柳工装载机液压系统(画过)综述课件.ppt

1、CLG856液压系统液压系统Hydraulic System标题CLG856液压系统组成液压系统组成Hydraulic System CompositionHydraulic SystemWorking Hydraulic SystemSteering Hydraulic SystemBrake Hydraulic System标题CLG856液压系统组成液压系统组成Hydraulic System CompositionWorking Hydraulic System标题CLG856液压系统组成液压系统组成Hydraulic System CompositionSteering Hydrau

2、lic System标题CLG856液压系统组成液压系统组成Hydraulic System CompositionBrake Hydraulic System标题CLG856液压系统原理液压系统原理Hydraulic System Principle标题Working Hydraulic SystemSingle Lever Pilot Valveu Principle:8Working Hydraulic SystemMain Valveu Principle:9PTPT标题工作系统参数工作系统参数Parameters of Working System工作泵工作泵:Working pum

3、p:排量:.140ml/rDisplacement:.140ml/r工作系统设定压力:.20 MPaWorking system setting pressure:.20 MPa额定转速:.2200 r/minRated revolution:.2200 r/min先导操纵阀先导操纵阀:Pilot valve:额定工作压力:.2.5 MPaRated working pressure:.2.5 MPa额定流量:.10 L/minRated flow:.10 L/min控制压力范围:Controlled pressure range:铲斗联:.0.52.5 MPa Bucket linkage:

4、.0.5-2.5 MPa动臂联:.0.52.0 MPa Movable arm linkage:0.5-2.0 MPa电磁铁工作电压:.DC 24 VElectromagnet working pressure:DC 24 V标题工作系统参数工作系统参数 Parameters of Working System组合阀组合阀:Combination valve:额定流量:20L/MRated flow:20 L/M溢流设定压力:4.0MPaOverflow setting pressure:4.0 MPa到先导阀入口压力:3.5MPaPressure to inlet of pilot valv

5、e:3.5 MPa单向阀单向阀:Check valve:开启压力:0.05MPaOpening pressure:0.05 MPa标题工作系统参数工作系统参数 Parameters of Working System分配阀分配阀:Distribution valve:类型:整体双联阀Type:integral dual valve额定流量:250L/MRated flow:250L/M主溢流阀设定压力:20MPaMain overflow valve setting pressure:20 MPa转斗油缸小腔设定压力:22MPaSetting pressure of small cavity

6、of rotating bucket cylinder:22 MPa转斗油缸大腔设定压力:22MPaSetting pressure of big cavity of rotating bucket cylinder:22 MPa液压油牌号液压油牌号:Brand of hydraulic oil一般地区:HM46 抗磨液压油General region:HM46 antiwear hydraulic oil寒冷地区:HV46 低温抗磨液压油Cold region:HV46 low-temperature antiwear hydraulic oil 液压油箱液压油箱:Hydraulic oil

7、 tank:容量:210L Capacity:210 L标题液压阀件介绍液压阀件介绍Introduction of Hydraulic Valves先导阀先导阀 Pilot Valve组成组成:Components:动臂联动臂联:实现动臂升、降及浮动 转斗联转斗联:实现铲斗的翻转动作Movable arm linkage:realize lifting,descending and floating of the movable armBucket linkage:realize turnover of the bucket工作速度与操作手柄的关系工作速度与操作手柄的关系:手柄动作角度越大，工

8、作速度越快Relation between working speed and operating handle:the greater the operating angle of the handle is,the higher the working speed is.Combination valve oil inOil returnEnclosed oil 计量阀计量阀Metering Valve顺序阀顺序阀Sequence Valve标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 组合阀组合阀 Combination Valve作用作

9、用:向先导阀提供控制油.Function:provide control oil to the pilot valve组成组成:溢流阀,减压阀,单向阀Components:overflow valve,pressure reducing valve and check valve溢流阀溢流阀:先导式,限定先导系统压力Overflow valve:pilot type,limit the pressure of pilot system减压阀减压阀:减小来自先导泵或动臂油缸大腔的油压Pressure reducing valve:reduce oil pressure from pilot va

10、lve or big cavity of movable arm cylinder标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 分配阀分配阀 Distribution Valve组成组成:动臂滑阀,转斗滑阀,主溢流阀，转斗油缸大小腔双作用安全阀.Components:movable arm slide valve,rotating bucket slide valve,main overflow valve,dual-action safety valve of big cavity and small cavity of rotating b

11、ucket cylinder 串串-并联式并联式 Series-parallel type进油进油:串联,转斗优先 Oil in:series,rotating bucket takes priority 回油回油:并联Return oil:parallel补油单向阀补油单向阀:Refilling check valve:防止油缸小腔内发生穴蚀Prevent cavity erosion in small cavity of cylinder当油缸活塞杆收回速度大于泵的供油速度时When the retraction speed of a piston rod of the cylinder

12、is greater than the oil supply speed of the pump当油缸受到突然冲击时When the cylinder is suddenly impacted补油单向阀补油单向阀Refilling Check Valve节流孔节流孔Throttle HolePilot Operated Check Valve标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 分配阀分配阀 Distribution Valve主溢流阀主溢流阀:先导式,调定主工作系统压力.Main overflow valve:pilot type,a

13、djust main working system pressure压力调节压力调节:旋出、旋进调节螺钉来增加或减小系统压力 Pressure adjustment:screw off and screw in the adjusting screw to increase or reduce the system pressure 压力调节螺钉压力调节螺钉Pressure Adjusting Screw标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 分配阀分配阀 Distribution Valve转斗油缸卸载阀转斗油缸卸载阀(即转斗油缸大小腔

14、双作用安全阀即转斗油缸大小腔双作用安全阀)Rotating bucket cylinder unloading valve标题检测与调整检测与调整 Inspection and Adjustment工作时间检查工作时间检查Working time inspection动臂起升时间动臂起升时间:6.5 秒内(正常工作温度,额定载荷,额定转速)Movable arm lifting time:within 6.5 s(normal working temperature,rated load and rated revolution)动臂下降时间动臂下降时间:3.6 秒内(怠速,空载)Movabl

15、e arm descending time:within 3.6 s(idle speed,no load)翻斗时间翻斗时间:1.7 秒内Bucket turnover time:within 1.7 s压力检查压力检查Pressure inspection最大工作压力最大工作压力:20MPaMaximum working pressure:20 MPa在分配阀进油接头处接量程为25MPa 压力表Connect 25 MPa pressure gage at oil in joint of distribution valve在正常温度下At normal temperature额定转速下At

16、 rated revolution将动臂升到水平位置Lift the movable arm to horizontal position收斗并读取最大读数.Retract the bucket and read maximum reading.注意注意:在拆装、调整前确保先导切断阀在“断开”位置。（若有此阀）Caution:make sure the pilot cut-off valve is in“OFF”position prior to disassembly and adjustment(if possible).标题检查与调整检查与调整Inspection and Adjustm

17、ent转斗油缸大腔压力转斗油缸大腔压力:22MPaPressure of big cavity of rotating bucket cylinder:22 MPa检查检查:Inspection:在正常温度与怠速条件下。At normal temperature and idle speed在油缸大腔油管测量口接量程为 25MP 压力表Connect 25 MPa pressure gage at oil tube measuring port of big cavity of cylinder将动臂举升到最高位置Lift the movable arm to highest position

18、将铲斗完全收回 Completely retract the bucket然后降低动臂以获取读数Reduce the movable arm to acquire reading调整调整:Adjustment:松开大腔卸荷阀的锁紧螺母Loosen the locking nut of big cavity unloading valve转动调节螺钉来调节压力Rotate the adjusting screw to adjust pressure理想压力调定后装回螺母Install the nut after ideal pressure adjustment反复操作铲斗以检查压力调定的准确性

19、Operate the bucket repeatedly to inspect the accuracy of pressure adjustment标题检查与调整检查与调整 Inspection and Adjustment铲斗油缸小腔压力铲斗油缸小腔压力:22MPaPressure of small cavity of bucket cylinder:22 MPa 检查检查:Inspection:在正常工作温度与怠速条件下At normal temperature and idle speed在小腔检测口处接量程为 25MPa 的压力表Connect 25 MPa pressure ga

20、ge at detection port of the small cavity将动臂置于水平位置Place the movable arm to horizontal position将铲斗翻到卸料位置以获取读数Turn the bucket to unloading position to acquire reading调节:Adjustment:参照大腔压力调节方法Refer to the pressure adjustment method of the big cavity 标题检查与调整检查与调整 Inspection and Adjustment动臂下沉动臂下沉:小于 15毫米/

21、5分钟Movable arm descending:smaller than 15 mm/5 min检查检查:Inspection:满载,正常工作温度下Full load,normal working temperature将动臂升至最高位置Lift the movable arm to highest position熄火，测量动臂油缸活塞杆的长度Shut down,measure the length of the piston rod of the movable arm cylinder注意注意:Caution:在松开检测螺塞前，确认:Prior to loosening the de

22、tection screw,make sure动臂与铲斗已降至地面The movable arm and the bucket are descended to ground发动机熄火Engine is shut down连续操纵先导手柄数次以消除系统中残余压力Continuously operate the pilot handle to eliminate residual pressure in the system标题故障排除故障排除 Troubleshooting工作装置无力工作装置无力Working device powerless可能原因可能原因:Possible causes:

23、液压油不足 Insufficient hydraulic oil液压油污染严重Hydraulic oil polluted seriously泵吸油不畅Unsmooth oil absorption of pump泵严重内漏Serious internal leakage of pump阀杆磨损导致内漏严重Valve rod wear causes serious internal leakage主溢流阀弹簧失效导致系统压力低Low system pressure caused by main overflow valve spring failure由于组合阀溢流阀卡死或弹簧失效导致先导控制

24、压力不足Insufficient pilot control pressure caused by clamping of the overflow valve in the combination valve or spring failure标题故障排除故障排除Troubleshooting工作装置无动作工作装置无动作Working device inactive可能原因可能原因:Possible causes:分配阀阀杆卡死Valve rod of distribution valve is clamped主溢流阀弹簧失效导致系统压力低Low system pressure caused

25、 by main overflow valve spring failure溢流阀卡死导致系统压力不足Insufficient system pressure caused by the clamping of the overflow valve先导泵严重内漏Serious internal leakage of the pilot valve组合阀溢流阀卡死或弹簧失效导致先导控制压力不足Insufficient pilot control pressure caused by clamping of the overflow valve in the combination valve o

26、r spring failure减压阀阀杆卡死或组合阀弹簧失效Clamping of valve rod of the pressure reducing valve or spring failure of the combination valve组合阀内单向阀密封不良导致油缸大腔油流回油箱Oil in the big cavity of the cylinder flows back to the oil tank due to poor sealing of the check valve in the combination valve 标题故障排除故障排除 Troubleshoot

27、ing动臂下沉或掉斗动臂下沉或掉斗Movable arm descending or bucket dropping可能原因可能原因:Possible causes:油缸油封破损导致内漏Internal leakage caused by cylinder oil seal damage阀杆磨损导致内漏Internal leakage caused by valve rod wear溢流阀内单向阀密封不良 Poor sealing of the check valve in the combination valve组合阀内单向阀密封不良导致大腔油流回油箱Oil in the big cavi

28、ty flows back to the oil tank due to poor sealing of the check valve in the combination valve 标题故障排除故障排除 Troubleshooting油温过高油温过高Too high oil temperature可能原因可能原因:Possible causes:液压油不足insufficient hydraulic oil泵磨损Pump wear机器超负荷运行，液压系统连续溢流Overload operation of the machine,continuous overflow of the hyd

29、raulic system 系统设定压力过低引起频繁溢流Frequent overflow caused by too low system setting pressure标题转向系统参数转向系统参数Parameters of Steering System转向齿轮泵转向齿轮泵Steering gear pump排量排量 63毫升/转Displacement63 ml/r系统设定压力系统设定压力 16兆帕System setting pressure16 MPa额定转速额定转速 2200转/分钟Rated revolution.2200 r/min 标题转向系统参数转向系统参数 Parame

30、ters of Steering System转向器转向器Steering gear排量排量 125毫升/扎Displacement.125 ml/r出口压力出口压力.2.5兆帕Outlet pressure2.5 MPa进口压力进口压力 4.0兆帕Inlet pressure 4.0 MPa标题转向系统参数转向系统参数 Parameters of Steering System流量放大阀流量放大阀Flow amplifying valve额定流量额定流量.125升/分钟Rated flow.125 l/min工作压力工作压力.16兆帕Working pressure.16 MPa标题液压阀件

31、介绍液压阀件介绍Introduction of Hydraulic Valves流量放大阀流量放大阀 Flow Amplifying Valve组成组成:Components:主阀杆,流量控制阀,梭阀,先导型溢流阀,节流孔Main valve rod,flow control valve,shuttle valve,pilot overflow valve and throttle hole特点特点:流量只受转向速度影响,与转向阻力无关Characteristics:flow is only influenced by steering speed and is irrelevant to s

32、teering resistance.流量控制阀流量控制阀:稳定进、出口压差Flow control valve:stabilize inlet and outlet pressure difference 溢流阀溢流阀:稳定系统压力Overflow valve:stabilize system pressure 梭阀梭阀:通过向流量控制阀和溢流阀施加转向油缸压力来稳定系统 Shuttle valve:stabilize system by applying steering cylinder pressure to the flow control valve and the overflo

33、w valve进油口进油口Oil Inlet出油口出油口Oil Outlet流量控制阀流量控制阀Flow Control Valve溢流阀溢流阀Overflow Valve梭阀梭阀Shuttle Valve标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 转向器转向器 Steering Gear随动转阀随动转阀Slave Rotating Valve 计量机构计量机构Metering Mechanism标题液压阀件介绍液压阀件介绍 Introduction of Hydraulic Valves 转向器转向器 Steering Gear特点特点:不

34、转向时进、出油口与工作油口相互隔断 Characteristics:the oil inlet,the oil outlet and the working oil port are mutually isolated while not steering.随动转阀随动转阀Slave rotating slave由阀体,阀套和滑阀组成.控制流动方向.Consisting of the valve body,valve bush and slide valve.To control the flow direction.计量机构计量机构Metering mechanism由定子、转子组成.保证出

35、口流量与方向盘转动速度成正比Consisting of stator and rotor.To ensure that the outlet flow is in direct proportion to the rotating speed of the steering wheel.标题检测与调整检测与调整Inspection and Adjustment转向时间调整转向时间调整Steering time adjustment条件条件:在平直水泥路面,空载,高速Conditions:on flat and straight cement pavement,no load and high

36、speed如果左右转向时间差超过0.3秒，需要进行调整.If left and right steering time difference exceeds 0.3 s,adjust the time.调整调整:Adjustment:取下流量放大阀端盖Remove the end cap of the flow amplifying valve加调整垫片 1 能减小右转向时间，增加左转向时间.减垫片则相反Adding adjusting washers 1 can reduce right steering time and increase left steering time.Reduci

37、ng adjusting washers is to the contrary.垫片类型有两种:0.25mm,0.12mmTypes of washers:0.25 mm,0.12 mm添加或减少两个 0.25mm 垫片能改变 0.1秒转向时间 Adding or reducing two 0.25 mm washers can change steering time by 0.1 s添加一个垫片添加一个垫片 4 能减少系统转向反应时间约能减少系统转向反应时间约 0.1秒秒Adding one washer 4 can reduce system steering response time

38、 by 0.1 s or so.调整垫片调整垫片 1Adjusting Washer 1调整垫片调整垫片 4Adjusting Washer 4标题检查与调整检查与调整 Inspection and Adjustment溢流压力检查与调整溢流压力检查与调整Overflow pressure Inspection and Adjustment将前后车架锁定Lock front and back frames在检测口处接 25MPa测压表Connect 25 MPa pressure gage at the detection port启动发动机，高怠速运转Start the engine to

39、rotate at high idle speed转动方向盘直到溢流阀开启Rotate the steering wheel until the overflow valve is opened如果读数不是 16+0.3MPa,松开螺塞 2 并添加或减少垫片3 来调节压力If the reading is no 16+0.3 MPa,loosen the screw 2 and add or reduce washer 3 to adjust pressure(每个垫片厚度为 0.25mm，每加一片将增加3.4bar压力)(The thickness of each washer is 0.2

40、5 mm,and adding one washer can increase the pressure by 3.4 bar.)调整垫片调整垫片 3Adjusting Washer 3检测口检测口Detection Port标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System转向沉重转向沉重Heavy steering可能原因可能原因:Possible causes:油温低Low oil temperature控制油路阻塞Blocked control oil way控制油路错接Misconnected control oil way转向泵压力低

41、Low steering pump pressure转向器内计量马达过度上紧Metering motor in steering gear it tightened excessively单向阀内钢球丢失Steel ball in the check valve is lost泵内漏Internal pump leakage转向器安装错误 Wring installation of steering gear标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System转向不平稳转向不平稳Unsmooth steering可能原因可能原因:Possible

42、causes:主阀杆运动不顺畅Unsmooth motion of main valve rod左右转向慢左右转向慢Slow left and right steering可能原因可能原因:Possible causes:泵流量不足Insufficient pump flow主阀杆不能移动到头Main valve rod can not move to utmost主阀复位弹簧调节不正确Incorrect adjustment of main valve return spring标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System左右转向速度不同

43、左右转向速度不同Different left and right steering speed可能原因可能原因:Possible causes:调节垫片数量不对Incorrect quantity of adjusting washers转向性能随转向阻力增加而降低转向性能随转向阻力增加而降低Steering property is reduced along with increase in steering resistance可能原因可能原因:Possible causes:梭阀泄漏严重Serious shuttle valve leakage溢流阀泄漏严重Serious overflo

44、w valve leakage溢流阀阀座泄漏严重Serious overflow valve seat leakage标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System当转向阻力小时正常，但当阻力大时一边转当转向阻力小时正常，但当阻力大时一边转向慢向慢Normal when steering resistance is small and one side steering is slow when steering resistance is large.可能原因可能原因:Possible cause:梭阀泄漏严重serious shuttle

45、 valve leakage转动方向盘机器不转向转动方向盘机器不转向Machine does not steer while rotating the steering wheel 可能原因可能原因:Possible causes:转向器故障Steering gear fault组合阀中溢流阀故障Overflow valve in combination valve fault先导油路泄漏Pilot oil way leakage主溢流阀故障Main overflow valve fault标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System机器自

46、动转向机器自动转向Automatic machine steering可能原因可能原因:Possible causes:主阀杆不能回中位Main valve rod can not return to neutral position阀紧固螺栓过度上紧Fastening bolt of valve is tightened excessively端盖螺栓过度上紧End bolt is tightened excessively阀杆与阀套不配合Valve rod is not matched to valve bush机器在高速时转向速度过快机器在高速时转向速度过快Too high steeri

47、ng speed when machine is at high speed可能原因可能原因:Possible causes:流量控制阀调整不正确Incorrect adjustment of flow control valve主阀杆运动不顺畅Unsmooth motion of main valve rod两端计量孔阻塞或错位Metering holes on two ends are blocked or staggered.标题故障排除故障排除Troubleshooting转向系统转向系统 Steering System泵噪音大泵噪音大,油缸动作慢油缸动作慢Great pump noi

48、se and slow cylinder action可能原因可能原因:Possible causes:油路中混入空气Air mixed in oil way泵磨损，供油不足Pump wear,insufficient oil supply油黏度低Low oil viscosity液压油量不足Insufficient hydraulic oil控制油路溢流阀或减压阀压力设定不正确Incorrect pressure setting of control oil way overflow valve or pressure reducing valve油缸内漏Internal cylinder

49、leakage方向盘自转方向盘自转Steering wheel autorotation可能原因可能原因:Possible causes:转向器内阀套卡死Valve bush in the steering gear is clamped.转向器内弹簧片断Spring sheet in the steering gear is broken.标题Hydraulic System Maintenance Interval ScheduleItem for checkOperating hours10 50 100 250 500 1000 2000Check Hydraulic Oil Leve

50、lClear the return oil filter element of the hydraulic system Replace the return oil filter element of the hydraulic system Replace hydraulic oil,clean oil tank and check the oil suction hose Check airtight condition of the control valve and work cylinder by measuring natural sediment of the cylinder