With the rapid development of China's transportation, energy and other infrastructure construction processes, the demand and quantity of large and medium-sized construction machinery have grown rapidly in recent years.
Among many construction machinery, especially imported equipment, hydraulic transmission and full hydraulic drive are very common, such as tunnel boring machine, shield, large tonnage beam truck, crane, lifting trolley, and paver, excavation Machines, bulldozers, etc. The hydraulic closed circuit has low energy consumption, compact structure and easy to realize stepless speed change. It has been widely used in engineering machinery hydraulic system, but compared with open circuit, closed circuit installation and debugging are more difficult. And technical requirements, the following is a brief summary of the main points of installation and commissioning of closed circuits.
1. Preparation before installation
1.1 Keep the system components clean: Carefully check the pump and motor and all system components: fuel tank, piping, valves, joints, radiators, etc., to ensure no damage, no pollution, the chip of the processing part of the valve block should be cleaned Clean and clean.
1.2 Cleaning of hydraulic oil: Pay attention to the pollution degree and humidity of the oil to avoid any dirt entering the fuel tank. It must pass through the filter when refueling. If the inside of the tank is coated, it must be compatible with the oil used.
2 Implementation of the installation process:
2.1 It is forbidden to use strong force on the hydraulic system to avoid the lateral force and internal stress of the pipeline system and components. Be sure to protect the pipeline system!
2.2 It is forbidden to use twine and adhesive as sealing material, otherwise it will pollute the system and may cause system failure.
2.3 Arrange the hose correctly to avoid twisting, squeaking, scratching and bumping of the hose.
2.4 The connection of the system must comply with the recommended standards. All system piping must be connected and sealed to be reliable and no leakage occurs.
3. Put into operation, commissioning
If the hydraulic system is installed as required, it can be put into operation and the hydraulic system can be commissioned. Before commissioning, it is necessary to add as much clean hydraulic oil as possible in the hydraulic tank. At the same time, the pump, motor casing, main system piping, etc. should be oiled, mainly due to the high viscosity of the oil, the long pipeline, and the oil pump suction line. The air in the middle can not be discharged. If the installation worker puts the speed of the diesel engine from the starting speed to the maximum speed within 30 seconds, the early wear of the charge pump is inevitable.
When the system is initially started, it is best to follow the procedures described below to maximize protection of hydraulic components such as pumps and motors:
3.1 Install a pressure gauge of the appropriate range at the charge pressure pressure port to detect the charge pressure during start-up and commissioning.
3.2 Disconnect the pump's input control signals (mechanical link, hydraulic control line, electronic control plug, etc.) to ensure that the pump is in the neutral position.
3.3 Take the necessary way to remove the system load (set up the main unit to drive the drive wheel off the ground, disconnect the motor load, etc.).
3.4 Start the prime mover in the lowest possible speed until the charge pressure is established.
3.5 After the charge pressure is established, increase the prime mover to the rated speed and check the charge pressure value. If the charge pressure does not meet the requirements, immediately turn off the prime mover, find out the cause and solve it; for example, the charge pressure If it is normal, turn off the prime mover, connect the pump's control signal and restart the prime mover to check if the pump's neutral state is good.
3.6 Increase the prime mover to the rated speed and input a control signal to the pump to put the system into operation as slowly as possible and check the forward and reverse working conditions of the system. (Note: In a typical system configuration, when the system is out of neutral position, in the forward and reverse working state, the charge pressure value will be slightly reduced.)
3.7 Continuously and slowly let the system work alternately in the forward and reverse for at least five minutes.
3.8 Turn off the prime mover, check the oil level of the fuel tank and, if necessary, refuel to the specified value.
3.9 If there are more bubbles in the oil, wait for the bubble to disappear, then start the prime mover again and let the system work alternately in the forward and reverse directions for a few minutes. Then turn off the prime mover. If necessary, this process should be repeated several times until the bubbles disappear completely.
3.10 Inspect all piping and fittings to ensure that there are no leaks and looseness, ensuring that the tank does not contain water and other impurities.
In short, only the installation and commissioning of the closed hydraulic system are carried out in accordance with the correct operation method, in order to fully protect the hydraulic components such as pumps and motors, so that they can exert their maximum functions, and the failure frequency of the main engine is greatly reduced.
Among many construction machinery, especially imported equipment, hydraulic transmission and full hydraulic drive are very common, such as tunnel boring machine, shield, large tonnage beam truck, crane, lifting trolley, and paver, excavation Machines, bulldozers, etc. The hydraulic closed circuit has low energy consumption, compact structure and easy to realize stepless speed change. It has been widely used in engineering machinery hydraulic system, but compared with open circuit, closed circuit installation and debugging are more difficult. And technical requirements, the following is a brief summary of the main points of installation and commissioning of closed circuits.
1. Preparation before installation
1.1 Keep the system components clean: Carefully check the pump and motor and all system components: fuel tank, piping, valves, joints, radiators, etc., to ensure no damage, no pollution, the chip of the processing part of the valve block should be cleaned Clean and clean.
1.2 Cleaning of hydraulic oil: Pay attention to the pollution degree and humidity of the oil to avoid any dirt entering the fuel tank. It must pass through the filter when refueling. If the inside of the tank is coated, it must be compatible with the oil used.
2 Implementation of the installation process:
2.1 It is forbidden to use strong force on the hydraulic system to avoid the lateral force and internal stress of the pipeline system and components. Be sure to protect the pipeline system!
2.2 It is forbidden to use twine and adhesive as sealing material, otherwise it will pollute the system and may cause system failure.
2.3 Arrange the hose correctly to avoid twisting, squeaking, scratching and bumping of the hose.
2.4 The connection of the system must comply with the recommended standards. All system piping must be connected and sealed to be reliable and no leakage occurs.
3. Put into operation, commissioning
If the hydraulic system is installed as required, it can be put into operation and the hydraulic system can be commissioned. Before commissioning, it is necessary to add as much clean hydraulic oil as possible in the hydraulic tank. At the same time, the pump, motor casing, main system piping, etc. should be oiled, mainly due to the high viscosity of the oil, the long pipeline, and the oil pump suction line. The air in the middle can not be discharged. If the installation worker puts the speed of the diesel engine from the starting speed to the maximum speed within 30 seconds, the early wear of the charge pump is inevitable.
When the system is initially started, it is best to follow the procedures described below to maximize protection of hydraulic components such as pumps and motors:
3.1 Install a pressure gauge of the appropriate range at the charge pressure pressure port to detect the charge pressure during start-up and commissioning.
3.2 Disconnect the pump's input control signals (mechanical link, hydraulic control line, electronic control plug, etc.) to ensure that the pump is in the neutral position.
3.3 Take the necessary way to remove the system load (set up the main unit to drive the drive wheel off the ground, disconnect the motor load, etc.).
3.4 Start the prime mover in the lowest possible speed until the charge pressure is established.
3.5 After the charge pressure is established, increase the prime mover to the rated speed and check the charge pressure value. If the charge pressure does not meet the requirements, immediately turn off the prime mover, find out the cause and solve it; for example, the charge pressure If it is normal, turn off the prime mover, connect the pump's control signal and restart the prime mover to check if the pump's neutral state is good.
3.6 Increase the prime mover to the rated speed and input a control signal to the pump to put the system into operation as slowly as possible and check the forward and reverse working conditions of the system. (Note: In a typical system configuration, when the system is out of neutral position, in the forward and reverse working state, the charge pressure value will be slightly reduced.)
3.7 Continuously and slowly let the system work alternately in the forward and reverse for at least five minutes.
3.8 Turn off the prime mover, check the oil level of the fuel tank and, if necessary, refuel to the specified value.
3.9 If there are more bubbles in the oil, wait for the bubble to disappear, then start the prime mover again and let the system work alternately in the forward and reverse directions for a few minutes. Then turn off the prime mover. If necessary, this process should be repeated several times until the bubbles disappear completely.
3.10 Inspect all piping and fittings to ensure that there are no leaks and looseness, ensuring that the tank does not contain water and other impurities.
In short, only the installation and commissioning of the closed hydraulic system are carried out in accordance with the correct operation method, in order to fully protect the hydraulic components such as pumps and motors, so that they can exert their maximum functions, and the failure frequency of the main engine is greatly reduced.
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