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Serial Number Fault Phenomenon Cause Solution 1 Pump fails to start (1) The valve stem of the inlet valve is broken, preventing the valve from opening. (2) Water accumulates inside the cylinder. (3) The rocker arm pin has come loose or the conical pin is broken. (4) The piston rings in the steam and oil cylinders are damaged. (5) Excessive wear gap in the cylinder. (6) Poor contact between the valve plate and the valve seat. (7) Insufficient steam pressure. (8) The piston rod is in the middle position, causing the valve to close. (9) The discharge valve plate is installed incorrectly, blocking the outlet. (1) Replace the valve or its stem. (2) Open the drain valve to remove water from the cylinder. (3) Reinstall the rocker arm pin and replace the conical pin. (4) Replace the piston rings in the oil cylinder. (5) Replace the cylinder or piston rings. (6) Grind and polish the valve plate and valve seat. (7) Adjust the steam pressure. (8) Adjust the position of the piston rod. (9) Reinstall the discharge valve correctly. 2 Pump becomes vacuumed (1) High inlet temperature causes vaporization, or low liquid level allows air to be drawn in. (2) The inlet valve is not open or is only partially open. (3) The piston nut is loose. (4) The inlet valve gasket is damaged, allowing communication between the inlet and outlet. (5) Wear in the cylinder liner causes the piston rings to fail. (1) Lower the inlet temperature, maintain an appropriate liquid level, or adjust the number of reciprocations. (2) Open the inlet valve to the appropriate degree or adjust the number of reciprocations. (3) Tighten the piston nut. (4) Replace the inlet valve gasket. (5) Replace the cylinder liner or piston rings. 3 Noise or vibration occurs (1) Excessive piston stroke or vaporization leading to vacuum. (2) Loose piston nut or piston rod nut. (3) Loose cylinder liner. (4) Fragments from a broken valve fall into the cylinder. (5) Loose foundation bolts. (6) Loose connection at the crosshead center bracket. (1) Adjust the piston stroke and number of reciprocations. (2) Tighten the piston nut and piston rod nuts. (3) Tighten the cylinder liner screws. (4) Remove fragments from the cylinder and replace the valve. (5) Secure the foundation bolts. (6) Repair or replace the crosshead. 4 Leakage of oil or air from the gland (1) Wear on the piston rod or uneven surface. (2) Damaged packing. (3) The packing gland is not tightened properly or there is insufficient packing. (1) Replace the piston rod. (2) Replace the packing. (3) Add more packing or tighten the gland. 5 Overheating of the cylinder piston rod (1) Failure of the check valve in the injector. (2) Insufficient lubrication. (3) Packing is too tight. (1) Replace the check valve. (2) Apply sufficient lubricant. (3) Loosen the packing gland. 6 Unstable pressure (1) Valve does not close properly or spring tension is uneven. (2) Piston rings are not flexible within their grooves. (1) Grind the valve or replace the spring. (2) Adjust the fit between the piston rings and their grooves. 7 Insufficient flow rate (1) Valve is not sealed properly. (2) Excessive gap between piston rings and cylinder liner. (3) Too few reciprocations. (4) Short stroke length. (1) Grind or replace the valve, adjust the spring. (2) Replace the piston rings or cylinder liner. (3) Adjust the number of reciprocations. (4) Adjust the stroke length