At the same time, the perpendicularity of the end faces and the holes and the parallelism of the two end faces must be 5 μm. Within the scope, use the oil stone to make the sharp edge blunt, but do not chamfer, so that there is no burr, flashing edge.
3 When the meshing surface of the gear wears, the application of the oil stone removes the burr generated by the wear; at the same time, the gear meshing orientation is changed, so that the tooth surface which is not engaged with the meshing work is engaged, so that the original working performance can be ensured. It can also extend the working life of the gear.
(2) KCB gear pump (kcb stainless steel gear pump) pump body
The wear of the pump body is mainly on the side where the inner cavity is in contact with the circle of the gear, and occurs mostly on the oil suction side. If the pump body is symmetrical, the pump body can be turned over 180 degrees before use; if the pump body is asymmetric, the plated bronze alloy process or brush plating method should be used to repair the wear parts of the pump body cavity.
(3) bearing race
The wear of the bearing race is generally on the end face that is in contact with the gear and the inner bore that is in contact with the needle roller. When the end face is worn or the wire is pulled up, the four bearing races can be placed on the surface grinder, and the roughened end faces are grounded on the basis of the side not in contact with the gears, and the precision should be within the range of 10 μm. The bearing races are generally less worn and can be ground if the wear is severe; or the hole diameter is appropriately increased and the needle roller is re-selected; or the bearing race is replaced.
(4) long and short axes
The failure of the long and short shafts is mainly caused by the contact with the needle bearing. If the wear is slight, a buff finish (and a new needle bearing) can be used; if the wear is severe or broken, it needs to be repaired by chrome plating or reworked. When reworking, the requirements of the parallelism and symmetry of the keyway on the long and short axes should be satisfied; the matching clearance between the flat key and the gear keyway installed on the shaft should not be too large; the shaft must not be in the gear bore. Radial oscillation is generated; the coaxiality of the journal and the mating surface of the mounting gear portion shall not exceed 10 μm, and the coaxiality of the journals at both ends shall not exceed 20-30 μm.

The processing flow of the pump is mostly similar. Now take the KCB gear pump as an example to talk about the processing flow of our company.

First, various castings, including pump bodies, pump covers, raw steel, etc., are purchased by the foundry. The warehouse is stored and quality inspection is carried out. Through strict checks, qualified castings are transported to the workshop for a series of processing and finally assembled into pump heads.
Secondly, in terms of process, the technical department designs the pump type and carries out the design of the process flow. It is sent to the workshop workers to process according to the process flow of each pump type, including car, milling, drilling, hobbing, grinding and drawing. Line and other procedures, each processing of the first piece must be handed over to the measuring room for strict inspection, after the qualified can be batch processing. Highly accurate parts are machined by the machining center. After the parts are processed, they are sent to the inspection station, and the professional inspectors inspect the parts one by one. Overall, the workshop roughed the parts of the KCB gear pump and then sent it to the assembly shop for finishing. After this series is completed, it is sent to the laboratory for the first test. The test is successful before it can be sold.

KCB18.3 gear pump (KCB 18.3),capacity: 18.3 L/min or 1.1 m³/h, discharge pressure:1.45 MPA, KCB 18.3 gear pump another nameris 2cy1.1/1.45 gear pump
Motor with 1.5 kw-4.
Port size: 3/4″ flange connection
Material: cast iron gear pump, copper gear pump, 304、316、316L stainless steel gear pump, alloy steel

KCB33.3 gear pump (KCB 33.3),capacity: 33.3 L/min or 2 m³/h, discharge pressure:1.45 MPA, KCB 33.3 gear pump another nameris 2cy2/1.45 gear pump
Motor with 2.2 kw-4.
Port size: 3/4″ flange connection
Material: cast iron gear pump, copper gear pump, 304、316、316L stainless steel gear pump, alloy steel

KCB55 gear pump (KCB 55),capacity: 55 L/min or 3.3 m³/h, discharge pressure:0.33 MPA, KCB 55 gear pump another nameris 2cy3.3/0.33 gear pump
Motor with 1.5 kw-4.
Port size: 1″ flange connection
Material: cast iron gear pump, copper gear pump, 304、316、316L stainless steel gear pump, alloy steel

1. When the KCB gear pump is tightening the end face bolts, the force should be symmetrical and uniform; If you encounter a click, loosen the bolt and tighten it.
2. KCB gear pump drive shaft can not bear any radial vertical force, and lateral drive modes such as belt, chain and gear are prohibited.
3. The connection between the drive shaft of the base plate and the motor shaft is made of a flexible coupling or a chain coupling.

MODEL: KCB-18.3,KCB-33.3,KCB-55,KCB-83.3,KCB-135,KCB-200,KCB-300,KCB-483.3,KCB-633, KCB-960,KCB-1200,KCB-1600,KCB-2500,KCB-3800,KCB-5400,KCB-7600,KCB-9600.
Caliber：3/4 “-14 ”
Capacity: 18.3-9600 lpm
Flow rate: 1.1 m³/h-570 m³/h
Rotational speed: 740 r/min-1440 r/min
Discharge pressure: 0.28 Mpa-1.45 Mpa
Suction head: 3-4 m
Motor power: 1.5KW-250KW.

The KCB gear pump is equipped with a pair of slewing gears in the pump body, one active and one passive. The two working parts in the pump are divided into two separate parts by the mutual engagement of the two gears. A is the suction chamber and B is the discharge chamber. When the gear oil pump is in operation, the driving gear drives the driven gear to rotate. When the gear is engaged to disengage, a partial vacuum is formed on the suction side (A), and the liquid is sucked. The inhaled liquid fills the respective valleys of the gear and is brought to the discharge side (B). When the gear enters the mesh, the liquid is squeezed out to form a high-pressure liquid and exit the pump through the pump discharge port. KCB gear pumps are widely used in petroleum, chemical, marine, electric power, grain and oil, food, building materials, metallurgy and national defense research. The gear oil pump is suitable for conveying lubricating oils without solid particles and fibers, non-corrosive, temperature not higher than 150 ° C, viscosity 5 to 1500 cst or other liquids similar in lubricating oil. Try various types of occasions where outdoor installation and process in the coagulation and alpine regions require heat preservation at room temperature.
KCB gear pumps generally transport more acid-base media, and such media tend to have very low viscosity. Due to the large coefficient of thermal expansion of 304 stainless steel, the general manufacturer is likely to cause the pump to lock and hold the shaft when it is assembled with the pump. Therefore, when the stainless steel KCB gear pump is assembled, the clearance will be too large. some. Due to the low viscosity of the conveying medium, the large internal clearance of the pump will cause the stainless steel gear pump to not suck or flow and the head is insufficient. For the inspection of the KCB gear pump, refer to the following standard steps:

1. The pump can be decomposed in order. After disassembly, the parts should be cleaned and checked one by one to see if they are cracked, damaged or worn. If there are serious defects, they should be replaced.
2. Check the pump body and pulley for wear and damage, and replace if necessary.
3, oil seal and seat repair: oil seals such as wear and groove, can be smoothed with abrasive cloth, if the wear is too serious should be replaced; oil seal seat if there are rough scratches, can be repaired. Replace the new oil seal assembly during overhaul.
4. KCB gear pump can be repaired when it has the following damages: the length is less than 30mm, and it does not extend to the crack of the bearing housing hole; KCB gear pump is equipped with control valve, which can automatically protect the motor when the pump is overloaded. However, it cannot be used as a normally open relief valve to regulate the working pressure of the pump.
5. Check if the bearing is flexible or has abnormal noise. If there is any problem with the bearing, it should be replaced.
6. After installing the KCB gear pump, turn it by hand, the pump shaft should be free of jams, and the impeller and pump casing should be free from rubbing. Then check the pump’s oil discharge. If there is a problem, the coolant can’t work, its performance will not be effectively played, and then it will affect the work of the engine. Therefore, it is necessary to strengthen the inspection and maintenance of the KCB gear pump.

At present, the KCB gear pump products we often see on the market are often made of stainless steel. In fact, the KCB gear pump is not only stainless steel in terms of material. We always see the stainless steel KCB gear pump. It is rare to see other materials. This is mainly related to the user’s habits. If we think about the underlying reasons, it is not difficult to find that the stainless steel KCB gear pump has obvious advantages in practical applications.
The main difference between the cast iron KCB gear pump and the stainless steel KCB gear pump is the raw material. In contrast, the stainless steel gear pump market has advantages over the cast iron pump, but it is also not conducive to the stainless steel KCB gear pump. KCB stainless steel gear oil pump is made of 304 or 316 material into pump body, main shaft, gear and bushing. When the medium to be transported has corresponding corrosiveness, the material of the casting body can not meet the requirements. It is necessary to choose stainless steel gear pump. Or if the liquid is food grade, it also needs to use food grade stainless steel gear pump, and the temperature requirement does not exceed 250 degrees. If it exceeds 250 degrees, the customer will communicate with our sales, we will improve when we arrange production. Process to meet high temperature requirements and extend service life. KCB gear pump body adopts forging process, all parts of pump body are nitrided to enhance wear resistance. Under normal circumstances, stainless steel KCB gear oil pump adopts packing seal form. When the working environment requires no leakage, then we A stainless steel corrosion-resistant mechanical seal process is used. KCB gear pumps use involute spur gears. When the medium to be conveyed is thicker, the involute helical gears are used. Another feature of the KCB gear pump is that the gear and the shaft are made in one piece, so that the rigidity and durability of the KCB gear pump will be greatly extended.