Etesia HYDRO 124D Technical Training Manual
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Etesia HYDRO 124D Technical Training Manual

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Summary of Contents for Etesia HYDRO 124D

  • Page 2 - 2 -...
  • Page 3 PRESENTATION/CONTENTS ALL HYDRAULIC • Drive transmission • Differential lock • Steering • Grassbox lifting • Grassbox opening • Tool-holder triangle • Power take-off STEERING • Height and angle-adjustable column • Hydraulic assistance (Power steering) NB : The steering wheel effort depends on the rotational speed of the steering wheel and on the engine speed.
  • Page 4 GRASSBOX. - 4 -...
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  • Page 6 ENGINE ENGINE ENGINE ENGINE Arguments 1) All the technology of a modern high-performance engine 4-stroke diesel engine In-line cylinders Liquid cooling Injection with injector pump on the cylinder head Distribution by overhead camshaft Camshaft drive by notched belt Double power take-off on the crankshaft Power take-off on the camshaft Pressure lubrication with lobe-type pump on the crankshaft External total pass oil filter...
  • Page 7 TECHNICAL SPECIFICATIONS Description Value Unit Cylinders Displacement Bore Stroke Compression ratio 22.8 : 1 Power (at 3600 rpm) 23.4 Maximum torque (at 2000 rpm) 53.5 Operating speed 2850 Idling speed (minimum) 1200 Oil sump capacity With filter :2.4 / without filter : 2.3 Litre Weight (empty) ALTERNATOR The alternator is placed at one end of the crankshaft and is integrated with the flywheel.
  • Page 8 POWER CURVES / CONSUMPTION / TORQUE LUBRICATION - 8 -...
  • Page 9 AIR SUPPLY CIRCUIT (COMBUSTION). AIR FILTER - 9 -...
  • Page 10 COOLING SYSTEM. A thermostatic valve allows the engine to come up to its operating temperature more rapidly from cold (starting), hence 2 possible routes of the coolant (main and by-pass circuits). Engine cold - 10 -...
  • Page 11 ENGINE HOT. - 11 -...
  • Page 12 FUEL SUPPLY SYSTEM. NB : The rotational speed of the camshaft is half the rotational speed of the crankshaft, in other words of the engine speed, as the camshaft works on a full engine cycle ( 1 engine cycle = 4 engine strokes = 2 crankshaft rotations). Stroke Inlet Compression...
  • Page 13 Breakdowns and their possible causes. The table below indicates various breakdowns liable to occur during use of the engine and their possible causes. It is absolutely vital that the simplest checks be systematically made before any dismantling or replacement work. Some of these anomalies may also be due to elements of the H124D ride-on mower (for example : will not start due to the absence of one or more safety conditions …) BREAKDOWN...
  • Page 14 ANOMALIES ON LDW903FOCS ENGINE The following checks must be made after you have ensured that the electrical parts of the machine are working correctly (safety contactors, rodding…). 1.ENGINE DOES NOT START (Starter not working) Check the battery is in good condition (voltage and density) Check the terminals and battery terminals are in good condition and clean Check the electrical harness is in good condition (correct connection of the different plugs, check for traces of oxidation).
  • Page 15 Warning ! There are 3 different cylinder head gaskets : be sure to put back the same one. If in doubt, measure the piston overrun at TDC and contact us. Without hole : Ref.Lombardini : 4730 595 Ref.ETESIA : 30509 One hole : Ref.Lombardini : 4730 596 Ref.ETESIA : 30510...
  • Page 16 TIGHTENING TORQUES Combustion pre-chamber 1st phase : 100 Nm 2nd phase : 180 Nm Heater plugs : 20 Nm Rocker-arm assembly : 40 Nm Flywheel : 80 Nm Grooved pulley : 360 Nm (Careful : left thread) Rocker cover : 8 Nm Rack fixing screw : 1.1 to 1.3 Nm...
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  • Page 18 HYDRAULICS HYDRAULICS HYDRAULICS HYDRAULICS Contents 1) General points 2) The H124D equipment circuit. Introduction 2.1) Power unit 2.1.1) General points 2.1.2) External gear pump (tandem pump) 2.2) Control 2.2.1) Control valves 2.2.2) Pressure limiting devices 2.2.3) Flow limiters 2.2.4) Safety valves (parachute valve) 2.3) Receivers 2.3.1) Rams 2.3.2) Hydraulic steering (ORBITROL)

  • Page 19: Hydraulic System

    1) 1) General points General points General points General points ENERGY ENERGY CONVEYOR TRANSFORMATION -oils -Power units (pumps) -Receivers (Ram, motor…) HYDRAULIC SYSTEM CONTROL ENERGY TRANSFER - Control valves - Flow limiter -Flexible hoses - Pressure limiting device -Connection -Hydraulic tubes - 19 -...
  • Page 20 2) The equipment circuit Introduction This circuit is of the open type. An open circuit is defined as follows : The oil is sucked into a tank (1) by a power unit (pump) (2), delivered to a receiver (ram…) (3) then returned to the tank.
  • Page 21 2.1.2) The external gear pump The disengagement of the pinion teeth liberates a volume that fills with oil. This is suction. The oil is transferred from the suction chamber to the discharge chamber. The engagement of pinions leads to a reduction in the volume causing the oil to be expelled. This is discharge.
  • Page 22 2.2) Control 2.2.1) The control valves General points The control valves control the movements of the receivers (rams or motors). They act as "points" switching the hydraulic flow from the pumps to the different uses. They are characterised by "O/P" (O= number of openings / P= number of positions) In our case, we use only two types of control valve in the equipment circuit : 4/3 Control valve Centre closed...
  • Page 23 On the Hydro 124 D, the control valves are controlled electrically. They are grouped together in 2 blocks. Grassbox controls. The first block is situated underneath the engine cover, under the electric module. It controls the grassbox functions, namely : grassbox up / down (1) grassbox flap opening / closing (2) grassbox opening / closing (3)
  • Page 24 The second block is situated underneath the ORBITROL (assisted steering component), behind the coupling plates (at the front of the machine). It controls the functions of the front parts of the machine, namely : Accessory-holder triangle up / down (1) Control of ram mounted on the accessory (depending on accessory.
  • Page 25 2.2.2) The pressure limiting devices General points The pressure limiting devices are controlled by the pressure in the circuit. When the maximum pressure predetermined by the valve loading is reached, the flow from the pump is directed towards another use or to the tank. The role of this component is to protect the hydraulic components against the risks due to overloading.
  • Page 26 2.2.3) The flow limiters General points The flow limiters serve to check the speed of the receivers. They are throttles that reduce the section through which the hydraulic fluid passes. The excess flow is evacuated to the tank by means of the pressure limiting device.
  • Page 27 Application to the Hydro 124D A flow limiter is placed in the grassbox function control valve block. It is placed on the on the grassbox lifting ram circuit in parallel with a by-pass. Working on the principle that the oil takes the easiest route (the one that offers the least resistance), when we direct the flow towards the "large chambers"...
  • Page 28 2.3) The receivers General points A receiver transforms hydraulic energy into mechanical energy. With the notion of receiver appear the notions of pressure and power. In our application, for the circuits connected to the tandem pump, we have two types of receivers mounted in series on the Hydro124D, that is rams and the ORBITROL.
  • Page 29 2.3.2) HYDRAULIC STEERING or ORBITROL The device is a rotary piston system for controlling vehicle steering. Connected mechanically to the steering wheel, it orients the wheels by means of a conventional ram (on the Hydro124D : single rod ram). The position of the steering ram is obtained from an ORBIT type metering hydraulic motor.
  • Page 30 3) The drive transmission circuit Introduction The drive transmission circuit is of the closed type. A closed circuit is defined as follows : The supply is closed at once on the pump (1) and the hydraulic motor (2). There is no communication between the power branches and the tank.
  • Page 31 Operation The shaft (5) is coupled with a drive system (for example : an engine). The pistons are fixed on the tilting plate by means of a ball joint and are driven in their rotation by the cylinder barrel in which they are lodged. The oil is distributed by the distribution plate (this plate is fixed).
  • Page 32 3.2) Control : The flow divider The flow divider mounted in our circuit is intended to compensate for wheel skid on one of the Hydro 124D's wheels. In normal operation, as soon as a wheel is blocked, all the oil is directed to the "free" wheel : this wheel then skids.
  • Page 33 3.3) Slow internal gear motors The hydraulic motor transforms hydraulic energy into rotary mechanical energy (rotational movement). It is characterised by its cubic capacity (in cm3). The hydraulic motor is equipped with a drain to evacuate the external leakage. Because of the way it is built, the internal pinion must turn 6 times for one turn of the wheel.
  • Page 34 4) Application to the Hydro 124D 4.1) Formulae used. FLOW FLOW = (CUBIC CAPACITY OF PUMP x ROTATIONAL SPEED OF PUMP) / 1000 The flow is expressed in litres/minute (l/min) The cubic capacity is expressed in cubic centimetres / revolution (cm3/rev)
  • Page 35 4.2) The equipment circuit. WARNING : HYDRAULIC FLUID UNDER PRESSURE CAN HAVE ENOUGH FORCE TO PENETRATE THE SKIN. IN THE EVENT OF AN ACCIDENT CONTACT A DOCTOR OR THE NEAREST EMERGENCY SERVICES IMMEDIATELY. Always use measuring equipment that is in good condition. Always ensure that the instrument is appropriate for the measurement to be made.
  • Page 36 Knowing the pressure and the flow of the 4cc pump, we can determine the power available. Max. power of the equipment circuit : 1.05 kW The power take-off at the end of the camshaft (diesel engine) can transmit 7000 Watts (7kW) at most. We have seen that we need 1.05 kW for the equipment circuit.
  • Page 37 (for example : movement on a slope) ETESIA sells a manometer kit under the reference number 30075. It includes a manometer graduated up to 15 bars, another graduated up to 250 bars as well as the couplings allowing the measurement of all the pressures.
  • Page 38 Checking the efficiency of the drive transmission system. MEASUREMENT OF THE MAX. SPEED of the Hydro 124D. This is the simplest means of testing the performances of the drive transmission system. Take a distance of 50 metres in a straight line on a flat tarmac surface (not on a slope). With the machine already running (not starting from stop), at max.
  • Page 39 The negative effects of modifications to the settings. The Hydro124D as it leaves the factory is set for optimum mowing and grass collection. Its accessories are designed to operate with the parameters imposed such as the pressure available from the power take-off. There is therefore no justification for modifying certain parameters.
  • Page 40 Increase in the pressure limitation value of the PTO circuit (diesel engine speed = 2850 rpm) (max. value not to be exceeded : 7 kW).From 160 bars, the power required at the power take-off camshafts exceeds 7kW => There is a risk of damage to the diesel engine. PTO pressure limitation Moreover, we have seen the characteristic curves for the FOCS engine in the engine chapter.
  • Page 41 OILS OILS OILS OILS Introduction The fluid used to transmit the hydrostatic energy is mineral oil (except in certain cases, when there are problems of inflammability). The right choice of a hydraulic fluid is a determining factor in the reliability of the hydraulic transmission. The hydraulic fluid must meet two essential criteria : transmit the energy lubricate and protect the moving parts.
  • Page 42 Application to the l’hydro 124 D The hydraulic oil recommended for the Hydro 124D is of the HV 46 type. "46" is the viscosity value (in centistokes or cSt) at 40° C. At 100° C, the viscosity is 8 cSt.
  • Page 43 Mounting a flexible hose : INCORRECT CORRECT Too much tension on the connectors Curves too small Too many curves - 43 -...
  • Page 44 POLLUTION POLLUTION POLLUTION POLLUTION Introduction. Pollution is the major enemy of hydraulic circuits and components. A large proportion of the operating incidents with hydraulic equipment is due to high pollution. ⇒ Pumps and piston motors as well as the control systems are becoming more and more efficient, with higher yield rates, whilst reducing the internal clearances to limit leakage (internal and external).
  • Page 45 NATURE OF SOLID POLLUTANTS The main pollutants found on examining hydraulic fluids are : silica (sand…) metallic material residue of plastics, fabrics and fibres of all kinds. In general silica comes from outside the circuit inside (equipment operating out of doors), unless it is original pollution due to sandblasting, which is definitely not recommended in hydraulics.
  • Page 46 Debris from components that have been subjected to temperatures that are too high or to cavitation phenomena should be classified as coarse pollution. This justifies the use of a safety filter whose filtration fineness is lower than 15µm. b) Ultra-fine pollution This corresponds to particles smaller than 5 µm.
  • Page 47 10 µm air filter. This filter must be replaced regularly (see maintenance table). Ram rod seals : on the Hydro 124D a cartridge of the oil is placed on the oil return circuit to avoid spreading the pollution to other components.
  • Page 48 OIL RETURN FILTER H124D - 48 -...
  • Page 49 EQUIPMENT CIRCUIT HYDRAULIC DIAGRAM EQUIPMENT CIRCUIT HYDRAULIC DIAGRAM EQUIPMENT CIRCUIT HYDRAULIC DIAGRAM EQUIPMENT CIRCUIT HYDRAULIC DIAGRAM - 49 -...
  • Page 50 DRIVE TRANSMISSION CIRCUIT HYDRAULIC DIAGRAM - 50 -...
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  • Page 53 ELECTRIC MODULE ELECTRIC MODULE ELECTRIC MODULE ELECTRIC MODULE This component is situated under the engine cover, to the left of the engine, above the equipment circuit control valves. It receives all the information coming from the safety contactors and switches (except those for the lights and sens indicators). Depending on the information received, it will authorise, or not : the starting of the diesel engine the starting of the cutting system...
  • Page 54 Wear of the cables of a switch/contactor coming into contact with each other. THE ELECTRICAL HARNESSES There are 5 harnesses, which group together all the cables of the Hydro 124D, thus allowing the components to be connected to each other. They are :...
  • Page 55 The safety contactors or limit switches Their aim is to give information on the condition or position of a part, of a system. There are 4 types on the Hydro124D : plunger-type contactors : they are activated by a translation movement roller-type contactors : they are activated by a rotational movement flat contactor (seat) : it is activated by pressure on its surface.
  • Page 56 3 positions : two-directional control the positions can be "fixed" : stop is controlled by activating the switch to force it to come back to the neutral point. On the Hydro 124D, these are : cutting deck down / neutral / cutting deck up...
  • Page 57 2 positions : single direction control a) fixed positions : power take-off on / power take-off off electromagnetic clutch on / electromagnetic clutch off. Hazard warning lights on / Hazard warning lights off dipped headlights on / dipped headlights off b) automatic return positions differential lock on / differential lock off The ignition switch :...
  • Page 58 The monitors An indicator light gives visual information on the status of a function. There are eight on the Hydro 124D : Symbol Situation Circuit dashboard Return filter clogging and/or hydraulic oil temperature sensor Steering console Low diesel level indicator Steering console Preheating indicator Steering console...
  • Page 59 (or neutral) position by the action of springs. In the same way, a two-position slide will only require one coil, the resting position being obtained with a spring. OPERATION OF THE HYDRO 124D. Although the most of the functions are driven by the hydraulics by, the control valves are controlled electrically.
  • Page 60 DESCRIPTION OF THE SAFETY FUNCTIONS 1) The engine can only be started if : Power take-off is stopped The pedals are at dead centre the electromagnetic clutch switch is on the "off" position (Parking brake on driver sitting on the seat) From the point of view of the contactors and switches : PTO switch = open dead centre contactor = closed...
  • Page 61 2) The engine is stopped if : The machine moves (parking brake on ) removable part(s) of frame missing) Operator leaves the seat (cutting system in operation PTO engaged) From the point of view of the contactors and switches : Dead centre contactor = open (parking brake contactor = closed) (removable part contactor(s) = open)
  • Page 62 3) The blade clutch is on if : Operator is sitting on the seat Fixed grassbox is in the working position Mobile grassbox is closed Mobile part(s) of frame mounted From the point of view of the contactors : Seat contactor = closed Fixed grassbox contactor = closed Mobile grassbox contactor = closed Mobile part contactor = closed...
  • Page 63 EMPTYING THE BASKET When emptying the basket, several operations automatically occur in sequence as the information from the contactors arrives at the electric module, whereas the operator only does one thing : presses the control switch for the function. There are two ways of emptying the basket : - on the ground - raised (at a height between that of ground level emptying and 1.90m inclusive).
  • Page 64 From the point of view of the inputs and outputs to the electric module : = Input Then = Output Closed = current passes Open = no current passes Live = +12V Stop = 0V Initial stage : Input : horizontal flap contactor = closed Input : mobile basket contactor = closed Input :...
  • Page 65 EMPTYING WHEN RAISED Principle Opening and closing : the flap must be brought to the vertical position so that the lifting system can be moved. Detail : Initial stage : flap in the horizontal position, mobile basket closed, basket in the lower position (normal working situation).
  • Page 66 From the point of view of the inputs and outputs to the electric module : Initial stage : flap in the horizontal position, mobile basket closed, basket in the lower position (normal working situation). Inputs : flap horizontal contactor = closed / mobile basket contactor = closed basket in lower position contactor = open.
  • Page 67 BREAKDOWNS AND THEIR PROBABLE CAUSES 1.ENGINE DOES NOT START (Starter doesn’t work) -Check if the blade switch is not engaged. -Check if the power take-off switch is not engaged. -Check that the drive pedals are really at dead centre. -Check if the blade switch is not engaged. -Check if the power take-off switch is not engaged.
  • Page 68 3.ENGINE STARTS BUT DOES NOT RUN CORRECTLY -Check if the diesel tank is full. -Ensure the diesel filter is in good condition -Ensure the air filter is in good condition. -See if the diesel prefilter is not clogged. -Check the length of the fuel pump control rod (dimension : 153.25mm). -Ensure fuel system is working properly (air intake).
  • Page 69 7.ENGINE RUNNING : The cutting system does not start. -Check the seat contactor is working properly. -Check if the side parts of the cutter housing are correctly mounted. -Check if the frame bundle is correctly connected to the main bundle. -Check the contactors on the mobile parts are working and positioned correctly .
  • Page 70 12. DURING MOWING : Poor cutting quality. Check : - the sharpness of the blades and their general condition - the engine speed - the condition of the cutting system drive belt. - the tyre pressure - the adjustment of the cutting deck - If the operating speed is not too high in relation to the height of the grass to be cut, - that the blades are not mounted the wrong way round ;...
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  • Page 72 LUBRICATION Position Elements Number of Once a After the Every 125 lubricators week first 50 hours Remarks hours STEERING Axle Shell Retinax HD2 Mobil Mobilplex 47 Steering ram Shell Alvania G2 Steering joint Shell Alvania G2 PEDAL Parking brake Shell Alvania G2 FRAME Mobile parts With a...
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  • Page 74: Regular Maintenance

    REGULAR MAINTENANCE. Elements Before each After the first Every 125 Every 250 Every 1000 Every Remarks 50 hours hours hours hours 2500 hours ρ ρ Engine oil level ρ ρ Hydraulic oil level ρ ρ Coolant level ρ Clogging indicator Change filter if indicator light on...
  • Page 75 Lubrication of the machine (see training manual or instructions for use) 8) Check the safety functions See chapter in the training manual IMPORTANT SUPPLIES AND WEAR PARTS ( FILTER, OIL, DIESEL, LOST BOLTS AND NUTS, ETC…) AND CLEANING ARE NOT COVERED BY ETESIA. 75 -...
  • Page 76 LOMBARDINI LDW903FOCS ENGINE MAINTENANCE 10hrs 125hrs 250hrs 500hrs 1000hrs 2500hrs 5000hrs ρ AIR FILTER ρ VENTILATION GRILLE ρ INJECTOR ρ OIL LEVEL ρ COOLANT LEVEL ρ FLEXIBLE AIR PIPES ρ SET OF ROCKER-ARMS ρ CALIBRATION OF INJECTORS ρ(1) OIL SUMP ρ(2) COOLANT ρ(1)
  • Page 77 SETTINGS Adjustment of the electro-jack travel (cutting height) Left screw : adjustment of X in retracted position Right screw : adjustment of X in out position Turn the screw to the left : X increases Turn the screw to the right : X diminishes Cutting height max.
  • Page 78 Adjustment of the cutting deck 1) Left-Right alignment Before making any adjustments, it is essential to check the pressure of the tyres (1.2 bars front and rear) as well as the flatness of the ground on which the machine is standing. Use the eccentrics (rep.1) to compensate for any differences between the right and left sides.
  • Page 79 Adjustment of the drive transmission To be sure that the drive transmission is working properly, the dead centre must be adjusted. This is guaranteed when the three "zeros" coincide. -The hydraulic zero -The mechanical zero -The electrical zero HYDRAULIC ZERO The hydraulic zero consists of positioning the pump distribution plate on the "displacement nil"...

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