Diagnosing and Fixing Vibration Issues in the Volvo 160BLC During Swing Start and Stop

[MikePhua]

When operating heavy machinery like the Volvo 160BLC excavator, the smooth functioning of its hydraulic and mechanical systems is crucial for both productivity and safety. One common issue reported by operators of such machines is vibration during the start and stop of the swing function. These vibrations can lead to discomfort, reduce the precision of operations, and, in some cases, even cause premature wear on components. Understanding the causes of these vibrations and how to resolve them is key to maintaining the machine’s longevity and optimal performance.
Understanding the Problem: Vibration During Swing Operations
The Volvo 160BLC, like many modern excavators, is equipped with hydraulic swing systems that allow for the rotation of the upper structure (cab, boom, arm, etc.) relative to the undercarriage. This system is vital for maneuvering the machine on construction sites, but when vibration occurs during the starting and stopping phases of the swing, it can be a sign of underlying issues.
The vibration can manifest as a sudden jerking motion when the swing function is initiated or when it is stopped. This is especially noticeable when the machine is at rest and operators attempt to start the swing motion, or when they stop it suddenly. These vibrations, while not always causing immediate damage, can negatively affect the precision and comfort of the operation.
Common Causes of Vibration During Swing Operations

1. Hydraulic System Issues: The most common cause of vibration during swing start and stop is related to the hydraulic system. The Volvo 160BLC uses a hydraulic motor and a set of gears to drive the swing function. If the hydraulic fluid is contaminated, low on pressure, or if there are leaks, the system may struggle to maintain smooth flow during the start and stop phases.
   Solution: Start by inspecting the hydraulic system. Check the oil levels, ensure the fluid is clean, and replace filters if necessary. If the hydraulic pump is not delivering the correct pressure, it may need to be recalibrated or replaced. Regular maintenance of the hydraulic system is crucial to preventing vibration issues.
   
2. Swing Motor Malfunctions: Another common cause of vibration is a malfunctioning swing motor. The motor could be faulty or have excessive play in its bearings, causing uneven rotation and vibration when it is engaged.
   Solution: Inspect the swing motor for any signs of wear or damage. Look for fluid leaks or abnormal noises that might indicate bearing failure or internal damage. If the motor is excessively worn, it may need to be rebuilt or replaced.
   
3. Loose or Damaged Components: Vibration during the swing cycle can also be caused by loose or damaged parts within the swing mechanism. This could include the swing bearing, the swing frame, or the associated bolts and joints. Over time, these components can become worn, misaligned, or loose, leading to uneven swings and vibrations.
   Solution: Perform a visual inspection of the swing bearing and the mounting points to ensure everything is secure. Tighten any loose bolts and check the swing gear for wear. If the swing bearing is worn out, it may require replacement to eliminate the vibration.
   
4. Improper Swing Speed or Settings: Some operators may inadvertently set the swing speed too high for the task at hand, or the swing control system might have issues with its speed regulation. Excessively high swing speeds can cause jerking motions when starting or stopping the swing cycle.
   Solution: Check the swing speed settings and ensure they are calibrated correctly for the type of work being performed. Slower swing speeds may reduce vibration and allow for more controlled movements.
   
5. Control Valve Issues: The swing system relies on control valves that regulate the flow of hydraulic fluid to the swing motor. If these valves are malfunctioning or dirty, they can cause irregular fluid flow, leading to jerky starts and stops during the swing motion.
   Solution: Inspect and clean the control valves. If necessary, have the valves professionally serviced or replaced. Valve issues are often associated with contamination, so it's essential to keep the hydraulic system clean.
   

The Role of Regular Maintenance
Regular maintenance is the backbone of preventing vibration and other mechanical issues in the Volvo 160BLC. Vibration issues often arise from wear and tear or neglect of the equipment’s maintenance schedule. For operators, staying on top of routine checks and servicing is essential to avoid costly repairs and maintain optimal performance.
A few key maintenance tasks to address are:

• Hydraulic Oil Maintenance: Ensure that the hydraulic fluid is checked regularly, and replace the fluid and filters as per the manufacturer’s recommendations. Contaminated or old oil can cause the system to malfunction, contributing to vibration.
  
• Inspecting Swing Components: The swing bearing and gears should be inspected for wear and replaced if necessary. Also, check for tightness of bolts and joints around the swing mechanism. Loose or worn components can exacerbate vibration issues.
  
• Calibrating the Controls: Make sure the control settings are properly calibrated, particularly if you notice jerky motions or inconsistent behavior when starting and stopping the swing. Over time, these settings can drift and may need adjustment.
  

Testing and Verification
Once potential causes are identified and addressed, it's essential to test the swing function to verify that the vibration issue has been resolved. Run the machine through its normal operations, particularly focusing on the start and stop phases of the swing. Check for any unusual noises, jerking motions, or abnormal vibrations.
If the issue persists after addressing the most common causes, it may be necessary to consult with a professional technician who can perform more in-depth diagnostics, such as pressure tests or further mechanical inspections.
Conclusion: Maintaining Smooth Operations
Vibrations in the Volvo 160BLC during the swing start and stop cycles can be frustrating, but they are often indicative of common hydraulic or mechanical issues. By following a systematic approach to diagnosis and performing routine maintenance, operators can reduce the risk of vibration, ensuring smooth, efficient operation.
Maintaining the hydraulic system, inspecting swing components for wear, and addressing any control valve issues early on can prevent these problems from escalating. By paying attention to the details and keeping the equipment in top shape, the Volvo 160BLC can continue to perform reliably on the job site, ensuring productivity and safety.
Understanding the importance of preventive maintenance and knowing how to handle common issues can make a significant difference in keeping equipment running efficiently and prolonging its lifespan.