Professional Documents
Culture Documents
1900SRM1107 (01 2004) Uk en
1900SRM1107 (01 2004) Uk en
1900SRM1107 (01 2004) Uk en
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... Main Hydraulic Tank .................................................................................................................................... Main Hydraulic Pump ....................................................................................................................................... Description ..................................................................................................................................................... Load Sensing Pressure .................................................................................................................................. Main Pump Controller................................................................................................................................... LS Servo..................................................................................................................................................... LS Control Valve........................................................................................................................................ Power Servo ............................................................................................................................................... Adjust ............................................................................................................................................................. Load Sensing Pressure LS1 ...................................................................................................................... Load Sensing Pressure LS2 ...................................................................................................................... Standby Pressure ...................................................................................................................................... Power Control Valve.................................................................................................................................. Main Control Valve ............................................................................................................................................ Description ..................................................................................................................................................... Adjustment..................................................................................................................................................... Relief Pressures......................................................................................................................................... Main....................................................................................................................................................... Derricking Up........................................................................................................................................ Derricking Down ................................................................................................................................... Telescoping Out ..................................................................................................................................... Telescoping In........................................................................................................................................ Spreader Supply.................................................................................................................................... Spreader Standby.................................................................................................................................. Steering Supply..................................................................................................................................... Derricking Cylinder .............................................................................................................................. Flow Control Settings ............................................................................................................................... Derricking Down Speed ............................................................................................................................ Derricking Up Speed ................................................................................................................................. Telescoping Speeds .................................................................................................................................... Steering .............................................................................................................................................................. HR45-25, HR45-27, HR45-31, and HR40S................................................................................................... Description................................................................................................................................................. Adjust ......................................................................................................................................................... HR45-36L, HR45-40LS, and HR45-45LSX .................................................................................................. Description................................................................................................................................................. Pilot System ....................................................................................................................................................... Pilot Pump ..................................................................................................................................................... Telescoping Retract Control Valve............................................................................................................ Manipulator Pressure Valve ..................................................................................................................... Description ............................................................................................................................................ Operation............................................................................................................................................... Adjust..................................................................................................................................................... Engine Cooling System ............................................................................................................................. Adjust (Standby Pressure).................................................................................................................... Adjust (Maximum Pump Pressure)...................................................................................................... Hydraulic Cooling System ................................................................................................................................. Description ..................................................................................................................................................... Brake Oil Cooling System ................................................................................................................................. Description ..................................................................................................................................................... 1 2 2 2 2 3 4 4 4 5 5 6 6 6 7 7 8 8 8 8 8 9 9 9 9 9 9 9 9 10 10 10 10 10 10 11 11 11 11 11 11 11 12 13 13 14 14 14 14 16 16
Table of Contents
ii
Description
Description
This section describes the hydraulic system at the frame side of the Laden Yardmaster. A location overview of the hydraulic system components is shown in Figure 1. Related items for the hydraulic system can be found in the following: Electrical System 2200 SRM 1106 Diagrams 8000 SRM 1084 Boom 4500 SRM 787 Extendable Container Attachment, PPM 5000 SRM 1063 NOTE: Information on the Elme spreaders can be found in Extendable Container Attachment 5000 SRM 776.
PUMP COOLING SYSTEM SERVICE BRAKE AND PILOT PUMP FUEL TANK PARK BRAKE SOLENOID VALVE MAIN HYDRAULIC PUMP MAIN HYDRAULIC OIL TANK AIR CONDITIONING CONDENSER BRAKE OIL TANK 5H 96" RETRACT TELESCOPING CONTROL VALVE 170 bar (2466 psi) LOAD SENSING SWITCH 210 bar (3046 psi) LOAD SENSING SWITCH SPREADER AND BOOM CONTROL SOLENOIDS OPTIONAL DEAD MAN SOLENOID OPTIONAL WINCH CONTROL VALVE
15. JOYSTICK PRESSURE VALVE 16. 4H 96" RETRACT TELESCOPING CONTROL VALVE 17. AIR/COOLANT/TRANSMISSION OIL COOLER 18. BRAKE ACCUMULATOR 19. HYDRAULIC AND BRAKE SYSTEM OIL COOLER 20. HYDRAULIC SYSTEM FILTER 21. BRAKE SYSTEM FILTER 22. BRAKE COOLING PRESSURE REGULATOR 23. BRAKE COOLING SOLENOID VALVE 24. HYDRAULIC AND BRAKE SYSTEM COOLING PUMP 25. TRANSMISSION OIL FILTERS 26. ENGINE AIR FILTER
1900 SRM 1107 incorporates the oil return screen, which is accessible after the bracket is removed. Just in front of the cover is the suction shutoff, which allows replacement of pump suction hoses without having to empty the entire tank. Verify the suction valve is open before starting the engine.
1. 2. 3. 4. 5. 6.
LOAD SENSING SERVO PLUNGER PLUNGER HOUSING SWASH PLATE POWER SERVO PUMP SHAFT
7. 8. 9. 10. 11.
there is high oil pressure, the bigger LS servo will overcome forces of both the spring and the smaller power servo and moves the swash plate toward minimum supply. The position of the swash plate is primarily determined by the pressure in the LS servo, which is regulated by the LS control valve.
1. 2. 3. 4.
5. PUMP 6. SWASH PLATE 7. VARIABLE METERING ORIFICE Figure 3. Main Pump Controller
LS Servo
The LS servo is directly connected with the swash plate. The piston side of the LS servo receives pressure from the LS control valve. The rod side is directly pressurized by pump pressure. Apart from a spring that moves the LS servo toward maximum supply, the pressure difference between the pump and the LS control valve determines the position of the LS servo.
At relatively higher LS pressures, when there is less oil demand, the spool supplies pump pressure to the LS servo, which will move the swash plate to minimum supply. The LS controller cannot be adjusted separately, but its function relates to the pressure settings of LS1 and LS2. See Adjust.
Power Servo
Maximum supply flow of the pump is 420 liter (111 gal) per minute at 2350 rpm. This supply flow would overload the engine at higher pressures. When demanded oil flow and pressure represent a higher engine power than the available engine power, the power servo reduces supply flow by pressurizing the LS servo. See Figure 4.
LS Control Valve
The LS control valve controls pressure at the piston side of the LS servo by comparing pump pressure with load sense (LS) pressure. At higher pressure differences, when LS pressure is relatively low, pressure for the LS servo is drained to tank. The LS servo will move the swash plate toward maximum supply.
ADJUST
NOTE: Adjustments must be made with engine temperature 60 to 80 C (140 to 176 F) and with hydraulic oil temperature between 45 to 65 C (113 to 149 F). The engine must be running at full speed, spreader fitted, no load.
A. PRESSURE B. FLOW 1. MAIN RELIEF VALVE PRESSURE 2. POWER REGULATION 3. MAXIMUM SUPPLY Figure 4. Power Regulation The pressure at which the power servo starts pressurizing the LS servo depends on the absolute pump pressure and the momentary force of the power servo spring. The momentary force of the power servo spring depends on the position of the swash plate (equal to pump supply). The power servo spring is less compressed at maximum pump supply, allowing the power servo to be opened more easily. At decreasing oil supply, it takes a higher pump pressure until the power servo opens to pressurize the LS servo. When pump supply volume has decreased to a third of maximum supply, the power servo will no longer open. This is because the maximum system pressure has been reached, which is determined by the main relief valve. The power servos are adjusted regulators X1 and X2 for each of the pump sections. See Adjust. To cover for low power at idle engine speeds or just above, oil supply is reduced by the manipulator valve. See Manipulator Pressure Valve.
1. 2. 3. 4. 5. 6. 7. 8. 9.
X1 TEST PORT X1 POWER REGULATOR X2 POWER REGULATOR X2 TEST PORT LS2 REGULATOR LS1 REGULATOR DUMMY LS2 PORT PUMP CONTROLLER Figure 5. Pump Controller Adjustments
Standby Pressure
NOTE: To verify the minimum available pressure, measure the pump pressure at the main valve bank at port M. See Figure 7. 1. Run engine at idle with no functions operating. NOTE: Standby pressure must be 30 to 35 bar (435 to 508 psi). 2. Adjust LS1 and LS2 accordingly.
1. 2. 3. 4. 5. 6. 7.
MAIN SECTION SPREADER SECTION TELESCOPING SECTION DERRICKING SECTION STEERING PRIORITY VALVE SPREADER STANDBY RELIEF VALVE STEERING RELIEF VALVE, P2 Figure 7. Main Control Valve Ports
A PORT RELIEF VALVES A2 PORT A4 PORT B PORT RELIEF VALVES 1. 2. 3. 4. STEERING/MAIN VALVE SECTION SPREADER VALVE SECTION TELESCOPING VALVE SECTION DERRICKING VALVE SECTION
P1 PORT R2 PORT ZA PILOT PORTS ZB PILOT PORTS 5. DERRICKING VALVE SECTION 6. MAIN RELIEF VALVE SECTION 7. FLOW CONTROL VALVES
ADJUSTMENT
NOTE: Adjustments must be made with engine temperature 60 to 80 C (140 to 176 F) and with hydraulic oil temperature between 45 to 65 C (113 to 149 F). The engine must be running at full speed, spreader fitted, no load.
4. Adjust the two main relief valves to 420 bar (6092 psi) with the engine at full throttle. 5. With the boom still raised, reset the derricking up relief valves, B3 and B4, to 350 bar (5076 psi).
Derricking Up
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. 2. Fully raise the boom and keep the joystick in derricking position. 3. With the engine at full throttle, set the derricking up relief valves, B3 and B4, to 350 bar (5076 psi).
Relief Pressures
Main
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. See Figure 7. 2. Temporarily increase the pressure of the derricking up relief valves, B3 and B4, to over 420 bar (6092 psi). 3. Fully raise the boom and keep the joystick in derricking position.
Derricking Down
1. Attach a pressure gauge of 600 bar (8702 psi) at port M.
1900 SRM 1107 2. Fully lower the boom and keep the joystick in derricking down position. 3. With the engine at full throttle, set the derricking down relief valve A4 to 110 bar (1595 psi).
Steering Supply
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. 2. Operate the steering wheel at full stroke. 3. With the engine at full throttle, set steering supply relief valve P2 to 220 bar (3191 psi).
Telescoping Out
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. 2. Fully extend the boom and keep the joystick in the extending position. 3. With the engine at full throttle, set extension relief valve A2 to 350 bar (5076 psi).
Derricking Cylinder
Maximum occurring pressure at the derricking cylinder is set at the holding valve. See Boom 4500 SRM 787 for adjustment procedure. For adjustment of the spreader functions see Extendable Container Attachment, PPM 5000 SRM 1063 and for boom functions see Boom 4500 SRM 787.
Telescoping In
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. 2. Fully retract the boom and keep the joystick in retraction position. 3. With the engine at full throttle, set retraction relief valve B2 to 190 bar (2756 psi).
Spreader Supply
1. Attach a pressure gauge of 600 bar (8702 psi) at port M. 2. Disconnect solenoids E16 and E17 at the spreader control valve. 3. Operate and hold the sideshift lever. 4. With the engine at full throttle, set spreader supply relief valve B1 to 200 bar (2901 psi). 5. Reconnect solenoids E16 and E17.
Spreader Standby
1. Remove and plug the hose from port Z. 2. Attach a pressure gauge at port Z. 3. Remove the plug from the relief valve. 4. Run the engine at elevated idle and set the spreader standby relief valve to 25 bar (363 psi). 5. Replace the plug, remove the gauge, and reconnect the hose to port Z. 2. Adjust the holding valves as necessary. Boom 4500 SRM 787. See
3. Tighten the flow control valve at A4 until derricking down speed is reduced. 4. Release the socket head screw until flow restriction is again influenced by the holding valves.
Steering
1900 SRM 1107 affect derricking down speed as well. Time to derrick up completely at full throttle is 22 to 23 seconds.
Derricking Up Speed
NOTE: First adjust derricking down speed before adjusting derricking up speed. Derricking up speed is set by the flow control valves at A3 and A4. The total resulting flow of ports B3 and B4 determines the derricking up speed. Try to keep the setting of B3 and B4 at an equal value by keeping the socket head screws equally tightened. When derricking up speed has to be reduced, tighten flow control valve A3. Do not tighten A4, because this will
Telescoping Speeds
Both telescoping retraction and extension speeds are restricted by the flow control valve at A2. This implies that a compromise must be found between both speeds. The time required to fully extend the telescoping cylinder is 28 to 30 seconds. The time required to fully retract is 25 to 28 seconds.
Steering
HR45-25, HR45-27, HR45-31, AND HR40S Description
The supply oil to the steering control unit comes from port P2 in the main control valve. Pressure of port P2 is controlled by the steering relief valve, which is set at 220 bar (3191 psi). See Figure 7. The relief pressure of the steering control unit must be set a little higher to prevent an almost continuous flow over the relief. The 20 bar (290 psi) pressure difference is to absorb shocks caused by objects or bumps in the road. Depending on the rotation of the steering wheel, the steering control unit pressurizes and relieves oil at the desired side of the steering cylinder. Flow demand is monitored by the LS (Load Sense) line. When the steering wheel is turned, the increased flow demand will drop pressure in the LS line, which results into an increased supply by the main pump. A pressure drop in the LS line also actuates the steering priority valves 1 and 2 at either side of the main valve, blocking off oil flow to other functions. See Figure 9. When the engine is not running, a check valve in the line between P2 and the steering control unit closes and permits the steering control unit to operate as a hydraulic motor. The vehicle is difficult to steer without sufficient oil supply, but steering is possible.
Adjust
NOTE: Maximum supply pressure is set by the steering relief valve on the main control valve. 1. Install a pressure gauge of 600 bar (8702 psi) at main pressure port M on the main control valve. 2. With the engine at full throttle and the steering cylinder at full stroke, adjust the relief valve P2 to obtain 220 bar (3191 psi).
10
Pilot System pressure to enter the line of the steering control unit. The steering cylinder is now pressurized by oil from the main control valve until the amplifier valve is closed by oil pressure of the steering control unit. Flow demand is monitored by the LS (Load Sense) line. When the steering wheel is turned, the increased flow demand will drop pressure in the LS line, which results into increased supply by the main pump. A pressure drop in the LS line also actuates the steering priority valves 1 and 2 at either side of the main valve, blocking off oil flow to other functions. The cushion and suction valves reduce pressure peaks in the steering cylinder and avoid cavitation when there is force on the steering wheels. NOTE: Steering the lift truck manually can be difficult. When the engine is OFF, it is possible to steer the vehicle by rotating the steering wheel manually.
Pilot System
PILOT PUMP
The pilot pump is bolted on the service brake pump at the right rear side of the engine. The pilot pump provides oil pressure to the following systems: Telescoping retract valve Manipulator pressure valve Joystick Optional sliding cab system
11
Pilot System Reducing the joystick pressure results in the following: Preventing engine stalls at low speed and high system pressure. Smoothing operation of the joystick at high system pressure.
1900 SRM 1107 The manipulator valve reduces joystick pressure, depending on the pressure in the load sense line. Pressure in the LS line is measured by the 170 bar (2466 psi) and 210 bar (3046 psi) LS pressure switches. Depending on the pressures measured, solenoids E9, E10, and E11 of the manipulator valve are opened or closed. When E10 and E11 are energized, the related spools are opened. When E9 is energized, the related spool blocks oil flow. See Figure 10, Figure 11, and Table 2.
Operation
When ordering a replacement LS pressure switch, the switch-on setting has to be adjusted. The red setscrew at the top allows setting the switch-on pressure to the required 170 or 210 bar (2466 of 3046 psi). By turning the red setscrew clockwise, switching occurs at higher pressures. By turning counterclockwise, switching occurs at lower pressures. Determine switch-on setting by connecting a voltmeter on solenoid E9 for 170 bar (2466 psi) pressure, and on solenoid E11 for 210 bar (3046 psi) pressure. Maximum torque for the hydraulic connection fitting is 70 Nm (52 lbf ft).
1. FROM 8CC PILOT PUMP 2. TO JOYSTICK Figure 11. Manipulator Pressure Valve Schematic 1. PRESSURE SWITCH 170 bar (2466 psi) 2. LOAD SENSING PRESSURE SWITCH PLUG 3. PRESSURE SWITCH 210 bar (3046 psi) Figure 10. Load Sensing Pressure Switches
12
1900 SRM 1107 Table 2. Pressures in Relation to the Position of Solenoids and Spools Pressure at LS Line Below 170 bar (2466 psi) 170 to 210 bar (2466 to 3046 psi) Above 210 bar (3046 psi) E9 Solenoid Spool De-energized Open Energized Blocked Energized Blocked E10 Solenoid Spool De-energized Blocked Energized Open De-energized Blocked E11 Solenoid Spool De-energized Blocked De-energized Blocked Energized Open
Pilot System
Regulated Control Pressure 17 to 26 bar (247 to 377 psi) 15 to 26 bar (218 to 377 psi) 13 to 26 bar (189 to 377 psi)
Adjust
NOTE: On the hydraulic schematic, the pressure plug is connected with port U. 1. Attach a gauge of 60 bar (870 psi) at the pressure plug of the manipulator pressure valve. See Figure 12.
4. Adjust the 15 bar (218 psi) relief valve at E10 with the engine at idle, solenoids E9 and E10, and the joystick at full stroke in the derricking up position. 5. Adjust the 13 bar (189 psi) relief valve at E11 with the engine at idle, solenoids E9 and E11 activated, and the joystick at full stroke in the derricking up position.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
SOLENOID (E9) SOLENOID (E10) SOLENOID (E11) RELIEF VALVE 13 bar (189 psi) RELIEF VALVE 15 bar (218 psi) RELIEF VALVE 17 bar (247 psi) RELIEF VALVE 26 bar (377 psi) 3 mm (0.12 in.) RESTRICTION 0.85 mm (0.033 in.) RESTRICTION PRESSURE PLUG Figure 12. Manipulator Pressure Valve
2. Adjust the 26 bar (377 psi) relief valve with the engine at full throttle and without operating the joystick. 3. Adjust the 17 bar (247 psi) relief valve at E9 with the engine at idle and the joystick at full stroke in the derricking down position.
13
1. STANDBY PRESSURE ADJUSTMENT 2. MAXIMUM PUMP PRESSURE ADJUSTMENT 3. PRESSURE GAUGE FITTING Figure 13. Cooling Pump
14
1. 2. 3. 4. 5. 6. 7. 8.
COLD OIL BYPASS BRAKE OIL COOLER HYDRAULIC OIL COOLER COLD OIL BYPASS BRAKE COOLING SOLENOID HYDRAULIC SYSTEM COOLING PUMP BRAKE SYSTEM COOLING PUMP MAIN HYDRAULIC TANK
BREATHER BRAKE COOLING OIL TANK HYDRAULIC SYSTEM FILTER SERVICE BRAKE BRAKE SYSTEM OIL FILTER FAN MOTOR TEMPERATURE SENSOR
15
16
Service Brakes Legend for Figure 16 1. PRESSURE PLUG 2. BRAKE COOLING PUMP 3. HYDRAULIC SYSTEM COOLING PUMP
Service Brakes
DESCRIPTION
NOTE: For further information, see Service Brake 1800 SRM 1038. The brake oil pump is fitted at the RH side of the engine and provides oil pressure to the brake control valve. When the brake pedal is applied, the brake pistons in the drive axle push against the friction discs for braking action. Releasing the pedal relieves pressure from the brake pistons. See Figure 17. The pressure regulator maintains pressure at 160 bar (2321 psi) for the brake pedal valve, park brake cylinder, and accumulator. Excess oil is returned to the tank. The brake control valve has two pressure switches. The 105 bar (1523 psi) switch activates the brake warning light, when regulated brake pressure is below 105 bar (1523 psi). The 5 bar (73 psi) switch activates the brake lights, when the brakes are applied. The accumulator has the capability to provide a limited supply of oil when the brake pump has stopped. As oil pressure is being used up, the lights for park brake and low brake pressure will go ON, the APC 100 will switch the transmission into neutral, and the springs in the park brake caliper will overcome residual pressure and gradually apply the park brake.
17
Service Brakes
18
1900 SRM 1107 Legend for Figure 17 1. 2. 3. 4. 5. 6. BRAKE PEDAL ACCUMULATOR BRAKE CONTROL VALVE LOW BRAKE PRESSURE SWITCH PRESSURE REGULATOR FROM SERVICE BRAKE PUMP 7. 8. 9. 10. 11.
Parking Brake
PARKING BRAKE SWITCH BRAKE COOLING LINE SERVICE BRAKE BRAKE LIGHT PRESSURE SWITCH PARKING BRAKE SOLENOID
Parking Brake
DESCRIPTION
The parking brake system uses a disc brake that is installed at the rear of the differential. Spring force applies the disc brake. When applying oil pressure to the piston, spring pressure is overcome, which releases the parking brake. Oil pressure from the brake control valve is admitted to the disc brake by energizing parking brake solenoid E227. When pressure has reached 105 bar (1523 psi), the two pressure switches will open. One is for the Park Brake Warning Light to go OFF and the second switch is for the APC 100 system to allow a gear to be selected. See Figure 18.
1. 2. 3. 4. 5.
SOLENOID VALVE MANIFOLD PRESSURE SWITCH PARKING BRAKE SWITCH PLUG Figure 18. Parking Brake Solenoid Valve
19
NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________
20
TECHNICAL PUBLICATIONS
1900 SRM 1107 1/04 Printed in United Kingdom