Inspection and Repair of Integrated Hydraulic System of Taishan-12 Tractor

Taishan-12 tractor adopts integrated hydraulic system, which is mainly composed of piston type oil pump, control valve and cylinder assembly. The ram pump is integrated with the control valve and is mounted on the front of the rear axle housing cover. The cylinder is housed in the tank and is mounted behind the top of the rear axle housing. The plunger-type hydraulic oil pump and control valve maintenance plunger type hydraulic oil pump is composed of a pump body, a plunger, a spring, a check valve and an eccentric shaft drive mechanism; the control valve is composed of a valve body and a valve housing. The common failure of the plunger type hydraulic oil pump and the control valve is that the mating surfaces of the plunger and the plunger hole, the one-way valve and the valve seat, and the control valve and the valve hole are worn, so that the fitting clearance is increased, the suction force of the oil pump is reduced, and the pump oil amount is reduced. The reduction in internal oil leakage has resulted in slower or even unacceptable elevation of agricultural implements. Agricultural implements have been falling automatically in transport locations and noise has been generated during work. 1. Inspection of plunger and plunger holes (1) Wear characteristics and influences Due to abrasive wear and scratches caused by mechanical impurities in the oil, the plunger and plunger holes are seriously worn, roundness deviation and cylindricity deviation are increased, and Pull out the uneven grooves along the running direction of the plunger, increase the clearance between the plunger and the plunger hole, and reduce the sealing performance. During the pumping process, the leakage increases, the pump oil pressure decreases, the pump oil decreases, and the farm implements The increase is slow. When the contact surface of the plunger and the driving eccentric sleeve is worn, the stroke of the oil pump is reduced, and the pump oil amount is also reduced, thereby affecting the improvement of the agricultural implement. Plunger and plunger hole wear can be measured with a dial gauge and a dial indicator. When the deviation of roundness and cylindricity exceeds 0.01mm and the clearance exceeds 0.03mm, it should be repaired. (2) Repair method The plunger and the pump body are made of 20 chrome steel and high-strength cast iron, respectively. When the abrasion is light, the grinding rod can be made according to the actual size of the plunger hole, coated with M7 grinding paste for grinding, then the plunger is chrome plated, and the plunger is ground according to the size of the trimmed plunger hole (remaining 0.01 Milling margin (mm), and finally dry ground mutual study to restore normal fit. When the wear is serious, it can be repaired by inserting sleeves. Firstly, dig the hole in the piston and then use the HT25-47 high-strength cast iron to make the bushing according to the actual size of the hole. After the bush is dry cooled, insert the bush into the hole of the plunger. The surplus is 0.08-0.10mm. 2. Check of one-way valve The check valve is opened and closed repeatedly in the work. Due to the mechanical impurities in the high-speed oil, the abrasion and partial wear are generated due to the erosion and friction of the mechanical impurities, so that the valve is not closed tightly and the suction stroke is in the vacuum of the plunger hole. Decreased, reduced suction, insufficient oil absorption, reduced pump oil, and reduced pump oil. When the one-way valve and the valve seat are worn with slight or only shallow scratches, a grinding paste may be applied on the mating surface to perform mutual grinding, remove the wear marks, and restore the normal fit. When the wear is serious and the grooves and depressions are deep, the plane of the valve seat can be milled using a face milling cutter, and then the seal can be recovered by checking with the check valve. During the inspection, kerosene is injected into the upper part of the check valve, and the oil surface can be maintained for 5 minutes without falling. 3. After driving the eccentric shaft and the eccentric sleeve and bush for maintenance, the eccentric shaft supporting the bearing surface of the journal and the bush, the mating surface of the eccentric protrusion and the eccentric sleeve, and the contact surface of the eccentric sleeve and the plunger end will wear out. This increases the fit clearance, causes the plunger stroke to decrease, the pump oil volume decreases, the oil pump operates unstably, and generates noise. When the deviation between the roundness and cylindricity of the eccentric shaft journal exceeds 0.02mm, the fitting gap between the journal and bushing, the eccentric cam and the eccentric sleeve exceeds 0.15mm, and it should be repaired. The repair method is to grind shaft journals and eccentric cams, restore the correct shape, and formulate bushings and eccentric bushings of corresponding sizes to restore the normal fit clearance; after chrome plating or surfacing of journals and cams, grinding to standard Size, matching the standard size of the bushing, restore normal fit clearance. 4. Manipulation of valve and valve hole Inspection valve and valve hole under the pressure of mechanical impurities in the high-pressure oil, make the mating surface wear, and produce strip groove, reduce the sealing, increase the internal oil leakage, farm tool upgrade is slow, or After the lift, it will fall automatically. In severe cases, the farm tool cannot be kept in the transport position. Therefore, when the fitting gap between the valve and the valve hole exceeds 0.03 mm, or when the groove is visible to the naked eye, it should be repaired. When repairing, first make a grinding rod according to the actual size of the valve hole, apply M7 grinding paste to grind the valve hole, and chrome plate the control valve. Grind the outer circle according to the actual size of the valve hole (leave a grinding amount of 0.01mm) Finally, the allocation of research, to meet the normal gap. 5, plunger-type pump and the operating valve assembly points (1) before assembly, all parts must be cleaned, blown clean air with compressed air. (2) After assembly, the plunger and control valve should slide freely in the hole without blockage. (3) Under conditional conditions, after assembly, the pressure test shall be carried out on the test bench together with the rear cover assembly. The plunger shall be at the lowest position and the opening pressure of the safety valve shall be adjusted to 14 MPa within 3 min. There must be no leakage. (4) After passing the pressure test, the opening pressure of the safety valve shall be adjusted to 12MPa and sealed with a lead seal. Hydraulic cylinder inspection 1, cylinder wear and its impact Hydraulic cylinder assembly installed in the tank, composed of cylinder, piston, piston ring and piston rod. In the work, the inner wall of the oil cylinder and the piston ring rub against each other, and the effect of mechanical impurities in the oil causes the cylinder wall to wear, and the strip groove marks are pulled out in the direction of piston movement. The ring grooves on the piston ring and the piston collide with each other and the friction wears. After the cylinder, piston ring and ring groove are worn out, the fitting clearance is increased, the sealing performance is reduced, the oil is leaked, the agricultural implement is promoted slowly and there is a phenomenon of shaking. In severe cases, the working ability will be lost. When the fit clearance between the cylinder and the piston exceeds 0.20mm, the opening clearance of the piston ring exceeds 0.5mm, the edge clearance exceeds 0.15mm, or there is a serious strain, it should be repaired or replaced. 2. Repair method When the cylinder wear is light, the old piston can be coated with a fine abrasive cloth and coated with a grinding paste for grinding, and replace the piston ring with an enlarged size. If the wear is serious, it can be repaired by using a helium cylinder, an oversized piston, and a piston ring. The deviation of the roundness and cylindricity of the repaired cylinder and piston shall not exceed 0.008mm, the surface roughness parameter Ra shall not be greater than 0.8μm, the fitting clearance shall be 0.03-0.09mm, the opening clearance of the piston ring shall be 0.20-0.40mm, and the edge clearance shall be 0.05-0.09mm, after the assembly pressure test, under the pressure of 18MPa, the joints of the oil circuit should be no leakage phenomenon, the piston and the cylinder with the surface leakage does not exceed 2L/min.

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