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The ZL50 Loader's Difficult Failure and Its Reason Analysis
Pan Xiuqiang Hu Jianyong (Shandong Aluminium Company) ZL50 loaders often have some problems during use and maintenance. The reasons are difficult to find. The following author makes specific analysis of several difficult faults and their causes to help them find out faults as soon as possible. Cause, take measures to troubleshoot. ? 1. The oil sump of the engine keeps rising. This failure made us wonder that the turbine oil in the gearbox could not be leaked into the oil pan of the engine at all, but there was a channel between the two. This was the oil return line at the rear of the crankshaft. When conditions are met, the turbine oil in the transmission goes to the oil sump of the engine. There are two main reasons: (1) The clearance gap between the guide wheel and the gear is too large, resulting in a large amount of oil discharged from the rotary oil seal. The clearance between the guide wheel and the gear should be 0.2 mm. The rotary oil seal at this position is also allowed. With a certain amount of leakage, the leaked oil is returned to the transmission oil sump through the return line on the torque converter housing. When the clearance between the guide wheel and the gear is too large, the amount of oil discharged is too large. The oil return pipe cannot timely return the oil leaking into the torque converter housing back to the transmission oil sump, and the oil level rises. The flywheel housing is connected with the torque converter housing and communicates with each other. The distance between the flywheel gear ring and the flywheel housing is only 10mm. When the flywheel gear ring contacts the oil surface, a large amount of oil splashes everywhere and splashes onto the rear wall of the cylinder block. The 6135K9a engine does not have a rear crankshaft oil seal. Its seal is based on the normal clearance between the oil deflector, the rear thrust plate and the crankshaft, and the oil return line at the rear of the crankshaft. When the leaked oil flows to the rear of the crankshaft, it will follow the crankshaft. The department’s oil return line is sucked into the oil sump of the engine so that the turbine oil continuously enters the oil sump. (2) The oil seal of the working pump or steering pump leaks. The leaked turbine oil flows into the oil sump of the transmission case. We cannot find long-term leaks. When the oil level of the gearbox rises to a certain height, the gearbox penetrates through. The flat oil will flow into the torque converter housing and the engine flywheel housing. When the flywheel gear ring contacts the oil surface, the turbine oil will splash to the back wall of the engine block and flow back to the oil return line at the rear of the crankshaft. It is sucked into the oil sump of the engine. ? 2. The overhauled engine oil consumed too much and was blue smoke. Sometimes the engine oil that has just been overhauled consumes too much oil and emits blue smoke. The reasons are as follows: (1) The cylinder wall clearance is too large and the piston ring is not elastic enough. (2) The scraper ring is damaged. (3) Valve stem and valve stem with excessive clearance or valve oil seal damage. (4) Piston ring backlash and backlash are too large. The first three reasons are generally noted during overhaul. The technical data of the backlash and backlash of the piston ring can be easily ignored. However, the piston ring's backlash and backlash are too large to consume oil to a greater extent than other causes. Much more, because when the piston ring backlash and backlash is too large, due to the high-speed reciprocating motion of the piston, the piston ring jumps up and down in the piston ring groove, the oil around the piston ring will be pushed to the upper part of the piston ring, in the intake stroke When there is vacuum at the upper part of the piston, the oil will be sucked into the top of the piston to burn or carbonize. Due to the high-speed operation of the engine, a large amount of engine oil is sucked into the top of the piston, resulting in excessive oil consumption. ? 3. Bad braking effect. The braking system of the ZL50 loader is a gas-oil pan brake. When the braking effect is not good, we can do routine inspections. The specific contents include whether the oil brake master cylinder and the pipeline are leaky or total. Whether the size of the pump has exceeded the amount of gas, whether the piston of the afterburner is stuck, and whether the bowl and apron of the oil brake master cylinder are damaged. If the routine inspection can not find the cause of the fault, we can use quantitative analysis methods to determine the location of the fault, and find the segment. By calculation, when the brake pressure is 6.5 kg/cm2, the pressure of the oil brake line should be 100kg/cm2. We remove the bleed screw of the brake cylinder and connect a pressure gauge when the brake pressure is 6.5. At the time of kg/cm2, step on the brake pedal to measure the pressure of the oil brake line. If the pressure is around 100kg/cm2, it means that the fault is not in the master cylinder. The cause of the fault is that the piston of some brake cylinder is stuck. The moving cylinder can not work completely, so the braking effect is not good. If the pressure is insufficient and the maximum pressure is constant, it can be determined that the piston, cup or apron of the master cylinder has a poor seal, and there is a leak inside the master cylinder. If the brake pedal is pressed 3 times in a row, the pressure in the brake pipe is higher than once and the maximum pressure is less than 100kg/cm2. There are two causes of this failure: (1) Afterburner push rod and oil Master cylinder piston clearance is too large. Its normal value should be 0.5mm, the gap is too large, reducing the piston's oil stroke, so that the amount of brake fluid subsidies. (2) The seal of the oil brake master cylinder is poor, and a small amount of brake fluid in the brake line returns to the master pump, so that the oil pump push amount cannot be made up. The emergence of these failures, we feel at the time of maintenance can not start, but as long as we are guided by theory and practice, careful analysis, identify the possible causes of failure, develop a troubleshooting process, then our maintenance work is easy Much more.