Repair guidance for break fluid vacuum filling machine

Ⅰ. Equipment failure alarm picture

Failure code display

Code 00 failure
01-low air pressure 07-overcurrent of filling
pump
02-empry barrel 08- vacuumizing pimp
fails
03-low fluid level 09-vacuum retention fails
04-high fluid level 10-TK1 leaks
05-overflow of vacuum 11-ABS communication
pump fails
06-overlfow of DOT 12. low filling pressure
pump
Silence Reset Failure reset

Number Name Guide to handle failure

1. The air source pressure is not sufficient and check
the air source section.
Low air
pressure
1
 2. The pressure switch works abnormally

1、the external fluid supply barrel is empty and

replace it in time.
2、the filter of equipment is blocked, which affects
the fluid intake speed.

2 Empty barrel

1、the photoelectric sensor is invalid.

1、the normal fluid level indicates that the

photoelectric sensor is invalid.

3 Low fluid level

2、Check the fluid level of fluid storage tank. If the

level is low, please conduct manual fluid
replenishment.
1、Check the fluid level of fluid storage tank. If the
level is high, please conduct manual discharge.
2、 The normal fluid level indicates that the
photoelectric sensor is invalid.
4 High fluid level

1、Please check whether the power circuit of vacuum

pump is normal.
5 Over-current of
vacuum pump 2、Please check whether abnormal sound exists when
the vacuum pump operates.
 3、Please check whether the vacuum pump oil is
normal or not.

4、Please check whether the vacuum pipe leaks or

not.

1、请检查DOT泵供电线路是否正常 please check

whether the power circuit of DOT pump is normal
or not.
2、请检查DOT泵运行时有无异please check
whether abnormal sound exists when DOT pump
operates.

DOT泵过流
6 DOT pump
over-current
3、请检查DOT泵油是否正常 please check whether
EOT pump oil is normal or not.
 4、请检查储液罐是否存在泄漏 please check
whether the fluid storage tank leaks.

1、请检查加注泵供电线路是否正常 please check

whether the power circuit of filling pump is
normal or not.
2、请检查加注泵运行时有无异响 please check
加注泵过流
whether abnormal sound exists when the filling
7 Filling pump pump operates.
over-current
3、请检查加注管路过滤器是否堵塞 please check
whether the filter of filling pipe is blocked or not.
4、请检查加注压力是否异常 please check whether
the filling pressure is normal or not.
1、可用手堵加注枪头上抽真空口，检查相应阀
是否打开 hand may be used to block the
vacuumizing port of the filling gun and check the
openness of corresponding valves.
2、检查枪头与汽车储液罐用于密封的密封圈是
抽真空失败 否存在磨损 check whether the sealing ring of gun
8 Vacuumizing head and fluid storage tank is worn or not.
fails 3、检查枪头内部密封圈是否存在磨损，安装是
否正确到位 check whether the inner sealing ring
of the gun head is worn or not and whether it is
installed properly or not.
4、检查设备内部是否存在泄漏 check whether the
inside of equipment leaks or not.
1、可用手堵加注枪头上抽真空口，检查相应阀
是否打开 hand may be used to block the
vacuumizing port of the filling gun and check the
openness of corresponding valves.
2、检查枪头与汽车储液罐用于密封的密封圈是
保真空失败 否存在磨损 check whether the sealing ring of
9 Vacuum gun head and fluid storage tank is worn or not.
retention fails 3、检查枪头内部密封圈是否存在磨损，安装是
否正确到位check whether the inner sealing ring
of the gun head is worn or not and whether it is
installed properly or not.
4、检查设备内部是否存在泄漏 check whether the
inside of equipment leaks or not.
 1、请检查真空压力表是否工作正常 please check
whether the vacuum pressure meter is normal or
not.

TK1泄漏
10
TK1 leaks

2、请检查储液罐是否存在泄漏 please check

whether the fluid storage tank leaks or not.
1、齿轮泵溢流阀故障 overflow valve of gear pump
fails.

加注压力高
11 High filling
pressure

2、加注管路中过滤器堵塞 the filling filter of filling

pipe is blocked.
1、齿轮泵溢流阀故障overflow valve of gear pump
fails.
2、加注管路中过滤器堵塞the filling filter of filling
pipe is blocked.
3、储液罐排气阀故障 the air discharge valve of
加注压力低 fluid storage tank fails.
12 Low filling
pressure

电路控制
13
Circuit control

1、 主回路启动接触器 main circuit starting contactor

2、 D16C真空泵控制接触器 control contactor of D16C vacuum pump
 3、 DOT4真空泵控制接触器 control contactor of DOT4 vacuum pump

4、加注泵控制接触器 control contactor of filling pump

5、 排风扇开关 switch of exhaust fan
6、维修照明 service illumination
7、控制电源 control power supply
8. 24V电源 24V power supply

Ⅱ. Guidance for troubleshooting

1、强烈建议设备维护人员充分掌握该设备控制流程，认真研读PLC控制程序对设备
控制架构进行“指令级”把握，以根据可能的故障现象迅速、准确地判断出故障部
位及原因，及时做出有效处理。 It is strongly recommended that the equipment
maintenance personnel should fully master control flow of the equipment and study PLC
control program and master the control framework of equipments at instruction level,
judge the failure position and reasons quickly and correctly and make effective treatment
in time.
2、在维护人员充分了解控制流程后，若设备出现故障，请根据情况进行故障排除
（一般为机械方面的故障）。设备控制思路为PLC根据外部输入情况进行相应的
输出，输出控制电磁阀进行相应的动作，电磁阀得电后控制对应的气控角阀动作
达到控制目的。 After the maintenance personnel fully understands the control flow, if
the equipments breaks down, please make troubleshooting according to conditions (it is
mechanical failure generally). The control process of equipment is: PLC makes
corresponding output according to external input. The output controls the solenoid valve
to make corresponding action and the solenoid valve controls the action of corresponding
pneumatic angle valve to achieve the control purpose.
3、检查步骤（输出部分）： Check step: (output unit):
1）当设备出现故障时，可进入单步操作进行观察，以确定相应故障点
1）When the equipments breaks down, conduct single-step operation for observation to
determine the corresponding failure spot.
2）确定故障点后，可重复开关单步测试，检查角阀是否动作，若动作，说明正
常；若无动作，请拔下气管确认是否气管内有气，且气流是否通畅，若有气且通
畅，说明角阀存在故障，请进行更换（此问题不易发生），若有气但气流不通
畅，则说明气管堵塞，请观察气管是否存在折弯，或直接进行更换；若气管内无
气说明电磁阀未工作。电磁阀带有指示灯，在工作时指示灯点亮，气路控制也应
有相应变化（如原先无气的气管吹气），若气路控制无变化，说明电磁阀存在问
题，请进行更换；若指示灯未点亮，请检查电磁阀内接线是否牢靠，若有脱线请
重新接牢；若无脱线，请检查其工作电压是否存在；若有电压说明线圈烧毁，请
进行更换；若无工作电压，请检查相应线路，是否存在断点；若无断点存在请检
查PLC是否有相应输出，PLC输出时模块上相应点点亮，并检查PLC相应输出电
压，若无电压请检查对应的1L或2L是否有电压，若无电压请检查1L或2L接线是
否有断点，若正常则PLC有故障，请更换相应模块。
 2）After the failure spot is determined, repeat switch single-step test to check whether
the angle valve acts. If it acts, this indicates that it is normal. If it does not act, pull off
the air pipe and confirm whether it has air inside and whether the air flow is unobstructed,
if there is air in the pipe and the air is unobstructed, this indicates that the angle valve
breaks down and make replacement (this problem seldom occurs). If there is air inside,
but the air flow is not smooth, this indicates that the air pipe is blocked. Please observe
whether the air pipe has bend, or make replacement directly. If there is no air in the air
pipe, this indicates that the solenoid valve. The solenoid valve is equipped with an
indicator light that is on when the valve works. The air circuit control also has
corresponding change (for example, the air free pipe begins to blow air). If no change
occurs to the air circuit, this indicates that the solenoid valve ahs problem. Please replace
it. Please check whether the wire connection inside the solenoid valve is firm or not if the
indicator light is not on. If the wire drops off, please connect firmly again. If the is no
dropping off of wire, please check whether the working voltage is provided. If the voltage
is available, this indicates that the coils are burned. Please replace it. If there is no working
voltage, please check the breaking point of corresponding wire circuit. If there is no
breaking point, please check whether PLC has corresponding output. The corresponding
point on the module is on when PLC outputs. Check the corresponding voltage of PLC.
If there is no voltage, please check whether corresponding 1L or 2L has voltage. If there
is no voltage, please check the breaking point of wire connection of 1L and 2L. If it is
normal, this indicates that PLC breaks down, please replace corresponding module.
操作万用表检测时应小心，设备中含有交流电压，避免触电事故发生。
Please operate the multi-purpose meter carefully to avoid the occurrence of shock
because the equipment has AC voltage inside.

4、输入部分检查：inspection of input unit

若输入没有响应，请参照电气接线原理图检查相应输入点是否有输入（也可用短
接相应点的方法进行测试），若没有，请检查M点及公共点D24G是否接牢且无断
线，若都正常且用短接法测试时相应点不点亮，请更换PLC主机，若短接法测试
正常，则说明线路存在断点，请参照电气接线图仔细查找。

If input does not respond, check whether the corresponding input point provides input
according to electrical connection diagram (make short circuit for corresponding points
to make test). If there is no input, check whether point M and public point D24G are
connected firmly and have no breaking wire. If both conditions are normal and
corresponding points are not on when tested with short circuit, please replace the
mainframe of PLC. If the test with short circuit is normal, this indicates that the circuit
has breaking point. Please look for carefully according to the electrical connection
diagram.

三、定期保养
Ⅲ. Regular maintenance
1、真空泵
1. Vacuum pump
A、禁止在未加油或电机转向错误的情况下使用真空泵
A. The vacuum pump is forbidden to be used under the condition that oil is not charged or
the rotation direction of motor is wrong.
B、禁止在泵的入口与大气连通的情况下使用真空泵，禁止在真空泵使用时打开泵
的加油口或排油口。
B. The vacuum is forbidden to be used when the entrance of pump is connected with
atmosphere. The oil filler or oil discharge outlets are forbidden to open when the vacuum
pump is used.
C、真空泵在使用时，某些泵体表面温度会超过80℃，请注意。
C. Please pay attention that the surface temperature of some pumps may exceed 80℃ in
use.
D、每天检查一次真空泵的油位，真空泵油的油位应在油窗的“MAX”标记处，若油
位低于此标记应进行填加；若非人为因素使油位达到“MIN”标记处或以下，应及时
将真空泵停掉进行检查。
D. Check the oil level of the vacuum pump once every day and the oil level of the vacuum
pump should be at the “MAX” mark. Fill the oil if the level is lower than this mark. If the oil
level reaches the “MIN” mark or below it due to inartificial factor, the vacuum pump should
stop and check it.
E、第一次使用150小时后必须要更换真空泵油。以后使用可依据情况每500-1500小
时更换一次真空泵油或至少每半年更换一次真空泵油。
E. The vacuum oil must be replaced when it is used for first time for 150 hours. The vacuum
pump oil should be replaced once every 500 to 1500 hours according to conditions or half a
year at least.
F、更换真空泵油应在停泵不久后进行，打开排油口，将油排放到某一容器内，当
油位较低时将排油口紧上，点动真空泵（不得超过5秒），然后再打开排油口将残油
排出。将排油口紧上，打开加油口，倒入新油，将油补充至“MIN”处，将加油口紧
好，将真空泵开2-3分钟，然后将油排出，此时即可将新油一次性补充至“MAX”处，
真空泵油更换结束。
F. the replacement of vacuum pump oil should be done not long after the pump stops. Open
the oil discharge outlet and discharge the oil to a container. Tighten the oil discharge outlet
when the oil level is low. Conduct inching for the vacuum pump (not exceeding 5 seconds)
and discharge the residual oil by opening the oil discharge outlet again. Tighten the oil
discharge outlet and open the oil filler and pour new oil to replenish the oil to “MIN” mark.
Tighten the oil filler and run the vacuum pump for 2 to 3 minutes and discharge the oil. Then
replenish the new oil to “MAX” mark one time. The replacement of vacuum pump is ended.
除上述内容外，其他请参照附件中的真空泵说明书对真空泵进行定期保养、维
护。
In addition to above content, please refer to instruction book for vacuum pump in the
attachment to conduct regular care and maintenance for vacuum pump.
2. Three direct links of air circuit
Drain the water regularly

3. Pipe
If the fluid filling speed in the pipe is small, it is necessary to clean the filter in the pipe
according the system drawing. Cleaning should be done once a month.

4. Valves
Check the action of all values regularly and replace the problem parts in time to ensure
normal operation of equipments.

5. Sealing of filling gun

It suggests replacing the sealing ring every three months to ensure good operation of
equipments.

Ⅳ. Diagnosis of other failures

1. The indicator light is not on after the equipments starts and there is no display on the touch
screen.

Please check the supply of system power according to electric wiring diagram.

2. The equipment is powered on but does not work or stop during working.

Check whether the failure indicator light is on.

3. The touch screen display abnormally or the program run in a disorder manner.

Please contact the manufacturer for replacement or repair. Don’t disassemble or assemble
without authorization or change the program.

4. The indicator light is not on.

Restart the machine again. If this light does not light when all lights flash, please replace it.

5. “Low fluid level” failure

This failure may cause the equipment to stop working. Check the fluid level or the state
of sensor. The senor indicator light will be on when the level is above the sensor. The
 senor indicator light will be off when the level is below the sensor. Otherwise, the sensor
breaks down.

6. “High fluid level” failure

This failure may cause the equipment to stop working. Check whether the fluid level
sensor malfunctions. The check method is the same as that of “Low fluid level” failure.

7. “Low air pressure” failure

This failure may cause the equipment to stop working. Check the air source. The
equipments resume working when the air source pressure restores.

If the abnormal conditions occur to equipment during operation, please disconnect the
equipment with power and restart it. If it still cannot resume working, please inform the
manufacturer.

Note: Don’t change the pipe, circuit connection, PLC program and touch screen
program with authorization. Our company will not be responsible for repair if any
above phenomenon is found.