Pages de SERVICE MANUAL-6

Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment
V. Adjustment
5.1. Preparation before adjustment:

(1) Check connection of manifold for errors.
(2) Check level of oil tank.
(3) Check accumulator for nitrogen filling pressure, maintain the nitrogen filling
pressure for 4MPa.
(4) Turn on the stop valve at the oil absorbing port and oil discharging port of plunger
pump; turn off the stop valve for accumulator group. When cooler not required to
work, then turn on bypass stop valve of cooler; if cooler required to work, and then
turn off the bypass stop valve of cooler.
(5) Knock the motor, check its rotation direction for correctness (the rotation direction
of plunger pump is clockwise, i.e. the direction of red arrow on the pump).
5.2 Adjustment:
(1) Start up motor
(2) Adjust rated pressure, maximum pressure of the system.
Adjusting steps shall be as follows:
A. Start up motor group for one pump.
B. Loosen nut of safety valve and turn it clockwise to 3/4 position.
C. Remove pressure relief valve protective cap of the pump and loosen the nut of
pressure relief valve of the pump. Turn screw clockwise by inner hexagonal
wrench to increase pressure. Observe readings in pressure gauge of the system,
stop when it is up to 10MPa. If pressure stops to increase during adjusting, turn
the safety valve little. Adjust the safety valve and the pressure relief valve of
plunger pump alternately until readings of pressure gauge is up to 10MPa.
D. Adjust safety valve downward until the readings of pressure gauge is up to
9.5MPa, then tighten the nut of the safety valve.
E. Readjust the pressure adjusting screw downward until the reading of MA is up
to the rated pressure and maintain. Tighten nut, install protective cap and
tighten it.
Notice: maximum pressure of hydraulic power source has been adjusted before
ex-factory. Adjustment must be forbidden unless required by special conditions.
(3) Observe the pressure gauge on hydraulic power source and confirm whether it is on
the rated value.
(4) Discharge air: connect air discharging pipe to the air discharging connector on oil
cylinder, then pull slightly the electronic brake handle, and make the pressure of
main service caliper is in about 1MPa until discharged oil not contains air foam.
Discharge air for main service calipers one by one. Discharge air for the emergency
calipers by the same way when the oil cylinder has pressure.
(5) Pull the electronic brake handle, when the pressure of left and right calipers are up
to maximum value, pull out the emergency button, turn the parking switch to
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Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment
“loose” position, three pressure gauges are up to the system pressure value, then
stop, hold the pressure for 10 minutes; observe MA pressure gauge of hydraulic
power source, if the pressure value is unchanged, then the system is normal; if
pressure value reduces, it indicates leakage, solve it in time.
(6) Adjustment of brake clearance of brake caliper：
The distance between brake pad and brake disc is called brake clearance when oil
pressure of the main service caliper cylinder is zero and oil pressure of emergency
caliper oil cylinder is maximum.
The normal brake clearance of the main service caliper (unilateral) shall be 1～2mm;
the normal brake clearance of emergency caliper shall be (unilateral)0.5～1mm. It shall
be adjusted when the brake clearance exceeds normal value.
The adjustment procedures for the brake clearance are as follows:
A. Unscrew the screw plug, and connect a special oil gun filled with the clean
hydraulic oil. Seal washer in it must be ringed.
B. Rotate the oil gun handle and inject the oil to move the adjusting plunger
outward. Observe the change of the brake clearance until the normal clearance
occurs. Under normal circumstance, the brake clearance of the main service
caliper shall be adjusted to 1mm and 0.5mm for emergency caliper).
C. Remove the oil gun, and cover and tighten the screw plug. Note that combined
washers are added.
Note: Make sure the oil pressure of main caliper assembly oil tank is zero, and
that of emergency caliper assembly oil tank is the maximal.
(7) Pull slowly “electronic brake handle”, check pressure of left and right pipeline for
increasing steadily, check actuation of main service calipers for sensitivity and
response. Operate repeatedly for several times to ensure reliable performance.
(8) Backfit brake pads. Rotate brake disc, pull slowly “electronic brake handle”, make
brake pads contact with brake disc, repeat for several times.
(9) New brake pad must be contacted to 75% and above interface area before using.
Notice to control oil pressure of brake during contacting, it will be running-in under
3MPa in general.
(10) Check crown-block protecting device；
(11) Must make oil pump run for 10～30 minutes before normal using after installation
and adjustment, and operate “brake handle” repeatedly for several times. At the
same time, check level, oil pipeline system for good conditions, especially, the level
of oil tank shall be maintained between the highest and lowest level surfaces.
(12) The system can be used only after all are normal.
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Service manual Electric Control Hydraulic Disc and Caliper Installation Adjustment

5.1. Preparation before adjustment:

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