6977
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(ru)果該(gai)系(xi)統(tong)出(chu)(chu)現(xian)故(gu)障，先(xian)導系(xi)統(tong)統(tong)壓(ya)力過(guo)(guo)低，使先(xian)導油(you)無法(fa)對(dui)主控(kong)(kong)(kong)閥(fa)進(jin)行相應(ying)(ying)的(de)控(kong)(kong)(kong)制(zhi)(zhi)或主控(kong)(kong)(kong)閥(fa)閥(fa)芯行程過(guo)(guo)小，從而使主油(you)路流量(liang)不足，也可能(neng)(neng)導致機(ji)(ji)器動(dong)(dong)作(zuo)過(guo)(guo)緩。主泵(beng)(beng)電子(zi)(zi)控(kong)(kong)(kong)制(zhi)(zhi)系(xi)統(tong)如(ru)果出(chu)(chu)現(xian)故(gu)障，也可引起上(shang)述整機(ji)(ji)的(de)故(gu)障現(xian)象，對(dui)此(ci)，可按附圖排查。電子(zi)(zi)控(kong)(kong)(kong)制(zhi)(zhi)系(xi)統(tong)通過(guo)(guo)主控(kong)(kong)(kong)制(zhi)(zhi)器來(lai)控(kong)(kong)(kong)制(zhi)(zhi)主液壓(ya)泵(beng)(beng)從發動(dong)(dong)機(ji)(ji)吸(xi)收(shou)的(de)功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)，使發動(dong)(dong)機(ji)(ji)輸(shu)出(chu)(chu)功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)與液壓(ya)泵(beng)(beng)吸(xi)收(shou)的(de)功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)相匹(pi)配，以適(shi)應(ying)(ying)不同(tong)的(de)工作(zuo)環(huan)境。電子(zi)(zi)控(kong)(kong)(kong)制(zhi)(zhi)系(xi)統(tong)的(de)主要功(gong)(gong)(gong)能(neng)(neng)是(shi)：當(dang)機(ji)(ji)器負(fu)載很大時，系(xi)統(tong)使液壓(ya)泵(beng)(beng)有較大的(de)排量(liang)，使之輸(shu)出(chu)(chu)與發動(dong)(dong)機(ji)(ji)相匹(pi)配的(de)最(zui)大功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)；根據負(fu)載情況，系(xi)統(tong)有3種不同(tong)的(de)功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)模式，將液壓(ya)泵(beng)(beng)的(de)輸(shu)出(chu)(chu)功(gong)(gong)(gong)率(lv)(lv)(lv)(lv)控(kong)(kong)(kong)制(zhi)(zhi)在(zai)最(zui)佳狀態，減少(shao)燃油(you)消耗(hao)(hao)；空(kong)載或負(fu)荷很小時，系(xi)統(tong)自動(dong)(dong)降(jiang)低發動(dong)(dong)機(ji)(ji)的(de)轉(zhuan)速并使主泵(beng)(beng)排量(liang)減至(zhi)最(zui)小，可達到節能(neng)(neng)、降(jiang)耗(hao)(hao)且(qie)降(jiang)低噪聲(sheng)。
電子(zi)控(kong)制(zhi)系(xi)統的(de)工作(zuo)過程：電子(zi)控(kong)制(zhi)系(xi)統的(de)主(zhu)要部(bu)件——主(zhu)控(kong)制(zhi)器(qi)(qi)接(jie)收來自各方(fang)面的(de)輸入(ru)信(xin)(xin)(xin)號(hao)(hao)（如，油門旋鈕(niu)的(de)位(wei)(wei)置、監控(kong)器(qi)(qi)設(she)置功率模式、主(zhu)泵壓(ya)(ya)(ya)(ya)力傳(chuan)感(gan)器(qi)(qi)傳(chuan)回的(de)壓(ya)(ya)(ya)(ya)力信(xin)(xin)(xin)號(hao)(hao)、油門馬(ma)達的(de)位(wei)(wei)置傳(chuan)回的(de)壓(ya)(ya)(ya)(ya)力信(xin)(xin)(xin)號(hao)(hao)、油門馬(ma)達的(de)位(wei)(wei)置傳(chuan)感(gan)器(qi)(qi)信(xin)(xin)(xin)號(hao)(hao)，以及(ji)發動(dong)(dong)機(ji)速(su)度(du)傳(chuan)感(gan)器(qi)(qi)信(xin)(xin)(xin)號(hao)(hao)等）。主(zhu)控(kong)制(zhi)器(qi)(qi)處理這些(xie)輸入(ru)信(xin)(xin)(xin)號(hao)(hao)后，輸出指(zhi)令給(gei)發動(dong)(dong)機(ji)的(de)油門馬(ma)達和主(zhu)液(ye)壓(ya)(ya)(ya)(ya)泵的(de)主(zhu)要控(kong)制(zhi)部(bu)件——比例減(jian)壓(ya)(ya)(ya)(ya)閥(fa)。油門馬(ma)達的(de)相應動(dong)(dong)作(zuo)可(ke)以改(gai)變(bian)發動(dong)(dong)機(ji)的(de)轉速(su)，而比例減(jian)壓(ya)(ya)(ya)(ya)閥(fa)的(de)動(dong)(dong)作(zuo)則可(ke)調(diao)節泵的(de)排量，二(er)者在主(zhu)控(kong)制(zhi)器(qi)(qi)的(de)控(kong)制(zhi)下(xia)，使發動(dong)(dong)機(ji)和液(ye)壓(ya)(ya)(ya)(ya)系(xi)統達到最佳匹配。因此(ci)，只(zhi)要電子(zi)控(kong)制(zhi)系(xi)統任何部(bu)位(wei)(wei)出現(xian)問題，都可(ke)能使機(ji)器(qi)(qi)無(wu)常(chang)工作(zuo)。液(ye)壓(ya)(ya)(ya)(ya)泵自身(shen)調(diao)節系(xi)統有故(gu)障(zhang)(zhang)，可(ke)能是液(ye)壓(ya)(ya)(ya)(ya)泵調(diao)節器(qi)(qi)或者控(kong)制(zhi)信(xin)(xin)(xin)號(hao)(hao)油壓(ya)(ya)(ya)(ya)出現(xian)故(gu)障(zhang)(zhang)所致。
排(pai)除故(gu)(gu)(gu)障(zhang)的(de)(de)方法(fa)是(shi)，根據上(shang)述分析，依次進行了相(xiang)應的(de)(de)檢查(cha)(cha)。大家知道，如果(guo)液(ye)(ye)(ye)(ye)壓(ya)(ya)系統有(you)故(gu)(gu)(gu)障(zhang)，不(bu)能(neng)再輕易在啟動(dong)(dong)發動(dong)(dong)機(ji)，因(yin)為(wei)那樣就(jiu)有(you)可能(neng)造成(cheng)某些(xie)液(ye)(ye)(ye)(ye)壓(ya)(ya)部件(jian)進一步地(di)損(sun)壞，從而(er)污(wu)染(ran)整個液(ye)(ye)(ye)(ye)壓(ya)(ya)系統。故(gu)(gu)(gu)首先(xian)檢查(cha)(cha)了液(ye)(ye)(ye)(ye)壓(ya)(ya)油(you)(you)(you)箱的(de)(de)油(you)(you)(you)位，發現(xian)油(you)(you)(you)位正(zheng)常；進而(er)取出(chu)液(ye)(ye)(ye)(ye)壓(ya)(ya)油(you)(you)(you)箱中的(de)(de)主(zhu)回油(you)(you)(you)濾(lv)芯(xin)以及殼體(ti)泄油(you)(you)(you)濾(lv)芯(xin)和先(xian)導油(you)(you)(you)濾(lv)芯(xin)，并逐一剖開檢查(cha)(cha)，看是(shi)否有(you)銅(tong)屑等(deng)異物(wu)，檢查(cha)(cha)結果(guo)是(shi)3個濾(lv)清器均正(zheng)常。于是(shi)，裝上(shang)新的(de)(de)濾(lv)芯(xin)，啟動(dong)(dong)發動(dong)(dong)機(ji)并以怠(dai)速運轉，傾聽液(ye)(ye)(ye)(ye)壓(ya)(ya)泵(beng)的(de)(de)聲音，結果(guo)液(ye)(ye)(ye)(ye)壓(ya)(ya)泵(beng)并無異響；再測量系統壓(ya)(ya)力(li)，得到主(zhu)安全閥的(de)(de)溢(yi)流壓(ya)(ya)力(li)為(wei)34.3MPa，即系統壓(ya)(ya)力(li)正(zheng)常。因(yin)此(ci)，可排(pai)除液(ye)(ye)(ye)(ye)壓(ya)(ya)泵(beng)出(chu)現(xian)機(ji)械損(sun)壞的(de)(de)結論。重新設置功率(lv)(lv)模式(shi)(shi)(shi)于重載模式(shi)(shi)(shi)，試機(ji)，動(dong)(dong)作依然緩慢，以此(ci)可以排(pai)除因(yin)功率(lv)(lv)模式(shi)(shi)(shi)設置不(bu)正(zheng)確(que)而(er)出(chu)現(xian)故(gu)(gu)(gu)障(zhang)的(de)(de)可能(neng)原因(yin)。
測試先導(dao)壓力，其(qi)值為4.1MPa，屬正(zheng)常(chang)。因(yin)(yin)此(ci)，可(ke)以(yi)排除先導(dao)系(xi)統出(chu)現故障的可(ke)能(neng)性。于是(shi)，驗證電(dian)子(zi)控(kong)制(zhi)(zhi)系(xi)統是(shi)否出(chu)現故障。此(ci)故障的判(pan)斷(duan)方(fang)(fang)法比(bi)較簡單(dan)，因(yin)(yin)為系(xi)統上(shang)(shang)設置(zhi)有手(shou)動備用開(kai)關(guan)，當(dang)主(zhu)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)或監控(kong)器(qi)(qi)(qi)(qi)出(chu)現問題(ti)時，將(jiang)備用開(kai)關(guan)扳至手(shou)動位(wei)置(zhi)，可(ke)使(shi)機(ji)器(qi)(qi)(qi)(qi)繼續工(gong)(gong)作(zuo)(zuo)。按(an)上(shang)(shang)述方(fang)(fang)法操作(zuo)(zuo)機(ji)器(qi)(qi)(qi)(qi)，結(jie)果動作(zuo)(zuo)依然緩(huan)慢。故可(ke)初(chu)步認為主(zhu)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)正(zheng)常(chang)；后(hou)又將(jiang)開(kai)關(guan)反扳回自(zi)動位(wei)置(zhi)，再檢(jian)驗主(zhu)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)上(shang)(shang)的3個發光二(er)極管，見3個二(er)極管均為綠光，再次證明主(zhu)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)以(yi)及(ji)主(zhu)控(kong)制(zhi)(zhi)器(qi)(qi)(qi)(qi)與監控(kong)器(qi)(qi)(qi)(qi)之間的通(tong)信線(xian)路正(zheng)常(chang)。卡特彼勒公司的挖掘機(ji)上(shang)(shang)監控(kong)系(xi)統有很強的自(zi)檢(jian)及(ji)數據記憶功能(neng)，因(yin)(yin)此(ci)，我(wo)們可(ke)以(yi)通(tong)過監控(kong)器(qi)(qi)(qi)(qi)了解其(qi)他電(dian)子(zi)元(yuan)件的狀態和數據，從(cong)而判(pan)斷(duan)它們工(gong)(gong)作(zuo)(zuo)是(shi)否正(zheng)常(chang)。從(cong)監控(kong)器(qi)(qi)(qi)(qi)上(shang)(shang)輸(shu)入密碼后(hou)。
進(jin)入卡特彼勒的(de)(de)(de)(de)維修模式，先檢查(cha)稆種開關(guan)的(de)(de)(de)(de)狀態，結果表明各種開關(guan)均處于正(zheng)常狀態位置(zhi)；然后檢查(cha)發動機(ji)額定(ding)轉速以(yi)及泵在(zai)主(zhu)安全(quan)閥泄流時(shi)的(de)(de)(de)(de)壓(ya)(ya)(ya)力，監(jian)控器(qi)顯(xian)(xian)示(shi)這項數據(ju)為(wei)1800r/min和34.3MPa，均為(wei)正(zheng)常值；檢查(cha)比例減速壓(ya)(ya)(ya)閥的(de)(de)(de)(de)壓(ya)(ya)(ya)力變化范(fan)(fan)圍，在(zai)正(zheng)常的(de)(de)(de)(de)操作過程中，監(jian)控器(qi)顯(xian)(xian)示(shi)比便減壓(ya)(ya)(ya)閥的(de)(de)(de)(de)壓(ya)(ya)(ya)力變化范(fan)(fan)圍為(wei)3.2~0.76MPa，即(ji)比例減壓(ya)(ya)(ya)閥的(de)(de)(de)(de)壓(ya)(ya)(ya)力變化正(zheng)常。再查(cha)盾現實故障(zhang)(zhang)代碼和以(yi)前記錄的(de)(de)(de)(de)故障(zhang)(zhang)代碼，監(jian)控器(qi)均未顯(xian)(xian)示(shi)何故障(zhang)(zhang)代碼，至(zhi)此可以(yi)肯定(ding)，問題(ti)(ti)不(bu)是出(chu)在(zai)電子控制系(xi)(xi)統。最(zui)后，檢查(cha)液壓(ya)(ya)(ya)泵自身調(diao)節(jie)系(xi)(xi)統。其上、下泵的(de)(de)(de)(de)調(diao)節(jie)器(qi)是分開的(de)(de)(de)(de)，通(tong)過對左(zuo)、右單邊行走的(de)(de)(de)(de)測試表時(shi)均存在(zai)問題(ti)(ti)，由于兩泵調(diao)節(jie)器(qi)均出(chu)現故障(zhang)(zhang)的(de)(de)(de)(de)可能性較(jiao)小，我們先將其放在(zai)一邊。
從(cong)外部著看查起(qi)。液壓(ya)(ya)泵(beng)調節器(qi)(qi)的(de)外部控(kong)(kong)(kong)(kong)制(zhi)信號有(you)(you)兩(liang)個：一(yi)個取自主(zhu)(zhu)控(kong)(kong)(kong)(kong)閥(fa)(fa)中(zhong)心油道的(de)壓(ya)(ya)力PN，上(shang)(shang)(shang)、下(xia)(xia)泵(beng)各一(yi)；另一(yi)個是(shi)來自同時控(kong)(kong)(kong)(kong)制(zhi)上(shang)(shang)(shang)、下(xia)(xia)泵(beng)的(de)比例(li)減(jian)壓(ya)(ya)閥(fa)(fa)的(de)壓(ya)(ya)力PS。先(xian)分(fen)別測(ce)(ce)量上(shang)(shang)(shang)、下(xia)(xia)泵(beng)的(de)壓(ya)(ya)力PN值(zhi)，得到當主(zhu)(zhu)控(kong)(kong)(kong)(kong)閥(fa)(fa)中(zhong)位(wei)時壓(ya)(ya)力為(wei)(wei)4.07MPa，無論(lun)有(you)(you)任何一(yi)下(xia)(xia)動(dong)作，PN即下(xia)(xia)降為(wei)(wei)0.35MPa，PN值(zhi)正(zheng)常。再測(ce)(ce)量PS值(zhi)，雖(sui)然已經通過(guo)監控(kong)(kong)(kong)(kong)器(qi)(qi)已查看到了PS值(zhi)的(de)變化(hua)范圍，且其壓(ya)(ya)力變化(hua)值(zhi)正(zheng)常，但這(zhe)并不一(yi)定準確(que)，因為(wei)(wei)比例(li)減(jian)壓(ya)(ya)閥(fa)(fa)上(shang)(shang)(shang)并沒有(you)(you)壓(ya)(ya)力傳(chuan)感器(qi)(qi)直接給主(zhu)(zhu)控(kong)(kong)(kong)(kong)制(zhi)器(qi)(qi)經信號輸(shu)入，監控(kong)(kong)(kong)(kong)器(qi)(qi)顯示的(de)壓(ya)(ya)力值(zhi)是(shi)主(zhu)(zhu)控(kong)(kong)(kong)(kong)制(zhi)器(qi)(qi)通過(guo)對比例(li)減(jian)壓(ya)(ya)閥(fa)(fa)的(de)輸(shu)出(chu)電流信號經分(fen)析(xi)轉換而成的(de)、也就是(shi)說，此(ci)壓(ya)(ya)力值(zhi)對應主(zhu)(zhu)控(kong)(kong)(kong)(kong)制(zhi)器(qi)(qi)對比例(li)減(jian)壓(ya)(ya)閥(fa)(fa)輸(shu)出(chu)電流的(de)強弱(ruo)。為(wei)(wei)此(ci)，在泵(beng)體上(shang)(shang)(shang)的(de)PS壓(ya)(ya)力側(ce)點接上(shang)(shang)(shang)壓(ya)(ya)力表。
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