APPLICATION

Application Three

table of Contents

　　Chapter 1 General Instructions

　　1-1 Introduction

　　1-2 Factory warranty of hydraulic station

　　Chapter 2 Operation of Hydraulic Station

　　2-1 Precautions before hydraulic station operation

　　2-2 Operation description and precautions of hydraulic station

　　Chapter 3 System Structure

　　3-1 Structure of hydraulic system

　　3-2 Electrical system

　　Chapter 4 Common Fault Handling and Maintenance of Hydraulic Station

　　4-1 Diagnosis and elimination of common faults

　　4-2 List of Yuan accessories

　　Attachment: hydraulic schematic

　　Chapter 1 General Instructions

　　1-1 Introduction

　　This hydraulic system manual is written for the hydraulic system designed and manufactured by our company; this manual explains the composition, parameters, functions, operation methods and common faults of the hydraulic system.

　　Generally speaking, most failures and accidents of hydraulic systems can be prevented and avoided by formulating effective maintenance programs and doing routine and regular maintenance. Therefore, we recommend that users formulate maintenance and repair plans suitable for the hydraulic system used in accordance with this manual, and perform routine and regular maintenance and repair to reduce downtime.

　　1-2 Our company guarantees the quality of the hydraulic station after leaving the factory

　　The hydraulic system assembly provided by our company, if the fault occurs within one year of the product inspection, if it is confirmed that the responsibility lies with our company, our company will take full responsibility for free repair or replacement. But for the following situations, our company does not take any responsibility.

　　1) When the user has wrong operation method of hydraulic system. For example, if the user's motor wiring is incorrect or the voltage is incorrect, the oil pump is damaged due to continuous reverse rotation.

　　2) The user is not responsible for the maintenance of the hydraulic system, or the damage caused by the unauthorized modification of the system structure and the accident caused by the user shall be liable by the user.

　　3) Damage caused by irresistible natural factors;

　　4) The following consumables are not part of the warranty series:

　　Consumables such as seals, working media, and filter elements are not covered by the warranty series.

　　Chapter 2 Operation of Hydraulic System

　　2-1 Check items before operation

　　1) Please read this instruction manual carefully before starting, and fully understand the structure and operation of the system in conjunction with the actual pump station;

　　2) Confirm that the working oil level and oil temperature of the oil tank are normal;

　　3) Check whether the rotation direction of power supply and motor is normal;

　　4) Check whether there is any abnormality such as looseness at the connection of each component pipeline;

　　5) Check whether the control device has an alarm signal, and start the system if the abnormality is eliminated;

　　6) The plunger pump must be filled with 46# anti-wear hydraulic oil from the pump drain port before each use.

　　2-2 Precautions for operation, use and maintenance of hydraulic station

　　1) Perform daily and regular maintenance and repairs, and understand the performance status of the hydraulic station at any time;

　　2) Repair of the hydraulic system must be carried out under the guidance of professionals;

　　3) Dismantle and inspect the parts with voltage and voltage on the system, which must be shut down to release the pressure and cut off the power supply; when the system is in the unsupervised state, it must be stopped;

　　4) The system must be equipped with an appropriate number of spare parts to ensure its efficient operation.

　　5) If you encounter problems during system use, please consult our technical department.

　　Chapter 3 System Structure

　　3-1 hydraulic system

　　3-1-1 Basic parameters

　　1) The effective volume of the fuel tank: 　 about 1000 L (length 1650 * width 900 * height 700) 　;

　　2) Main motor power: 　40 HP(　30　kW);

　　3) Power of auxiliary motor: 　10 HP(　7.5　kW);

　　4) Working medium temperature range: 20-65℃

　　3-1-2 Motor pump set

　　The type of oil pump used in this hydraulic system is: main pump A11VL0190LRDS/11R-NZD12KB4, maximum flow 275.5L/min, maximum pressure 31　Mpa. auxiliary pump LRR-030D-PC 18 NN-NN-N-3-C2AG-A6N-PLB -NNN-NNN, the maximum flow rate is 43.5L/min, and the working pressure is 12　Mpa.

　　3-1-4 control valve group

　　The hydraulic station is composed of a main lower pressure cylinder, left and right cylinders, upper leg motor 1, upper leg motor 2, lower leg motor 1, lower leg motor 2, measuring cylinder, clamping cylinder and guide cylinder.

　　3-1-5 Measurement and Control Device

　　The system is equipped with pressure gauges, liquid level gauges, oil temperature sensors, liquid level switches, and other measurement and control devices.

　　3-1-6 Filter

　　80% of the failures of the hydraulic system are caused by unclean oil, so the oil should be replaced regularly, and the filter element should be replaced and cleaned in time. High pressure filter PLFA-H660*5FP, high pressure filter PLFA-H110*5FP, oil return filter FRA-800*30Y to ensure the cleanliness of the working oil.

　　3-2 Electrical system

　　3-2-1 power supply

　　The operating voltage of electrical equipment is as follows:

　　Motor pump set and model of hydraulic station: 40HP*4P+A11VL0190LRDS/11R-NZD12KB4, 10HP*4P+LRR-030D-PC 18 NN-NN-N-3-C2AG-A6N-PLB-NNN-NNN Motor voltage: AC 380　V/50　Hz, the control valve group voltage is DC24V.

　　3-2-2 Motor start conditions

　　1) Confirm that the main power supply is powered.

　　2) Confirm that there is no alarm signal.

　　3) Confirm that the oil level is within the normal range.

　　4) Please jog when the motor is started to confirm whether the rotation direction of the motor is correct.

　　3-2-3 Motor stop

　　When not using the system for a long time, turn off the main power

　　3-2-4 Wiring diagram of terminal box (attached)

　　Chapter 4 Maintenance and Repair

　　4-1 General troubleshooting

　　1. Insufficient pressure and flow in hydraulic system

　　1. Check whether the hydraulic pump drains oil, whether the internal leakage is too large;

　　2. Check whether the oil level is normal and the pump oil is normal;

　　3. Check whether the electrical is normal;

　　4. Check whether the pressure valve and flow valve are adjusted normally;

　　5. Check the system for external leaks;

　　6. Check whether the motor turns correctly.

　　2. The actuator does not operate normally

　　1. Check whether the direction of the directional valve is normal;

　　2. Check whether the system pressure is normal;

　　3. Check whether the actuator is normal;

　　4. Air is mixed in the system;

　　5. Failure of related machinery;

　　3. Excessive oil temperature and excessive noise

　　1. The pressure is adjusted too high;

　　2. Large oil viscosity or large pump leakage;

　　3. The amount of oil in the fuel tank is insufficient.

　　4-2 List of main components and accessories:

　　1. Details of main components Quantity Remarks

　　1 Motor 30KW 200L 1 ABB

　　2 Variable pump A11VL0190LRDS/11R-NZD12KB4 1 REXROTH

　　3 Check valve S25A 1 REXROTH

　　4 Air cooler OKAF-EL4S/28/3.0/C/M/A/DF-180/8/1 1 HYHAC

　　5 Motor 7.5KW 132M 1 ABB

　　6 Pressure measuring connector PT-7 12 MCS

　　7 Variable pump LR-R-030D-PC-13-NN-NN-N-3-K2NR-A6N-AAA-NNN-NNN 1 REXROTH

　　8 Solenoid directional valve 4WE6HA6X/EG24N9K4 1 REXROTH

　　9 Ball Valve BKH-G1/2" 1 Xinhua

　　10 Check valve S10A 1 REXROTH

　　11 Pressure gauge YN60Ⅳ(0-25Mpa) 1 Dawn

　　12 Pressure gauge YN60Ⅳ(0-40Mpa) 1 Dawn

　　13 High pressure filter PLFA-H660*5FP 1 Dawn

　　14 High pressure filter PLFA-H110*5FP 1 Dawn

　　15 Return oil filter FRA-800*30Y 1 Dawn

　　16 Temperature sensor TA10/0-150/M4/6/50H 1 BANNA

　　17 Level switch LM004-NC NPT1/2"HKQ 1 BANNA

　　18 Level Gauge YWZ-300T 1 Dawn

　　19 Air filter PAF1-0.07-0.75-20-L 1 Dawn

　　20 Motor shock absorber MDL 200L 2 KTR

　　21 Electro-hydraulic directional valve 4WEH22D7X/6EG24N9ETK4/B10 1 REXROTH

　　22 Proportional pressure reducing valve DREM 20-6X/315YMG24K4M 1 REXROTH

　　23 Electro-hydraulic directional valve 4WEH22D7X/6EG24N9EK4/B10 1 REXROTH

　　24 Two-way throttle valve Z2FS22-3X/S 1 REXROTH

　　25 Electro-hydraulic directional valve 4WEH22D7X/6EG24N9ETK4/B10 1 REXROTH

　　26 Proportional pressure reducing valve DREM10-5X/315YMG24K4M 1 REXROTH

　　27 Electro-hydraulic directional valve 4WEH 16 D4X/6EG24N9EK4/B10 1 REXROTH

　　28 Two-way throttle valve Z2FS16-3X/S 1 REXROTH

　　29 Electro-hydraulic directional valve 4WEH 16J4X/6EG24N9ETK4/B10 1 REXROTH

　　30 Three-way pressure reducing valve ZDR6DP2-4X/75YM 1 REXROTH

　　31 Two-position solenoid directional valve 4WE6C6X/EG24N9K4 1 REXROTH

　　32 Cartridge check valve CXID-XCN 1 SUN

　　33 Cartridge shuttle valve CSAD-XXN 3 SUN

　　34 Pressure switch HED 8 OH-2X/100K14AV 2 REXROTH

　　35 Solenoid directional valve 4WE6J6X/EG24N9K4 1 REXROTH

　　36 Solenoid directional valve 4WE6E6X/EG24N9K4 4 REXROTH

　　37 Solenoid directional valve 4WE6J6X/EG24N9K4/B12 1 REXROTH

　　38 Check valve Z1S6T05-4X/V 1 REXROTH

　　39 Hydraulic lock Z2S6-3-6X 1 REXROTH

　　40 Two-way throttle valve Z2FS6-2-4X/2QV 7 REXROTH

　　41 One-way hydraulic lock Z2S6A1-6X/ 1 REXROTH

　　42 Cleaning window YG500-F 2 domestic high-quality

　　43 Stacked pressure reducing valve ZDRK6VP5-1X/100YMV 1 REXROTH

　　44 Coupling CL-28 1 KTR

　　45 Motor shock absorber MDL 132M 2 KTR

　　46 Bell cover PK300 1 KTR

　　47 Coupling CL-19 1 KTR

　　48 Pump outlet valve block 80*90*72 1 Kettle positive hydraulic

　　49 VT-VSPA1-1X enlarged version 1 REXROTH

　　50 VT-VSPA1-1X enlarged version 1 REXROTH

　　51 1000L fuel tank (1650*880*680) 1 kettle positive hydraulic

　　52 Pressure measuring hose HFH2P1-2-P-1 2 Domestic high quality

　　53 minute valve block 1 (200*100*350) 1 kettle positive hydraulic pressure

　　54 valve block 2 (400*300*100) 1 kettle positive hydraulic pressure

　　55 valve block 3 (300*300*100) 1 kettle positive hydraulic pressure

　　56 Main valve block 750*260*160 1 Kettle positive hydraulic