LH204 Hydrostatic Transmission

&title1=Hydrostatic Transmission
&model=LH204
&rev=Revision 0.10
&training_txt=Training
&company=© 2017, Sandvik Mining and Construction
&cmt=94
&comment1=When engine is running but machine is not moving,
auxiliary pump lubricates all internal moving parts with fresh oil from reservoir
and generates the control pressure to the system. Controller and swash plate of
pump are in the neutral position.
&comment2=The flow provided by the auxiliary pump is fed
through the low pressure circuit filter to the DA –valve. From there it goes
through pressure cut-off to pump controller.
&comment3=Same time, the main lines A and B are filled with
equal pressure (28bar).
&comment4=Low pressure relief valve is activated (28bar) when
both pump and motor are filled with pressure.
&comment5=Oil then flows from pump and motor housing, through
cooler to reservoir.
&comment6=Now the system is filled with an oil, and the
loader is ready to drive.
&comment7=When the solenoid Y3005 of drive direction valve is
activated, the pilot pressure from the speed pedal is allowed to go to port B and
to control port Y1.
&comment8=Pilot pressure goes to pump controller and it moves
control spool to right. Control pressure is allowed to flow to control piston
chamber X1.
&comment9=Pump’s swash plate angle is increasing from neutral
position proportionally compare to control pressure. Now pump is starting to pump
flow from port A to B.
&comment10=Pressure is increasing on the line B by
proportionally to load. Line B is now the high pressure side of the circuit
&comment11=Mechanical force feedback lever forces control
cylinder to move the pump controller near to neutral position.
&comment12=Flushing valve of the motor is controlled with
high pressure side (B) and low pressure side (A) is opened to the motor housing.
From the housing the oil flows through cooler to reservoir. At the same time the
auxiliary pump pumps new fresh oil from tank to the closed loop system through
check valve.
&comment13=To stop the machine. Pedal is lifted
up and pilot pressure is decreasing to zero.
cylinder to move the pump controller to opposite position.
&comment15=Pump controller returns to neutral positions and
also pump’s swash plate angle is decreasing to neutral position.
&comment16=Pressure is decreasing in high pressure line (B).
Now pressure lines A and B have equal pressure.
&comment17=Flushing valve moves to middle position because
both A and B working lines are under same pressure.
&comment18=Loader is now stopped and is on stand by.
&comment31=Drive direction is now set to neutral
position.
&comment19=When the solenoid Y3004 of drive direction valve
is activated, the pilot pressure from the speed pedal is allowed to go to port A
and to control port Y2. Pedal is pressed fully down.
&comment20=Pilot pressure goes to pump controller and it
moves control spool. Control pressure is allowed to flow to control piston chamber
X2. At the same time motor’s control valve is moving down.
&comment21=Pump’s swash plate angle increasing from neutral
position proportionally compare to control pressure. Now pump is starting to pump
flow from port B to A.
&comment22=Pressure is increasing on the line A by
proportionally to load. Line A is now the high pressure side of the circuit.
high pressure side pressure (A) and low pressure side (B) is opened to the motor
housing. From the housing the oil flows through cooler to reservoir. At the same
time the auxiliary pump pumps new fresh oil from tank to the closed loop system
through check valve.
&comment25=Motor’s control valve starts to feed pressure to
the piston side of control cylinder. The motor’s swivel angle starts to go toward
minimum and the speed of motor increasing. Feedback from motor’s control cylinder
makes control valve to move up.
&comment26=Pump’s swash plate is on maximum angle and motor’s
swivel angle is on mimimun. Rolling resistant is sufficiently small.
&comment27=When driving incline, pressure in high pressure
side (A) is rising.
&comment28=High pressure side is over the pressure control
valve spring setting point and then the control cylinder piston side is controlled
to tank. That makes motor’s swivel angle to go towards maximum angle.
&comment29=Motor’s swivel angle goes toward maximum
angle.
&comment84=Loader is now driven reverse on incline.
&comment30=When the engine starts to stall and decreases it’s
running speed, the flow from the auxiliary pump start to decrease. That causes the
pressure difference over the measuring orifice of the DA -valve becomes smaller and
DA -valve start to reduce the pilot pressure.
&comment32=When pilot pressure is decreasing in control
cylinder chamber, it makes pump’s swash plate go to towards minimum angle.
&comment33=Pilot pressure in line Y2 moves pump controller.
 The motor stays on maximum displacement.
&comment34=The smaller swivel angle involves lower power
consumption and therefore, the engine recovers from stalling.
&comment35=The pump is constantly adjusting itself based on
the engine load.
&comment36=When load is decreasing, pump’s swash plate is
increasing towards maximum angle.
&comment85=Now loader is driven reverse. Motor and
pump is on maximum angle. Next we are going to move full traction force
state.
&comment38=When loader has a full traction force. Driving is
described as "driving towards wall". Pedal is pressed, pump’s swash
plate is on maximum angle and also motor’s swivel angle is on maximum. High
pressure side (B) is over the pressure control valve spring setting point.
&comment39=When more torque is needed it makes high pressure
side (now B) rise.
&comment40=Pressure cut-off valve is reducing the pilot
pressure.
&comment41=Pilot pressure to pump controller is
decreasing.
&comment42=The lower pressure in the control cylinder allows
to move the swivel toward neutral position.
&comment43=Pressure from pedal moves pump controller
proportionally to pedal position.
&comment44=
&comment48=Next we are going to move driving flat. After that
we are moving to driving deceleration state.
&comment49=Machine is driven on flat surface with about half
speed.
&comment50=During the decelerating of machine, the drive
motor starts to working like pump and pump like motor, so the energy direction is
reversed from motor to pump. In this situation there is a big risk to overspeed of
driveline component, if there is not enough engine braking force.
&comment51=When driving decline with full speed, pedal is
pressed fully down. Pilot pressure is increasing.
&comment52=Pump’s swash plate angle is increasing to maximum
angle. Motor’s control valve is moving down because pressure from pedal is
rising.
&comment54=The low pressure side pressure starts to rise, if
the potential energy of machine is more than rolling resistance. High pressure
fluid starts to flow from motor to pump by trying to rotate it faster.
&comment55=Flushing valve moves to opposite position because
high pressire line A is now high pressure side.
&comment56=The engine braking force starts to working against
overspeed and pressure level rising (A) in the circuit.
&comment57=As absorbed momentum increases, reach of the set
point of pressure control valve makes valve to move down.
angle.
&comment87=Next we are going switch to driving on flat
surface before doing braking.
&comment59=Driving again on flat with full speed, motor is
working like a motor and pump like a pump. Pressure line B is high pressure side
and A low pressure side.
change of high pressure side.
&comment61=Pressure control valve moves up because there is
not enough load of torque. Rolling resistant is sufficient small.
&comment63=Before braking quickly (lifting pedal up) machine
is driven on flat surface with full speed. Pump’s swash plate is on
maximum angle and motor’s swivel angle is on mimimun.
&comment64=By braking the machine quick by hydrostatic, the
operator will lift up the foot from speed pedal. Pressure to pump’s pump controller
and motor’s main control valve will decrease.
cylinder to move the pump controller and motor’s main control valve moves
up.
&comment66=The motor start to work like pump and pump like
motor. Pressure line A becomes high pressure side. Pump controller
returns to neutral positions and also pump’s swash plate angle is decreasing to
neutral position.
change of high pressure side.
&comment68=Load torque causes the system pressure to reach
the set point of the pressure control.
angle.
&comment70=Pressure cut-off valve is reducing the pilot
pressure. In case pedal is lifted up only about half way, cut-off valve
makes sure that pump goes to minimum displacement.
&comment72=High pressure relief valve opens and decreases the
pressure.
&comment73=When movement is stopped, pressure in high
pressure line is decreasing, high pressure relief valve closes.
&comment74=When pressure in high pressure line is decreasing
more, cut-off valve let pilot pressure to rise. Now flow from auxiliary pump can go
through pump controller.
&comment75=Pressure control valve moves up because there is
no load anymore.
&comment76=Flushing valve moves to middle position because
both A and B working lines are under same pressure.
&comment77=Loader is now stopped and is on stand by.
&comment78=On the remote control drive mode, the speed is
only controlled by pump. Shuttle valve controls the pilot pressure only to pump.
This way the speed of machine is limited.
&comment79=Remote control gets enabled.
&comment80=When moved remote joystic little, solenoid Y3005
or solenoid Y3004 of drive direction valve is activated depending of which
direction joystic is moved, forward or reverse. Now joystic is moved forward and
Y3005 solenoid is activated.
&comment90=Remote joystic (throttle) works now as pedal.
Pressure is rising.
&comment81=Pilot pressure goes to pump controller and it
moves control spool to right. Control pressure is allowed to flow to control piston
chamber X1.
&comment82=Pump’s swash plate is increasing towards maximum
angle.
&comment83=Pressure is increasing on the line B by
proportionally to load. Line B is now the high pressure side of the circuit.
high pressure side (B) and low pressure side (A) is opened to the motor
housing.
&comment89=Loader is now driven with remote control. Max
speed of machine is limited. All driving situations work with remote
control just like in manual, except motor stays all the time on maximum
angle.
&comment94=When loader is towed, driveline by-pass valve is
activated electrically same time with brake releasing pump.
&comment93=In the LH204 machine the maximum towing speed is
only 0.5 km/hr. Towing distance of machine may only be towed out of the
immediate danger zone.
&comment92=Training is now finished. You can now select
different situation from event index from top left corner, or restart the
program.
&menubtn1=1. Stand on

&menubtn2=2. Drive forward with slow speed
&menubtn3=3. Drive backward full speed
&menubtn4=4. Driving incline with high traction force
&menubtn5=5. Driving incline with high traction power, Diesel
overloading
&menubtn6=6. Full traction force
&menubtn7=7. Driving decline
&menubtn8=7.1 Driving on flat
&menubtn9=8. Braking
&menubtn10=9. Remote control drive
&menubtn11=10. Towing
&mover1=Variable axial piston pump Generate the flow to the
close loop circuit.
&mover2=Variable axial piston motor Convert hydrostatic flow to
mechanical rotation.
&mover3=Travel direction valve Selects the travel
direction.
&mover4=Speed pedal Controls the pilot pressure signal to pump
and motor.
&mover5=Cooler Cools down the system.
&mover6=Filter Removes the contamination from fluid.
&mover7=Pressure sensor Low pressure side pressure
monitoring.
&mover8=Pressure sensor High pressure side pressure
monitoring.
&mover9=Pressure switch Control pressure feedback to control
system.
&mover10=Shuttle valve The highest control pressure
selecting.
&mover11=Temperature sensor Flushing oil temperature
monitoring.
&mover12=Driveline releasing valve Driveline releasing for
towing by remotely (electrically).
&mover13=Remote control valve assembly Control valves for remote
control drive.
&mover14=Shuttle valve Shuttle valve for normal or remote
control drive.
&mover15=Auxiliary pump Generates and keep up the pilot pressure
in the system.
&mover16=Low pressure circuit filter Low pressure circuit filter
is mounted to main pump or it will be shifted to the better place for
maintenance.
&mover17=Electric contamination indicator Filter element is
monitored with contamination indicator. If the pressure difference over the filter
element is more than 5 bar, then the pressure switch chance the position and
control system or light will warning the operator.
&mover18=Cold start valve Protects the system from damage, if
the filter element is blocked by dirt or oil viscosity is too high on account of
the low temperature of oil.
&mover19=DA –control valve Works like load limiting or anti-
stall valve. DA –valve generate the pressure to control valve in relation to the
rotation speed of pump.
&mover20=Low pressure relief valve The maximum pressure in the
low pressure circuit is limited with low pressure relief valve.
&mover21=High pressure relief valve Protects the hydrostatic
transmission (pump and motor) against the pressure spikes which occur during fast
swiveling of the swashplate and limit the maximum pressure in the system.
&mover22=High pressure relief valve Protects the hydrostatic
transmission (pump and motor) against the pressure spikes which occur during fast
swiveling of the swashplate and limit the maximum pressure in the system.
&mover23=Pressure cut-off The pressure cut-off is a pressure
control which, after reaching the set pressure, to adjusts the displacement of pump
back to minimum displacement. This valve prevents the operation of the high-
pressure relief valves when accelerating the machine.
&mover24=Pump controller Hydraulically piloted HP controller is
the main controller of the pump. The position of pump control cylinder is
proportionally related to pilot pressure.
&mover25=Control cylinder Controls the angle of wash plate, that
is proportional to displacement of pump.
&mover26=Swash plate pump The drive shaft is rotated by torque
and this turning the cylinder group with pistons. The amount of fluid which is
pumped, depends on rotation speed and swash plate angle.
&mover27=By-pass valve A connection between two high-pressure
lines A and B can be established by using the bypass valve (e.g. for machine
towing). When the bypass valve is activated, the fluid will flow freely inside the
pump.
&mover28=Control cylinder The swivel angle is changed
hydraulically by using the control cylinder. In the beginning, the stroke of
control cylinder is in the minimum and displacement is on maximum. By increasing
pressure in the piston side via control valve, the piston moves swivel angle toward
minimum displacement.
&mover29=Piston group The piston group converts the fluid flow
and pressure to the mechanical rotation and torque.
&mover30=Motor control valve Is the main control valve of the
motor. The motor displacement is proportional to the pilot pressure in the port x.
Controller type is negative, which mean that control begins from maximum
displacement (maximum torque, minimum speed at minimum pilot pressure) and ends to
minimum displacement (minimum torque, maximum permissible speed at maximum pilot
pressure).
&mover31=Pressure control valve Overrides the motor control
function. If the load torque or a reduction in motor swivel angle causes the system
pressure to reach the set point of the pressure control, the motor will swivel
towards a larger displacement. The increase in the displacement and the resulting
reduction in pressure cause the control deviation to decrease. With the increase in
displacement the motor develops more torque, while the pressure remains
constant.
&mover32=Speed sensor Motor is equipped with a toothed ring on
the rotary group to where the speed sensor is mounted. The sensor’s signal is
proportional to motor the speed and can measures direction of rotation as
well.
&mover33=Flushing valve The flushing and boost pressure valve is
used to dissipate heat from the closed circuit and flush the housing..

LH204 Hydrostatic Transmission

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&title1=<span class='title'>Hydrostatic Transmission</span>

&menubtn1=<span class='event'>1. Stand on</span>

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