Service Training Basiswissen / Fundamentals Release 2011-10-07 EN EN EN 2150228 2150228 2150228 Fundamentals HAMM COMPACTORS Fundamentals HAMM COMPACTORS Fundamentals HAMM COMPACTORS 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 H159 H169 H269 H206 H160 H161 H162 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 H188 H189 H179 H139 H170 H171 H172 H122 H152 H153 H163 H185 H184 H199 H200 H201 H173 H187 H174 H181 H175 H182 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 H180 H176 H177 2 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 HAMM AG 13/10/2009 1/14 # 2145194 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 HAMM AG 13/10/2009 2/14 # 2145194 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 3/14 # 2145194 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. HAMM AG 13/10/2009 4/14 # 2145194 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 HAMM AG 13/10/2009 5/14 # 2145194 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 HAMM AG 13/10/2009 6/14 # 2145194 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 HAMM AG 13/10/2009 7/14 # 2145194 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 HAMM AG 13/10/2009 8/14 # 2145194 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 HAMM AG 13/10/2009 9/14 # 2145194 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 HAMM AG 13/10/2009 10/14 # 2145194 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 HAMM AG 13/10/2009 11/14 # 2145194 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 HAMM AG 13/10/2009 12/14 # 2145194 Top 10 hydraulic symbols Pressure limit valve adjustable Cylinder double-acting HAMM AG 13/10/2009 13/14 # 2145194 Notes Notes HAMM AG 13/10/2009 14/14 # 2145194 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 HAMM AG 18/08/2009 1/14 # 2145192 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 HAMM AG 18/08/2009 2/14 # 2145192 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 HAMM AG 18/08/2009 3/14 # 2145192 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 HAMM AG 18/08/2009 4/14 # 2145192 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) HAMM AG 18/08/2009 5/14 # 2145192 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 HAMM AG 18/08/2009 6/14 # 2145192 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 HAMM AG 18/08/2009 7/14 # 2145192 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 HAMM AG 18/08/2009 8/14 # 2145192 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 HAMM AG 18/08/2009 9/14 # 2145192 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 HAMM AG 18/08/2009 10/14 # 2145192 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 HAMM AG 18/08/2009 11/14 # 2145192 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 HAMM AG 18/08/2009 12/14 # 2145192 Notes Notes HAMM AG 18/08/2009 13/14 # 2145192 Notes HAMM AG 18/08/2009 14/14 # 2145192 Terminal designations agreeable to DIN 72552 HAMM AG 18/08/2009 1/8 # 2145190 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 HAMM AG 18/08/2009 2/8 # 2145190 Ignition system 1. Ignition system Terminal 1 1a, 1b Meaning ignition coil, ignition distributor, low voltage 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 HAMM AG 18/08/2009 3/8 # 2145190 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 Meaning charge control 4/8 # 2145190 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 HAMM AG 18/08/2009 5/8 # 2145190 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 HAMM AG 18/08/2009 6/8 # 2145190 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 HAMM AG 18/08/2009 7/8 # 2145190 Notes Notes HAMM AG 18/08/2009 8/8 # 2145190 Cable colours and cross-sections agreeable to DIN 72551 HAMM AG 18/08/2009 1/4 # 2145186 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 HAMM AG 18/08/2009 2/4 # 2145186 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 HAMM AG 18/08/2009 3/4 # 2145186 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 < 2,5 A Cross-section Application 2 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) 4/4 # 2145186