SWE210 Service Manual [PDF]

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Service Manual SWE210NB



HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.



Foreword This manual enables maintenance technician to be familiar with products by instructing proper means to trouble-shooting and service. Make certain fully understand this manual and use it during every service process for better result. This manual includes technical information required in service. For easier reference and understanding, this manual consists of below chapters with several sections contained. 1、safety precautions This chapter provides safety guidelines during maintenance and service for personnel’s safe operation. 2、chapter overview This chapter provides dimensions, technical specifications, and working range information of complete machine and master parts. 3、structural function and maintenance standard This chapter illuminates structure and function of individual parts, and provides reference about trouble shooting, maintenance and service. 4、test and failure diagnosis This chapter provides instruction for inspection before or after service, and all adjustment required in maintenance and service. 5、disassembly and assembly This chapter provides all procedure that should be followed during disassembly and assembly, and all safety precautions required in operation. 6、others This chapter provides hydraulic system & electrical drawing, and air conditioning system drawing (if equipped with air conditioning).



(Note: design and specification are subject to change without notice and obligation)



I



CONTENTS 1. Safety precaution........................................................................................................................................ 1 1.1 Gerneral attention ................................................................................................................................. 1 1.2 Prepareation.......................................................................................................................................... 1 1.3 Attention in working hours ................................................................................................................... 2 2. Summary .................................................................................................................................................... 3 2.1 Dimensional drawing............................................................................................................................ 3 2.1.1 Drawing ............................................................................................................................................. 3 2.1.2 Dimention datas .......................................................................................................................... 3 2.1.3 Working range figure .................................................................................................................. 4 2.1.4 Working range datas ................................................................................................................... 4 2.2 Technical specification ......................................................................................................................... 5 2.3 Weight datas ......................................................................................................................................... 6 2.4 Engine oil, fuel and coolant.................................................................................................................. 7 3. Structure function and maintenance standard............................................................................................. 8 3.1 For mechanical device.......................................................................................................................... 8 3.1.1. Engine parts...................................................................................................................................... 8 3.1.2 Cool system ................................................................................................................................ 9 3.1.3 Power drive system................................................................................................................... 10 3.1.4 End drive (traveling motor reductor) ........................................................................................ 11 3.1.5 Swing bearing ........................................................................................................................... 11 3.1.6 Track frame and tension spring................................................................................................. 12 3.1.7 Guiding wheel........................................................................................................................... 13 3.1.8 Carrier roller ............................................................................................................................. 14 3.1.9 Thrust wheel ............................................................................................................................. 15 3.1.10 Track plate .............................................................................................................................. 16 3.1.11 working device........................................................................................................................ 17 3.2 Function and maintenance standard for hydraulic equipments .......................................................... 18 3.2.1 Hydraulic arrangement plan ..................................................................................................... 18 3.2.2 hydraulic oil tank ...................................................................................................................... 20 3.2.3 Hydraulic pump ........................................................................................................................ 21 3.2.4 Swing motor ............................................................................................................................. 34 3.2.5 Pilot control valve..................................................................................................................... 42 3.2.6 Electromagnetic valve .............................................................................................................. 47 3.2.7 Pilot filter.................................................................................................................................. 48 3.2.8 Travel motor ............................................................................................................................. 48 3.2.9 Multiple way valve ................................................................................................................... 56 3.2.10 Rupture valve.......................................................................................................................... 73 3.3 For electric equipments ...................................................................................................................... 78 3.3.1 Power supply circuit ................................................................................................................. 78 3.3.2 Starting circuit（key switch：START） ................................................................................. 79 3.3.3 Pilot closing circuit（key switch：ON） ................................................................................ 80 3.3.4 Engine closing circuit（key switch：OFF）........................................................................... 81 3.3.5 Wiper and scrubber circuit........................................................................................................ 82 3.3.6 Controller.................................................................................................................................. 83 3.3.7 Engine control........................................................................................................................... 86 3.3.8 ECM system ............................................................................................................................. 87 3.3.9 Multifunction moniter system................................................................................................... 92 4. Test and adjustment and Failure Diagnosis .............................................................................................. 95 4.1 Test and adjustment of mechanical structure device........................................................................... 95 4.1.1 Standard table of engine spare parts ......................................................................................... 95 4.1.2 Standard table of complete machine ......................................................................................... 96 4.2 Test and adjustment of hydraulic device........................................................................................... 105 4.2.1 Test and adjustment of system working pressure.................................................................... 105 4.2.2 Test and adjustment of pilot oil supply pressure..................................................................... 109 II



4.2.3 Inspection for main return oil pressure of the system..............................................................111 4.2.4 Inspection for output pressure of the pilot solenoid valve ...................................................... 113 4.2.5 Measuring for output pressure of pilot control valve.............................................................. 115 4.2.6 Measuring for hydraulic drift of working devices .................................................................. 117 4.2.7 Release the residual pressure in hydraulic oil circuits ............................................................ 118 4.2.8 Check for leakage volume ...................................................................................................... 118 4.2.9 Adjusting of main pump ......................................................................................................... 121 4.2.10 Devices exhaust .................................................................................................................... 125 4.3 Fault diagnose................................................................................................................................... 126 4.3.1 Inspection before fault diagnose ............................................................................................. 126 4.3.2 Fault sorts and check methods ................................................................................................ 127 5. Disassembly and assembly ..................................................................................................................... 133 5.1 How to read this manual................................................................................................................... 133 5.2 Instruction during operation ............................................................................................................. 134 5.3 Working device ASSY assemly and disassembly ............................................................................. 137 5.4 Counterweight ASSY assembly and disassembly ............................................................................ 139 5.5 Cab ASSY assembly and disassembly.............................................................................................. 140 5.6 Engine disassemble and assembly.................................................................................................... 142 5.7 Radiator ASSY disassembly and assembly ...................................................................................... 144 5.8 Hydraulic pump ASSY disassembly and assembly .......................................................................... 147 5.9 Hydraulic pump body disassembly and assembly ............................................................................ 150 5.10 Main pump adjustor disassembly and assembly............................................................................. 158 5.11 Rotary motor ASSY disassembly and assembly ............................................................................. 166 5.12 Rotary motor noumenon disassembly and assembly...................................................................... 168 5.12 Handle pilot valve disassembly and assembly................................................................................ 178 5.13 Multiple way valve ASSY disassemble and assemble.................................................................... 185 5.14 Travel motor ASSY disassembly and assembly ............................................................................. 188 5.15 Central rotary joint ASSY disassembly and assembly.................................................................... 190 5.16 Hydraulic tank ASSY. disassembly and assembly.......................................................................... 191 5.17. Carrier roller ASSY disassembly and assembly ............................................................................ 194 5.18. Thrust wheel ASSY disassembly and assembly ............................................................................ 195 5.19. Guiding wheel ASSY. disassembly and assembly ......................................................................... 196 5.20. Tension device disassembly and assembly .................................................................................... 199 5.21 Sproket wheel disassembly and assembly ...................................................................................... 202 5.22. Track shoe ASSY disassembly and assembly................................................................................ 203 5.23. Rotary bearing ASSY disassembly and assembly ......................................................................... 207 5.24. Rotary table ASSY disassembly and assembly.............................................................................. 208 5.25. Air-conditioning ASSY disassembly and assembly....................................................................... 210 6. Figures and others .................................................................................................................................. 213 6.1 Hydraulic system schematic diagram ............................................................................................... 213 6.2 Electrical system drawing................................................................................................................. 214



III



1. Safety precaution Important safety precaution For the sake of safety operation, it is particularly important to maintain and check machine properly.The maintenance and check techniques in this manual or introduced by SUNWARD are safe and effective operation methods and some of them need to use the special tools which are designed by SUNWARD. Sign



is used in this manual for safety precautions in case of injuring workers.



Pay attention to these marks. If danger happens or may occur, safety should be considered first then take the necessary steps according to the circumstances.



1.1 Gerneral attention Improper operation is quite dangerous. Before repair and maintenance are carried out, it is essential to read this manual carefully. 1. Before lubrication or repair is carried out, read all the safety notes on labels that are fixed on the machine. 2. Before any operation, do wear safety shoes and hard hat. Do not wear loose work clothes or clothes without buttons. z Wear safety glasses when knocking some parts with a hammer. z Wear safety glasses when polishing some parts with a grinding wheel. 3. If welding is needed, it should be carried out by trained skilled welder. During welding, wear special gloves, apron, helmet, hard hat and work clothes that are suitable. 4. When an operation is carried out by two or more workers, the operating procedure should be agreed upon before the operation. Before any operating procedure begins, you should inform your partner workers of it. Hang a label reading “repairing” on the control table of control room before any work. 5. All tools should be kept in good condition and operators are required to learn how to use them. 6. Put the tools and disassembled parts in an appointed place in the repair shop. Do put the tools and disassembled parts in a proper place. Keep the work area clean and make sure there are no dirty things or oil stain on the floor. Smoke in the appointed area only. It is not allowed to smoke during work hours. 1.2 Prepareation 1. Before you fill oil or carry out any repair, put the machine on a level and hard ground, underlay the wheels or tracks with pads to prevent the machine from moving. 2. Before operation, lower the push plate, ridger teeth, bucket and other working parts onto the ground. If some working parts can not be lowered, apply the safety pin or pad to prevent them from falling down. 3. When disassembly or assembly is needed, use pads, lifting jacks or racks to support the machine before any operation. 1



4. Clean the steps by which you get on and off the machine and the pedals. When you get on or off the machine, use handrails, steps or gangboards. Do not just jump in or off the machine. If handrails, steps or gangboards are not available for use, racks should be used in sake of safety. 1.3 Attention in working hours 1. When disassembling the cover of oil filling opening, oil drain plug or hydraulic measurement plug, release them gradually to prevent the oil from ejecting. a) When disconnect or disassemble pipes for oil, water or gas supply, release the pressure in pipeline first. 2. When the engine flames out and the water and oil in the pipeline are hot, be careful to avoid being scalded. 3. Disconnect battery cable prior to operation. Make sure to disconnect negative terminal first. 4. When lifting heavy loads of parts, use winch or crane to check steel rope, chain and hook for damage.Be certain to use over rated power crane.Assembling the crane at correct place.Operating a winch or crane slowly to prevent lifting parts colliding with other objects and do not work on the parts which is lifted by winch or crane. 5. When removing caps under internal pressure or spring pressure, maintain two bolts on the other side. With pressure relieved, loosen bolts to remove. 6. Pay attention not to crash or damage cable during parts removal. Failure to do so can cause electric spark. During pipeline disassembly, prevent any leakage of fuel or oil from pipeline. In case of 7. any leakage on the floor, wipe it immediately, because fuel or oil on the floor can result in personnel slip or fire. 8. Do not clean parts with gasoline in normal situation. However a small amount of gasoline is allowed in an exceptional case. 9. Make sure to position all parts properly, and replace defective parts with new ones. 10. During hose or cable installation, do not let them make contact with other parts. 11. Make sure all high-pressure hose is free of distortion during hose installation. Damaged pipeline is of highly dangerous. Therefore, pay undivided attention to it during high-pressure hose installation. In addition, check connecting piece for proper installation. 12. Always operate with specified tightening torque during assembly or disassembly. When assembling protective parts (e.g. protective guard) or installing other parts with sharp vibration and high-speed rotation. Make sure they are properly installed. 13. When aligning two holes, do not insert fingers or hands into them so as to prevent finger from being caught in. 14. Make sure all tools for measuring purpose are properly installed before attempting hydraulic pressure measurement or other measuring procedures. 15. During track disassembly or assembly, please note that track may disengage out of place abruptly; make sure the area on both end of the track is clear of persons.



2



2. Summary 2.1 Dimensional drawing 2.1.1 Drawing



2.1.2 Dimention datas Item



Unit



SWE210NB



A



Wheel track



mm



3655



B



Track total length



mm



4450



C



Platform distance



mm



1060



D



Platform Swing radius



mm



2750



E



Upper carriage width



mm



2500



F



Track gage



mm



2040



G



Chassis swidth



mm



2540



H



Track width



mm



500



I



Chassis distance



mm



470



J



cab height



mm



2965



L



Transportion length



mm



9590



M



boom height



mm



3045



to



to



ground



ground



3



2.1.3 Working range figure



2.1.4 Working range datas Item



Unit



SWE210NB



A



Max. digging height



mm



9740



B



Max. dumping height



mm



6980



C



Max. digging depth



mm



6690



D



8 feet level digging depth



mm



6500



E



Max. vertical digging depth



mm



6040



F



Max. digging radius



mm



9950



G



Max. parking digging distance



mm



9785



H



Min. swing radius



mm



3530



level



4



2.2 Technical specification Model



SWE210NB



Standard bucket capacity



m



Operation weight



kg



21



Bucket max.digging force



kN



137



Arm max.digging force



kN



100



Swing speed



rpm



12.5



Traveling speed



km/h



5.5/3.2



°



35



Perf orma nce para mete rs



Max.climbing capacity



3



Engine model



AI-4HK1X



electro, water cool, four strok, pressurization, intercool



Type Cylinder numer-diameter X stroke



Pow er Discharge plant Rated power/rotational speed Max.torque/ rotational speed Fuel tank capacity



mm



4—115ｘ125



L



5.193



kW/rp m Nm/rp m L



Main pump



122±4/2000 655±60/1500



370



2×plunger pump L/mi



Flow



n



Working device pressure Travel pressure Hydr aulic Swing pressure syste Pilot pump m Flow



oil



2×206



Mpa



32.4(34.3)



Mpa



32.4



Mpa



26



1×gear pump L/mi n



Pilot pressure setting Hydraulic capacity



0.95



tank



30



Mpa



3.9



L



190



5



2.3 Weight datas The table can de referred during maintenance or transportion.



Unit：kg Model



SWE210NB



Total machine



21000



Uppercarriage



8084



Undercarriage



8011



Boom



2470



Arm



1195



Bucket



828



Cab



294



Blance weight



4000



6



2.4 Engine oil, fuel and coolant Ambient temperature -22 1220F



-4



14



32



50



68



86



104



-30 500C



-20



-10



0



10



20



30



40



SAE 30 SAE 10W Engine oil pan



SAE 10W-30 Engine oi



SAE 15W-40 SAE 5W-30



Swing reductor API-GL-4 85W-90 API-GL-5 80W-90 Travel reductor



32#wear hydraulic oil Hydraulic system



Hydrau lic oil



46# wear hydraulic oil 68# wear hydraulic oil



GB252 premium 0#



GB252 premium -10# Engine



Diesel GB252 premium -20#light diesel GB252 premium -35#light diesel



Swing mechanism grease chamber



Grease



NLGI No.2



Oil cup Cool system



Coolan t



add proper anti-freezing fluid 7



Speci fied capac it



Refill capac ity



3. Structure function and maintenance standard 3.1 For mechanical device 3.1.1. Engine parts



1. Fan blade



Technical specification：



2. Engine installation bracket



Front shock pad： 750602000073(2 pieces)



3. Rear shock pad



Rear shock pad： 750602000077(2 pieces)



4. Engine installation front bracket



Muffler： 750205000046(1 piece)



5. Front shock pad 6. Muffler



8



3.1.2 Cool system



1．Engine exhalent siphon



Technical specification：



2．Engine water inlet pipe



Affix water tank: 750203000086(1 piece)



3．Affix water tank



Radiator: 730701000044 (1 piece)



4．Radiator 5．Air director cover 6．Condenser 7．Oil cooler



9



3.1.3 Power drive system



SWE210NB



Guiding wheel



750105000035



Centre swing joint



739802000019



Main pump



730302000082



Traveling motor



730250000119



Hydraulic pump



730201000127



Engine



750201000121



Electromagnetic valve group



730305000085



Swing motor



730250000241



Swing bearing



750550000053



10



3.1.4 End drive (traveling motor reductor)



1. Chain wheel: 817-MA-B3000 2. Traveling motor: MAG-170VP-3800G-1



3.1.5 Swing bearing



1．Outer race of swing bearing 2．Steel ball 3．Inner race of swing bearing



11



3.1.6 Track frame and tension spring



1．Track frame 2．Carrier roller：80X-MH-C3000



Number：2 in one side



3．Thrust wheel：80X-MH-A1000



Number： 9 in one side



4．Track assy：190MH-49360



Track plate number： 49 in one side



5．Track cover sheet 6．Driving wheel 7．Traveling mortor 8．Tension spring 9．Guiding wheel



12



3.1.7 Guiding wheel



Unit：mm NO.



Checking item



satandard Standard dimension



Repayment limit



1



Total width



159



－



2



Flange width



84



－



3



4



Track bearing surface outer diameter Flange outer diameter



φ500



φ488



φ538



－



13



measures



Repair or replace



3.1.8 Carrier roller



Unit：mm NO.



1



2



Checking item Flange outer diameter Track bearing surface outer diameter



Standard Standard dimention



Repair limit



φ145



－



φ120



φ106



3



Total width



170



－



4



Track bearing surface width



43



－



5



Flange width



14



－



14



Measures



Repair or replace



3.1.9 Thrust wheel



Unit：mm NO. 1



2



3 4 5



Checking item Flange outer diameter Track bearing surface outer diameter Total width Track bearing surface width Inner side width



Standard Standard dimention



Repair limit



φ188



－



φ156



φ144



230



－



174



－



85



－



15



Measures



Repair or replace



3.1.10 Track plate



Unit：mm NO.



Checking item



1 2



Standard Standard dimention



Repair limit



Hight



25



15



Thickness



35



－



16



Measures



Repair or replace



3.1.11 working device



1．Bucket



5．Arm



2．Connecting rod



6．Arm cylinder



3．Rocker arm



7．Boom



4．Bucket oil cylinder



8．Boom cylind



17



3.2 Function and maintenance standard for hydraulic equipments 3.2.1 Hydraulic arrangement plan



1: Tee joint shutoff valve 2: Hydraulic tank 3: Right side counterbalance valve (4.5Mpa) 4: Main pump 5: Right travel motor 6: Pilot filter 7: Multiple way valve 8: Pilot solenoid valve 9: Left side counterbalance valve (2.5Mpa) 18



10: Auxiliary pedal valve 11: Travel pedal valve 12: Central swing joint 13: Oil collecting block 14: Right handle valve 15: Left handle valve 16: Swing motor 17: Oil return block 18: Right trave motor



19：Arm cylinder



20：Right boom cylinder



21：Left boom cylinder



22：Bucket cylinder



23：Shutoff valve- right side



24：Shut off valve- left side



19



3.2.2 hydraulic oil tank



1：Pressure signal 2：Drain plug 3：Air filter 4：Liquid level gage 5：Tank body 6：Oil suction filter gauze 7：Oil return filter gauze 8：By-pass check valve 9：Magnetic filter core



20



Technical parameters oil tank oil tank capacity oil tank capacity



oil return filter core



oil suction filter core



190L



flow



750L/min



flow



1000L/min



155L



rated pressure



1.6MPa



filtering accuracy



100μ



filtering accuracy By-pass valve opening pressure



10μ



0.3MPa



3.2.3 Hydraulic pump Summary K3V112DT-1x7R-9ND9-9V



The pump includes two variable cam-type plunger pumps、pilot oil source、one electromagnetic proportional valve and two main pump adjusters.



21



1：Front main pump 2：Back main pump 3：Pilot oil source 4：Electromagnetic proportional valve 5：Adjuster A1：Output port-front pump pressure oil A2：Output port-back pump pressure oil B1：Port-main pump suction oil Dr：Drain oil port Pi1：Feedback port-front pump negative flow Pi2：Feedback port-back pump negative flow Psv：Input port-electromagnetic proportional valve a1：Pressure test port-front pump vent a2：Pressure test port-back pump vent a3：Pressure test port-pilot oil source vent A3：Pressure oil output port-pilot oil source B3：Pump suction port-pilot oil source



Function (front pump & back pump) z Convert the engine rev motion which transferred to the pump spindle and torque to hydraulic energy. Export pressure oil according to the amount of load. z It is possible to change the output quantity of pressure oil through changing the angle of sloping cam plate. Structure (front pump & back pump) z



(see JPG0002)：two variable cam-type plunger pumps are connected by spline joint (114)，



transfer motor revolution to the drive axle of the front F(111)and drive the two pumps. Oil suction and output ports are placed at the valve block (312)-the connecting place of the two 22



pumps. Front pump and back pump use the same suction port. Take the two pumps for example because the sameness of the two pumps construction and motion theories. This pump is mainly consists of rotary mechanisim for pump rotary motion, tilted plate mechanism for adjusting output flow and valve cover mechanism for doing oil suction and output motions alternately. z



Rotary mechanism：consists of drive axle F(111),oil tank body(141),



Plunger (151), slipper (152), pressure plate (153), spherical cylinder (156), shim (158) and oil tank spring (157). The end sides of drive axle are supported by roller bearing (123) and needle bearing (124). Install piston shoe on piston, form sphero joint and reduce the pushing force. There is a shell part on piston shoe (211) to adjust the balance of oil pressure. For the servive mechanism of piston shoe to move smoothly on supporting plate, oil pressure spring would press piston shoe on supporting plate by pressure plate and spherical cylinder liner. And oil tank body also is pressed on the valve plate (313) by oil tank spring. z



Sloping cam plate mechanism：consists of sloping cam plate(212), piston shoe(211)，sloping



cam plate supporter(251), tilting cylinder liner(214), tilting pin(531) and servo-oil tank(532). Sloping cam plate is supported on the supporting platform which formed a cylindraceous part at the opposite side of piston shoe moving face. Adjuster controls the oil pressure and makes the service piston move side-to-side under the direction of oil pressure cavity，Then the tilting angle (α)can be changed in the presence of the ball part of tilting pin and the shaking of sloping cam plate. z



Valve cover mechanisim：Consists of valve block (312), valve plate (313) and valve plate



pin (885). The valve plate with two legena holes is placed on the valve block and supplying and recovering oil for cylinder. The oil switched by valve plate is connected with exterior piping by valve block. Working process (front pump & back pump) 1．Working process of pump i Tank body(141)and axle(1)rotate together(see JPG0003)，slipper(152)slips on level A . Sloping cam plate(212)moves around column face B ，so the angle changed between the central line X of sloping cam plate(212)and the axis of tank bady(141). (This angle α is called sloping cam plate obliquity). ii The central line X of sloping cam plate(212)remains the obliquity α. Level A does cam movement relatively with slipper(152). So plunger(151)does axial motion in tank body(141)，and procucts the capacity difference E and F in tank body(141). Capacity differenc F-E results in pump oil suction and oil drain. That is, drain oil as tank body (141)rotating and the capacity of tank cavity E reduced. On the other hand, tank cavity F increased and would suck oil in this position. iii As the central line X of sloping cam plate(212)in line with the axial ine direction of tank body(141)(sloping cam plate obliquity=0) ， the capacity difference E and F in tank body(141)turns to be zero，pump would not suck and drain oil.(It will not form the position Z (obliquity =0) actually). 23



111：Drive axle 123：Roller bearing 124：Needle bearing 141：Oil tank body 151：Plunger 152：Slipper 153：Pressure plate 156：Spherical cylinder 157：Oil tank spring



24



158：Shim 211：Piston shoe 212：Sloping cam plate 214．Tilting cylinder liner 251：Sloping cam plate support table 312：Valve block 313：Valve plate 531：Tilting pin 532：Servo-oil tan



25



Maintenance standard (front pump and back pump) When the wear extents of every parts of pump exceed the following standard, change or adjust it again. While apparent damage happens it must be replaced.



Name and inspection Item



standard dimension / recommend replacing value pump type



Disposal



K3V112



K3V140



0.039～0.067



0.043～0.070



replace piston or oil tank



gap part looseness of piston and piston shoe(δ)



0～0.3



0～0.3



replace piston and coupling parts



thickness of piston shoe( t )



4.7～4.9



5.0～5.4



free height of oil tank spring(L)



40.3～41.1



47.1～47.9



assembly height of pressure plate and spherical liner(H-h)



11.0～12.0



12.5～13.5



gap value in piston and oil tank (D-d)



26



replace piston and coupling parts replace oil tank spring replace pressure plate and spherical liner



Function (adjuster) Use adjuster to realize the adjusting and controlling output power and flow of main pump automatically. Structure (adjuster) Main pump adjuster(see JPG0006)：Front and back pump adjusters are also consist of plunger units 1,plunger units,servo-valve core unit 3, connecting rod(612、613), feedback rod(611),shell and end cover. They are the parts that make up the flow and power adjusting units of main pump.Pin shaft(548 ) connects feedback rod(611)with servo-piston on main pump.The whole adjuster is connected to the body of main pump by four hexagon socket screws(438). Working procedure (adjuster) The adjuster of main pump could adjust the flow and power automatically and prevent engine from overloading operations. 1. Flow control The obliquity (output flow) could be controlled randomly by changing leading pressure Pi. The working way of adjuster: Control negative flow (negative sense control) as leading pressure Pi increasing and output flow Q decreasing. This unit could give leading pressure instruction in line with the necessary operation flow.Piston pump only output essential flow. Therefore power will not be exhausted in vain. z Motion illustration See as the following figure (JPG0004). The output flow of piston pump could be controlled randomly as the changing of leading pressure Pi.



27



z



Motion of flow reduction As leading pressure Pi increased, leading piston (643) moves right. As the pressure of guide spring(646)and oil pressure resting at the equilibrium position, the pin(875)fixed on connecting rod 2(613)is embedded in the groove part [A part]of leading piston.Therefore, as the moving of leading piston, connecting rod 2 pivots on point B[fixed by pivot plug(614)，pin(875)]. Because of the pin (897)fixed on feedback connectiong rod (611)lies in the big hole part [C part]of connecting rod 2, pin (897)would move right as connecting rod 2 rotating. The (D) part of feedback connecting rod tables the pin (548) fixed on tilted pin (531)(tilted pin shakes tilted plate ). So when pin(897)moves，feedback connecting rod pivots on point D. Short pipe would move right because feedback connection rod connects pin (874) with short pipe (652).As moving procedure, output pressure P1 is led to the port of servo-piston through pipe C1. While output pressure P1 is led to the small port of servo-piston and makes it move right to reduce obliquity as area difference. When servo-piston moves right, point D will also move right. Offsetting spring(654)on short pipe produces a pull force that will make short pipe move left and that makes pin(897)pressed to the big hole part[C patr] of connecting rod 2. As the moving of point D, feedback connecting rod pivot on point C and short pipe moves left. These moving make sleeve aperture (651) and short pipe aperture (652) close slowly, and servo-piston would stop as it closed completely. z Motion of increasing flow When leading pressure Pi decreased, the pressure of guide spring (646) makes leading piston (643) move left. Connecting rod 2(613)pivots on point B. Pin (897) is pushed to the big hole[C part] of connecting rod 2 by offsetting spring (654) through short pipe (652), pin (874) and feedback connecting rod (611). As the moving of connecting rod 2, feedback connecting rod 2 pivots on point D and short pipe moves left. As short pipe moving, pipe C would open to oil tank, the pressure on big port of servo-piston would reduce. Output pressure P1 on small port would act on servo-piston and make it move left and flow increased. Point D also moves left as servo-piston moving. Feedback connecting rod pivots on point C. Short pipe moves right. This moving repeated until the aperture of sleeve and short pipe closed and would stop at the closed place.



28



2.



Power control The increasing of output pressure P1 and P2 of piston pumps makes the obliquity (output flow) reduces automatically and controls output torque under fixed value (input power remains if rev remains). Operate according to the summation of load pressure on two piston pumps of the double piston pumps in series and take full power way. Therefore, under the power control status, make the obliquitis (output flow) the same by controlling the adjusters of every piston pumps. In spite of how variable the two piston pumps loads are, this mechanism could prevent the overloading operations of engine automatically. The motiong of power control is the same as flow control. The following are simple illustration. (Refer to flow control about the details of every units motion). z Motion instruction Increase load pressure (see fig JPG0005) and decrease obliquity of piston pump to prevent engine overloading. As the adjuster adopts the synchronous power control way, so control the obliquities of the two piston pumps (extrusion capacity) to make them the equivalent. See as the following formula.



Tin=P1*q/2π+ P2*q/2π= （P1+P2）*q/2π



z



Prevent overloading motion When the output pressure P1 and P2 of two sides piston pumps increased，P1 and P2 would



act on the compensation piston(621)，push compensation rod (623)to the right until the elasticity and oil pressure of exterior spring(625) and interior spring(626) reach the equilibrium position and stop moving. The motion of compensation rod is conveied to connecting rod 1 through pin (875). Connecting 1 pivots on pin (875)[point E] which is fixed on pump case(601). There is a prominent pin (897) fixed on feedback connecting rod (611) on the big hole [F part] of connecting 1. As rotating of connecting rod 1, feedback connecting rod 1 pivot on point D, short pipe (652) moves right and output flow Q reduced to get negative flow control. As short pipe moving, output pressure P1 is led to the big port of servo-piston through pipe Cℓ，servo-piston moves right, output flow of piston pump is reduced to prevent motor overloading. The motion of servo-piston conveies to feedback connecting rod through point D. Feedback rod pivots on point F, short pipe moves left and keeps moving until the port with sleeve(651) closed and then it would stop. 29



z



Flow resetting motion When the output pressure P1 and P2 of two sides piston pumps decreased, compensation



rod(623) is pushed back by spring(625，626). Connecting rod 1 pivots on point E. As it moving, feedback connecting pivots on point D and short pipe moves left. Pipe Cℓ would open to oil tank, servo-piston moves left and its pressure on big port decreased, output flow of piston pump increased.The motin of servo-piston would convey to short pipe by feedback units and keep moving until the port of short pipe and sleeve closed. 3. Priority mechanism of instruction According above stated，tilting instruction of flow and power control are conveyed to feedback connecting rod and short pipe through the big port [part C & F ]of connecting rod 1 and 2. Part C & F adopt the structure of prominent pin (φ4), therefore, only lesser connecting rod can get to pin (897) while the holeφ8 of connecting rod with big tilt instruction would not get to pin (897). The little tilt instruction of flow control and power control would be adopted first.



30



601．Pump shell



626．Internal spring



651．Sleeve



611．Feedback rod



627．Telescopic link (C)



652．Slide valve



612．Connecting rod (1)



628．Regulating screw (C)



653．Spring



613．Connecting rod (2)



629．Cover (C)



654．Offsetting spring



614．Bearing pin



630．Locknut



655．Regulating spring



615．Regulating pole



631．Sleeve PF



621．Compensation piston



641．Guide housing



622．Piston cover



643．Guide piston



623．Compensation rod



644．Spring (Q)



624．Spring (C)



645．Spring (Q)



625．External spring



646．Guide spring



31



Function (pilot oil source) Provide stable pressure oil for pilot control of multiple way valve, unlocking of swing motor, high and low speed control of traveling and electronic proportional valve of main pump, ect. The maximum pressure in pilot oil circuit is set by the relief valve in pilot oil source. Structure (pilot oil source) Pilot oil source (see figure JPG0007) ：consists of two meshed gears(354、353)，two drive shafts (354、353) standing on shell, relief valve module and shell (351). Spline end of power input shaft (353) connects with spline hole on main shaft end (113) of back pump. Bolt (435) connects shel l (351) of pilot oil source to supporting plateform (251) of sloping cam plate on main pump.



353．Gear 354．Gear 351．Shell 435．Hexagon socket screw 32



Function (electromagnetic proportional decompression) It can set the output power of main pump momently. When coil of electronic proportional valve gets a current value from host machine controller, the output port of proportional decompression valve would export a corresponding pressure value. The force acts directly on plunger rod (621) of adjuster to counteract parts of the spring force and reaches the output power of main pump which has been set. Structure (electromagnetic proportional decompression) Electromagnetic proportional valve(see figure JPG0008)：It is a screw thread plug-in valve and is installed in valve plate (313) of main pump. It consists of valve pocket (312), valve core (311), offsetting spring (324) and electromagnetic coil (801).



311．Valve core 312．Valve pocket 324．Offsetting spring 801．Proportional electromagnetic coil 33



3.2.4 Swing motor Summary M5X180CHB-12A-1PA/265-149 It consists of valve units, motor and swing reductor.



1. valve units



PG：Unlocking pressure oil import



2.



SH：Unlocking pilot opening



swing motor



3. swing reductor



L：Gear oil detecting and blow vent



A、B：Main oil opening



IP：Gear oil filling opening



M：Replenishing opening



DP：Gear oil drain opening



PA、PB：Main oil pressure detecting opening



AN：Bearing vent opening



DR：Oil drain opening



GN；Butter smear opening



Function (motor noumenon) Convert the oil flow and pressure which provided by hydraulic pump to torque and rev, and then convey them to swing redactor so as to drive the running of uppercarriage. Swing stop brake fits for wet multichip brake. Releasing pressure by brake is input by pilot pump only as the operating of working device and swing mechanism. The other operating besides swing and working devices or during the engine nonoperating, Brake releasing pressure returns to hydraulic tank, so brake works automatically by spring.



34



Structure (motor noumenon) Motor noumenon consists of sloping cam plate, rotor, plunger, port plate,shell, output shaft and swing stop brake (consists of spring, brake piston, sheet steel, friction disk and swing stop brake switch ), ect.



121：Plunger



702：Brake piston



124：Sloping cam plate



743：Sheet steel



111：Rotor



742：Friction disk



131：Port plate



031：Swing stop brake switch



301：Shell



161：Drive shaft



712：Spring



Working procedure (motor noumenon) 1. power and rev output After high pressure oil flowing into rotor through input hole (a)of port plate(1)(see figure JPG0153)，the produced hydraulic pressure works on plunger and produces force F on axial direction. Force F produces upright force F1 and axis right angle force F2 separately on sloping cam plate (3) through slipper(2). Force F2 conveys to rotor (4) through plunger and produces turning pair around output shafts. There are nine plungers arranged equidistantly in rotor. Plunger communicates with input hole of high pressure oil and conveys swing torque to output shafts in turn. When change oil in and out direction in reverse, the swing direction of power shaft would turn reverse. 35



2. brake releasing 1） When swing or working device joy stick operating, swing stop brake release valve rod in signal pilot pressure control valve moves and pilot hydraulic oil flows into oil port SH through pilot pump. 2） Valve rod is pushed right by pilot pressure which flows into oil port SH. Pilot pressure in oil port PG comes into brake piston room through valve rod and the upper and the under cavities in brake piston room are broken, brake piston moves up and motor releases brake. 3. brake works 1) When swing and joy stick of working devices release, swing stop brake release valve rod in signal pilot pressure control valve returns to free position, pilot pressure flows into oil port SH would be decreased. 2) Valve rod returns back. Pilot pressure from oil port PG is blocked up and time-delay valve opened. 3) Hydraulic oil in brake piston room returns to swing motor shell through time-delay valve. 4) Spring force 1 acts on sheet steel and friction disk. Sheet steeel and friction disk mesh with rotor outer diameter and shell inner diameter by brake piston. So rotor outer diameter is supported by friction force. When engine stops working, there is no pilot pressure into oil port SH and makes brake to work automatically. 4. brake delay 1) When the order of releasing brake for hole SH disappears, valve rod moves left under the act of spring and cuts off hole PG and PR. 2) Oil in hole PR flow into hole D through orifice in time-delay valve. Brake has certain stroke volume (V：cm3). Assume the flow through orifice is Q, then the delay time from releasing status of brake piston to contact friction disk and sheet steel is : t=V／S.



36



Maintenance and service standard (motor noumenon) 1. Replace standard for friction parts When friction extent of every friction parts over the standards in the following figure, it should be replaced or adjusted again. While there are evident damages in appearance, it should not refer to the following standards and should be replaced in advance. replacement standard recommended item remedy dimension(mm) value(mm) fit replace plunger or clearance-plunger 0.027 0.052 rotor & rotor(D-d) hinge replace plunger and clearance-plunger 0 0.3 slipper units &slipper sphere(δ) slipper thickness(t)



5.5



5.3



37



replace plunger and slipper units



2.



Refacing standard for swing engagement face As the degrees of roughness of every parts’ swing engagement faces over the following standards, it should be refaced or replaced. parts description



standard degree of roughness



need to be refaced degree of roughness



slipper



0．8 一 Z(Ra：0．2) (grind)



3 一 Z(Ra；0．8)



sloping cam plate



0．4 一 Z(Ra=0．1) (grind)



3 一 Z(Ra=0．8)



rotor



1．6 一 Z(Ra：0．4) (grind)



12．5 一 Z(Ra：3．2)



port plate



O．8 一 Z(Ra=0．2)



(grind)



6．3 一 Z(Ra=1．6)



Sructure (valve units) Valve unit consists of compensation valve, relief valve and anti-reverse-rotation valve, etc.



351： Compensator valve 38



051： Overflow valve



Function (valve units) Compensator valve：Prevent motor sucking air or cavitation erosion due to oil unable to supply in time during the process of braking. Overflow valve：When swing operation starts or stops, oil pressure in swing oil way increased. Relief valve could prevent oil way pressure from going up above the setting pressure. Anti-reverse-rotation valve：When swing stops, it reduces revolution shaking owing to inertia of revolving body, recoil strength and rigidity of mechanical system and compressibility of hydraulic oil, ect. And it could prevent the load things in bucket from coming out and reduce cycle time efficiently. (Good locating performance and fast moving for the next operation).



Working procedure (valve units) 1. Compensator valve During swing stops, swing motor is pushed by the inertia force from swing platform of upper carriage. Motor pushed by inertia force runs faster than pushed by output pressure oil from pump. So cavity would be produced in oil way. To prevent cavity, when pressure in swing oil way is much little than pressure in return oil way (oil port M), check valve would open and hydraulic oil enter into oil way from hydraulic tank to eliminate the status of lacking oil. 2.



Overflow valve Low-pressure overflow operation(shock absorption function)：



1) 2) 3) 4)



Pressure of oil port HP (swing oil way) enter oil cavity C through thr orifice of lift valve. Pressure oil in oil cavity C enter oil cavity A and B separately through oil way A and B. Pressure area in oil cavity B is bigger than that in oil cavity A, so piston moves left. Piston moves continuously and pressure difference presents in lift valve. When pressure 39



difference over spring force, lift valve leaves its position and makes pressure oil enter into oil port LP. 5) When piston moves total excursion, pressure difference of lift valve disappears and makes lift valve back to its position. High-pressure overflow operation(prevent over loading)： 1) After piston moves total excursion, spring is compressed to increase the pressure in oil way to the setting pressure. 2) If the pressure in oil port HP increased above the setting pressure of spring, lift valve leaves its positon and makes pressure oil flow into oil port LP through oil port HP. 3) When pressure in oil port HP decreased to the setting pressure, lift valve returns to its position because of the spring force.



3.



Anti-reverse-rotation valve



See figure JPG0159 ， figure 1 shows the connection between neutral condition of anti-reverse-rotation valve and hydraulic circuit. Assume that there was brake pressure at the side of port A and is in brake state. When port A is pressed, the pressure flows into room n through way 1, port above the shaft of valve base 313 and way m of plunger 311. When pressure P exceeds the setting value of pring 321, plunger 311 leads spring 321 moving left. Valve base 313 is pushed by plunger 311 and leads spring 322(week elasticity) moving left. [as figure 2]. When inertia load stops moving, brake pressure decreases. When P