Maintenance manual for hydraulic drive system of scraper scraper

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Hydraulic drive system for scraper scraper










Use and maintenance instructions


























1. Main technical parameters






2. Technical parameters and settings of pumps and motors






3. hydraulic system installation and maintenance instructions






4.List of hydraulic components






5. Hydraulic power station dimensions




Outline diagram of the power station




Hydraulic schematic diagram




Electrical wiring diagram of terminal box




Hydraulic piping layout diagram




Hydraulic pump station assembly diagram














Main technical parameters




Main working voltage: 380V/50Hz




Oil tank volume: 300L




Liquid level switch


Distance from the top of the tank: Low level 250 mm


                    Lowest liquid level 320 mm




Temperature switch: Maximum temperature 65℃


                    Warning temperature 60°C


                    Cooler start temperature 50°C


Low temperature alarm 20°C


Electric heater start temperature 10℃






Filtration accuracy: 5µm


Contaminant clogging switch: 2.5 bar


Bypass valve: 3.5bar




Air cooler:


Design ambient temperature: 30°C


Motor rated voltage: 380V/50Hz


Motor power: 0.55KW


Motor rated speed: 1450rpm














Pump and motor technical parameters and settings




Pump unit                              






Model: PV046R1K1T1NMFC                       


Max. flow rate (1480rpm): 70L/min


Maximum pressure: 350 bar


Pump pressure compensator pressure: 200 bar


Differential pressure: 30 bar


P oil port pressure sensor: 0 to 400 bar






Model: QA200L4A B35


Power: 30KW


Rotational speed: 1480rpm








Hydraulic motor


Model: CA210C


Rated torque: 42000NM


Maximum torque: 63000NM














Power station installation and maintenance instructions




1. Working principle


The function of the power station is to provide the necessary flow and pressure for the hydraulic motor (or other hydraulic system) at the right time. The principle is as shown in the figure, there is a hydraulic pump driven by a motor in the power station, the main pump is an axial piston variable pump for open system, the oil from the main pump enters the hydraulic motor through the electro-hydraulic proportional reversing valve to push the motor to run. The pressure difference between the front and rear of the system through the electro-hydraulic proportional reversing valve is introduced into the hydraulic variable pump variable control mechanism, and the system output flow is automatically adjusted according to the size of the pressure difference. When increasing the opening of the electro-hydraulic proportional reversing valve, the pressure difference between the two ends becomes smaller, in order to keep the pressure difference between the two ends unchanged, the flow through the increase, the output flow of the variable pump will increase, and vice versa, the flow is reduced. The hydraulic pump itself with the highest pressure limit, when the system pressure exceeds the set maximum pressure, the hydraulic pump displacement will automatically be zero, no hydraulic oil output. The hydraulic oil output from the hydraulic motor flows back to the tank through the valve block and return filter and air cooler. Motor leakage oil returns to the tank through the leakage oil circuit and the leakage oil filter. A quick coupling is provided on the leakage oil circuit for refueling the system.


The hydraulic system is equipped with oil temperature and oil level warning and alarm signals. When the oil temperature exceeds 60℃ and the oil level is lower than the set low oil level, the oil temperature meter and level meter will operate and issue a warning signal. When the oil temperature exceeds 65℃, or the oil level is lower than the set minimum level, the oil temperature meter and level meter will act again and issue an alarm signal. When the oil temperature exceeds the set air cooler start temperature, the air cooler will open automatically.




2. Description of some components of hydraulic system




2.1 Plunger variable pump PV046R1K1T1NMFC, see the sample of the pump concerned for details


2.2 Motor ABB QA200L4A 30KW 380V 50Hz IP55 B35


2.3 Position of the internal dial on the temperature switch






Temperature standard


Standard position of the internal dial


Alarm signal, need to stop


Reaching 65℃ or more, need to stop




Warning signal


Reaching 60℃ or more to give warning






Cooler starts to work


Over 50℃ start cooler






Low temperature alarm


Warning for below 20℃ or more




Electric heater starts to work


Below 10℃ start electric heater




2.4 Isolation valve on the pressure gauge


When the pressure gauge is not in use, tighten the isolation valve. If the pressure gauge is under continuous pressure action, it will likely be damaged.


2.5 Level switch


Level of the liquid level switch


Liquid level


Related action


Liquid level distance from the top of the tank mm (in)






250 (9.84)




Alarm with power station stop


320 (12.6)






3. Hydraulic fluid


3.1 Selection of hydraulic fluid


The power station is designed to use hydraulic fluids refined primarily on a conventional petroleum basis. The selection of hydraulic fluid can be checked with the fluid supplier. However, the hydraulic fluid used must meet the following requirements.


¾ Meet the requirements of paragraph 11 of the FZG90 test as described in IP334 (DIN51354).


¾ Contains antioxidants to avoid oxidation, rusting and blistering.


¾ The hydraulic fluid viscosity is within the permissible range during the specified time interval when either the power station or the hydraulic motor is in operation. (can be measured on the motor circuit)


¾ The water content does not exceed 0.1%, while for industrial applications where high demands are placed on equipment life, the water content does not exceed 0.05%.




Viscosity Limits


Viscosity Index VI






For applications with large temporary differences




Viscosity n


Minimum continuous operation




Minimum intermittent working




Max. continuous working




Maximum intermittent operation




At operating temperature, the recommended viscosity is 40 to 150 cSt (187 to ~720 SSU)


When cold starting, operating at low pressure and low flow rate, the maximum allowable viscosity is 1600 cSt.


In this system, the hydraulic oil selected is N100# anti-wear hydraulic oil.




            Hydraulic oil cleanliness requirements


This power station is equipped with filters on the drain and return lines. In order to achieve the specified service life, it is important to follow the following recommendations to maintain the cleanliness of the fluid and regular maintenance.




Cleanliness recommendations


¾ The system must be flushed before starting, see "Flushing before starting" for details.


¾ When filling the hydraulic fluid in the tank, it is important to add oil through the specific oil fill connection, see "Filling the system with hydraulic fluid".


¾ The solids in the system should not exceed ISO/DIS 4406 16/13 (NAS 1638, Class 7).


¾ The water content should not exceed 0.1%, and for industrial applications where high equipment life is required, the water content should not exceed 0.05%.


¾ Use cartridges supplied or recommended by PARKER.


¾ Periodically analyze the hydraulic fluid according to the specified maintenance intervals (see chapter "Maintenance chart"). Be especially careful not to allow dirt to enter the hydraulic system when removing components for repair or maintenance, and to clean them first before opening them. 4.




4. Placement of the power station


A certain amount of space should be left around the power station to ensure free ventilation and sufficient space for maintenance. All tubing (either water or hydraulic lines) must be installed with sufficient space for maintenance. Larger maintenance (e.g. motor or hydraulic pump replacement, etc.) will require more space.


Also note the following points.


¾ The foundation should be solid. (Avoid vibration)


¾ Easy to maintain and repair.


¾ Proper protection from weather, water mist, heavy pollution and radiation.


¾ Ensure smooth air circulation to allow the motor and air-cooled cooler to work well.


¾ Make the pipe network as short as possible.




The scattered pipes in the pipeline should preferably be clamped with pipe clamps and fixed to a solid foundation to avoid vibrations. The main line connection must be matched with a hose. If the air-cooled cooler is installed elsewhere than at the power station, safety must be considered, the cooler has a sharp edge and will start unnoticed.




5. Hydraulic connections




When installing the hydraulic connection, the following points must be kept in mind.


¾ The connection protector must be retained until final assembly and then removed.


¾ It is very important that all lines are installed with sufficient space to facilitate maintenance of the power station.


¾ Always use a hose connection between the hydraulic pump and the piping.


Before installation, inspect the sealing surface of the connection with the naked eye, there must be no scratches or cracks on the surface. The joint body should be handled very carefully, and if it is accidentally dropped on the ground, it should be checked for scratches, whether the seal is out of place, and tested with hydraulic oil to determine whether cracks are produced by leaking. The packaging on the joint must wait until the final installation before removing it.




a. Flange connections.


Bolts on flanges must be cross-tightened.


b. Jic joints (SAE J514, ISO8434).


Tighten 1/4 to 1/2 turn is sufficient, do not over tighten the joint.


Use the correct size tool or the fitting may be damaged or difficult to remove.


Note: All joints can be loosened by thermal expansion or by vibration, in which case it is necessary to retighten the


   The fitting will need to be tightened again.


c. Clamps


The usual distance between pipe clamps is as follows.


D£25mm (1 in), 1500 to 2000mm (59 to 79 in).


D³25mm (1 in), 2000-2500mm (79-98 in).


Steel pipe must be clamped with pipe clamps at the front and back sections of the bend and at the transition to the hose.




6. Electrical connection




a. Junction box


Connect the wires to the wiring ports in the junction box according to the wiring diagram on the accompanying technical documents.




b. Air-cooled cooler


Voltage and connection are marked on the nameplate. Connect the motor to the power supply. Check the direction of rotation of the fan, marked on the cooler with the direction shown by the airflow arrow. The standard is the extracted air form.




c. Main motor


Make the main voltage connection according to the value on the nameplate.




7. Flushing before starting


Connect a pressure filter and a check valve to the main oil line of the power station. The filter should be connected to the return line side of the hydraulic pump. The filter should have a filtration accuracy of b10 = 75 or higher. The size of the flushing filter should be matched to the relevant flow rate of the hydraulic pump, and the pressure and flow rate through the filter should not exceed the maximum pressure and flow rate allowed by the filter. The main oil line is connected to the motor connection with a hose at both ends of the fitting oil port to form a circuit that allows the entire system to be flushed. Care should be taken to ensure that the oil coming from the hydraulic pump flows in the direction of the check valve.


Power stations with low installed power should be flushed with maximum flow for at least 2 hours. For more powerful power stations, the flushing time should be extended accordingly.




8. Start-up procedure


8.1 Before start-up


Cleanliness requirements


¾ The hydraulic system must be thoroughly flushed to ensure absolute cleanliness inside the system.


¾ Check the cleanliness of the system again before filling with hydraulic oil.


Piping system check


¾ Are the connection parts tightened?


¾ Has the piping system been cleaned?


¾ Are there any stresses present in the piping system after installation?


¾ Are all piping arranged according to the installation drawing or piping layout?


Inspection of electrical control components


¾ Check that the voltage of the motor, control system and other electrical components is correct.


¾ Manually check the function of the electrical components and monitoring system. For the components that do not operate correctly, check whether the wiring is correct and whether manual operation is possible. When filling the tank, check the level switch and level gauge.




8.2 Filling the system with hydraulic oil


Before refueling

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