Zoomlion 1020500757 launch relay

1. The structure of the product

Electromagnetic system: mainly consists of a coil, an iron core and anchor. The coil is wound with an enameled wire with high magnetic permeability, which is able to quickly generate a strong magnetic field when current passes through it. The core is usually made of high -quality magnetonogy materials, such as electrical pure iron, which allows you to enhance the magnetic field strength and improve the sensitivity of the relay. Under the influence of the magnetic field strength, the anchor is attracted and released along with the iron core, thereby controlling the inclusion and off of contacts.

Contact system: includes normally open contacts and normally closed contacts. Contact material is mainly made of an alloy of silver or copper, which has good conductivity and wear resistance. During operation, the normally open contact is in the open state, when the relay is not connected to the power source, and is closed when the power is supplied; Normally closed contact is in the opposite state, is closed in the absence of power and open when feeding. This design can satisfy the requirements for managing various chains.

Corps: made of high -strength, heat -resistant structural plastic, such as polycarbonate (PC) or nylon (PA). The outer shell not only protects the internal electromagnetic system and the contact system from the influence of the external environment, but also has good insulating properties that ensure safe use. In this case, the housing is usually provided with installation holes to facilitate the attachment of the relay to the equipment.

2. Operational characteristics

High reliability: after strict quality control and durability tests, the device can work steadily in difficult working conditions. In the temperature range from -40 ℃ to 125 ℃, as well as in such harsh conditions as high humidity and strong electromagnetic interference, it can still maintain good performance, ensuring the reliable operation of the SHANTUI 220 bulldozer system and reducing the downtime of equipment caused relay refusal.

Fast answer: The electromagnetic system is optimized in design. Upon receipt of the launch signal, it can complete the closing or opening of contacts in a very short time (usually within a few milliseconds), quickly connect or turn off the starter circuit so that the engine can quickly start and increase the efficiency of operation.

High current load: Contacts are made of special materials and processed using special processes and have a high current -renovation capacity. He is able to withstand instant strong currents when starting the SHANTUI 220 bulldozer, for example, a starting current of hundreds of amperes, without such problems as burning and sticking contacts, which extends the life of the relay.

High noise immunity: the internal scheme uses the technology of shielding and filtration for effective protection against external electromagnetic interference and preventing the relay failures due to interference signals. Even if there are strong sources of electromagnetic interference nearby, such as large engines and welding machines, the launch management instructions can be accurately executed, which guarantees the normal launch of the equipment.

3. Applicable models

It is mainly suitable for Shantui bulldozers of the 220 series, including, among other things, SD220, SE220 and other models. These bulldozers are widely used in various excavation works, such as road construction, mining industry, large -scale construction of buildings and other areas. In these difficult operating conditions, the Shantui 220 launch relay may provide reliable control of the bulldozer launch system, guaranteeing the possibility of normal equipment and commissioning at any time.

4. The installation method

Preparation: Before installation, make sure that the Shantui 220 bulldozer is in a safe shut -off state, remove the key and disconnect the negative battery cable to prevent lesions with electric shock or a short circuit during the installation process. Prepare the necessary tools, such as wrenches, screwdrivers, pliers, etc., as well as a new starter relay and appropriate installations, such as gaskets, bolts, etc. At the same time, check if the model of the new relay is not appropriate and there is no equipment whether it is damaged by appearance.

Remove the old relay: find the installation site of the old starter relay, which is usually located in an electric control unit under the cabin or in an electric unit near the engine. Using a screwdriver, unscrew the screws holding the relay, and carefully remove the old relay. Be sure to mark the connection places for each wire on the relay for the subsequent installation. If the connection of the wire is dense, you can carefully pull it out with pliers, but be careful and do not make too much effort so as not to damage the wire or fork.

Install a new relay: combine a new starting relay with an mounting hole in accordance with the marked position and fix it with screws, but do not tighten them. Then connect the wires in the order specified earlier, making sure that the connections are reliable, and the plugs are tightly tightened. Finally, tighten the fasteners with a screwdriver so that the relay is reliably installed and does not stagger and does not weaken.

Checking and debugging: After installation, check if the relay is reliably installed, whether the wires are connected correctly, whether there are weakening or short circuit. Connect the negative wire of the battery, start the Shantui 220 bulldozer and check the working condition of the launch relay. The relay should quickly work when pressing the start button, closing the starter circuit and ensuring the smooth start of the engine. If it is found that the relay works non -normally, for example, there is no operation or abnormal sparks appear on contacts, etc., the machine should be immediately stopped for verification and restart after eliminating the malfunction.

5. Precautions when using

Proper operation of the start -up switch: When starting the bulldozer, Shantui 220, do not press and do not release the starting switch often and quickly. Launch time each time should not exceed 5 seconds. If the launch failed, you should wait for more than 15 seconds before re -launch to avoid frequent relay operation, which can lead to overheating and damage to contacts.

Avoid overload: do not use the relay for current and voltage exceeding nominal values, otherwise this will accelerate wear and aging of contacts and may even cause burning and sticking of contacts, which will lead to the impossibility of proper operation of the relay. Regularly check the equipment system to make sure of voltage and current stability, as well as avoid relay overload due to electrical malfunctions.

Keep it in cleanliness and dryness: regularly clean the starter relay body to prevent dust, oil and moisture inward and violation of its normal operation. Especially in difficult working conditions, for example, at dusty or wet construction sites, cleaning and protection should be strengthened. If water or moisture is found on the surface of the relay, it should be wiped dry and dried in a timely manner to ensure good insulation characteristics.

Regular inspection and maintenance: regularly check the working condition of the relay, including contact wear, reliability of attaching connecting lines, etc. If the contacts are very worn out or have signs of burning, the relay should be replaced in a timely manner. At the same time, check if the insulating layer of the connecting line is damaged. If it is damaged, it should be replaced in a timely manner in order to ensure the safety and reliability of the electrical connection.

Prevent electromagnetic interference: try to avoid installation near the starting relay sources of strong electromagnetic interference, such as large engines, welding machines, etc. If this is impossible to avoid, you should take measures to screen, for example, cover the relay with a metal protective casing to reduce the effect of electromagnetic interference on the relay and prevent its faulty work.

The method of installing the bulldozer launch relay

1. Preparation before installation

1. Preparation of tools and materials

Instruments for installation: Prepare wrenches of various specifications, such as unfortunate, lacture and end keys, to remove and install bolts and nuts related to the starter relay. Prepare the screwdrivers, including the cross and flat, for the removal and installation of the screws that attach the base or the relay body. You will also need sharp drives to capture and retain small parts and ticks for cleaning wires to remove insulation from wires and facilitate the connection.

Tools for electrical tests: Prepare a multimeter to check the chain parameters as integrity, voltage and resistance to make sure that the circuit is about the installation and proper operation of the relay after installation. Prepare the tester to determine whether the circuit is under voltage and ensure safe operation.

Preparation of the material: Prepare the wires of the corresponding length and characteristics in accordance with the bulldozer model and the characteristics of the starting relay, and also make sure that the permissible current load of wires corresponds to the needs of the starting relay and the related chains. Prepare the insulating tape to wrap the wire connections to prevent short circuits and leaks. Prepare the mounting bracket or the base of the relay (if a separate installation is required) to ensure a reliable installation of the starter relay.

(II) verification of the relay and related components

Relay verification: thoroughly check whether the model and technical characteristics of the starting relay are corresponded to an electric system of the bulldozer. Check the appearance of the relay to make sure that there are no damage or deformations of the case, as well as in the absence of bent, broken or corrosion pins. Use the multimeter resistance range to measure the resistance of the relay coil and compare it with the standard value specified in the operation manual to determine whether the coil is good. For example, under normal conditions, the resistance of the coil of a certain model of the starting relay can be from tens of ohms to hundreds of ohms. If the deviation of the measured value is too large, this may indicate a reel malfunction.

Checking related parts: Check the bulldozer battery to make sure that it is quite charged, and the electrodes do not have traces of corrosion and oxidation. Measure the battery voltage. Typically, the voltage of the bulldozer battery is about 24 V (depending on the model). If the voltage is too low, this can affect the normal operation of the starter relay. Check the reliability of the wiring connection to the starter and make sure that there are no signs of damage on the engine. At the same time, check whether the appropriate control switches, fuses and other components work correctly.

3. Preparation of the site and safety measures

Choosing a place: choose a flat, dry, well -ventilated and lit place, for example, a maintenance workshop or a safe open air work site. Make sure that there are no obstacles around the venue that facilitate the work, and stay away from flammable and explosive objects to prevent accidents.

Precautions: operators must wear insulating gloves, protective shoes and other personal protective equipment to prevent accidents associated with electric shock. Before starting work, disconnect the negative terminal of the battery of the bulldozer to avoid randomly turning on the power during installation. If you need to do high -rise work on the bulldozer, fasten the seat belt to ensure your own safety.

2. Stages of installation

1. Determine the installation site

Select the appropriate installation site based on the electrical circuit of the bulldozer and the convenience of maintenance. As a rule, the starter relay should be installed next to the battery and starter to reduce the length of the wires, the resistance of the line and the voltage drop. At the same time, make sure that the installation site is dry and clean to avoid moisture, dust and oil.

If you need to install a bracket or base, first fix it in a selected place. Use suitable bolts and nuts for reliable mounting the bracket or the base to the bulldozer frame or another constructive element, guaranteeing that the fastening will be reliable enough to withstand the weight and vibration of the relay.

(II) connecting wires

According to the fundamental electrical circuit, determine the function of each contact of the starter relay. As a rule, the starter relay has a coil conclusions and contact pins. Coil conclusions are used to connect the control circuit, and contact findings are used to connect the main circuit, i.e., the battery and starter.

Use ticks to clean the wires to remove insulation from the wires and expose the metal conductors of the desired length. Connect one end of the wire to the corresponding pin of the starter relay. For pins with a bolt connection, insert the wire into the pin hole and tighten the nut to provide a reliable connection and good contact. For pins, carefully insert the wire plug into the pin nest and make sure that it is tightly inserted.

Connect the wire connected to the positive terminal of the battery to one of the main contact pins of the starter relay, and the wire connected to the starter to the other main contact pin. The wires connected to the control circuit, for example, from the ignition switch or other control device, are connected to the contacts of the relay coil. During the connection process, pay attention to the difference between positive and negative poles to avoid a reverse connection.

Once the connection is complete, wrap the wire connection points with insulating tape to ensure good insulation and prevent short circuits and leaks. At the same time, organize the wires so that they don't get tangled, squeezed, or rubbed against other components.

(iii) Fixed Relay

Install the starter relay on the bracket or base. If it is a plug-in relay, gently insert it into the base socket and make sure it is securely inserted; If it is a bolt-on relay, use a screwdriver or wrench to secure the relay to the bracket or base, tighten the mounting screws, and make sure the relay is securely seated and will not wobbly or loosen while the bulldozer is running.

Check the relay installation location and wire connections to make sure there are no deviations. Double-check that the wires are securely connected, the relay is installed correctly, and the contacts are not loose or have bad contact.

3. Post-installation debugging and verification

1. Electrical Testing

Use the voltage range of the multimeter to measure the battery voltage and make sure the voltage is normal. Next, measure the voltage on the starter relay coil. When the control circuit is engaged, normal control voltage must be detected on the coil. For example, if the voltage of the control circuit is 24 V, then when the ignition is turned on, a voltage close to 24 V should be detected on the relay coil.

Use the resistance range of the multimeter to measure the resistance of the relay contacts when they are closed and open. When the contacts are closed, the resistance value should be close to zero, indicating good contact; When the contacts are open, the resistance value should be infinite, indicating normal open contact. With these tests, it is possible to determine whether the operating condition of the relay is normal.

(ii) Functional testing

Once the electrical inspection is complete, reconnect the negative battery terminal on the dozer, making sure the connection is secure.

Turn on the ignition to start the dozer. Check if the starting relay is working normally, i.e. if you can hear the relay closing and opening sound, and also check if the starting motor is working normally. If the starter relay is working normally, then when the ignition is turned on, the relay should quickly turn on by connecting the battery to the starter, and the starter will start rotating; When the ignition is turned off, the relay should quickly shut down, breaking the connection between the battery and the starter.

If the starting relay is not working properly, first check that the electrical connections are correct and reliable, and that there are no short circuits, breaks, etc. If the relay itself is faulty, it must be replaced with a new one.

(III) Security Checks

Once the starter relay is installed and commissioned, perform a comprehensive safety check. Check that all wire connections are secure, the insulation tape is intact, and that there is no risk of current leakage. Make sure the relay is securely fastened and will not loosen or fall off while the dozer is running.

Start the bulldozer and check for abnormal heating of the starting relay and its associated circuits, smoke, odor, etc., during operation. If any abnormalities are detected, the machine should be stopped immediately for inspection in order to eliminate the malfunction and ensure safety.