Use and maintenance of gas pressure controller 2
The gas pressure controller is a component used in the travel braking system of construction machinery to control the service brake so that the air pressure is maintained at 0.70 MPa to meet the requirement for traffic control. If the pressure of the pressure controller is less than 0.65Mpa, the friction plate will not contact with the Brake Disc well when the service brake is applied, resulting in a long braking distance and a decline or failure of the braking performance; if the pressure is greater than 0.70Mpa, the friction plate will It is easy to get burned with the brake disc, resulting in a short braking distance, severe wear of the tires, and even an “emergency brake†phenomenon during normal braking. In severe cases, the driver is also thrown from the front window of the cab. , resulting in major accidents, so the use and maintenance of the pressure controller must not be ignored.
The air compressor driven by the engine discharges compressed air, enters the pressure controller through the air inlet A, pushes the inlet check valve to the right, enters the air chamber I and the air chamber II, and the compressed air enters the air reservoir through the air outlet B and stores The high pressure gas of the gas cylinder leads to the brake valve and barometer for braking. If the compressed air pressure in the air chamber I is less than 0.07Mpa, the compressed air in the air chamber II cannot push the tympanic of the valve upward, and the compressed air continues to inflate the air reservoir until the gas pressure reaches 0.07Mpa; if the air chamber I The compressed air pushes the tympanic membrane upwards (the tympanic membrane spring and the valve tympanic membrane are adjusted by the adjusting screw and the pressure is maintained at 0.70 MPa), and the compressed air in the chamber II enters the gas through the gap between the valve burr and the deflation valve. In chamber III and chamber IV, the high-pressure air in chamber III pushes the cup and stem to the right, the valve stem pushes the open gas check valve to the right, the left end of the stem leaves the open orifice seat, and the high pressure in chamber III and chamber IV The gas is discharged from the bleed holes C and D respectively. The gas pressure in the gas chamber III and the gas chamber IV drops below 0.70 MPa. Then the bleed-off check valve, the stem and the cup recover under the action of the deflation check valve spring. In situ, at the same time, the tympanic membrane of the valve is returned to the original position by the tympanic membrane, and the valve tympanic membrane and the deflation valve are closely fitted, and the gap disappears. The air pressure in the air chamber I and the air chamber II dropped to 0.70 MPa, and the air compressor continued to inflate the air reservoir, and the cycle was repeated. In order to use safety, the performance of the pressure controller should be inspected periodically: first, the engine should be turned off and the brake pedal should be depressed continuously (or open the air inlet switch of the air cylinder so that the gas in the air cylinder is exhausted) until the barometer pointer is zero. , And close the water switch, and then start the engine, and stabilized at 700-800r/min, so that the system pressure reaches 0.70Mpa, continue to inflate when compressed air is discharged from the pressure controller vent hole. If the air pressure is less than 0.65Mpa when exhausting, it means that the pressure of the air release valve is low, and the adjustment screw of the pressure controller should be screwed into the small one. If the air pressure is higher than 0.70Mpa before venting, indicating that the pressure of the vent valve is too large, the adjustment screw should be screwed out a little. If the system air pressure is maintained at 0.70 MPa, the pressure controller is working properly. The pressure controller has been adjusted and sealed before leaving the factory. Do not disassemble it if there is no fault.
Common faults, causes, and remedies for pressure controllers are as follows:
1. Air leaks between the upper and lower shells. Bubbles appear after smearing with detergent powder. The upper and lower shell castings have defects; the seal ring between the upper and lower shells is damaged or the fastening bolts are loose; the tympanic membrane of the valve is aged, and air leaks from the adjustment screw. Wipe the surface of the shell, repair defects with metal repair agent; replace the seal ring or tighten the bolt; replace the valve tympanic membrane.
2. The air pressure is less than 0.65Mpa and decreases continuously, but the gas is always discharged from the pressure controller vent hole D. The valve tympanic membrane, tympanic membrane spring, or deflated valve is damaged and the seal fails; the bleed hole C is blocked; the deflation check valve leaks; the deflation check valve spring loses and fails; the cuff is aging and leaks. Check the sealing of valve tympanic membrane, tympanic membrane spring or deflated valve. If it is damaged, replace it with a new one to clear the bleed hole C; replace the deflation check valve; replace the deflation check valve spring; replace the cup.
3. When the air pressure is less than 0.65Mpa, the adjustment screw is too loose, the valve tympanic membrane has low air pressure, and the air release valve is aged and leaks. Screw the adjusting screw a little; replace the bleed valve.
4. The air pressure is normal, but air constantly leaks from the pressure controller vent D or D. The tympanic membrane of the valve is in close contact with the deflation valve and is not tightly attached, forming a gap and leaking; the tympanic membrane spring is damaged and fails, and the tympanic membrane of the valve cannot be compressed. Check valve tympanic and deflated valve seals and replace if damaged; replace tympanic membrane spring.
5. After the air compressor stops pumping, the bleed hole D or C does not deflate, but the air pressure drops quickly. The inlet check valve is worn out, damaged, and leaks airtightly; the intake check valve spring is damaged and fails. Check the inlet check valve and its sealing condition. If it is damaged, replace it with a new one; replace the inlet check valve spring.
6. When the air pressure is higher than 0.70Mpa, the adjustment screw is too tight, the compression of the tympanic membrane spring is too high, and the valve tympanic membrane deflation pressure is too high. Loosen the adjustment screw a little to reduce the amount of compression of the tympanic membrane spring.
7. The air pressure is higher than 0.70Mpa, and keeps rising, but the air is not stuck out of the bleeder spring from the bleed hole D or C; the air hole in the deflation valve is blocked; the deflation check valve spring is stuck; the valve The rod was stuck. Replace the tympanic membrane spring; clear the air hole on the air release valve; replace the deflation check valve spring; trim or replace the stem. When maintaining the pressure controller, it is necessary to keep the various seals, joints, and air inlet and outlet of the pressure controller clean, to prevent the entry of dirt and impurities, causing the pipeline to be clogged or the seal not tight. Its internal rubber valve and rubber material are replaced to prevent premature aging of rubber parts and affect safety. After the maintenance, the working performance of the pressure controller shall be checked and calibrated with an accurate pressure gauge. Only after adjusting the pressure controller can it be used.
The air compressor driven by the engine discharges compressed air, enters the pressure controller through the air inlet A, pushes the inlet check valve to the right, enters the air chamber I and the air chamber II, and the compressed air enters the air reservoir through the air outlet B and stores The high pressure gas of the gas cylinder leads to the brake valve and barometer for braking. If the compressed air pressure in the air chamber I is less than 0.07Mpa, the compressed air in the air chamber II cannot push the tympanic of the valve upward, and the compressed air continues to inflate the air reservoir until the gas pressure reaches 0.07Mpa; if the air chamber I The compressed air pushes the tympanic membrane upwards (the tympanic membrane spring and the valve tympanic membrane are adjusted by the adjusting screw and the pressure is maintained at 0.70 MPa), and the compressed air in the chamber II enters the gas through the gap between the valve burr and the deflation valve. In chamber III and chamber IV, the high-pressure air in chamber III pushes the cup and stem to the right, the valve stem pushes the open gas check valve to the right, the left end of the stem leaves the open orifice seat, and the high pressure in chamber III and chamber IV The gas is discharged from the bleed holes C and D respectively. The gas pressure in the gas chamber III and the gas chamber IV drops below 0.70 MPa. Then the bleed-off check valve, the stem and the cup recover under the action of the deflation check valve spring. In situ, at the same time, the tympanic membrane of the valve is returned to the original position by the tympanic membrane, and the valve tympanic membrane and the deflation valve are closely fitted, and the gap disappears. The air pressure in the air chamber I and the air chamber II dropped to 0.70 MPa, and the air compressor continued to inflate the air reservoir, and the cycle was repeated. In order to use safety, the performance of the pressure controller should be inspected periodically: first, the engine should be turned off and the brake pedal should be depressed continuously (or open the air inlet switch of the air cylinder so that the gas in the air cylinder is exhausted) until the barometer pointer is zero. , And close the water switch, and then start the engine, and stabilized at 700-800r/min, so that the system pressure reaches 0.70Mpa, continue to inflate when compressed air is discharged from the pressure controller vent hole. If the air pressure is less than 0.65Mpa when exhausting, it means that the pressure of the air release valve is low, and the adjustment screw of the pressure controller should be screwed into the small one. If the air pressure is higher than 0.70Mpa before venting, indicating that the pressure of the vent valve is too large, the adjustment screw should be screwed out a little. If the system air pressure is maintained at 0.70 MPa, the pressure controller is working properly. The pressure controller has been adjusted and sealed before leaving the factory. Do not disassemble it if there is no fault.
Common faults, causes, and remedies for pressure controllers are as follows:
1. Air leaks between the upper and lower shells. Bubbles appear after smearing with detergent powder. The upper and lower shell castings have defects; the seal ring between the upper and lower shells is damaged or the fastening bolts are loose; the tympanic membrane of the valve is aged, and air leaks from the adjustment screw. Wipe the surface of the shell, repair defects with metal repair agent; replace the seal ring or tighten the bolt; replace the valve tympanic membrane.
2. The air pressure is less than 0.65Mpa and decreases continuously, but the gas is always discharged from the pressure controller vent hole D. The valve tympanic membrane, tympanic membrane spring, or deflated valve is damaged and the seal fails; the bleed hole C is blocked; the deflation check valve leaks; the deflation check valve spring loses and fails; the cuff is aging and leaks. Check the sealing of valve tympanic membrane, tympanic membrane spring or deflated valve. If it is damaged, replace it with a new one to clear the bleed hole C; replace the deflation check valve; replace the deflation check valve spring; replace the cup.
3. When the air pressure is less than 0.65Mpa, the adjustment screw is too loose, the valve tympanic membrane has low air pressure, and the air release valve is aged and leaks. Screw the adjusting screw a little; replace the bleed valve.
4. The air pressure is normal, but air constantly leaks from the pressure controller vent D or D. The tympanic membrane of the valve is in close contact with the deflation valve and is not tightly attached, forming a gap and leaking; the tympanic membrane spring is damaged and fails, and the tympanic membrane of the valve cannot be compressed. Check valve tympanic and deflated valve seals and replace if damaged; replace tympanic membrane spring.
5. After the air compressor stops pumping, the bleed hole D or C does not deflate, but the air pressure drops quickly. The inlet check valve is worn out, damaged, and leaks airtightly; the intake check valve spring is damaged and fails. Check the inlet check valve and its sealing condition. If it is damaged, replace it with a new one; replace the inlet check valve spring.
6. When the air pressure is higher than 0.70Mpa, the adjustment screw is too tight, the compression of the tympanic membrane spring is too high, and the valve tympanic membrane deflation pressure is too high. Loosen the adjustment screw a little to reduce the amount of compression of the tympanic membrane spring.
7. The air pressure is higher than 0.70Mpa, and keeps rising, but the air is not stuck out of the bleeder spring from the bleed hole D or C; the air hole in the deflation valve is blocked; the deflation check valve spring is stuck; the valve The rod was stuck. Replace the tympanic membrane spring; clear the air hole on the air release valve; replace the deflation check valve spring; trim or replace the stem. When maintaining the pressure controller, it is necessary to keep the various seals, joints, and air inlet and outlet of the pressure controller clean, to prevent the entry of dirt and impurities, causing the pipeline to be clogged or the seal not tight. Its internal rubber valve and rubber material are replaced to prevent premature aging of rubber parts and affect safety. After the maintenance, the working performance of the pressure controller shall be checked and calibrated with an accurate pressure gauge. Only after adjusting the pressure controller can it be used.
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