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卡特彼勒CAT320B型挖掘機動作緩慢故障的排除

2020/6/30

CAT320B型挖掘機該機在施工過程中突然出現整機各人動作均異常緩慢（如空載回轉一圈需13s）的現象，而滿負荷運轉時，發動機轉速正常，煙色也正常。針對故障現象進行分析后，基本上可以排除來自發動機的原因，斷定故障出自液壓系統，可能是因液壓泵自身的機械故障造內泄嚴重，也可能是系統壓力不夠。別外，也可能是功率模式設定不正確。320B型液壓挖掘機設計有3種不同的功率模式：重載模式、普通模式，以及精細模式。液村系統所吸收的發動機功率分別是100%、90%和75%，如果將功率模式設置在精細模式，就有可能造成機器的動作緩慢。先導泵是為先導系統提供壓力油的，先導系統的作用之一就是控制主油路，使之完成相應的動作挖掘機維修,挖掘機修理,維修挖掘機,修理挖掘機。
如果(guo)該系統(tong)出現(xian)故障(zhang)，先(xian)導系統(tong)統(tong)壓(ya)力過低(di)，使(shi)先(xian)導油(you)(you)無法對主(zhu)(zhu)控(kong)(kong)閥進(jin)行相應(ying)的(de)控(kong)(kong)制(zhi)(zhi)或主(zhu)(zhu)控(kong)(kong)閥閥芯行程(cheng)過小(xiao)，從而使(shi)主(zhu)(zhu)油(you)(you)路流量(liang)不(bu)(bu)足，也可(ke)能(neng)導致機(ji)(ji)器動(dong)(dong)(dong)作過緩。主(zhu)(zhu)泵電子控(kong)(kong)制(zhi)(zhi)系統(tong)如果(guo)出現(xian)故障(zhang)，也可(ke)引起上述(shu)整機(ji)(ji)的(de)故障(zhang)現(xian)象，對此(ci)，可(ke)按附圖排(pai)查。電子控(kong)(kong)制(zhi)(zhi)系統(tong)通過主(zhu)(zhu)控(kong)(kong)制(zhi)(zhi)器來(lai)控(kong)(kong)制(zhi)(zhi)主(zhu)(zhu)液(ye)壓(ya)泵從發(fa)動(dong)(dong)(dong)機(ji)(ji)吸收的(de)功(gong)率，使(shi)發(fa)動(dong)(dong)(dong)機(ji)(ji)輸出功(gong)率與液(ye)壓(ya)泵吸收的(de)功(gong)率相匹配，以適(shi)應(ying)不(bu)(bu)同(tong)的(de)工作環境(jing)。電子控(kong)(kong)制(zhi)(zhi)系統(tong)的(de)主(zhu)(zhu)要功(gong)能(neng)是：當機(ji)(ji)器負載很大時(shi)，系統(tong)使(shi)液(ye)壓(ya)泵有較大的(de)排(pai)量(liang)，使(shi)之輸出與發(fa)動(dong)(dong)(dong)機(ji)(ji)相匹配的(de)最(zui)大功(gong)率；根據負載情(qing)況，系統(tong)有3種不(bu)(bu)同(tong)的(de)功(gong)率模式，將(jiang)液(ye)壓(ya)泵的(de)輸出功(gong)率控(kong)(kong)制(zhi)(zhi)在最(zui)佳狀態(tai)，減(jian)少燃油(you)(you)消耗；空載或負荷很小(xiao)時(shi)，系統(tong)自動(dong)(dong)(dong)降(jiang)低(di)發(fa)動(dong)(dong)(dong)機(ji)(ji)的(de)轉速并使(shi)主(zhu)(zhu)泵排(pai)量(liang)減(jian)至最(zui)小(xiao)，可(ke)達(da)到節能(neng)、降(jiang)耗且降(jiang)低(di)噪(zao)聲。
電(dian)(dian)子(zi)控(kong)制(zhi)(zhi)系統(tong)(tong)的(de)(de)(de)(de)(de)工作(zuo)過程：電(dian)(dian)子(zi)控(kong)制(zhi)(zhi)系統(tong)(tong)的(de)(de)(de)(de)(de)主要部(bu)(bu)(bu)件——主控(kong)制(zhi)(zhi)器接收來自各方面的(de)(de)(de)(de)(de)輸(shu)入信(xin)(xin)(xin)號(hao)（如，油(you)門旋鈕的(de)(de)(de)(de)(de)位置(zhi)、監控(kong)器設置(zhi)功率模(mo)式、主泵壓(ya)(ya)(ya)力傳(chuan)(chuan)(chuan)感器傳(chuan)(chuan)(chuan)回的(de)(de)(de)(de)(de)壓(ya)(ya)(ya)力信(xin)(xin)(xin)號(hao)、油(you)門馬(ma)達的(de)(de)(de)(de)(de)位置(zhi)傳(chuan)(chuan)(chuan)回的(de)(de)(de)(de)(de)壓(ya)(ya)(ya)力信(xin)(xin)(xin)號(hao)、油(you)門馬(ma)達的(de)(de)(de)(de)(de)位置(zhi)傳(chuan)(chuan)(chuan)感器信(xin)(xin)(xin)號(hao)，以及發(fa)動機(ji)(ji)(ji)速度傳(chuan)(chuan)(chuan)感器信(xin)(xin)(xin)號(hao)等(deng)）。主控(kong)制(zhi)(zhi)器處理這些輸(shu)入信(xin)(xin)(xin)號(hao)后，輸(shu)出(chu)(chu)指令給發(fa)動機(ji)(ji)(ji)的(de)(de)(de)(de)(de)油(you)門馬(ma)達和主液(ye)壓(ya)(ya)(ya)泵的(de)(de)(de)(de)(de)主要控(kong)制(zhi)(zhi)部(bu)(bu)(bu)件——比例(li)減(jian)(jian)壓(ya)(ya)(ya)閥。油(you)門馬(ma)達的(de)(de)(de)(de)(de)相應(ying)動作(zuo)可(ke)(ke)以改變發(fa)動機(ji)(ji)(ji)的(de)(de)(de)(de)(de)轉速，而比例(li)減(jian)(jian)壓(ya)(ya)(ya)閥的(de)(de)(de)(de)(de)動作(zuo)則可(ke)(ke)調(diao)節泵的(de)(de)(de)(de)(de)排量，二者在主控(kong)制(zhi)(zhi)器的(de)(de)(de)(de)(de)控(kong)制(zhi)(zhi)下，使發(fa)動機(ji)(ji)(ji)和液(ye)壓(ya)(ya)(ya)系統(tong)(tong)達到最佳(jia)匹配(pei)。因此，只要電(dian)(dian)子(zi)控(kong)制(zhi)(zhi)系統(tong)(tong)任何部(bu)(bu)(bu)位出(chu)(chu)現(xian)問(wen)題，都可(ke)(ke)能使機(ji)(ji)(ji)器無(wu)常(chang)工作(zuo)。液(ye)壓(ya)(ya)(ya)泵自身調(diao)節系統(tong)(tong)有故障，可(ke)(ke)能是液(ye)壓(ya)(ya)(ya)泵調(diao)節器或者控(kong)制(zhi)(zhi)信(xin)(xin)(xin)號(hao)油(you)壓(ya)(ya)(ya)出(chu)(chu)現(xian)故障所(suo)致。
排除(chu)故障(zhang)的(de)(de)(de)方法(fa)是(shi)，根據上(shang)述分析，依次進(jin)行了(le)相應的(de)(de)(de)檢查(cha)。大家知(zhi)道，如果液壓(ya)(ya)(ya)(ya)系統(tong)有故障(zhang)，不(bu)能再輕(qing)易在啟動(dong)(dong)發(fa)動(dong)(dong)機，因(yin)為那樣就有可(ke)(ke)能造成某些液壓(ya)(ya)(ya)(ya)部(bu)件進(jin)一步(bu)地損(sun)壞(huai)，從(cong)而污染整個液壓(ya)(ya)(ya)(ya)系統(tong)。故首先(xian)檢查(cha)了(le)液壓(ya)(ya)(ya)(ya)油(you)(you)箱的(de)(de)(de)油(you)(you)位，發(fa)現(xian)油(you)(you)位正(zheng)常(chang)(chang)；進(jin)而取出液壓(ya)(ya)(ya)(ya)油(you)(you)箱中的(de)(de)(de)主(zhu)回油(you)(you)濾(lv)芯以及殼體泄油(you)(you)濾(lv)芯和先(xian)導油(you)(you)濾(lv)芯，并(bing)逐(zhu)一剖(pou)開檢查(cha)，看是(shi)否有銅屑等異(yi)(yi)物，檢查(cha)結(jie)果是(shi)3個濾(lv)清(qing)器均正(zheng)常(chang)(chang)。于是(shi)，裝(zhuang)上(shang)新的(de)(de)(de)濾(lv)芯，啟動(dong)(dong)發(fa)動(dong)(dong)機并(bing)以怠(dai)速運轉，傾聽(ting)液壓(ya)(ya)(ya)(ya)泵(beng)的(de)(de)(de)聲音，結(jie)果液壓(ya)(ya)(ya)(ya)泵(beng)并(bing)無異(yi)(yi)響；再測量(liang)系統(tong)壓(ya)(ya)(ya)(ya)力(li)，得到主(zhu)安全(quan)閥的(de)(de)(de)溢流壓(ya)(ya)(ya)(ya)力(li)為34.3MPa，即系統(tong)壓(ya)(ya)(ya)(ya)力(li)正(zheng)常(chang)(chang)。因(yin)此，可(ke)(ke)排除(chu)液壓(ya)(ya)(ya)(ya)泵(beng)出現(xian)機械損(sun)壞(huai)的(de)(de)(de)結(jie)論。重(zhong)(zhong)新設置功率模式于重(zhong)(zhong)載(zai)模式，試(shi)機，動(dong)(dong)作依然緩慢，以此可(ke)(ke)以排除(chu)因(yin)功率模式設置不(bu)正(zheng)確(que)而出現(xian)故障(zhang)的(de)(de)(de)可(ke)(ke)能原因(yin)。
測試先導(dao)壓(ya)力，其(qi)(qi)值(zhi)為4.1MPa，屬正(zheng)常(chang)。因(yin)此(ci)(ci)(ci)，可(ke)(ke)以(yi)排除(chu)先導(dao)系統出現(xian)(xian)故(gu)(gu)障(zhang)(zhang)的可(ke)(ke)能性。于是，驗證電子(zi)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)系統是否出現(xian)(xian)故(gu)(gu)障(zhang)(zhang)。此(ci)(ci)(ci)故(gu)(gu)障(zhang)(zhang)的判斷方(fang)法比(bi)較簡單，因(yin)為系統上設置(zhi)有手動(dong)(dong)備用開(kai)關(guan)(guan)，當主(zhu)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)器(qi)(qi)或監(jian)控(kong)(kong)(kong)(kong)器(qi)(qi)出現(xian)(xian)問(wen)題(ti)時，將備用開(kai)關(guan)(guan)扳(ban)至手動(dong)(dong)位(wei)(wei)置(zhi)，可(ke)(ke)使機(ji)器(qi)(qi)繼續工(gong)作(zuo)。按上述方(fang)法操作(zuo)機(ji)器(qi)(qi)，結果(guo)動(dong)(dong)作(zuo)依(yi)然緩慢。故(gu)(gu)可(ke)(ke)初(chu)步(bu)認為主(zhu)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)器(qi)(qi)正(zheng)常(chang)；后又將開(kai)關(guan)(guan)反扳(ban)回自動(dong)(dong)位(wei)(wei)置(zhi)，再(zai)檢驗主(zhu)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)器(qi)(qi)上的3個發光二(er)極(ji)管，見3個二(er)極(ji)管均為綠光，再(zai)次證明(ming)主(zhu)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)器(qi)(qi)以(yi)及主(zhu)控(kong)(kong)(kong)(kong)制(zhi)(zhi)(zhi)(zhi)器(qi)(qi)與監(jian)控(kong)(kong)(kong)(kong)器(qi)(qi)之(zhi)間的通信線路(lu)正(zheng)常(chang)。卡特(te)彼勒公司(si)的挖掘機(ji)上監(jian)控(kong)(kong)(kong)(kong)系統有很強的自檢及數據記憶功能，因(yin)此(ci)(ci)(ci)，我(wo)們可(ke)(ke)以(yi)通過監(jian)控(kong)(kong)(kong)(kong)器(qi)(qi)了解其(qi)(qi)他電子(zi)元件(jian)的狀態和數據，從而判斷它(ta)們工(gong)作(zuo)是否正(zheng)常(chang)。從監(jian)控(kong)(kong)(kong)(kong)器(qi)(qi)上輸入(ru)密碼(ma)后。
進入(ru)卡特彼勒(le)的(de)維修模(mo)式，先檢(jian)查(cha)(cha)稆(lv)種開關(guan)的(de)狀態(tai)，結(jie)果表(biao)明各種開關(guan)均(jun)處于(yu)正(zheng)常狀態(tai)位置；然(ran)后(hou)檢(jian)查(cha)(cha)發動(dong)機額(e)定(ding)轉速(su)以及(ji)泵在(zai)(zai)主(zhu)安全閥(fa)泄(xie)流時(shi)的(de)壓(ya)(ya)力(li)，監控器(qi)顯示這項數據為(wei)1800r/min和34.3MPa，均(jun)為(wei)正(zheng)常值；檢(jian)查(cha)(cha)比例減(jian)(jian)速(su)壓(ya)(ya)閥(fa)的(de)壓(ya)(ya)力(li)變化(hua)范圍，在(zai)(zai)正(zheng)常的(de)操作過程中，監控器(qi)顯示比便減(jian)(jian)壓(ya)(ya)閥(fa)的(de)壓(ya)(ya)力(li)變化(hua)范圍為(wei)3.2~0.76MPa，即比例減(jian)(jian)壓(ya)(ya)閥(fa)的(de)壓(ya)(ya)力(li)變化(hua)正(zheng)常。再查(cha)(cha)盾現(xian)實故障(zhang)代(dai)碼(ma)和以前記錄的(de)故障(zhang)代(dai)碼(ma)，監控器(qi)均(jun)未(wei)顯示何故障(zhang)代(dai)碼(ma)，至(zhi)此可以肯定(ding)，問題(ti)不(bu)是(shi)出(chu)在(zai)(zai)電子控制(zhi)系統(tong)。最(zui)后(hou)，檢(jian)查(cha)(cha)液壓(ya)(ya)泵自身調節(jie)系統(tong)。其(qi)上、下(xia)泵的(de)調節(jie)器(qi)是(shi)分開的(de)，通過對(dui)左、右單(dan)邊行走的(de)測(ce)試(shi)表(biao)時(shi)均(jun)存(cun)在(zai)(zai)問題(ti)，由(you)于(yu)兩泵調節(jie)器(qi)均(jun)出(chu)現(xian)故障(zhang)的(de)可能性較小，我(wo)們先將(jiang)其(qi)放在(zai)(zai)一(yi)邊。
從外(wai)部著看查(cha)起(qi)。液(ye)壓(ya)(ya)泵(beng)(beng)調節器(qi)(qi)(qi)的(de)(de)(de)(de)外(wai)部控(kong)制信(xin)號有(you)兩個(ge)：一(yi)(yi)(yi)個(ge)取(qu)自主(zhu)控(kong)閥(fa)中(zhong)心油道的(de)(de)(de)(de)壓(ya)(ya)力(li)(li)PN，上(shang)、下(xia)泵(beng)(beng)各一(yi)(yi)(yi)；另一(yi)(yi)(yi)個(ge)是來自同時控(kong)制上(shang)、下(xia)泵(beng)(beng)的(de)(de)(de)(de)比(bi)例(li)(li)(li)減壓(ya)(ya)閥(fa)的(de)(de)(de)(de)壓(ya)(ya)力(li)(li)PS。先分別測量(liang)(liang)上(shang)、下(xia)泵(beng)(beng)的(de)(de)(de)(de)壓(ya)(ya)力(li)(li)PN值，得(de)到(dao)當主(zhu)控(kong)閥(fa)中(zhong)位時壓(ya)(ya)力(li)(li)為4.07MPa，無論(lun)有(you)任何(he)一(yi)(yi)(yi)下(xia)動(dong)作，PN即下(xia)降為0.35MPa，PN值正常。再測量(liang)(liang)PS值，雖然已經通過(guo)監(jian)控(kong)器(qi)(qi)(qi)已查(cha)看到(dao)了PS值的(de)(de)(de)(de)變(bian)(bian)化范圍，且(qie)其壓(ya)(ya)力(li)(li)變(bian)(bian)化值正常，但這并不一(yi)(yi)(yi)定準確，因為比(bi)例(li)(li)(li)減壓(ya)(ya)閥(fa)上(shang)并沒有(you)壓(ya)(ya)力(li)(li)傳感器(qi)(qi)(qi)直接給主(zhu)控(kong)制器(qi)(qi)(qi)經信(xin)號輸入，監(jian)控(kong)器(qi)(qi)(qi)顯(xian)示的(de)(de)(de)(de)壓(ya)(ya)力(li)(li)值是主(zhu)控(kong)制器(qi)(qi)(qi)通過(guo)對比(bi)例(li)(li)(li)減壓(ya)(ya)閥(fa)的(de)(de)(de)(de)輸出電流(liu)信(xin)號經分析轉換而成的(de)(de)(de)(de)、也就是說，此壓(ya)(ya)力(li)(li)值對應主(zhu)控(kong)制器(qi)(qi)(qi)對比(bi)例(li)(li)(li)減壓(ya)(ya)閥(fa)輸出電流(liu)的(de)(de)(de)(de)強弱。為此，在泵(beng)(beng)體上(shang)的(de)(de)(de)(de)PS壓(ya)(ya)力(li)(li)側點(dian)接上(shang)壓(ya)(ya)力(li)(li)表。
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