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Section

8010

MAIN HYDRAULIC PUMP


DISASSEMBLY AND ASSEMBLY

8010

Copyright © 2007 CNH America LLC.


All rights reserved.
CNH Lep SM210B8010-0NA Printed in USA.
May 2007
8010-2
TABLE OF CONTENTS
SPECIFICATIONS .......................................................................................................................................................... 3

SPECIAL TORQUE SETTINGS...................................................................................................................................... 3

EXPLODED VIEW OF REGULATOR ............................................................................................................................. 4

CROSS - SECTIONAL VIEW OF REGULATOR ............................................................................................................ 6

EXPLANATORY DIAGRAM OF REGULATOR OPERATION ...................................................................................... 10

CROSS - SECTIONAL VIEW OF HYDRAULIC PUMP................................................................................................. 11

REGULATOR DISASSEMBLY...................................................................................................................................... 13

HYDRAULIC PUMP DISASSEMBLY............................................................................................................................ 16

WEAR INSPECTION..................................................................................................................................................... 18

REGULATOR ASSEMBLY............................................................................................................................................ 20

HYDRAULIC PUMP ASSEMBLY.................................................................................................................................. 22

TROUBLESHOOTING .................................................................................................................................................. 25

REGULATOR ADJUSTMENT....................................................................................................................................... 28

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SPECIFICATIONS
See Section 1002.

SPECIAL TORQUE SETTINGS


Pump:
Screw (401).....................................................................................................................................430 Nm (217.15 lbf-ft)
Screw (406).........................................................................................................................................29 Nm (21.39 lbf-ft)
Screw (414).........................................................................................................................................57 Nm (42.04 lbf-ft)
Plug (466) ...........................................................................................................................................36 Nm (26.55 lbf-ft)
Plug (467) ...........................................................................................................................................74 Nm (54.58 lbf-ft)
Plug (468) .......................................................................................................................................170 Nm (125.38 lbf-ft)
Plug (490) ............................................................................................................................................8.8 Nm (6.50 lbf-ft)
Pin (531) .........................................................................................................................................240 Nm (177.01 lbf-ft)
Piston (532).....................................................................................................................................240 Nm (177.01 lbf-ft)
Nut (806) ...........................................................................................................................................130 Nm (95.88 lbf-ft)
Nut (808) .........................................................................................................................................240 Nm (177.01 lbf-ft)
Regulator:
Screw (412), (413) ..............................................................................................................................29 Nm (21.39 lbf-ft)
Screw (436), (438) ................................................................................................................................12 Nm (8.85 lbf-ft)
Screw (418)..........................................................................................................................................6.9 Nm (5.09 lbf-ft)
Plug (466) ...........................................................................................................................................36 Nm (26.55 lbf-ft)
Plug (467) ...........................................................................................................................................74 Nm (54.58 lbf-ft)
Plug (496) ............................................................................................................................................8.8 Nm (6.50 lbf-ft)
Locknut (630) ..................................................................................................................................160 Nm (118.01 lbf-ft)
Nut (801) .............................................................................................................................................16 Nm (11.80 lbf-ft)
Nut (802) .............................................................................................................................................19 Nm (14.01 lbf-ft)
NOTE: The numbers within brackets refer to the diagrams from page 4 to 11.

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EXPLODED VIEW OF REGULATOR
Regulator breakdown (KR3G-9X04-HV)

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8010-5
Regulator breakdown (KR3G-9Y04-HV)

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CROSS - SECTIONAL VIEW OF REGULATOR
Regulator breakdown (KR3G-9X04-HV)

SECTION D-D

HYDRAULIC CIRCUIT

VIEW C SECTION B-B

SECTION A-A

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924 - SCREW 646 - PILOT SPRING
898 - PIN 645 - ADJUSTING RING
897 - PIN 644 - SPRING SEAT
887 - PIN 643 - PISTON
876 - PIN 641 - COVER
875 - PIN 631 - SLEEVE
874 - PIN 630 - LOCK NUT
858 - SNAP RING 629 - COVER
836 - SNAP RING 628 - ADJUSTING SCREW
814 - SNAP RING 627 - ADJUSTING RING
802 - NUT 626 - INNER SPRING
801 - NUT 625 - OUTER SPRING
763 - O-RING 624 - SPRING SEAT
756 - O-RING 623 - ROD
755 - O-RING 622 - PISTON
753 - O-RING 621 - PISTON
735 - O-RING 615 - ADJUSTING PLUG
734 - O-RING 614 - PLUG
733 - O-RING 613 - LEVER
732 - O-RING 612 - LEVER
730 - O-RING 611 - LEVER
728 - O-RING 601 - CASING
727 - O-RING 547 - SEAT
725 - O-RING 546 - SEAT
724 - O-RING 545 - BALL
722 - O-RING 496 - PLUG
708 - O-RING 467 - PLUG
656 - COVER 466 - PLUG
655 - SPRING 438 - SCREW
654 - RETURN SPRING 436 - SCREW
653 - SPRING SEAT 413 - SCREW
652 - SPOOL 412 - SCREW
651 - SLEEVE

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Regulator breakdown (KR3G-9Y04-HV)

HYDRAULIC CIRCUIT

SECTION B-B

SECTION A-A
SECTION D-D

VIEW C

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8010-9
924 - SCREW 646 - PILOT SPRING
898 - PIN 645 - ADJUSTING RING
897 - PIN 644 - SPRING SEAT
887 - PIN 643 - PISTON
876 - PIN 641 - COVER
875 - PIN 631 - SLEEVE
874 - PIN 630 - LOCK NUT
858 - SNAP RING 629 - COVER
836 - SNAP RING 628 - ADJUSTING SCREW
814 - SNAP RING 627 - ADJUSTING RING
802 - NUT 626 - INNER SPRING
801 - NUT 625 - OUTER SPRING
763 - O-RING 624 - SPRING SEAT
756 - O-RING 623 - ROD
755 - O-RING 622 - PISTON
753 - O-RING 621 - PISTON
735 - O-RING 615 - ADJUSTING PLUG
734 - O-RING 614 - PLUG
733 - O-RING 613 - LEVER
732 - O-RING 612 - LEVER
730 - O-RING 611 - LEVER
728 - O-RING 601 - CASING
727 - O-RING 547 - SEAT
725 - O-RING 546 - SEAT
724 - O-RING 545 - BALL
722 - O-RING 496 - PLUG
708 - O-RING 467 - PLUG
656 - COVER 466 - PLUG
655 - SPRING 438 - SCREW
654 - RETURN SPRING 436 - SCREW
653 - SPRING SEAT 418 - SCREW
652 - SPOOL 413 - SCREW
651 - SLEEVE 412 - SCREW

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EXPLANATORY DIAGRAM OF REGULATOR OPERATION

CI port
Leads to servo piston
large-bore chamber

direction

direction

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CROSS - SECTIONAL VIEW OF HYDRAULIC PUMP

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8010-12
983 - PIN 490 - PLUG
981 - PLATE 468 - PLUG
954 - SCREW 467 - PLUG
953 - SCREW 466 - PLUG
901 - BOLT 435 - FLANGE SOCKET
886 - PIN 414 - SCREW
885 - PIN 406 - SCREW
824 - SNAP RING 401 - SCREW
808 - NUT 326 - COVER
806 - NUT 314 - VALVE PLATE
792 - RING BACK-UP 313 - VALVE PLATE
789 - RING BACK-UP 312 - VALVE BLOCK
774 - SEAL 271 - PUMP CASING
732 - O-RING 261 - COVER SEAL
728 - O-RING 251 - SUPPORT
726 - O-RING 214 - BUSH
725 - O-RING 212 - SWASH PLATE
724 - O-RING 211 - SHOE PLATE
717 - O-RING 157 - SPRING
710 - O-RING 156 - SPHERICAL BUSH
702 - O-RING 153 - HOLDER PLATE
548 - PIN 152 - SHOE
545 - BALL 151 - PISTON
544 - STOPPER 141 - CYLINDER BLOCK
453 - STOPPER 127 - SPACER
541 - SEAT 124 - NEEDLE BEARING
535 - STOPPER 123 - ROLLER BEARING
534 - STOPPER 116 - 1st GEAR
532 - SERVO PISTON 113 - DRIVE SHAFT
531 - PIN 111 - DRIVE SHAFT

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REGULATOR DISASSEMBLY
NOTE: The numbers within brackets refer to the drawing from page 4 to 11.
NOTE: Always keep the components from different STEP 3
pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully. Always mark the
position of the parts.
STEP 1

After removing the cover (629) subassembly, remove


the outer spring (625), inner spring (626), and spring
seat (624) from the compensation section, and pull out
the adjusting ring (645), pilot spring (646), and spring
seat (644) from the pilot section.
Remove the screws (412, 413) and then remove the
• The adjusting ring (645) can be easily removed by
regulator.
pulling it out with an M4 bolt.
STEP 2

Remove the screws (438), and remove the cover (629).


• The cover is assembled with an adjusting screw
(628), adjusting ring (627), lock nut (630), hexagon
nut (801), and hexagon socket head stop screw
(924). Do not loosen these screws and nuts. Doing so
changes the adjusted pressure-flow setting.

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STEP 4 STEP 6

Remove the screws (436), and remove the pilot cover Remove the lever (2) (613). Do not pull out the pin
(641). (875).
Remove the pilot cover (641), and remove the pin 2 • This can be easily removed by using a pair of tweez-
(898) and sleeve (631) from the compensation section ers.
and the set spring (655) from the pressure adjustment
section. Remove the stop ring (814), and remove the STEP 7
spring seat (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a snap ring (836).
• When removing the stop ring (814), the return spring
(654) flies out, so be careful not to lose this part.
STEP 5

Remove the locking ring (858), and remove the fulcrum


plug (614) and adjusting plug (615).
• The fulcrum plug (614) and adjusting plug (615) can
be easily removed by pulling them out with an M6
bolt.

Pull out the pin (874), and remove the feedback lever
(611).
• Use a fine steel rod to push out the pin (874) (pin
diameter Ø4) from above without touching the lever
(1) (612).
STEP 8
Remove the lever (1) (612). Do not pull out the pin
(875).
STEP 9
Pull out the pilot piston (643) and spool (652).

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STEP 10
Pull out the piston case (622), compensation piston
(621), and compensation rod (623).
• The piston case (622) can be removed by pushing out
the compensation rod (623) from the opposite side of
the piston case (622).
STEP 11
Remove the screws (418), and remove the electromag-
netic proportional pressure reducing valve (079) from
the pilot cover (641). The regulator main unit is now dis-
assembled.
• This operation is only for KR3G-9Y04-HV.
• Be careful not to damage the connector of the electro-
magnetic proportional pressure reducing valve (079).
NOTE: The component parts are small, so be very
careful not to lose them.

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HYDRAULIC PUMP DISASSEMBLY
NOTE: The numbers within brackets refer to the drawing from page 11.
NOTE: Always keep the components from different STEP 4
pumps separate from one another. During disassembly
of the pump, place the components on a rubber mat.
Handle the components carefully. Always mark the
position of the parts.
STEP 1
Remove the oil drain port plug (468) and drain the oil
from the pump casing (271).
• Remove the plugs from both the front and rear
pumps.
STEP 1
Remove the screws (412, 413) and the regulator, and
then remove the screws (414) and the cover (326).
Loosen the screws (M6-60) securing the electromag- Face down the pump regulator installation surface hori-
netic proportional pressure reducing valve and casing zontally on the work surface, and separate the pump
subassembly (079), and remove the electromagnetic casing (271) and valve block (312).
proportional pressure reducing valve and casing sub- • When facing down the regulator installation surface,
assembly. be sure to place a rubber plate or similar material on
the work surface so as not to damage the regulator
STEP 2 installation surface.
• When separating the pump casing and valve block,
remove the 1st gear (116) at the same time.
STEP 5

Loosen the flange socket (435), and remove the gear


pump (04).
STEP 3
Remove the cylinder (141) straight out from the pump
casing (271) toward the drive shaft (111, 113), and
remove the piston subassembly (151, 152), holder
plate (153), spherical bush (156), and cylinder spring
(157) at the same time.
• Be careful not to damage the sliding surfaces of the
cylinder, spherical bush, shoes, and swash plate.

Loosen the screws (401) that fastens together the


swash plate support board (251), pump casing (271),
and valve block (312).

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STEP 6 STEP 9

Tap the mounting flange section of the swash plate


Remove the screws (406), and remove the seal cover support board (251) on the pump casing side, and sep-
(261). arate the swash plate support board and the pump cas-
• The seal cover can be easily removed by inserting a ing.
bolt into the hole (M6 tap) on the seal cover and pull- Remove the valve plate (313, 314) from the valve block
ing it out. (312).
• The seal cover has an oil seal, so be careful not to • This can also be removed in Step (7).
damage the oil seal when removing the seal cover.
STEP 10
STEP 7 If necessary, remove the stopper (534), stopper (535),
servo piston (532), and tilting pin (531) from the pump
casing (271), and remove the needle bearing (124)
from the valve block (312).
• To avoid damaging the head of the tilting pin, use a jig
when removing the tilting pin.
• The section where the tilting pin and servo piston are
bonded is coated with Locktite, so be careful not to
damage the servo piston.
• Do not remove the needle bearing unless it is at the
end of its service life.
• Do not loosen the hexagon nut of the valve block or
swash plate support board. This changes the flow vol-
Tap the rear of the drive shaft (111, 113), and separate ume setting.
it from the swash plate support board (251).
STEP 8

Remove the shoe plate (211) and swash plate (212)


from the pump casing (271).

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WEAR INSPECTION

Standard dimension / Replacement of parts


recommended

Location Pump types Part to be replaced


K3V63, K3V140 K3V180,
K3V112,
K5V80 K5V140 K5V200

0.028 / 0.039 / 0.043 / 0.0375 / Replace the pistons or the


Play between piston/bore (D-d)
0.056 mm 0.067 mm 0.070 mm 0.078 mm cylinder

Play at the shoe piston and the 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / 0.3 0-0.1 / Replace the pistons and the
guide (A) mm mm mm 0.35 mm piston retaining plate

Shoe thickness (t) 3.9 / 3.7 4.9 / 4.7 5.4 / 5.0 5.4 / 5.0 Replace the pistons and the
mm mm mm mm piston retaining plate

Free height of cylinder springs 31.3 / 41.1 / 47.9 / 40.9 / Replace the springs
(L) 30.2 mm 40.3 mm 47.1 mm 40.1 mm

Height of the base plate and 19.0 / 23.0 / 23.8 / 23.8 / Replace the base plate and
the spherical bushing (H-h) 18.2 mm 22.0 mm 22.8 mm 22.8 mm the spherical bushing

Cylinder over-pin-diameter 35.17 (Ø5)/35.57 Replace cylinder and spheri-


(spline in cylinder) cal bush
Spline in spherical bush

Overhaul dimension of the cylinder, the distribution machined plate and the swash plate (machined surface)
Distribution machined plate (sliding contact surface) Standard roughness after 3-Z
Swash plate (at the plate) grinding
Cylinder (sliding contact surface)
Roughness of the sur- 0.4 Z or lower (lapping)
Irregularity of each surface
face at the wear limit

d D

Piston to cylinder bore Free heigh of


clearance (D-d) cylinder spring (L)

A
H
t h

Piston, shoes, and Assembled height of holder plate

caulking section backlash (A) and spherical bush (Hh)


Shoe thickness (t)

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STEP 1
Check for cracks, breakage and pitting on the shafts,
the cylinder block pump body.
STEP 2
Check for heavy wear, cracks, pitting, deep scratches,
rough areas on the plate, the piston housing, the pis-
tons, and the control spools.
STEP 3
If one of these conditions is present, change the com-
ponent.

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REGULATOR ASSEMBLY
NOTE: Assembly is done in the reverse order of disassembly, taking into account the following instructions:
- Clean the components with detergent and dry them with compressed air.
- Tighten the screws and plugs to the recommended torque.
- Coat the moving parts with clean oil before assembling them.
- Install new seals and O-rings.
STEP 1 STEP 8
Select the location for assembling the regulator.
Find a clean location to assemble the regulator.
Place a rubber plate or cloth on the work surface so as
not to damage the parts.
STEP 2
Assemble the compensation rod (623) into the com-
pensation opening on the casing (601).
STEP 3
Insert the pin (875) injected in the lever (1) (612) into
the groove on the compensation rod (623), and assem-
ble the lever (1) (612) to the pin (875) injected in the
casing (601).
Assemble the fulcrum plug (614) and install the locking
STEP 4 ring (858) so that the pin (875) injected in the fulcrum
Assemble the spool (652) and sleeve (651) into the plug (614) is inserted into the pin opening on the lever
casing (601) and spool (652) opening. (2) (613).
• Check that the spool (652) and sleeve (651) slide
smoothly into the casing (601) without catching. STEP 9
• Be careful to assemble the spool (652) in the correct
direction.
STEP 5
Assemble the feedback lever (611), and insert the pin
(874) while aligning it with the pin opening on the feed-
back lever (611).
• This is easier to assemble by inserting the pin (874)
into the feedback lever (611) in advance.
• Be careful to assemble the feedback lever (611) in the
correct direction.
STEP 6
Assemble the pilot piston (643) into the pilot (643)
opening on the casing (601). Insert the adjusting plug (615), and install the locking
• Check that the pilot lever (643) slides smoothly with- ring (858).
out catching. • Be careful to insert the fulcrum plug (614) and adjust-
STEP 7 ing plug (615) into the correct openings.
• At this time, check that play of the feedback lever
(611) movement is not too great and that the feed-
back lever (611) does not catch on anything.

Insert the pin (875) injected in the lever (2) (613) into
the groove on the pilot piston (643), and assemble the
lever (2) (613).
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8010-21
STEP 10 STEP 13
Assemble the pilot cover (641), and tighten the screws
(436).
STEP 14
Assemble the spring seat (644), pilot spring (646), and
adjusting ring (645) into the pilot opening, and assem-
ble the spring seat (644), inner spring (626), and outer
spring (625) into the compensation opening.
• Be careful to assemble the spring seat (644) in the
correct direction.
STEP 15

Assemble the return spring (654) and spring seat (653)


into the spool (652) opening, and install the stop ring
(814).
STEP 11

Assemble the cover (629) with the set adjusting screw


(628), adjusting screw (925), adjusting ring (627), lock
nut (630), hexagon nut (801), and screw (924), and
tighten the screws (438). The regulator main unit is now
assembled.

Assemble the set spring (655) into the spool (652)


opening, and assemble the compensation piston (621),
piston case (622), sleeve (631), and pin (898) into the
compensation opening.
• Check that the sleeve (631) and pin 2 (898) move
smoothly.
STEP 12

Assemble the electromagnetic proportional pressure


reducing valve (079) to the pilot cover (641), and
tighten the screws (418).
• This operation is only for KR3G-9Y04-HV.
• Be careful not to damage the connector of the electro-
magnetic proportional pressure reducing valve (079).

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HYDRAULIC PUMP ASSEMBLY
NOTE: Assembly is done in the reverse order of disassembly, however, the following instructions need to be followed:
- Respect the reference marks made during disassembly.
- Lubricate the seals and the sliding parts.
- Do not mix the parts of the front and rear pumps.
- Use light Loctite when installing the control pivot.
STEP 1 STEP 3

Install the pump casing (271) by tapping the swash Install the drive shaft (111, 113) with attached cylinder
plate support board (251) with a hammer. roller bearing (123), bearing spacer (127), and stop
• If the servo piston, tilting pin, stopper , and stopper spring (824) to the swash plate support board (251).
have been removed, assemble these parts in the STEP 4
pump casing in advance.
• To avoid damaging the tilting pin head and feedback
pin, use a jig when tightening the servo piston and tilt-
ing pin. Also be sure to coat the screw sections with
Locktite (moderate strength).
STEP 2

Attach the shoe plate (211) to the swash plate (212).


Face down the regulator installation surface of the
pump casing, insert the tilting bush of the swash plate
into the tilting pin (531), and correctly mount the swash
plate and shoe plate on the swash plate support board
(251).
• Use the tips of both fingers to check that swash plate
moves smoothly. Attach the seal cover (261) to the pump casing (271),
• Coat the swash plate, swash plate support board, and and secure with the screws (406).
all sliding sections with grease for easier installation • Lightly coat the oil seal of the seal cover with grease.
of the drive shaft.
• Attach the oil seal while being careful not to damage
• Be careful not to damage the sliding surface of the it.
shoe plate.

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STEP 5 STEP 7

Assemble the piston cylinder subassembly (cylinder Face down the pump regulator installation surface hori-
(141), piston subassembly (151, 152), holder plate zontally on the work surface, and install the pump cas-
(153), spherical bush (156), spacer (158), cylinder ing (271) and valve block (312).
spring (157)), and insert it into the pump casing in align- • When facing down the regulator installation surface,
ment with the phase of the spherical bush and cylinder be sure to place a rubber plate or similar material on
spline. the work surface so as not to damage the regulator
STEP 6 installation surface.
• Install the valve block in the correct direction. (Install
the valve block with the regulator facing up and the
suction flange facing to the right when looking at the
valve block from the front.)
• When installing the pump casing and valve block,
install the 1st gear at the same time.
STEP 8

Install into the valve block (312) while aligning the valve
plate (313, 314) with the pin (885).
• Be careful not to mistake the intake and discharge
directions of the valve plate.

Tighten the flange socket (435), and install the gear


pump (04).

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STEP 9 STEP 11
Insert the feedback pin of the tilting pin into the feed-
back lever of the regulator, install the regulator, and
tighten the screws (412, 413).
Install the regulator, making sure not to mistake the
front and the rear of the regulator.
STEP 12
Tighten the screws (M6-60) to the valve block (312),
and install the electromagnetic proportional pressure
reducing valve and casing subassembly (079).
STEP 13
Attach the drain port plug (467) to finish assembly.

Tighten the valve block (312) and pump casing (271)


with the screws (401).
• It is easier to assemble when starting with the rear
pump.
STEP 10

Tighten the screws (414) to the valve block (312), and


install the cover (326).

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TROUBLESHOOTING
1) General precautions
Following are countermeasures if you find abnormality during the operation of Kawasaki swash plate type axial piston
pump and motor.
General precautions are:
a) Considerations before starting repair.
Determine the characteristics of the abnormality before starting repair. Consider if the cause is originated from the
wrong circuit, failure of regulator, or attached valve. Double check that the problem involves the pump motor.
b) Before disassembling a system, make sure to read through the service manual. Conduct the disassembly in a cor-
rect manner.
c) When disassembling a system, be careful not to allow dust to enter.
d) Parts are finished precisely. Be careful not to damage them when handling.
2) Troubleshooting for the pump main body
Pumps are often attached to a regulator, attached valves and attached pumps. It can be difficult to find the cause of the
problem. Checking the following points is useful to identify the problem area.
a) Filter check and drain oil check
Check the filter element. Check if a considerable amount of contamination is found.
It is normal that a little amount of metal dust originated from abrasion of the shoe or cylinders is seen. However, if the
amount of metal dust is extremely high in the filter, the shoe might be damaged. Check drain oil of inside the pump cas-
ing, as well.
b) Abnormal noise / abnormal vibration
Check for abnormal noise or abnormal vibration in the main pump. Examine if the sound repeats with regular frequency
such as, a hunching sound in the regulator or hunching sound of the valve relief.
If there is an abnormal vibration or sound, cavitation or damage inside the pump should be considered.
c) When using two pumps.
If piping uses two single pumps or two motors, change the pipe of each pump.
By changing the pipe, the problem can be identified whether it is caused by a pump failure or a piping failure after the
pump.
4) Perform pressure measurement.
If the problem is related to the controlling function, examine the problem areas using pressure measurement tools
instead of performing overhaul inspection.

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8010-26
3) Overload on the motor

Causes Countermeasures Notes


Rotational speed-check if pressure is Set pressure at an expected value.
set higher than expected value.
Check if the torque set of the regula- Recheck the regulator. Refer to the regulator instruction
tor is high. manual.
Damage and burning on the internal Replacement of damaged parts. Check filter and drain oil for abnor-
parts of the pump. mal dust from abrasion.
Wrong piping for the regulator. Correct the regulator piping.

4) When pump flow rate declines significantly or discharging pressure does not increase.

Causes Countermeasures Notes


Faulty regulator. Repair the regulator. Refer to the regulator instruction
manual.
Damage and burning on the internal Replacement of damaged parts. Check filter and drain oil.
parts of the pump.
Attached faulty pump. Replace damaged parts. Disconnect the attached pump and
check the shaft coupling section.
Attached faulty valve. Check attached valve. (Check espe- Refer to the attached valve instruc-
cially puppets and seat springs.) tion manual.
Wrong regulator piping. Correct the regulator piping.

5) Abnormal noise / abnormal vibration

Causes Countermeasures Notes


Cavitation Prevention of cavitation. Check - Boost pressure is too low.
hydraulic oil for white turbidness. - Failure of auxiliary pump.
- Air is drawn from the intake pipe.
- Intake resistance is too high.
Damage on the shoe Replacement of piston shoe, shoe
caulking area. plate or others.
Cracks on the cylinder Replacement of the cylinder
Failure of pump installation Reinstallation
Hunching of the regulator Repair of the regulator Refer to the regulator instruction
manual.
Hunching of the relief valve on the Repair the attached valve. Refer to the attached valve instruc-
attached valve tion manual.

6) Causes and Solutions for Regulator Trouble


If a malfunction occurs that is thought to be a result of the regulator, disassemble and inspect the regulator while refer-
ring to the maintenance procedures.

Lep SM210B8010-0NA Issued 05-07


8010-27
7) When motor overloads
Apply a single load to each pump and investigate whether there is a problem with the front or rear pump. If there is a
problem with both pumps, see steps (1) and (2) below. If there is a problem with only per side, start from step (3).

(1) Inspect whether the power shift command current value is correct.
(2) Power shift pressure is low. Inspect the amp dither.
Replace the electromagnetic pro-
portional pressure reducing valve.
(3) Sticking of the compensation piston (621) and compensation rod (623) Disassemble and clean.
(4) Sticking of the pin (898) Disassemble and clean.

8) When no maximum flow is output

(1) Check whether the pilot pressure Pi is correct.


(2) Sticking of the pilot piston (643) Disassemble and clean.
(3) Sticking of the spool (652) Disassemble and clean.

NOTE: If any parts have deep scratches, replace those parts.

Lep SM210B8010-0NA Issued 05-07


8010-28
REGULATOR ADJUSTMENT
Flow change
+11.7
(l/min.)
Flow control start pressure change
+0.15
MPa
Flow control properties adjustment
Adjusting screw
(924)
+1/4
Tightening amount
(rotation)
Input torque change
+44.2
N•m
Flow change
Inner +8.5
(l/min.)
spring
adjustment Adjusting ring
(627)
+1/4
Tightening amount
Input (rotation)
horse- A 1.87
power Input torque change
adjustment +57.9
N•m
Compensation control start pressure
Outer
change +1.88
spring
MPa
adjustment
Adjusting screw
(628)
+1/4
Tightening amount
(rotation)
+4.1
Minimum flow adjustment
+1/4
Flow change
-5.2
(l/min.)
Adjusting screw
Maximum flow adjustment
(954)
+1/4
Tightening amount
(rotation)
Engine speed
1800
(min.-1)

Lep SM210B8010-0NA Issued 05-07

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