Service Training
Basiswissen / Fundamentals
Release 2011-10-07
HAMM COMPACTORS
Fundamentals HAMM COMPACTORS
EN EN
2150228 2150228 2150228
Fundamentals
Fundamentals
HAMM COMPACTORS
EN
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Introduction - 01
01 - Introduction
Basic training
1
Introduction
HAMM – Rollers for soil and asphalt compaction
Basic training
2
Introduction
Products
Basic training
3
Introduction
Series
HD CompactLine
3000 Series Basic training
HD Series
HD+ Series
DV Series 4
GRW, Static rollers Introduction
Series 3000
Soil compaction
Visibility 3-point articulated joint Climbing ability Hammtronic VIO-drum Basic training
5
Introduction
Series HD CompactLine
Soil & Asphalt compaction
3-point articulated joint Visibility Clear side - offset Climbing ability Transportation Basic training
6
Introduction
Series HD
Soil & Asphalt compaction
Crab steering Visibility Climbing ability Articulated joint Water sprinkling system
Basic training
7
Introduction
Series HD+
Soil & Asphalt compaction
Visibility Operator´s platform 3-point articulated joint Crab steering Engine management
Basic training
8
Introduction
Series DV
Asphalt compaction
Think Forward Visibility Hammtronic Steering HI-Drive
Basic training
9
Introduction
Rubber tire rollers and static compactors
Soil & Asphalt compaction
Ballast variations Overlap of the wheels 1:1 pressure distribution Water sprinkling system
Basic training
10
Introduction
Basic training
11
Introduction
Hamm Intelligent Technology
Oszillation
Basic training
12
Introduction
Hammtronic
Diesel management Diesel management
Drive control Anti slip control
Anti slip control
DV Series
Series 3000
Drive control
Vibration control
Steering Vibration control
Additional functions
Basic training
13
Introduction
Hammtronic Advantages Diesel management Diesel management Drive control
Drive control Anti slip control
Lower fuel consumption
Anti slip control
Vibration control
Ease for the driver Steering
Less operating mistakes
Vibration control
Better compaction quality Additional functions
fuel saving profitability
fuel saving
fuel saving
ety
ty
Basic training
safety
safety
profitability
fuel saving
fuel saving
safety
safety
safety profitability 14
safety
profitability
safety
profitabil Introduction
Oscillation Vibration
Oscillation
Faster compaction – no grain crushing No destructive shock waves Longer life-time and reduced noise level Basic training
15
Introduction
Oscillation
Vibration
Oscillation
Basic training
16
Introduction
Oscillation
Application of compaction systems in various temperature ranges
Basic training
17
Introduction
HCQ-Indicator
HCQ-Indicator
HCQ-Printer HCQ-AsphaltNavigator
HCQ-GPS-Navigator
Basic training
18
Asphalt compaction
Soil compaction
Hamm Compaction Quality
Introduction
Hamm Compaction Quality
HCQ Indicator
HCQ-GPSNavigator
HCQ Printer
Basic training
19
Introduction
HCQ-GPS-Navigator HMV (rigidity) Number of passes Calibration of HMV-Values
Quality of compaction
Data analysis
Basic training
20
Introduction
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
General - 02
01 - Introduction
Necessary machine information in case of repair • Maschine type (e.g. HD O90V, DV 70 VO, 3414 HT VIO, etc...)
• 8-digit serial number • • • •
always stamped into the right side of the machine frame additional name plate (inside cabin, engine compartment or right side of the frame) the first 4 digits show the machine series the second 4 digits show the serial number for each series
H1800566 machine series Basic training
serial number 1
General
Serie 3000
Walzenzüge
Statische Walzen
Tandemwalzen knickgelenkt
Tandemwalzen schemelgelenkt
Soil compactors
Static rollers
Articulated tandem rollers
Pivot steered tandem rollers
3011/3012 4011/4012 5011 2210 2220 2315 2320 2420 2520 2620 2720 3205 3307 3410-11 3410-11 3410-11 3412-14 3516-20 3625
Basic training
H133 H134 H135 H127 H132 H124 H155 H141 H142 H144 H154 H158 H188 H159 H189 H169 H179 H269 H206 H160 H180 H161 H176 H162 H177
HW 90 HD 14 TT HD150 TT GRW 10-24
H123 H196 H168 H183 H193 H114 H178 H190
HD10-13 HD8-10C HD10-12 HD13-14 HD85-100 HD70-75 HD90-110 HD120-130 HD+90-110 HD+120-140
2
H139 H170 H199 H171 H200 H172 H201 H122 H152 H173 H187 H153 H174 H181 H163 H175 H182 H185 H184
DV 40-90
Serie 2000
EURO
Machine series - overview
DV 10 DV 2 DV 3 DV 6.4 DV 8.4 DV 6.4 PVC DV 8.4 PVC DV 6 Super DV 8 Super DV 40 DV 70 DV 90 DV 65 DV 85
H107 H125 H120 H143 H138 H150 H151 H156 H157 H164 H165 H191 H166 H192 H197 H198
General
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Information systems - 03
01 - Introduction
Wirtgen Group Information Systems
Wirtgen Group Network (www.hammag.net) Parts & More WIDOS
Basic training
1
Information systems
Wirtgen Group Information Systems
www.hammag.net Brochures Internal Reports Job Reports Ordering of information material Sales Training Training dates Technik-Infos Downloads Media database
Basic training
2
Information systems
Wirtgen Group Information Systems
Parts & More Most important wear and tear parts Service Kits Emergency Kits Lubricants
Basic training
3
Information systems
Wirtgen Group Information Systems
WIDOS Spare parts documentation Operating and maintenance manuals Hydraulic circuit diagrams Electric circuit diagrams Machine data Safety instructions Technik-Infos Parts information Service Forms
Basic training
4
Information systems
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Mechanics - 04
01 - Introduction
Dynamic compaction systems
Basic training
1
Mechanics
Working principles
Vibration
Basic training
Oscillation
2
Directed vibration
Mechanics
Vibration
Basic training
3
Mechanics
Circular vibrator with oil dampened change-over unbalances low frequency big amplitude
high frequency small amplitude
Direction of rotation Fixed unbalance Moving unbalance Amplitude
Basic training
4
Mechanics
Direction of rotation - vibrator Important! Big amplitude vibrator turns clockwise! Otherwise danger of bearing damages!
Left side view
Series HD / DV
Vibration • Big amplitude • Small amplitude
Direction of rotation
Series 3000
clockwise
Basic training
5
Mechanics
Vibration drum HD70
Basic training
6
Mechanics
Vibration drum HD130
Basic training
7
Mechanics
Vibration drum HD75.4 – split drum
Basic training
8
Mechanics
Oscillation
Basic training
9
Mechanics
Advantages of oscillation
• No shock waves • Greater temperature range • Better compaction results • Instant adjustment • Automatic system • No grain crushing • Good initial grip • Faster and better compaction Basic training
10
Mechanics
Drum design - Oscillation
Basic training
11
Mechanics
Drum design - Oscillation
Basic training
12
Mechanics
Drum design - HD120 Oscillation
Basic training
13
Mechanics
Basic training
14
Mechanics
VIO
Basic training
15
Mechanics
Drum design 3412-3414 VIO
Basic training
16
Mechanics
VIO Unbalance
Unbalance mass
Unbalance shaft
Basic training
17
Mechanics
Basic training
18
Mechanics
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Basics hydraulics - 05
01 - Introduction
Overview hydraulic symbols according to DIN ISO 1219-1
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Contents
CONTENTS: 1. Basic elements ............................................................................ 3 2. Reservoirs .................................................................................... 4 3. Service devices / service units .................................................. 5 4. Pumps and motors ...................................................................... 5 4.1 Pumps ...................................................................................................................... 5 4.2 Motors ...................................................................................................................... 5
5. Valves (actuators) ....................................................................... 6 5.1 Control valves .......................................................................................................... 6 5.2 Examples .................................................................................................................. 7 5.3 Check valves ............................................................................................................ 8 5.4 Pressure valves ....................................................................................................... 8 5.5 Flow-control valves ................................................................................................. 9 5.6 Types of activation (valves) .................................................................................. 10
6. Cylinders .................................................................................... 11 7. Measuring and indicating devices ........................................... 11 8. Top 10 hydraulic symbols ........................................................ 12 Notes.............................................................................................. 14
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Basic elements
1. Basic elements Working line; electr. wire
Control line; Leakage oil line
Component
Mechanic connection (drive shaft, lever, piston rod)
Flexible line (hose)
Crossing with / without connection
Closed pressure port
spring
choke
pneumatic/hydraulic
Basic symbol for pumps and motors
Adjustability in general
Basic symbol for a three-position valve HAMM AG 13/10/2009
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TReservoirs
Way and direction of a volume flow (inside a valve)
Rotary movement with rotation direction
Elektric motor
Non-electric drive unit
2. Reservoirs Pressure reservoir without/with gas-tensioning device
(Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level
3.
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T Service devices / service units
Service devices / service units Filter without with pollution indicator
Manually operated (water) separator
Cooler
Silencer
4. Pumps and motors 4.1 Pumps Hydraulic pump (fixed displacement) with one/two flow directions
Hydraulic pump (variable displacement) with one/two flow directions
4.2 Motors Hydraulic motor (fixed displacement) with one/two flow directions
Hydraulic motor (variable displacement) with one/two flow directions
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TValves (HTactuatorsTTTH)
5. Valves (actuators) 5.1 Control valves Control valve with three positions and four connections general symbol
Control valve with interim positions and two endpositions, also called proportional valve general symbol
One flow path
Two closed connections
Two flow paths
Two flow paths and one closed connection
Two flow paths connected to each other
One flow path in shunt connection
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TValves (HTactuatorsTTTH) 5.2 Examples
2-port/2-way valve
3-port/2-way valve
4-port/3-way valve directional blocked center valve
4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank
4-port/3-way valve with floating position
5.3
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TValves (HTactuatorsTTTH) Check valves Check valve simple/spring loaded
Controlled check valve closing/opening avoided by activation
Shuttle valve
Zweidruckventil (UND-Ventil)
Shut-off valve
5.4 Pressure valves
Pressure limit valve adjustable
Pressure control valve adjustable
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TValves (HTactuatorsTTTH) 5.5 Flow-control valves Choke valve Cross sectional area fixed/adjustable
Throttle-check valve
Orifice fixed cross-section
Flow-control valve
5.6
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TValves (HTactuatorsTTTH) Types of activation (valves) Activation by muscular strength
Activation by muscular strength pushbutton / pullbutton
Lever
Pedal with one/two directions
Electric activation with magnetic coil
Activation by fluid pressure directly operated; general symbol
Roller tappet
Spring
Activation by fluid pressure indirectly operated by a pneumatic pre-stage
In series activation e.g. solenoid operates a pneumatic valve which operates the main valve
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TCylinders
6. Cylinders Cylinder single-acting with return spring
Cylinder double-acting
Cylinder with (adjustable) damping at the bottom-side
7. Measuring and indicating devices Manometer
Thermometer
Volumetric flow meter / indicator
Pressure sensor
Pressure switch
Temperature sensor
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Top 10 hydraulic symbols
8. Top 10 hydraulic symbols (Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level
Filter without with pollution indicator
Cooler
Hydraulic pump (fixed displacement) with one/two flow directions
Hydraulic pump (variable displacement) with one/two flow directions
Hydraulic motor (fixed displacement) with one/two flow directions
Hydraulic motor (variable displacement) with one/two flow directions
4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank
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Top 10 hydraulic symbols
Pressure limit valve adjustable
Cylinder double-acting
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Notes
Notes
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02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Hydraulics - closed circuits - 06
01 - Introduction
Principle of closed hydraulic circuits
Basic training
1
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
2
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
3
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
4
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
5
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
6
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
7
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
Principle of closed hydraulic circuits
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
8
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Principle of closed hydraulic circuits
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Hydraulics - axial piston pumps - 07
01 - Introduction
Variable displacement pump with mechanic control unit
Basic training
1
Hydraulics – Variable displacement pumps
Basic training
2
Hydraulics – Variable displacement pumps
Variable displacement pump with mechanic control unit External charge pressure supply
Scheme
Orifices drive control pressure
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
3
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with mechanic control unit Design
Caution ! No charge pump installed! Charge pressure supply via steering pump!
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
4
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with mechanic control unit Mechanic control unit
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
5
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Basic training
6
Hydraulics – Variable displacement pumps
Variable displacement pump with mechanic control unit Charge pressure supply from steering return line via hydraulic oil filter
Centring hydr. neutral position
M 18x1,5
Centring mech. neutral position
Port PS oil supply to the brake release valve M 14x1,5
Charge and high pressure valve
Case drain port T2 from the brake release valve
(with bypass for towing) reverse forward max. 350bar
M 22x1,5
Charge pressure valve max. 22 bar
Basic training
7
Hydraulics – Variable displacement pumps
Variable displacement pump with mechanic control unit Emergency stop ports X3 ,X4
Connection drill
Test ports X1 ,X2
Bowden cable
5 - 22 bar (in front of orifice) M 12x1,5
Test port Fe = charge pressure max. 22 bar M 18x1,5
Air bleed R M 12x1,5
distributor block with scavenge system
Basic training
Port T1 to the cooler M 22x1,5
8
Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit
Basic training
9
Hydraulics – Variable displacement pumps
Basic training
10
Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit External charge pressure supply
Scheme
Orifices drive control pressure
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
11
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit Design
Caution ! No charge pump installed! Charge pressure supply via steering pump!
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
12
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit Hydraulic control unit
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
13
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Basic training
14
Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit Speisedruckversorgung FS Supply Valve Fa1 M 18x1,5
(von Filter) M 18x1,5
Variable displacement pump - vibration
Supply brake release valve Fa M 18x1,5
Case drain port T1 (vibration pump) M 22x1,5
High pressure cut-off max. 450 bar
Air bleed R M 12x1,5
High pressure port B = forward
Test ports control pressures X1 = forward X2 = reverse 5 - 22 bar M 12x1,5 (in front of orifice) Basic training
SAE ¾“
Remote control port Y2 = reverse
Centring hydr. neutral position 15
6 – 18 bar M 14x1,5 Hydraulics – Variable displacement pumps
Variable displacement pump with hydraulic control unit High pressure port Variable displacement A = reverse SAE ¾“ pump – vibration
Charge pressure valve
Case drain port T2
max. 22 bar
M 22x1,5
Test ports MA = reverse MB = forward max. 480 bar High pressure cut-off max. 450 bar M 12x1,5
Centring mech. neutral position
Test port PS = control pressure 22 bar (after orifice) M 14x1,5
Einspeise - u. HD.ventile (mit Bypass zum Abschleppen) Rückwärts Vorwärts max. 500 bar Basic training
16
Remote control port Y1 = forward 6 – 18 bar M 14x1,5
Test port G =charge pressure max. 22 bar M 12x1,5 Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit
Basic training
17
Hydraulics – Variable displacement pumps
Basic training
18
Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit Scheme
External charge pressure supply
Orifices drive control pressure
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
19
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit Design
Caution ! No charge pump installed! Charge pressure supply via steering pump!
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Lecköldruck Case drain pressure
20
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit Electric control unit with proportional solenoids
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
21
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Basic training
22
Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit Test ports Variable displacement pump drive
Control pressure X1 = small amplitude X2 = big amplitude 5-22 bar M12x1,5 (in front of orifice)
Air bleed R M12x1,5
Test port Ps = control pressure 22 bar (after orifice) M14x1,5
Test port G = Charge pressure max. 22 bar M12x1,5
Charge pressure valve not installed !!! Charge pressure controlled by drive pump
Centring
Frequency adjustment
mech.neutral position high frequency small amplitude
Basic training
Case drain port T2 (from drive pump) M 22x1,5
23
Test ports MB = small amplitude MA = big Amplitude max. 423 bar high pressure cut-off 420 bar M12x1,5
Hydraulics – Variable displacement pumps
Variable displacement pump with electric control unit Variable displacement pump - drive
Centring
Proportional solenoid b = big Amplitude a = small Amplitude
hydr. neutral position
High pressure cut-off max. 420 bar
High pressure port B = small Amplitude SAE ¾“
Charge and high pressure valves small amplitude big amplitude max. 420 bar
Frequency adjustment low frequency big amplitude
Test ports charge pressure M18x1,5
High pressure port A = big mplitude SAE ¾“
Basic training
Charge pressure supply Fa
Case drain port T1
(from drive pump port Fa1) M 18x1,5
M 22x1,5
24
Hydraulics – Variable displacement pumps
Different valve plate designs
Basic training
25
Hydraulics – Variable displacement pumps
Basic training
26
Hydraulics – Variable displacement pumps
Valve plate without high pressure cut off Charge and high pressure valves with bypass bypass for towing
valve movement – charging
valve movement – high pressure
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
27
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Valve plate with high pressure cut off Charge and high pressure valves with bypass bypass for towing
valve movement – charging
valve movement – high pressure
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
28
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Valve plate with high pressure cut off Charge and high pressure valves with bypass
bypass for towing
valve movement – high pressure
valve movement – charging
Hochdruck High pressure
Basic training
Niederdruck Return line pressure
Saugdruck Suction pressure
Lecköldruck Case drain pressure
29
Steuerdruck Pilot pressure
Stelldruck Control pressure
Hydraulics – Variable displacement pumps
Basic training
30
Hydraulics – Variable displacement pumps
Separating the hydrostatic drive power train (e.g. towing)
Basic training
31
Hydraulics – Variable displacement pumps
Basic training
32
Hydraulics – Variable displacement pumps
Separating the hydrostatic drive power train (e.g. towing) high pressure valves with bypass
A
B
Disengaging closed hydraulic circuits: Unscrew the nut (B) by two turns. Then screw in the hexagon socket bolt (A) on the high pressure valves until it is flush with the nut (Pos. 2). Re-engaging closed hydraulic circuits: Unscrew the hexagon socket bolt (A) up to the stop. Then tighten up the nut (B) Basic training
33
Hydraulics – Variable displacement pumps
Basic training
34
Hydraulics – Variable displacement pumps
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Hydraulics - axial piston motors - 08
01 - Introduction
Fixed displacement axial piston motors
Grundlagenschulung
1
Hydraulik - Axialkolbenmotoren
Grundlagenschulung
2
Hydraulik - Axialkolbenmotoren
Fixed displacement axial piston motors without scavenge valve Scheme
Hochdruck High pressure
Grundlagenschulung
Niederdruck Return line pressure
3
Lecköldruck Case drain pressure
Hydraulik - Axialkolbenmotoren
Fixed displacement axial piston motors with scavenge valve Scheme
B
B B
A
T A A
Hochdruck High pressure
Grundlagenschulung
Niederdruck Return line pressure
4
Lecköldruck Case drain pressure
Hydraulik - Axialkolbenmotoren
Fixed displacement axial piston motors with scavenge valve Scheme
T
(T)
Hochdruck High pressure
Grundlagenschulung
Niederdruck Return line pressure
5
Lecköldruck Case drain pressure
Hydraulik - Axialkolbenmotoren
Fixed displacement axial piston motors with scavenge valve High pressure port A
Important !
big amplitude M 27x2
Check direction of rotation after repair!
High pressure port B small amplitude M 27x2
Integrated scavenge system (controlled by orifice)
Scavenge valve
Connection T1
Case drain port T2
M 16x1,5 (closed)
M 16x1,5
Grundlagenschulung
6
Hydraulik - Axialkolbenmotoren
Axial piston motor with variable displacement – electrically controlled
Grundlagenschulung
7
Hydraulik - Axialkolbenmotoren
Grundlagenschulung
8
Hydraulik - Axialkolbenmotoren
Axial piston motor – variable displacement Scheme
Hochdruck High pressure
Grundlagenschulung
Niederdruck Return line pressure
9
Lecköldruck Case drain pressure
Stelldruck Control pressure
Hydraulik - Axialkolbenmotoren
Axial piston motor – variable displacement Design
Hochdruck High pressure
Grundlagenschulung
Niederdruck Return line pressure
10
Lecköldruck Case drain pressure
Stelldruck Control pressure
Hydraulik - Axialkolbenmotoren
Axial piston motor – variable displacement Adjusting screw displacement V min.
Proportional solenoid Verstellung
Case drain port T M 18x1,5
Test port G 80 - 400 bar M 14x1,5
Connection rpm sensor High pressure port A SAE ¾“
High pressure port B SAE ¾“
Test port M1
Grundlagenschulung
Adjusting screw
M 14x1,5
displacement V max.
Shuttle
Scavenge valve 11
Scavenge block Hydraulik - Axialkolbenmotoren
Grundlagenschulung
12
Hydraulik - Axialkolbenmotoren
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Hydraulics - radial piston motors - 09
01 - Introduction
Radial piston motors
Basic training
1
Hydraulic – Radial piston motors
Design
Basic training
2
Hydraulic – Radial piston motors
MS Motor – View and connectors
Case drain port - 1 High pressure - L
Gear shifting - Y Parking brake High pressure - R
Basic training
3
Hydraulic – Radial piston motors
MS Motor – Sectional view
Basic training
4
Hydraulic – Radial piston motors
MS Motor – Exploded view
Basic training
5
Hydraulic – Radial piston motors
MS Motor - Assembly
Bearing support
Basic training
Hydrobase
6
Parking brake
Hydraulic – Radial piston motors
Functioning
Basic training
7
Hydraulic – Radial piston motors
MS Motor - Functioning 1-Gear
Basic training
2-Gear
8
Hydraulic – Radial piston motors
Assembly: Hydrobase
Basic training
9
Hydraulic – Radial piston motors
MS Motor - Hydrobase MS MOTOR
Hydrobase
Bearing support
Parking brake
Drive unit Piston Cam ring Cylinder block Valving
Bearing support
Basic training
10
Hydrobase
Parking brake
Hydraulic – Radial piston motors
MS Motor – Cylinder block
Mono-block
block
Bi-block
Basic training
11
Hydraulic – Radial piston motors
MS Motor - Piston Roller Piston Bushing
block + piston without lunambule lateral skidding
Clip
block + piston + lunambule without clips rotation
Piston ring Lunambule
block + piston + Lunambule + Clips
Basic training
12
Hydraulic – Radial piston motors
MS Motor - Valving
2-C valving
1-C valving
Basic training
13
Hydraulic – Radial piston motors
MS Motor - Valving
Machined valving
Basic training
Molded valving
14
Hydraulic – Radial piston motors
MS Motor - Valving
nb of holes = 2x nb of cams Basic training
nb of pistons= nb of holes 15
Hydraulic – Radial piston motors
MS Motor - Valving
2 indexes
Mind mounting orientation!!! Basic training
16
Hydraulic – Radial piston motors
MS Motor – Valving sealings Static sealing
O-Ring Back-up ring
Spool / cover Basic training
17
Hydraulic – Radial piston motors
MS Motor - Bearing support MS MOTOR
Hydrobase
Bearing support
Parking brake
Roller Bearing Sealing
Bearing support
Basic training
Hydrobase
Parking brake
18
Hydraulic – Radial piston motors
MS Motor - Bearing support Bearing grease case / external ambiance sealing Tapered roller bearings – “O-Mounting” Front tapered roller bearing Snap ring
Valving tapered roller bearing
Shims
Housing / bearing grease case sealing Basic training
19
Hydraulic – Radial piston motors
Basic training
20
Hydraulic – Radial piston motors
Assembly: Parking brake
Basic training
21
Hydraulic – Radial piston motors
MS Motor - Parking brake MS MOTOR
Hydrobase
Bearing support
Parking brake
Discs Other parts
Bearing support
Basic training
Hydrobase
Parking brake
22
Hydraulic – Radial piston motors
MS Motor - Parking brake
Inner disc Outer disc
Basic training
23
Hydraulic – Radial piston motors
MS Motor - Parking brake
Static sealing
Dynamic sealing Basic training
24
Hydraulic – Radial piston motors
MS Motor - Parking brake
Gehäuse Valving Sealing Bearing
Brake piston
Belleville washer
Moving O-Ring
Brake shaft Basic training
25
Hydraulic – Radial piston motors
MS Motor - Parking brake
Release of parking brake without hydraulic pressure
Basic training
26
Hydraulic – Radial piston motors
MK 04
Basic training
27
Hydraulic – Radial piston motors
MK 04 Claw brake
SAE Flange Basic training
28
Hydraulic – Radial piston motors
MK 05 - radial
Basic training
29
Hydraulic – Radial piston motors
Basic training
30
Hydraulic – Radial piston motors
02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics
Basics electrics - 10
01 - Introduction
Electric symbols
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Contents
CONTENTS: CONTENTS:..................................................................................... 2 1. Earth, ground, equipotential ...................................................... 3 2. Fuses ............................................................................................ 3 3. Connectors .................................................................................. 3 4. Switches ....................................................................................... 4 4.1 Contacts in general ................................................................................................. 4 4.2 Delayed contacts ..................................................................................................... 4 4.3 Additional symbols ................................................................................................. 5 4.4 Schalter mit mehreren Schaltstellungen ............................................................... 6
5. Electromechanic drives .............................................................. 6 6. Accumulators und fuel cells ...................................................... 7 7. Electronic devices ....................................................................... 7 7.1 Resistors .................................................................................................................. 7 7.2 Capacitors ................................................................................................................ 7 7.3 Light sources ........................................................................................................... 8 7.4 Inductance ............................................................................................................... 8
8. Electronic devices ....................................................................... 8 8.1 Diodes ...................................................................................................................... 8 8.2 Transistors ............................................................................................................... 9
9. Monitoring and reproducing devices ........................................ 9 10. Antennas and radio .................................................................. 9 11. Measuring, control and feedback control systems............. 10 11.1
Displaying measuring devices ......................................................................... 10
11.2
Electrical clocks ................................................................................................ 10
11.3
Remote monitoring devices ............................................................................. 10
11.4
Indicator lamps, signaling devices .................................................................. 10
12. Top 10 Electric symbols ........................................................ 12 Notes.............................................................................................. 13
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Earth, ground, equipotential
1. Earth, ground, equipotential ground (general symbol)
function ground
2. Fuses fuse (general, lead fuse)
fuse with alarm contact
fuse switch
fuse disconnector
fuse load disconnector
3. Connectors female connector
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Switches
4. Switches 4.1 Contacts in general Normally open contact; switch in general three alternative display formats
break contact
4.2 Delayed contacts
normally open contact activation delayed
normally open contact activation delayed
break contact fall-back delayed
break contact fall-back delayed
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Switches 4.3 Additional symbols
power switch
disconnector
normally open contact with automatic fall-back
break contact with automatic fall-back
limit switch normally open contact
limit switch break contact
two-way switch with automatic fall-back from left position (filled triangle) and non-automatic fall-back from right position (open circle)
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Electromechanic drives 4.4 Schalter mit mehreren Schaltstellungen
multi-position switch with four positions
multi-position switch with position chart activation direction and field are shown by arrows positions are labeled by numbers
multi-position switch in any position three successive contacts are bridged
5. Electromechanic drives electromechanic drive with one coil
thermo relay e.g. with a bi-metal
electromechanic drive with a response delay
electromechanic drive with a fall-back delay
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Accumulators und fuel cells
6. Accumulators und fuel cells fuel cell, accumulator
7. Electronic devices 7.1 Resistors resistor
variable resistor
resistor with a sliding contact (potentiometer)
resistor with a sliding contact and „off“-position
varistor (resistor depending from voltage)
7.2 Capacitors capacitor
polarized capacitor; electrolytic capacitor
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Electronic devices 7.3 Light sources light bulb
light-emitting diode
7.4 Inductance
Inductance
*)
According to DIN EN 60617-4 only the version with the 4 arcs is valid. The version with the rectangle filled black is no longer valid.
8. Electronic devices 8.1 Diodes diode
photodiode
light-emitting diode
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Monitoring and reproducing devices
8.2 Transistors NPN-transistor with housing
PNP-transistor with housing
9. Monitoring and reproducing devices
speakers (SP)
microphone
10. Antennas and radio
antenna
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Measuring, control and feedback control systems
11. Measuring, control and feedback control systems 11.1 Displaying measuring devices voltmeter
amperemeter
11.2 Electrical clocks clock general symbol
clock with switch
11.3 Remote monitoring devices
telemetry transmitter
telemetry receiver
11.4 Indicator lamps, signaling devices indicator lamp lamp, general symbol
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Measuring, control and feedback control systems
indicator lamp flashing
visual alarm electromechanic, indicator, falling disk
position indicator idle position and two working positions
acknowledge indicator
horn
buzzer
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Top 10 Electric symbols
12. Top 10 Electric symbols ground (general symbol)
fuse (general, lead fuse)
normally open contact
electromechanic drive with one coil
fuel cell, accumulator
resistor
capacitor
inductance
diode (general symbol)
light bulb
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Notes
Notes
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Notes
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Terminal designations agreeable to DIN 72552
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CONTENTS:
CONTENTS: CONTENTS:..................................................................................... 2 1. Ignition system ............................................................................ 3 2. Preheating system ...................................................................... 3 3. Battery .......................................................................................... 3 4. Electric motors ............................................................................ 3 5. Direction indicators .................................................................... 4 6. Alternating current generator .................................................... 4 7. Alternator ..................................................................................... 4 8. Lighting system ........................................................................... 5 9. Washer system ............................................................................ 5 10. Akustische Warnanlage........ Fehler! Textmarke nicht definiert. 11. Switches .................................................................................... 6 12. Relays ........................................................................................ 6 13. Contacts .................................................................................... 7 14. Additional terminal designations............................................ 7 Notes................................................................................................ 8
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Ignition system
1. Ignition system Terminal
Meaning
1
ignition coil, ignition distributor, low voltage
1a, 1b
ignition distributor with 2 separate circuits
2
Kurzschließklemme, magneto
4
ignition coil, ignition distributor, high voltage
4a, 4b
ignition distributor with 2 separate circuits, high voltage
7
Terminal of base resistors, to / from ignition distributor
15
switched plus after battery
15a
output of series resistor to ignition coil and starter
2. Preheating system Terminal
Meaning
15
input ignition switch
17
start
19
preheat
50
starter control
3. Battery Terminal
Meaning
15
battery plus via switch
30
direct input from battery plus
30a
input 2nd battery and change-over relay 12/24V
31
return wire battery minus or ground
31a
return wire to 2nd battery minus, change-over relay 12/24V
31b
return wire to battery minus or ground via switch
31c
return wire to 1st battery minus, change-over relay 12/24V
4. Electric motors Terminal
Meaning
32
return wire
33
main connector (interchanging 32 und 33 possible)
33a
limit stop
33b
shunt field
33f
2nd lower speed step
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Direction indicators 33g
3rd lower speed step
33h
4th lower speed step
33L
rotation direction left
33R
rotation direction right
86
input terminal of contactor
5. Direction indicators Terminal
Meaning
49
input flasher unit
49a
output flasher unit, input direction indicator switch
49b
output 2nd direction indicator circuit
49c
output 3rd direction indicator circuit
C
1st direction indicator control lamp
C2
2nd direction indicator control lamp
C3
3rd direction indicator control lamp
L
direction indicators left
R
direction indicators right
L54
output for combined direction indicator and brake lights on tractors and trailers (left)
R54
output for combined direction indicator and brake lights on tractors and trailers (right)
6. Alternating current generator Terminal
Meaning
51
direct-current voltage at rectifier
51e
like 51, with additional choke coil for day operation
59
output alternating voltage, input rectifier, switch
59a
output charge armature
59b
output rear light armature
59c
output brake light armature
63
controller terminal to change voltage
63a
controller terminal to change current
64
generator control wire
7. Alternator Terminal 61 HAMM AG 18/08/2009
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Lighting system B+
battery plus
B-
battery minus
D+
generator plus
D-
generator minus
DF
dynamo field
DF1
dynamo field 1
DF2
dynamo field 2
U, V, W
three-phase current terminals
8. Lighting system Terminal
Meaning
54
brake light in case of combined lights and on trailer outlet
55
fog lights
56
high beam
56a
high beam and control lamp
56b
low beam
56d
headlight flasher
57
parking light motorcycle
57a
parking light
57L
left parking light
57R
right parking light
58
side-marker lamps, licence plate illumination, instument lighting, tail light
58L
light switch terminal for left side-marker lamps and tail light (if switchable separately)
58R
light switch terminal for right side-marker lamps and tail light (if switchable separately)
58b
Tail light changeover for two-wheel tractors
58c
Trailer plug, single-wired taillight fused in trailer
58d
adjustable instrument lighting
9. Washer system Terminal
Meaning
53
input wiper motor plus
53a
limit stop plus
53b
shunt coil
53c
window washer pump
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Acoustic warning system 53e
brake coil
53i
wiper motor with permanent magnet, third brush for higher speed
10. Acoustic warning system Terminal
Meaning
71
input tone sequence control unit
71a
output to horn 1 and 2 low
71b
output to horn 1 and 2 high
72
alarm switch - rotating flashing beacon
85c
alarm switch – sound on
11. Switches Terminal
Meaning
81
input for break contact, change-over contact
81a
1st output
81b
2nd output
82
input for normally open contact
82a
1st output
82b
2nd output
82z
1st input
82y
2nd input
83
input multi-position switch
83a
output 1
83b
output 2
12. Relays Terminal
Meaning
84
input actuator and relay contact (start of coil)
84a
output actuator (end of coil)
84b
output relay contact
85
output actuator (end of coil, minus)
86
input actuator (start of coil)
86a
input 1st coil
86b
input 2nd coil
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Contacts
13. Contacts Terminal 87 87z, y, x 87a 87b, c, d 88
Meaning input break contact and changeover contact input break contact and changeover contact (several inputs) output break contact and changeover contact output break contact and changeover contact (several outputs) input normally open contact
88z, y, x
input normally open contact (several inputs)
88a (87)
output normally open contact and changeover contact
88b, c, d
output normally open contact and changeover contact (several outputs)
14. Additional terminal designations Terminal
Meaning
52
signal from trailer
54g
solenoid valve for permanent brake in trailer
75
radio, cigarette lighter
77
door valve control
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Notes
Notes
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Cable colours and cross-sections agreeable to DIN 72551
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CONTENTS:
CONTENTS: CONTENTS:..................................................................................... 2 1. Cable colours: ............................................................................. 3 1.1 Most common colours, abbreviations and applications ...................................... 3 1.2 Most important wires of direction indication and lighting system...................... 3
2. Wire cross-sections .................................................................... 4
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Cable colours:
1. Cable colours: Um die einzelnen Leitungen einfacher auseinander zu halten, wird ein Farbsystem verwendet, mit welchem die einzelnen Leitungen gekennzeichnet sind. Je nach Herkunftsland und Alter des Fahrzeugs können diese Farben sich unterscheiden, die hier angegebenen Farben sollten sich aber in jedem deutschen Fahrzeug, das nach dem 2. Weltkrieg gebaut wurde, wiederfinden (wie in der DIN 72551 festgelegt). Viele Leitungen sind zweifarbig. Die erste Farbe (Grundfarbe) dient zur Feststellung des Verwendungszwecks, die zweite Farbe (Kennfarbe) dient zur Identifizierung der speziellen Leitung (z.B. Blinker links/rechts). Die Kennfarbe ist meist in Form einer (verdrillten) Linie oder Ringen auf der Leitung angebracht.
1.1 Most common colours, abbreviations and applications Colour
Abbreviation
Application
light blue
hb
control and signal lamps
brown
br
ground
yellow
ge
low beam
green
gn
ignition coils to interruptors
grey
gr
rear lights, side-marker lights and licence plate illumination
violet
li
code colour
red
rt
starter to alternator, ignition and light switch; load/fuses directly connected to terminal 30
black
sw
battery to starter, ignition and light switch, ignition in general
white
ws
high beam
1.2 Most important wires of direction indication and lighting system Base colour
Code colour
ws ws
Application high beam left
sw
ge
high beam right low beam left
ge
sw
low beam right
gr
sw
parking light left
gr
ro
parking light right
sw
ws
direction indicator left
sw
gn
direction indicator right
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Wire cross-sections
2. Wire cross-sections The most common cable cross-sections in vehicles are 0.5, 0.75, 1.0, 1.5, 2.5, 4, 6 and 10mm2. For single laid wires cable cross-sections above 1 mm2 are recommended for stability issues. For cable bundles the single wires may be thinner. There are two rules of thumb for wire cross-sections:
max. 5A/mm2 for permanent load max. 10A/mm2 for short-term load
If the load limit for a wire is achieved, the next bigger cross-section should be chosen especially for longer wires. Examples for cross-sections to use: Current
Cross-section
< 2,5 A
2
Application
0,5 - 0,75 mm rear light, parking light, inside light, control lamps
<8A
1,5 mm2
direction indicators, head lights, wipers, horn
< 16 A
2,5 mm2
collector wires for head lights
< 40 A
2
> 40 A
HAMM AG 18/08/2009
6,0 mm
power supply, ignition switch, fuse box 2
16 - 35 mm
starter (depending on cable length and power)
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