Find the cause of the fault from the following three points during maintenance and improve the system: (1) Check the internal leakage of the boom cylinder. The simple method of zui is to raise the boom to see if it has a clear free fall. If the drop is obvious, remove the cylinder of the ultra-high pressure manual pump and the seal should be replaced if it is worn.
(2) Check the pilot valve. First clean the safety valve and check if the spool is worn. If it is worn, it should be replaced. If there is no change after the safety valve is installed, check the wear of the valve stem of the control valve. The clearance limit is generally 0.06mm. If the wear is serious, it should be replaced.
(3) Measure the pressure of the ultra high pressure manual pump. If the pressure is low, then adjust the pressure applied is still not tune up, then pump serious wear and tear. In general, the main reasons for the failure to lift the boom are:
a. The hydraulic pump is severely worn. The pump leakage is serious at low speed operation; the ultra-high pressure manual pump is slightly improved at high speed operation, but the volumetric efficiency is significantly reduced due to the wear and internal leakage of the pump, and it is difficult to reach the rated pressure. Hydraulic exacerbated long working wear, temperature rise, thereby causing wear of hydraulic components and seals aging, damage, loss of sealing capacity, hydraulic oil deterioration, leading to failure after zui.
b. The selection of hydraulic components is unreasonable. The boom cylinder is 70/40 non-standard series, and the seals are also non-standard parts. The manufacturing cost is high and the seal replacement is inconvenient. The cylinder diameter of the boom cylinder is small, which will inevitably make the system set high pressure. c. High pressure hand pump hydraulic system design is unreasonable. The control valve and the full hydraulic steering gear are connected in series with a single pump. The safety valve is set to a pressure of 16 MPa, and the rated working pressure of the hydraulic pump is also 16 MPa. Hydraulic pumps often work under full load or a long time overload (high pressure) situation, and the system has a hydraulic impact, long-term oil changes, hydraulic oil contaminated, exacerbated by a hydraulic pump wear, so that the hydraulic pump pump shell burst (after have been found Such a fault).
Ultra-high pressure manual pump improvement and effect (l) Improved hydraulic system design. After many demonstrations, Zui adopts the advanced priority valve and load sensing full hydraulic steering gear. The new system can preferentially distribute the flow according to the steering requirements. No matter the load size or the steering wheel speed, the oil supply is sufficient. work feeding means may all be part of the circuit used, thereby eliminating the power loss due to excessive fuel supply caused by the steering circuit, to improve the system efficiency and reduce the operating pressure of the high pressure hand pump.
(2) Optimize the design of the boom cylinder and the ultra-high pressure manual pump to reduce the system working pressure. Through optimization calculations, the boom cylinders use the standard series 80/4. The displacement of the ultra-high pressure manual pump is increased from 10ml/r to 14ml/r, and the system setting pressure is 14MPa, which meets the lifting force and speed requirements of the boom cylinder.
(3) During the use, attention should also be paid to the correct use and maintenance of the loader. Regularly add or replace hydraulic oil, maintain the cleanliness of the hydraulic oil, and strengthen the daily inspection and maintenance of the ultra-high pressure manual pump.
(2) Check the pilot valve. First clean the safety valve and check if the spool is worn. If it is worn, it should be replaced. If there is no change after the safety valve is installed, check the wear of the valve stem of the control valve. The clearance limit is generally 0.06mm. If the wear is serious, it should be replaced.
(3) Measure the pressure of the ultra high pressure manual pump. If the pressure is low, then adjust the pressure applied is still not tune up, then pump serious wear and tear. In general, the main reasons for the failure to lift the boom are:
a. The hydraulic pump is severely worn. The pump leakage is serious at low speed operation; the ultra-high pressure manual pump is slightly improved at high speed operation, but the volumetric efficiency is significantly reduced due to the wear and internal leakage of the pump, and it is difficult to reach the rated pressure. Hydraulic exacerbated long working wear, temperature rise, thereby causing wear of hydraulic components and seals aging, damage, loss of sealing capacity, hydraulic oil deterioration, leading to failure after zui.
b. The selection of hydraulic components is unreasonable. The boom cylinder is 70/40 non-standard series, and the seals are also non-standard parts. The manufacturing cost is high and the seal replacement is inconvenient. The cylinder diameter of the boom cylinder is small, which will inevitably make the system set high pressure. c. High pressure hand pump hydraulic system design is unreasonable. The control valve and the full hydraulic steering gear are connected in series with a single pump. The safety valve is set to a pressure of 16 MPa, and the rated working pressure of the hydraulic pump is also 16 MPa. Hydraulic pumps often work under full load or a long time overload (high pressure) situation, and the system has a hydraulic impact, long-term oil changes, hydraulic oil contaminated, exacerbated by a hydraulic pump wear, so that the hydraulic pump pump shell burst (after have been found Such a fault).
Ultra-high pressure manual pump improvement and effect (l) Improved hydraulic system design. After many demonstrations, Zui adopts the advanced priority valve and load sensing full hydraulic steering gear. The new system can preferentially distribute the flow according to the steering requirements. No matter the load size or the steering wheel speed, the oil supply is sufficient. work feeding means may all be part of the circuit used, thereby eliminating the power loss due to excessive fuel supply caused by the steering circuit, to improve the system efficiency and reduce the operating pressure of the high pressure hand pump.
(2) Optimize the design of the boom cylinder and the ultra-high pressure manual pump to reduce the system working pressure. Through optimization calculations, the boom cylinders use the standard series 80/4. The displacement of the ultra-high pressure manual pump is increased from 10ml/r to 14ml/r, and the system setting pressure is 14MPa, which meets the lifting force and speed requirements of the boom cylinder.
(3) During the use, attention should also be paid to the correct use and maintenance of the loader. Regularly add or replace hydraulic oil, maintain the cleanliness of the hydraulic oil, and strengthen the daily inspection and maintenance of the ultra-high pressure manual pump.
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