大型養(yǎng)路機械常見故障處理

RAILWAYSECTORHandlingofcommonfailuresofballastplasticvehiclesCONTENTSCommonfaultsandtroubleshootingofpowertransmissionsystemCommonfaultsandtroubleshootingofdieselenginesCommonfaultsandtroubleshootingofdieselenginesForsomefaultsthatmayoccurduringtheoperationandoperationoflarge-scaleroadmaintenancemachinery,iftheyarenoteliminatedintime,itwillaffectthesafetyofoperationandoperation,theintegrityofthemachinery,andtheconsumptionoffuel.Therefore,asacrewmemberoftheballastplasticcar,theyshouldhavetheabilitytoanalyzeandeliminatecommonfaults.cardantransmissiondevice.1-connectingflange;2-crossshaft;3-universaljointfork;4-dustcover;5-splinesleeve;6-splineshaftuniversal-jointcrosstrunnion，1-bearingcap;2-universaljointfork;3-greasenipple;4-crossshaft;5-safetyvalve;6-connectingflange;7-oilseal;8-pinroller;9-setofsimpleTransfergearboxstructurediagramvariablepumpSchematicdiagramoftravelingdrivehydraulicsystem.1-Shuttlevalve,2-Electromagneticreversingvalve,3-Pressuregauge;4-Pilotvalve;5-Two-wayvariablepump:6-Oilfilter;7-Variablemotor;8-Flushvalve,9-Backpressurevalve:10-Cooler:11-Controlpressuregauge;12-Suctionoilfilter,13.14-Safetyvalve,15-Reliefvalve1.Difficultystartingdieselengine(1)Theambienttemperatureislow,andthepreheatingdeviceisfaulty:①Theoilcircuitoftheglowplugisblockedorthereisnovoltageonthesolenoidvalve.②Theflameglowplugisdamagedormustnotbepowered.(2)Theoilviscosityistoohigh,andthewrongbrandofoilisused,causingdifficultyinstarting.1Commonfaultsandtroubleshootingofdieselengines(3)Fuelsystemfailure:①Thereisnooilinthefueltank,orthesuctionpipeisblocked.②Thereisairinthefuelsystem.Atthistime,youneedtoloosenthebleedscrewplugofthefuelfinefilter,anduseittopumpfuel,andthentightenthebleedscrewplugafteralltheairinthefuelsystemisreleased.③Thefuelcontrolsystemisrusty,cardissuance,etc.④Thestart-upenrichmentsolenoidvalveontheboostpressuresmokelimiterisdamaged,whichlockstheadjustinggearrodandcannotenterthestart-upenrichmentposition.⑤Theinternalfuelsupplysystemofthedieselengineisfaulty.1Commonfaultsandtroubleshootingofdieselengines2.Startingmotorandelectricalfailure,causingtheenginenottostart(1)Startermotorfailure①Thereisnoresponsetothestartingmotor.Atthistime,checkwhetherthethreewiresofthestartingmotoraredisconnected.Ifitisnormal,checkwhetherthereis24Vvoltageonthe8thterminal.Ifnot,theJ14willnotactorbedamagedwhenitisnotpowered;ifitis,thereisanopencircuitfaultinsidethestartermotor.Atthistime,thebackcoverofthestartermotorneedstobedisassembledandcheckedcarefully.1Commonfaultsandtroubleshootingofdieselengines②Whenthestartswitchispulledtothestartposition,onlya"click"soundfromthestartermotorisheard,butthestartermotordoesnotrotate.Thereasonforthisfailureisthatalthoughthecoilthatattractstheelectromagnetcanattractthearmature,itcannotclosethecontactofthecontrolrelay.Therefore,allyouhearisthe"click"soundthatattractsthearmature,butthemaincircuitofthestartermotorisnotconnected.Pass.Thisiscausedbyshort-circuitorpoorcontactoftheelectromagneticcoil,andtheelectromagneticforceistoosmall.Thesurfaceoftheironcoreistoodirty,andthespringreplacedafterrepairistoohard,whichmayalsocausetheabove-mentionedfailures.1Commonfaultsandtroubleshootingofdieselengines③Startthemotoridling.Thestarteridlinghasthefollowingconditions:thestartermotorpiniondoesnotmeshwiththeflywheelringgearatallanditrunsidly;theattractionforceoftheattractingelectromagnetisreduced,andthestartermotorpiniongearcannotbemovedontheshaft.Whenthestartermotorpiniongearhasnotmeshedwiththeflywheel,Startthemotorandspin.1Commonfaultsandtroubleshootingofdieselengines(2)Thestartingmotorisnormal,buttheenginecannotbestarted①Firstchecktheexternalstarthandthrottleofthedieselengine(orwhentheairpressureofthemainaircylinderisgreaterthan400kPa,theairthrottlecontrolhandleshouldberaisedtotheidleposition).Itmaybethatthehandthrottleisnotpulledup,causingittofailtostart,andyouneedtopullupatthistimeThrottle,increasethethrottleposition.1Commonfaultsandtroubleshootingofdieselengines②Ifthereisnoproblemwiththeabove,youshoulduseamultimetertomeasurewhetherthegroundresistanceofterminal314is0.Ifitis,itmaybecausedbythefailureofthestopbuttontoreset,sothatthestoppneumaticvalve1s71mustnotbeenergized;otherwise,checkwhethertherelayJ17isdamaged.IfJ17isgood,thereisaproblemwiththeshutdownpneumaticvalve1s71.③Thecapacityofthebatterybecomessmallorlackselectricityorisnotcharged.Atthistime,youneedtouseamultimeterandacapacitymetertotestandcheck.1Commonfaultsandtroubleshootingofdieselengines3.ThestartermotorcannotstoprotatingafterthedieselengineisstartedThisfailureisverydangerous.Whenthiskindoffailureoccurs,thebatterygroundwireshouldbedisconnectedimmediately,otherwisethestartermotorwillburnoutinashorttime.ThecauseofthefailureisthatthethreepairsofcontactsoftheelectromagneticrelayJareweldedtogetherduetoburning,sothatthecircuitcannotbecutoff.Thesurfaceoftheironcoreortheholematchingtheironcoreistoodirty,andtheironcorereturnspringistoosoftorbroken,makingtheironcoreunabletoreturnfreely.1Commonfaultsandtroubleshootingofdieselengines4.Thedieselenginetemperatureistoohigh(1)Coolingsystemfailure①Thedustandoilontheheatsinkaretoothickandneedtobecleanedregularly.②Theelasticcouplingofthecoolingfandriveshaftisbroken,orthebearingofthepiniongearboxisbroken,causingthecoolingfantonotwork.③Thetemperaturesensororthermometerismalfunctioning,orthewiringofthesensorisgrounded.1Commonfaultsandtroubleshootingofdieselengines(2)Failureofgassupplysystem①Theairfilterisdirtyorthemaintenanceindicatorisdamaged.②Thecompressorendoftheturbochargerisdirty,whichcancausethedieselenginetooverheat.Atthistime,theturbochargermustbecleaned.1Commonfaultsandtroubleshootingofdieselengines5.Dieselengineoilpressureisloworoilconsumptionishigh(1)Theoilpressureistoolow①Improperoilviscosityorpoorquality.②Theoillevelistoolow.③Theoilhasbeenusedfortoolongandtheoilistoodirty,whichcontaminatesthelubricationsystemoftheentireengine.④Theoilpipelineisnotunblocked,suchastheoilfilterelementisblocked,themodelisincorrect,andtheoilleaks.1Commonfaultsandtroubleshootingofdieselengines⑤Theoilpressuresensorisdamagedortheoilpressuregaugeisnotworkingproperly.⑥Theoilpumpisnotworkingproperly.Forexample,theoilpumpisworn,theoilsuctionfilterisdirty,theconnectingpipeortheoilsuctionpipeisnotsealed,andtheone-wayvalveoftheoilpumpisnotsealed.1Commonfaultsandtroubleshootingofdieselengines(2)Engineoilconsumptionistoohigh①Poorrunning-inofnewengineorengineafternewoverhaul.②Improperoilviscosityorpoorquality.③Dieselengineleaksduetopoorsealing.④Thegapbetweenthepistonandthepistonringistoolarge,ortheoilscrapingeffectofthepistonringisnotgood,andtheoilfleesintothecombustionchambertoburn(theengineoftenemitsbluesmokeatthistime).⑤Thecrankcasebreatherisdamaged,andtheoilmistissuckedawayuncontrollably.1CommonfaultsandtroubleshootingofdieselenginesCommonfaultsandtroubleshootingofpowertransmissionsystem1.UniversaltransmissiondeviceTheuniversaltransmissiondevicebearshugetorqueanddynamicloadduringwork.Afterlong-termuse,thepartswillwearoutandthematchingclearancewillincrease.Inaddition,theshafttubeisbentanddented,whichwillcausetheuniversaltransmissiondevicetosqueakandshake.2.Commonfaultsandtroubleshootingofpowertransmissionsystem(1)AbnormalsoundofuniversaljointTheabnormalnoiseoftheuniversaljointisespeciallyobviouswhenthevehiclespeedchanges.Thecauseofthisfailureismainlytheuniversaljointcrossshaftandtheneedlerollerbearingareseverelywornandlooseortheneedlerollerisbroken.Thewaytotroubleshootistoreplacethebearing.Addinglubricatinggreaseinstrictaccordancewiththeuseandmaintenanceprocedurescaneffectivelypreventsuchfailuresfromoccurring.2.Commonfaultsandtroubleshootingofpowertransmissionsystem(2)AbnormalsoundofloosesplineTheloosenessofthedriveshaftsplinecanalsoproduceabnormalnoise,especiallyatthemomentofsuddenthrottlechange,thenoiseisparticularlyserious.Therefore,duringmaintenance,attentionshouldbepaidtolubricationtoreducethewearofthekeywayandensurethefreeexpansionandcontractionofthedriveshaft.2.Commonfaultsandtroubleshootingofpowertransmissionsystem(3)Chatteringofthedriveshaft①Thetransmissionshaftisunbalanced,andvibrationwilloccurduetothecentrifugalforceduringrotation.Inseverecases,thetransmissionshaftpartswillbequicklydamaged,whichwillaffectthenormaloperationofthetransfergearbox.Accordingtothestructuralcharacteristicsofthedriveshaft,duringuseandmaintenance,attentionshouldbepaidtomaintainingthebalanceconditionsoftheshaft,suchaseliminatingshaftdeformation;markingwhendisassemblingtheslidingfork;checkingthedynamicbalancesheettopreventfallingoff;repairingthecrossshaftbearing,etc.②Theelasticcouplingfails.2.Commonfaultsandtroubleshootingofpowertransmissionsystem2.GearboxThegearboxesofSPZ-200equippedwithballast-shapedvehiclesinclude:transfergearboxandaxlegearbox.Theirstructureandworkingprinciplearebasicallythesame.Inuseandmaintenance,thefaults,causesandtroubleshootingmethodsaresimilar..2.CommonfaultsandtroubleshootingofpowertransmissionsystemThegearboxshouldmeetthefollowingtechnicalrequirementsduringoperation:①Thetransmissionboxmustnotbeoverheated.②Theoperatingmechanismmustbelight,flexibleandreliable.③Itisnotallowedtohavepercussivesoundwithhighandlowchangesingeartransmission.④Thereshouldbenooilleakageoneachjointsurfaceandoilseal.Duringtheuseofthegearbox,duetothewearanddeformationoftheparts,thepartsarenotmatchedproperly,whichcausesaseriesoffailures.Commonfaultsincludeabnormalsoundandoilleakage.2.Commonfaultsandtroubleshootingofpowertransmissionsystem(1)AbnormalsoundTheabnormalnoiseofthegeartransmissionboxismainlycausedbythewearandtearofthebearingandtheabnormalmeshingbetweenthegears.①Bearingnoise.Bearingnoiseisamessycontinuousnoise.Gearboxbearingsoftenworkunderhigh-speed,heavy-dutyconditions,andbeargreatalternatingloads.Therefore,therollingelementsandracewayswillwearout,fatiguepeeling,ablation,etc.,andtheaxialandradialgapsofthebearingwillincrease,causingtherollingelementsandracewaystocollideandmakenoise.Abnormalnoisecanalsobeproducedwhentheouterraceofthebearingandtheboreofthebearingseatarewornandloose.Forthisreason,thebearingshouldbechecked,ifitisdamaged,itshouldbereplaced,andthebearingtightnessshouldbere-adjusted.2.Commonfaultsandtroubleshootingofpowertransmissionsystem②Thegearsounds.Thenormalmeshinggapandmeshingmarksofthegeararedestroyed,whichisthemainreasonfortheabnormalnoiseofthegear.Ifthenoiseisnotserious,youcancontinuetouseit;whenitisserious,youcanremovethetransmissionboxcoverforinspection;ifthemeshinggapexceedsthelimit,thegearisbroken,etc.,itshouldbereplaced.2.Commonfaultsandtroubleshootingofpowertransmissionsystem(2)LubricationandleakageThegeartransmissionboxisequippedwithalubricationsystemintheformofsplashtypeandforcedtype.Thetransfergearboxequippedwiththeballastplasticcaradoptsthesplashtype;therunninggearboxismainlyoftheforcedtype,andthesplashtypeissupplemented.Theaxlegearboxisequippedwiththecamoftheplungerpumpontheinneraxle.2.CommonfaultsandtroubleshootingofpowertransmissionsystemThefailureofthelubricationsystemismanifestedinthepressureofthesystem.Ifthesystempressureistoohigh,oilleakagewilloccur.Thereasonisthattheoilpipelineisblockedandunsmooth,andmustbecleaned.Toolowsys