Forward and Reversing Vibrating Plate LG 140/160/200/250/300

Forward and Reversing Vibrating Plate

LG 140/160/200/250/300/450/500/550/700

Work Shop Manual

WLGALLEN1, August 1998

These instructions apply from:

LG 140 PIN (S/N) *31400001*

LG 160 PIN (S/N) *31600001*

LG 200 PIN (S/N) *32000001*

LG 250 PIN (S/N) *32500001*

LG 300 PIN (S/N) *33000001*

LG 450 PIN (S/N) *34500001*

LG 500 PIN (S/N) *35000050*

LG 550 PIN (S/N) *35500049*

LG 700 PIN (S/N) *37000001*

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We reserve the right to change specifications without notice.

Printed in Sweden.

1

CONTENTS

Page

Technical data ........................................................................... 3

Principles of operation ............................................................... 4

Hydraulic diagram - LG 140/160/200/250/300/450/500/700 ..... 5

Hydraulic diagram - LG 550 ...................................................... 6

Hydraulic system ....................................................................... 7

Eccentric housing identification ................................................. 8

Assembly of eccentric element - Control shaft .......................... 9

Assembly of eccentric element - Drive shaft ........................... 10

Timing of eccentric element .................................................... 11

Assembly of eccentric element - Eccentric element ............... 12

Assembly of eccentric element - Hydraulic pump ................... 13

Assembly of eccentric element - Piston assembly ............ 14, 15

Troubleshooting ....................................................................... 16

WARNING SYMBOLS

WARNING

Safety instructions – Personal safety

Special caution – Machine or component damage

2

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TECHNICAL DATA

Model Engine Engine VPM

RPM

LG 140

Farymann 15D 2850

Honda GX160 3600

LG 160

Farymann 15D 3600

Honda GX160 3600

LG 200

Hatz 1B20 3000

Honda GX160 3600

LG 250

Yanmar L60AE 2850

LG 300

Hatz 1D31S 2850

LG 450

Yanmar L100AE 3000

LG 500

Hatz 1D60Z 3000

LG 550

Hatz 1D60S

LG 700

Hatz 1D81S

3000

3000

3900

3900

4920

4920

3900

3900

3900

3900

3300

3600

3300

3300

Fuel tank capacity lit. (qts)

4,0 (4.2)

3,6 (3.8)

4,0 (4.2)

3,6 (3.8) x,x (y.y)

3,6 (3.8)

3,5 (3.7)

5,0 (5.3)

5,5 (5.8)

7,0 (7.4)

7,0 (7.4)

7,0 (7.4)

Engine oil Hydraulic capacity

Eccentric tank capacity shaft lubrication lit. (qts) lit. (qts) lit. (qts)

1,0 (1.06)

0,6 (0.65)

1,0 (1.06)

0,6 (0.65)

1,0 (1.06)

0,6 (0.65)

1,1 (1.15)

1,2 (1.25)

1,5 (1.6)

1,5 (1.6)

1,5 (1.6)

1,5 (1.6)

1,5 (1.6)

1,5 (1.6)

1,6 (1.7)

1,6 (1.7)

1,65 (1.75) 3,5 (3.7)

2,0 (2.1) 3,5 (3.7)

1,7 (1.8)

2,0 (2.1)

3,5 (3.7)

3,5 (3.7)

0,4 (0.42)

0,4 (0.42)

0,4 (0.42)

0,4 (0.42)

0,5 (0.53)

0,4 (0.42)

0,5 (0.53)

0,5 (0.53)

0,8 (0.85)

0,8 (0.85)

0,8 (0.85)

1,5 (1.6)

OTHER SERVICE INFORMATION

Engine oil

Hydraulic oil

Eccentric housing

LG 140/160/200/250/300/450/700

SAE 10W-30

Shell Morlina 10

SAE 10W-30

LG 140/160/200/250/300/550

30°

35 bar (500 psi)

1 sec

Max force angle

Hyd. pressure

Response time

Tightening Torque

- Housing

- Ecc. weight

- Belt tension

Loctite

Bolts locked with

Sealing surfaces

Hyd. pump spline

Eccentric weight

140 Nm (103 lb.ft)

85 Nm (63 lb.ft)

3 mm/25 N (1/8"/6 lbs)

Loctite 242

Loctite 510

Loctite 648

Loctite 271

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LG 500/550

SAE 10W-40

Shell Tellus TX32

SAE 10W-40

LG 450/500/700

30°

50 bar (725 psi)

1 sec

140 Nm (103 lb.ft)

85 Nm (63 lb.ft)

3 mm/25 N (1/8"/6 lbs)

3

PRINCIPLES OF OPERATION

The vibrations of a reversable plate compactor are generated by 2 counter-rotating eccentric weights located in a housing and bolted directly to the bottom plate. The housing is centrally mounted to the bottom plate and the eccentric weights can be aligned to change the "direction of vibration", this allows forward motion, stand still and reverse motion. Changing the direction of travel is done hydraulically with a single lever at the operator handle.

Fig 1. Direction of vibration

A centrifugal clutch mounted on the engine transmits driving torque to the eccentric shafts through a V-belt at high engine speed and disengages at low engine speed to permit idling.

The driven shaft (1) also turns a hydraulic pump (2) providing flow to stroke a piston (3) in the control shaft (4). When the piston is fully stroked, the weights allign such that the machine travels

Forward. To reverse direction, pump flow is directed to tank and a return spring (5) in the control shaft alligns the weights so that machine travels in reverse. When the hydraulic system is not working, the machine will travel only in reverse. The same principal is valid for LG 550 but there is two pistons controlled shafts to enable the plate to return.

4 3 1

5 2

4

Fig 2. Eccentric weights

1. Driven shaft

2. Hydraulic pump

3. Piston

4. Control shaft

5. Return spring

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HYDRAULIC DIAGRAM (LG 140/160/200/250/300/450/500/700)

8

Fig 3. Hydraulic diagram

1. Control valve

2. Way valve

3. Relief valve

4. Check valve

5. Cylinder

6. Airfilter

7. Hydraulic pump

8. Hydraulic tank

2

1

5

4

7

A

P T

3

6

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5

HYDRAULIC DIAGRAM (LG 550)

5

1

101

Left cylinder

4

5

A1

ø1.0

ø0.8

B1

4

801

2

Right cylinder

5

501

4

2

A2

ø1.0

ø0.8

B2

4

701

P

2,4 l/min

0,76 cm

3

3

35 bar

Valve block

6

10 µm nom.

T

0,5 bar

7

8

Shell Tellus Oil T32

Left cylinder

Right cylinder

Forward

Reverse

Left

Right

6

Fig 4. Hydraulic diagram

1. Control valve

2. Three way valve

3. Relief valve

4. Check valve

5. Cylinder

6. Hydraulic filter

7. Hydraulic pump

8. Hydraulic tank

9. Test port

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HYDRAULIC SYSTEM

Checking hydraulic tank oil level.

1

2

3

4

1. Correct hydraulic tank oil level is 7 cm (2 3/4 in.) below edge of filler hole, use specified oil only.

2. If oil level is low, check connections and hoses.

3. If there is no visible leakage, check if oil is leaking into eccentric housing. Forward motion of the machine would also be effected.

4. Check piston seal if hydraulic oil is found in housing.

Fig 5. Hydraulic system

1. Four way valve

2. Hydraulic tank

3. Cylinder

4. Hydraulic pump

Control valve operation -

Adjusting hydraulic pressure

Fig 6. Valve operation

2

1

3

1. Connect a pressure gauge in-line at hose, position

(1) or in-line at pump outlet fitting. When control valve lever is moved forward, gauge should show pressure. There is pressure in only in forward.

When lever is set to reverse, pump flow is ported back to tank and the spring returns the piston.

2. If adjustment is necessary, adjust at position (2) to

500 psi for LG 140, 160, 200, 250, 300 and 550.

Adjust to 750 psi for LG 450, 500 and 700.

3. If pressure can’t be adjusted, check the hydraulic pump.

When machine operates in reverse only, this indicates that the hydraulic system is not working or piston seal at cylinder is damaged or pin control shaft may be broken.

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8

ECCENTRIC HOUSING IDENTIFICATION

PUMP SIDE

FRONT

Fig 7. Eccentric housing

1. Drive shaft location

2. Pulley

3. Control shaft location

1

DRIVE SIDE

3

2

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ASSEMBLY OF ECCENTRIC ELEMENT

Control shaft

1

4

2

3

2

5

1.

Fit bearings on control shaft’s pump side and driven shaft’s drive side.

2.

Place control shaft’s eccentric weight (1) in housing.

3.

Fit 2 bearings (2) in sleeve (3) and place in housing with gear next to housing drive side.

4.

Fit inner bearing race and snap ring on control shaft (4) pump side. Place shaft in housing.

5.

Fit spacer (5) on shaft.

6.

Fit bearing, inner race and snap ring, check shaft end play.

Fig 8. Control shaft

1. Eccentric weight

2. Bearing

3. Sleeve

4. Control shaft

5. Spacer

Control shaft

2

Pump side

3

1

Drive side

7.

Clean inside of control shaft.

8.

Fit piston (1) in shaft.

9.

Fit pin (2) through the groove in the sleeve, the groove in the shaft and piston. Make sure the groove in the pin is center of shaft.

10. Fit set screw (3) to lock pin (2) in position. Use

Loctite 242.

11. Fit spring (4), stop (5) and snap ring (6) in the shaft.

12. Check operation of spring and sleeve by pushing in on position.

1 2

Fig 9. Control shaft

1. Piston

2. Pin

3. Screw

4. Spring

5. Stop

6. Snap ring

3

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4 5 6

9

4

3

2

ASSEMBLY OF ECCENTRIC ELEMENT

5

6

LG 140, LG 160, LG 200, LG 250, LG 300

1.

Place driven shaft (1) with gear next to housing drive side.

2.

Fit bearing (2), inner race (3) and snap ring (4) on driven shaft pump side.

3.

Interlock the gears when holes (5) on control shaft and drive shaft face straight up. Drive shaft threaded hole faces up.

4.

Fit spacer (6), inner race and snap ring on driven shaft drive side.

5.

Check driven shaft end play, this can be done by carefully hitting the shaft with a mallet.

1

Fig 10. Drive shaft

1. Drive shaft

2. Bearing

3. Inner race

4. Snap ring

5. Hole in drive shaft/control shaft

6. Spacer

2

1

3

LG 450, LG 500, LG 550*, LG 700

Place snap ring (1) and gear wheel (2) on shaft with the punch marks toward the drive side of the housing, mount key (3) and the snap rings.

Interlock the gears as shown and install ring (4) with Loctite 648.

4

* The LG 550 is slightly different to the pictures but is mainly the same

Fig 11. Control shaft

1. Snap rings

2. Gear wheel

3. Key

4. Ring

6.

Fit sleeve (1) on driven shaft pump side, use

Loctite 648.

1

Fig 12. Eccentric housing - drive side

1. Sleeve

10

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TIMING OF THE ECCENTRIC ELEMENT

5

Fig 13. Eccentric Element

5. Hole in drive shaft/control shaft

LG 140, LG 160, LG 200, LG 250, LG 300

Interlock the gears when holes (5) on control shaft and drive shaft face straight up. Drive shaft threaded hole faces up.

LG 450, LG 500, LG 550, LG 700

Interlock the gears when the timing marks are correct.

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ASSEMBLY OF ECCENTRIC ELEMENT

1

2

3

4

7

5

6

8

9

Fig 14. Eccentric element

1. Eccentric weight

2. Cover

3. Sealing

4. Cover

5. Sleeve

6. Pulley

7. Key

8. Washer

9. Screw

1.

Fasten the eccentric weight (1) to the control shaft using the screw and washer. Use Loctite 271, torque 85,4 Nm (63 lb.ft).

2.

Repeat procedure for the driven shaft.

3.

Install the cover (2) on drive side control shaft using Nordlock lock washers. Puller hole in vertical position. Use Loctite liquid gasket.

4.

Install sealing (3) in cover (4).

5.

Repeat step nr. 3.

6.

Install sleeve (5) on pulley (6).

7.

Install pulley (6), key (7), washer (8) and screw (9).

Use Loctite 242.

12

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ASSEMBLY OF ECCENTRIC ELEMENT

1.

Install the splined sleeve on the pump using

Loctite 242.

Fig 15. Hydraulic pump

1. Splined sleeve

1

1

Fig 16. Hydraulic pump

1. Cylinder

2. Cover

3. Hydraulic pump

2

3

2.

Install the cylinder (1) at the control shaft pump side, hole facing back. Use Loctite liquid gasket and Nordlock washers.

3.

Install hydraulic pump on cover (2). Use Loctite liquid gasket and Nordlock washers.

4.

Install the cover. Inner threaded hole for hydraulic pump facing the cylinder, puller hole should be vertical.

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ASSEMBLY OF ECCENTRIC ELEMENT

1 3 2 1 4

Bearing assembly LG 140/160/200/250/300

1.

Install bearing (1) on the shaft.

2.

Install 5 pairs of opposite facing disc spring washers (2) see diagram. Fit spacer (3) over the washers.

3.

Install the second bearing (1) on the shaft.

4.

Install the snap ring (4).

Fig 17. Piston assembly

1. Bearing

2. Disc spring washer

3. Spacer

4. Snap ring

19

20

16

17

18

9

Fig 18. Piston assembly

9. Snap ring

16. Axial bearing

17. Spacer

18. Radial bearing

19. Disc spring washer

20. Washer

Bearing assembly LG 450/500/700

1.

Assemble axial bearing (16) on shaft, (outerring small and wide side).

Small side on bearing towards the sealing.

2.

Install spacer (17).

3.

Install second radial bearing (18) on the shaft.

4.

Install washer (19), washer (20) and lock with retaining ring (9).

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ASSEMBLY OF ECCENTRIC ELEMENT

Sealing assembly LG 140/160/200/250/300/450/700

1.

Install shaft in the piston with snap ring (1).

2.

Install the seal (2) on the shaft.

2 1

Fig 19. Piston assembly

1. Snap ring

2. Seal

19 20

10

16

17

18

9

11

12

13

Fig 20. Piston assembly

9. Snap ring

10,19. Disc spring washer

11,20. Washer

12. Shaft seal

13. Guide

16. Axial bearing

17. Spacer

18. Radial bearing

9

Sealing assembly LG 500

1.

Assemble guide (13).

2.

Install shaft seal (12), washer (11), 1 pair of opposite facing washers (10) and lock with snap ring (9).

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16

TROUBLESHOOTING

Low VPM or machine does not vibrate

- Check belt tension

- Check centrifugal clutch and drive pulley

- Check eccentric element

Machine travels in reverse only

- Check oil level in the hydraulic tank. If low and there are no external leaks, check oil level in the eccentric housing. If hydraulic oil has entered the housing, the seal on the piston is damaged and must be replaced.

- Loosen hydraulic nose near cylinder or below check valve, and check that you have pressure when control valve lever is moved forward. There is pressure only when is stroked forward.

- If no pressure check the pump.

- Inspect the check valve, that it is installed the right way, the side with the ball should be towards the control valve.

- Pin in control shaft may be broken, eccentric element must be disassembled to replace the pin.

During assembly it is most important that the two shafts are in the right position relative to each other. On the smaller plates, LG 140, LG 160, LG 200,

LG 250 and LG 300 the round hole in the sleeve on the control shaft should point up (12 o’clock) and in the driven shaft the threaded hole should also point straight up (12 o’clock). This is the position of the shafts when the two gears are intermeshed and the last bearing is pressed in the housing.

On the larger plates, LG 450, LG 500, LG 550 and LG 700 the gears have timing marks. Punch mark on single gear tooth is intermeshed with the two punched teeth on the other gear.

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Svedala Compaction Equipment AB

Box 504, SE-371 23 Karlskrona, Sweden

Phone: +46 455 30 60 00, Fax: +46 455 30 60 30

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