The reasons for this malfunction and the corrective measures can be as follows.
- There is not enough working liquid in the tank, therefore the distributor does not work (the liquid must be topped up to the level).
- The bypass valve freezes due to the ingress of dirt into the “valve shank - guide” interface; there are foreign particles on the seat of the bypass valve that prevent it from completely closing; the jet hole in the shoulder (plunger) of the valve is dirty. To eliminate valve sticking, it is necessary to remove the valve and guide from the distributor housing, wash them in diesel fuel, clean the jet hole and wipe the valve seat. When reinstalling the bypass valve parts, check that the valve stem moves freely in the guide.
- The safety valve does not close completely due to the accumulation of dirt under the ball on the edge of the seat hole. Therefore, the bypass valve of the distributor is fully or partially open and the hinged system does not work. To eliminate the malfunction, it is necessary to briefly hold the distributor handle in the “Forced lowering” position several times in order to wash away dirt from the edge of the safety valve with the flow of working fluid. If the dirt cannot be removed in this way, then the distributor must be removed and sent to a repair shop.
- The distributor may be OK, but the mounted machine will not lift. This may be for the following reasons:
- the hydraulic system pump is not turned on or the pump spontaneously turns off when the switching mechanism is faulty; leakage of working fluid in the pump
- the locking device does not let the working fluid through the oil pipeline
- air leakage through the seal of the pump drive shaft or through the sealing ring of the suction pipe or the oil pipe fitting, which causes foaming of the working fluid
- faulty power cylinder
- retarding valve calibrated port clogged
- increased leakage through the piston o-ring
- jamming in the seat of the piston stroke limiter valve
- the gap between the stop and the shank of the piston stroke limiting valve is less than 10 mm
- Low or high fluid temperature in the hydraulic tank. In this case, it is necessary to ensure the temperature of the working fluid in the tank in the range of +30-60°C.
Spool does not automatically return from "Raise" or "Forced Lower" position
The causes of this malfunction and how to fix them can be as follows:
- The relief valve set pressure is equal to or lower than the set pressure of the automatic spool return device. This cause is eliminated by changing the adjustment of the actuation pressure of the automatic spool return device to I-12 MPa (110-125 kgf/cm2) or the safety valve to 13.0-13.5 MPa (130-135 kgf/cm2) in repair shops.
- The bypass valve hangs, as a result of which the necessary pressure for operation does not develop automatic device. The remedy for this problem is described above.
- The temperature of the working fluid in the tank is above +60°C, therefore, the viscosity is insufficient; resulting in large fluid leaks through the gaps in the automatic spool return device. The temperature of the working fluid of the hydraulic system has increased due to a malfunction of the booster device, therefore, until the malfunction is eliminated, the tractor operator must manually return the handle from the working positions to "Neutral". The cause of the malfunction can be eliminated by cooling the working fluid to a temperature of + 60-30 ° C.
- The automatic spool return device is operational, but does not work due to a pump malfunction (it does not create the necessary pressure).
- The spool filter is clogged and the working fluid does not enter the booster device in sufficient quantity. It is possible to eliminate the malfunction only by disassembling the spool - remove the sleeve, the gasket with the filter and rinse it.
The spool (hence the handle) is not fixed when it is set to the working position (“Lifting” or “Forced lowering”) or returns to the neutral position before the end of the full stroke of the piston in the cylinder
The causes of the malfunction and remedies may be as follows:
- The actuation pressure of the booster device (device for automatic spool return) is below 11 MPa (110 kgf/cm2) and below the operating pressure that develops in the power cylinder when lifting the mounted machine. Therefore, the operation of the booster device occurs before the lifting of the machine to its highest position. To eliminate this cause, it is necessary to adjust the booster device to a pressure of 11 - 12.5 MPa (110-125 kgf / cm2).
- The weight of the mounted machine is greater than that installed for this tractor or the soil resistance is high when the machine is raised. In this regard, the fluid pressure in the power cylinder reaches a value greater than the actuation pressure of the booster device, and therefore the spool does not lock. In this regard, it is necessary to pay attention to the correct aggregation and to the depth of travel of the working bodies of the mounted machine. AT this case replace the mounted machine with a machine of less weight or set the required tillage depth.
- The spool booster valve is not tight due to the ingress of foreign particles on the valve seat or in the gap between the booster and the spool. Due to a leak in the booster valve, the automatic spool return device operates at lower pressures. This malfunction can be eliminated by holding the distributor handle in the working position five to seven times after the end of the power cylinder piston stroke in order to wash foreign particles from the parts of the booster device with the flow of working fluid. If this does not eliminate the malfunction, then it is necessary to sort out the spool assembly, wash it in diesel fuel and blow it with compressed air.
- The temperature of the working fluid in the tank is below +30°C. The operation of the distributor on a cold working fluid (high viscosity) causes a slow landing of the ball on the edge of the inlet hole. In this regard, the piston of the power cylinder reaches its extreme position before the booster valve closes the inlet. Therefore, premature unfixation occurs.
- The retarder valve bore is clogged or the bore does not match the cylinder bore. Therefore, there is an increase in fluid pressure in the booster device and premature release occurs. To eliminate the malfunction, it is necessary to clean the calibrated hole and flush the fitting in diesel fuel or check that the diameter of the calibrated hole matches the cylinder diameter. For cylinders Ts55, Ts75, Ts90, Ts100, Ts110, Ts125, Ts140, the bore diameter should be 2.5, respectively; 3; 3.5; four; 4.5; 5.5 and 7 mm.
- Incorrect installation of the retarding valve in the power cylinder. In this case, it is necessary to swap the fitting with a delay valve for the second fitting of the cylinder, i.e., install the fitting with a delay valve in the cylinder so that when the mounted machine is lowered, the working fluid passes only through the calibrated hole.
- The locking device of the oil pipeline does not allow the working fluid to pass through. In this case, the mounted machine rises slowly or does not rise at all, or it freezes in an intermediate position, and the pressure in front of the booster increases rapidly, which leads to premature release. The cause of the malfunction is eliminated by tightening the union nut of the locking device to failure. If the locking device is faulty, it must be replaced or freed from balls, springs and crosses, and then tighten the union nut.
- Jamming in the seat of the piston stroke control valve or the gap between the stop and the shank of the piston stroke control valve has become less than 10 mm. In this case, the oil line in the power cylinder is blocked and the pressure in the booster device rises, which leads to premature operation of the booster device. This malfunction can be eliminated in the first case by lifting the valve with pliers by the shank, and in the second - by raising the movable stop on the power cylinder rod to a distance of 20-30 mm from the valve shank.
- Retainer removal. In this case, you need to check the latch when the pump is not running. If it does not hold the spool in working positions, then the worn parts must be replaced.
Drop mounted machine
When the spool is set to the "Forced Lower" position, the mounted machine will drop rapidly due to the absence of a washer with a calibrated hole in the retarding valve. The malfunction is eliminated by installing a new washer with a calibrated hole with a diameter corresponding to the diameter of the cylinder.
Leakage of working fluid
- By spheres of levers. O-ring worn. To replace the ring, unscrew the anther plate and remove it without removing the corrugated anthers from the levers, remove the control levers, remove the sealing rings and replace the worn ones.
- Along the housing connector with covers, along the bolts that fasten the covers to the distributor housing. Fluid leaks through the connectors can be due to wear on the gaskets of the covers and in the event of a clogged hydraulic drain filter.
- When the filter is clogged, the pressure at the drain increases and the working fluid enters the tank through the filter safety valve. Increasing the pressure of the working fluid at the drain causes the leakage of the working fluid to the outside through the seals of the distributor caps. In this case, you need to rinse the filter without disturbing the adjustment of the safety valve.
- Worn top and bottom cover gaskets must be replaced with new ones. When replacing the top cover gasket, it is necessary to unscrew the anther plate and remove it without removing the corrugated anthers from the levers, remove the control levers, remove the cover and replace the gasket. When replacing the gasket of the bottom cover of the distributor, it is necessary to unscrew the nuts securing the triangular flange to the bottom cover and remove it, and then unscrew the nuts of the studs that secure the cover to the body, remove it and replace the gasket.
- Bypass valve guide stop connector. Leakage of the working fluid appears due to wear of the gasket or sealing ring of the guide. It is necessary to unscrew the bolts securing the bypass valve guide stop to the body, remove it, check the condition of the gasket and, if necessary, replace it. If leakage continues even after the gasket has been replaced, the valve guide O-ring must be replaced.
- Through fittings that supply the working fluid from the pump to the distributor and from the distributor to consumers, as well as through the plug.
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The press is equipped with three heating plates forming 2 working floors.
Dimensions heating plates 400x400, distance between heating plates 138 mm, maximum working temperature 250
`C, the drive is hydraulic.
To cool the plates, an oil cooling station is attached to the press.
The press is serviced from one side.
There is a pneumatic lift table for lifting the molds to the middle plate.
Specifications. 100-400 2E
| Nominal press force, MN (tf) | 1,0 (100) |
| Distance between heating plates, mm | 138±3 |
| Number of floors, pcs. | 2 |
| Time of closing (split) of plates, s, no more | 10 |
| Temperature difference at various points of the working area of the surface of the heating plate in the temperature range: | ±5 |
| Maximum operating temperature of heating plates, °C | 250 |
| plate heating | electric, induction |
| The total power of the heating plates of the press at a temperature of 200 °C, kW, not more than | 12 |
| Press plates heating time from 20 °C to 200 °C, min., no more | 40 |
| The number of automatically performed pre-pressing, pcs. | 0; 1-4 |
| Supply current - AC, three-phase | : |
| voltage, V | 380/220±10% |
| frequency Hz | 50±0.2 |
| Limits of oil pressure regulation in the hydraulic system, MPa (kgf/cm2) | 6 (60)-20 (200) |
| Drive unit | hydraulic, individual |
| Installed power of the electric motor of the hydraulic drive, kW, no more | 2,2 |
| The volume of oil in the hydraulic system, l | 60 |
| Oil volume in the heating plate cooling system, l | 80 |
| Installed power of the electric motor of the pump of the oil cooling station, kW | 2,2 |
| Water consumption in the cooling system, m3/h, no more | 1,5 |
| Compressed air consumption at a pressure of 0.6 MPa (6 kgf/cm2), m3/h, no more | 0,01 |
| Overall dimensions, mm, no more | 1120x2500x1820 |
| Weight, kg, no more | 2050 |
| Compressed air pressure in the pneumatic system, MPa (kgf/cm2) | 0,4 (4)-0,6 (6) |
| Lift table drive | pneumatic |