压路机液压振动系统典型故障诊断及维修

压路机液压振动系统典型故障诊断及维修

Typical fault diagnosis and maintenance of hydraulic vibration system of roller

1. 典型故障及原因分析

1 typical failures and reasons analysis

故障1：发动机工作正常，开启振动开关后，振动系统不工作。

1: the engine works properly, after the vibration switch, the vibration system does not work.

根据工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 发动机飞轮与振动泵输入轴之间的弹性传动盘脱落或损坏，造成振动液压泵没有动力输入，不能实现能量转换。

(1) the elastic transmission disc between the engine flywheel and the input shaft of the vibration pump can fall off or damage, resulting in the vibration hydraulic pump without power input, and the energy conversion can not be realized.

(2) 振动液压马达与振动轴之间的联轴节损坏，造成振动液压马达动力不能输出。

(2) the coupling vibration between the hydraulic motor and the vibration shaft damage caused by vibration, hydraulic motor power cannot output.

(3) 液压油箱缺油或吸油滤清器严重堵塞，系统主回路内不能及时补油，造成吸空，无法传递动力。

(3) the hydraulic oil tank is lack of oil or oil absorption filter, the main circuit can not fill up the oil in time, resulting in suction, can not pass power.

(4) 电磁换向阀没有或有很小的电流通过，使电磁阀内的先导阀芯不能推动排量控制阀芯动作，从而液压泵的排量控制液压缸不能供油，造成液压泵的斜盘不能倾斜，排量为零。

(4) solenoid valve with no or very small current through, the electromagnetic valve of the pilot valve can not promote displacement control valve action, so as to control the displacement of the hydraulic pump hydraulic cylinder can not supply oil, resulting in hydraulic pump of swash plate can not tilt, the displacement is zero.

(5) 系统补油压力太低或没有，使振动液压泵排量控制液压缸不能正常工作。

(5) the oil pressure of the system is too low or there is no, so that the hydraulic pump can not control the hydraulic cylinder can not work properly.

(6) 振动液压泵或振动液压马达磨损，内泄严重，建立不起系统压力。

(6) the vibration hydraulic pump or vibration hydraulic motor wear and tear, within the serious, can not establish the system pressure.

故障2：振动液压马达转速太低，达不到设计要求。

Fault 2: vibration hydraulic motor speed is too low, can not reach the design requirements.

根据工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 发动机转速没有达到额定值。

(1) the engine speed is not up to the rated value.

(2) 系统补油压力没有达到额定值，不能推动振动液压泵斜盘处于最大排量位置。

(2) the oil pressure without the system is not up to the rated value and can not drive the inclined plate of the vibration hydraulic pump in the maximum displacement position.

(3) 振动轴运动阻力太大，运转不灵活。

(3) the movement of the vibrating shaft is too high and the movement is not flexible.

(4) 振动液压泵或振动液压马达内泄漏，使系统效率降低。

(4) vibration hydraulic pump or hydraulic Madane leakage, so that the system efficiency is reduced.

故障3：系统只能在单一振幅状态下正常工作（即只能在大振幅状态下正常工作，而在小振幅状态不能工作；或者只能在小振幅状态下正常工作，而在大振幅状态下不能工作）。

Fault 3: system can work normally under the single amplitude state (that is, only in the large amplitude under the condition of normal work, and in the small amplitude state cannot work; or only in small amplitude under the condition of normal work, and in large amplitude under the condition of not working).

根据工作原理分析，主要原因有：

According to the principle of work, the main reasons are:

(1) 电磁阀没有或只有很小的电流通过，对应先导阀芯不能正常工作。

(1) the solenoid valve is not or only a small current passed, the corresponding pilot valve can not work.

(2) 振动液压泵内对应某一方向多功能阀损坏，建立不起高压。

(2) the vibration hydraulic pump corresponding to a certain direction of the multi-function valve damage, can not afford to build.

(3) 振动液压泵的排量控制阀内故障使排量控制液压缸只能向一个方向运动。

(3) the displacement control valve of the vibration hydraulic pump can cause the displacement control hydraulic cylinder to move only in one direction..

(4) 振动液压马达内对应某一方向冲洗梭阀阀芯卡死，建立不起高压。

(4) the vibration hydraulic Madane corresponding to a direction flushing shuttle valve spool card, can not afford to build.

2. 诊断及维修

2 diagnosis and maintenance

2.1. 诊断的原则及维修注意事项

The principle of 2.1. diagnosis and maintenance of attention

诊断的一般原则：根据液压系统的工作原理，如下图，由表及里，先机械电器，后液压自身。

The general principles of diagnosis: according to the working principle of the hydraulic system, as shown in the following picture, from the outside to the inside, to mechanical and electrical, hydraulic itself.

维修的一般注意事项：保持液压系统的清洁，防止污物和其它有污染的物质进入系统；只能根据使用的保养说明书使用液压油，禁止不同牌号液压油混加；当更换液压泵或马达后，重新启动液压系统时，首先给液压泵和马达加满液压油，而后把振动液压马达与振动轴脱开，尽可能慢地运转发动机，在不带载荷情况下启动液压系统。当振动液压泵2的Mc测压口处补油压力达到额定值2.4MPa时，再使发动机以额定转速运转，而后分别开启大小振幅振动开关，使振动液压马达无负荷空转。每个振动状态下至少运转5min，以便使液压系统内空气排出。同

General considerations of maintenance: to maintain the cleanliness of the hydraulic system, to prevent dirt and other polluting substances into the system; only according to the use of the use and maintenance manual, hydraulic oil, prohibit different grades of hydraulic oil mixed with; when replacing the hydraulic pump or motor, restart the hydraulic system, first of all to the hydraulic pump and motor is filled with hydraulic oil. Then it vibration hydraulic motor and shaft vibration disengaged, slow running engine as much as possible, in without load under the condition of hydraulic system is started. When the hydraulic vibration pump 2 MC pressure at the mouth of the fill oil pressure reaches the rated value 2.4Mpa, then the engine running at rated speed, and then open a small amplitude vibration switch, the vibration of hydraulic motor no-load idling. At least 5min of each vibration state, so that the air discharge within the hydraulic system. The same

时观察液压油箱油面，待无汽泡冒出时，把振动马达重新装好，必要时添加液压油，而后盖好油箱盖。液压系统工作正常后，应检查螺纹接头和法兰的密封性，必要时紧固。

Observation of hydraulic oil tank surface, to be no bubble burst out, the vibration motor re installed. If necessary, add the hydraulic oil, and cover the fuel tank cap. After the hydraulic system works, check the sealing of the threaded joints and flanges, and fastening when necessary.

2.2. 典型故障的诊断与排除

Diagnosis and removal of 2.2. typical fault

针对故障1“发动机工作正常，开启振动开关后，振动系统不工作”的情况，首先应检查液压油箱油位，吸油滤清器真空表（在连续状态下，当真空表读数0.03MPa时，表示滤芯堵塞，应更换滤芯），排除原因（3）引起的故障。然后，在电磁阀a和b的线圈与电源线插头之间串联一块电流表，开启相应的起振开关，如果电流达到额定值2.5A，则表示电源的电磁阀线圈工作正常，否则，可判断为由原因（4）引起的故障。排除故障（3）、（4）后，如果振动轮不振动，则在补油压力测压口Mc处接4MPa压力表一块。在发动机怠速运转状态下观察压力表读数，当补油压力大于或等于2.4MPa时，则表示正常；当补油压力大于零域或小于2.4MPa时，则表示振动液压泵上的补油压力溢流阀有问题，应检查排除；当补油压力为零时，应先检查传力盘，排除故障原因（1）引起的故障。而后检查振动泵内的补油泵。当补油压力在发动机怠速运转状态下正常时，使发动机在额定转速下运转，分别开启大小振幅状态的振动，再次观察补油压力。正常值为2.2MPa左右；如果补油压力远远低于此值，则把4MPa压力表接在振动液压马达3测压口Ms处并观察其读数，如果Ms处压力亦为2.2MPa左右则表示正常；否则当压力读数特别异常（远远偏低或偏高）时，应先检查振动马达上的冲洗梭阀及低压溢流阀。经查如果二者均正常，则应拆下振动泵上的排量控制阀，观察其是否出现严重泄漏现象。通过以上检查可排除补油压力不正常即原因（5）引起的故障。当发动机怠速运转和在额定转速下运转补油压力均正常时，则在振动泵2的高压测压口MA、MB处接60MPa压力表各一块，分别开启大小振动开关，并观察压力读数。正常情况下：小振幅时MA为高压，初始压力为42MPa~45MPa，连续工作压力14MPa左右；大振幅时MB为高压，初始压力为42MPa~45MPa，连续工作压力22MPa左右。如果振动液压泵2的MA或MB处高压压力很低，则首先应拆下装振动马达的法兰检查联轴节是否损坏，排除由原因（2）引起的故障，而后恢复原状。以上原因排除后，应先检查振动泵2多功能阀上的BYPASS拖阀，再检查多功能阀，观察阀座与阀体是否划伤，必要时更换或修复。排除多功能阀的原因后，应检查泵的排量控制阀，把4MPa压力表接在振动泵排量控制阀压力测压口S1处，并使柴油机在额定转速下运转，正常情况为：开启小振幅开关，S1处压力应近似等于补油压力；关掉振动开关，S1处压力应为零（相对于泵的壳体压力）；同样，开启大振幅开关，检查S2处压力，它也相当于补油压力；关掉开关，S2处压力亦为零。如有异常，则清理阀内的节流口或更换控制阀，而后，如还不能修复，则应拆下联接振动液压泵和液压马达的两个高压软管，用干净的螺塞封住振动液压泵2的A口和B口，拉住柴油机熄火门，短时间启动柴油机，然后，依次开启大小振动，观察振动液压泵测定MA、MB处压力表的读数，如果二者压力均能超过42MPa（不同时），则可判断为振动液压马达损坏，反之，则可判断为振动液压泵损坏，从而排除原因（6）引起的故障。

Aiming at fault "engine working normally, open the vibration switch, vibration system does not work", first of all, we should check the hydraulic oil level in oil tank, oil filter vacuum table (in the continuous state, when the vacuum gauge readings 0.03mpa, said filter plugging, should replace the filter), excluding (3) causes of failure. Then, the electromagnetic valve A and B of the coils and a power supply line between the plug series a current meter and the corresponding vibration switch is opened, if the current reaches the rated value 2.5A, said power supply of the electromagnetic valve coil is normal, otherwise, judgment on the grounds of reason (4) is caused by the fault. After troubleshooting (3) and (4), if the vibration wheel is not vibration, then a 4MPa pressure gauge is received at the oil fill pressure Mc.. Under engine idling to observe the pressure gauge readings, when the fill oil pressure is greater than or equal to 2.4Mpa, said normal; when the oil pressure is greater than zero field or less than 2.4Mpa, hydraulic vibration pump fill oil pressure relief valve has a problem, should check out; when the oil pressure is zero should be, first check the transmission force pan, exclude fault reason (1) caused by the fault. And then check the pump in vibration pump. When the oil pressure in the engine idle operation state, the engine running at the rated speed, respectively, the vibration of the amplitude of the amplitude of the state, and then observe the oil pressure. Normal value is about 2.2 MPa; if the complement of the oil pressure is far below this value, the 4MPa pressure meter is connected in the hydraulic vibration motor 3 pressure export MS office and observe the reading, if MS pressure also is about 2.2 MPa said normal; otherwise when the pressure readings in particular abnormality (far lower or higher) should be first check vibration motor flush shuttle valve and pressure relief valve. If the two are normal, you should remove the vibration on the pump displacement control valve, to observe whether the serious leakage phenomenon. Through the above examination can rule out the oil pressure is not normal that the cause (5) of the failure. When the engine idling and under the rated speed operation fill oil pressure were normal, in vibration pump 2 high pressure manometry Ma and MB at connected 60MPa pressure table, a piece of, respectively, on the size of the vibration switch, and observe the pressure readings. Under normal circumstances: small amplitude Ma is a high voltage, initial pressure 42MPa~45MPa, continuous working pressure is 14MPa around; the large amplitude MB for high pressure, initial pressure 42MPa~45MPa, continuous working pressure 22Mpa around. If the hydraulic vibration pump 2 mA or MB at high pressure is very low, it should first split whether the damage to the bottoms of the vibration motor check the flange coupling, excluding by (2) causes of the fault, and then restore the status quo ante. After the above reasons are excluded, should first check the vibration pump 2 multi-function valve on the BYPASS drag valve, then check the multi-function valve, observe the valve seat and valve body is scratched, if necessary, replace or repair. After exclusion of the multifunctional valve, should check the pump displacement control valve to 4MPa pressure meter is connected in the vibration pump displacement control valve pressure testing port S1, and the engine at rated speed operation, normal: the small amplitude switch, S1 pressure should be approximately equal to fill the hydraulic force; vibration switch is switched off, the S1 pressure should be zero (relative to the pump casing pressure); similarly, open the large amplitude switch, check the S2 pressure. It also equivalent to fill oil pressure; turn off the switch, S2 pressure is also zero. 2 and if abnormal, clean the valve orifice or replace the control valve, such as can not repair, should remove the coupling vibration of hydraulic pump and hydraulic motor of the two high-pressure hose, clean plug to seal the hydraulic vibration pump port a and B, pull diesel engine flameout door, short time between the start of diesel engine, and then, followed by the opening size of the vibration, the observation of vibration hydraulic pump for Ma, MB pressure gauge readings, if the two pressure than 42MPa (not simultaneously), can be judged for the vibration of hydraulic motor damage. On the other hand, can be judged for the vibration of hydraulic pump damage, so as to eliminate the cause (6) caused by the fault.

针对故障2“振动液压马达转速太低，达不到设计要求”的情况，首先应检查液压油箱油位、吸油滤真空表，其次，用转速表或频率仪检查发动机转速，标定额定转速为2300r/min。如果该转速正常，则可排除故障原因（1）。而后测量振动频率。大振幅时，振动频率为28Hz（1680r/min）；小振幅时，振动频率为25Hz（2100r/min）。当频率下降小于10%时，调整振动泵2上的双向手动排量调节装置，分别依照高低振动频率调整转速。

For fault 2 "vibration of hydraulic motor speed is too low, amounting to less than the design requirements", first of all, we should check the hydraulic oil level in oil tank, oil filter vacuum gauge. Secondly, tachometer or frequency of the instrument to check the engine speed, calibration rated speed 2300r/min. If the speed is normal, the cause of failure (1) can be excluded.. And then measure the vibration frequency. The vibration frequency of the large amplitude is 28Hz (1680r/min); the vibration frequency is 25Hz (2100r/min) when the small amplitude is. When the frequency drops is less than 10%, the bidirectional manual displacement adjustment device of the vibration pump 2 is adjusted according to the vibration frequency of the vibration frequency.

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