Press 100 400 2e passport. Faults in the hydraulic system due to valve failure. Fall of the mounted machine

The press is equipped with three heating plates forming 2 working floors.
Dimensions of heating plates 400x400, distance between heating plates 138 mm, maximum operating temperature 250`С, the drive is hydraulic.
To cool the plates, an oil cooling station is connected to the press.
The press is served from one side.
A pneumatic lift table is available to lift the molds onto the middle plate.

Specifications. 100-400 2E

The causes of this malfunction and remedial measures may be as follows.

1. There is little working fluid in the tank, therefore the distributor does not work either (the fluid must be topped up to the level).
2. The bypass valve freezes due to dirt entering the valve stem-guide interface; there are foreign particles on the bypass valve seat that prevent it from closing completely; orifice hole in the shoulder (plunger) of the valve is dirty. To eliminate the valve freezing, it is necessary to remove the valve and the guide from the distributor body, rinse them in diesel fuel, clean the orifice and wipe the valve seat. When replacing the bypass valve parts, check for free movement of the valve stem in the guide.
3. The safety valve does not close completely due to accumulation of dirt under the ball at the edge of the seat bore. 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 the dirt from the edge of the safety valve with the flow of working fluid. If it is impossible to remove dirt in this way, then it is necessary to remove the distributor and send it to a repair shop.
4. The distributor may be in good working order, but the mounted machine will not lift. This could be for the following reasons:
   • the pump of the hydraulic system is not turned on or the pump turns off spontaneously if the switching mechanism is faulty; leaks of working fluid in the pump
   • the shut-off device does not pass the working fluid through the oil line
   • air leaks through the pump drive shaft oil seal or through the O-ring of the suction inlet or the oil line connection, which causes foaming of the working fluid
   • faulty power cylinder
   • the calibrated opening of the retard valve is clogged
   • increased leakage through the piston o-ring
   • seizure in the piston stroke limiting valve seat
   • the clearance between the stop and the shank of the piston stroke limiting valve is less than 10 mm
5. Low or high temperature of the fluid 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.

The spool does not automatically return from the "Raise" or "Forced lowering" position

The reasons for this malfunction and how to fix them may be the following:

1. The response pressure of the safety valve is equal to or lower than the response pressure of the automatic spool return device. This reason 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.
2. The bypass valve hangs up, as a result of which the required pressure does not develop for the automatic device to operate. The remedy for this problem is described above.
3. The temperature of the working fluid in the tank is higher than + 60 ° С, therefore, the viscosity is insufficient; as a result of which there are large leaks of liquid through the gaps in the automatic return device of the spool. 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 driver must manually return the handle from the operating positions to the "Neutral" position. The cause of the malfunction can be eliminated by cooling the working fluid to a temperature of + 60-30 ° C.
4. The spool automatic return device is working properly, but does not work due to a pump malfunction (it does not create the required pressure).
5. The spool filter is clogged and the hydraulic fluid does not flow into the booster device in sufficient quantity. The malfunction can be eliminated only by disassembling the spool - remove the sleeve, the gasket with the filter and wash it.

The spool (and hence the handle) is not fixed when it is installed in the operating position ("Raise" or "Forced lowering") or returns to the neutral position until the end of the full stroke of the piston in the cylinder

The causes of the malfunction and remedies may be as follows:

1. The actuation pressure of the booster device (automatic spool return device) is below 11 MPa (110 kgf / cm2) and below the operating pressure that develops in the power cylinder when the mounted machine is lifted. Consequently, the actuation of the booster device occurs earlier than the raising of the machine to the extreme upper position. To eliminate this cause, it is necessary to adjust the booster device for a pressure of 11 - 12.5 MPa (110-125 kgf / cm2).
2. The mass of the mounted machine is greater than that established for this tractor or there is a lot of soil resistance when lifting the machine. 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 correctness of aggregation and to the depth of travel of the working bodies of the mounted machine. In this case, replace the mounted machine with a machine of less weight or set the required tillage depth.
3. The spool booster valve is not sealed due to foreign particles entering the valve seat or the gap between the booster and spool. Due to a leak in the booster valve, the automatic spool return is activated at lower pressures. This malfunction can be eliminated by holding the distributor handle five to seven times in the working position after the end of the working stroke of the power cylinder piston in order to flush 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, rinse it in diesel fuel and blow it with compressed air.
4. The temperature of the working fluid in the tank is below + 30 ° С. 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 end position earlier than the booster valve closes the inlet opening. Therefore, premature decoding occurs.
5. The calibrated hole of the retard valve is clogged or the calibrated hole does not match the diameter of the cylinder. Therefore, an increase in the pressure of the liquid in the booster device occurs and premature decalcification occurs. To eliminate the malfunction, it is necessary to clean the calibrated hole and flush the fitting in diesel fuel or check the correspondence of the calibrated hole diameter to the cylinder diameter. For cylinders Ts55, Ts75, Ts90, Ts100, Ts110, Ts125, Ts140, the hole diameter should accordingly be 2.5; 3; 3.5; 4; 4.5; 5.5 and 7 mm.
6. Incorrect installation of the retarding valve in the power cylinder. In this case, it is necessary to swap the fitting with the retarding valve to the second fitting of the cylinder, i.e. install the fitting with the retarding valve in the cylinder so that when the mounted machine is lowered, the working fluid passes only through the calibrated hole.
7. The oil line shut-off device does not allow the working fluid to pass through. In this case, the mounted machine rises slowly or does not rise at all or hangs in an intermediate position, and the pressure in front of the booster quickly increases, 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 tightened the union nut.
8. Jamming in the seat of the piston stroke adjustment valve or the gap between the stop and the shank of the piston stroke adjustment valve is 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 the 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 lifting the movable stop on the power cylinder rod at a distance of 20-30 mm from the valve shank.
9. Retainer wear. In this case, you need to check the lock while the pump is not running. If it does not hold the spool in working positions, then worn parts must be replaced.

Fall of the mounted machine

When the spool is set to the “Forced lowering” position, the mounted machine falls quickly, caused by the absence of a washer with a calibrated hole in the retard 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

1. By spheres of leverage. O-ring worn. To replace the ring, 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 O-rings and replace the worn ones.
2. Along the housing connector with covers, along the bolts securing the covers to the distributor housing. Fluid leaks through the connectors can be due to wear of the cover gaskets and in the event of a clogged hydraulic drain filter.
   • When the filter is clogged, the pressure at the drain rises and the working fluid enters the tank through the filter safety valve. An increase in the pressure of the working fluid at the drain causes the working fluid to leak out through the seals of the distributor caps. In this case it is necessary to rinse the filter without disturbing the regulation of the safety valve.
   • Worn top and bottom cover gaskets must be replaced with new ones. When replacing the upper 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 lower cover of the distributor, it is necessary to unscrew the nuts securing the triangular flange to the lower cover and remove it, and then unscrew the nuts of the studs securing the cover to the body, remove it and replace the gasket.
3. On the bypass valve guide stop connector. Leakage of working fluid appears due to wear of the gasket or the O-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 replace it if necessary. If the leakage continues after replacing the gasket, then the valve guide O-ring must be replaced.
4. Through the fittings supplying the working fluid from the pump to the distributor and from the distributor to the consumers, as well as through the plug.

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