FAN DRIVE

SB(R) 4000+/SB(R) 230 Euro 4/5

0907 DD007800

SB(R) 4000+/SB(R) 230

Introduction This maintenance manual contains all the relevant maintenance work. It also contains safety regulations, which must be strictly observed. Work which is not described in this maintenance manual, such as revision, fault finding, etc., is described in the VDL Bus & Coach Workshop Instruction Manual or the Workshop Instructions for the component concerned. Experienced mechanic The technical information and the explanation of the maintenance work given in this maintenance manual have been compiled with the utmost care. Whilst compiling this maintenance manual, it has been assumed that the mechanic has the necessary experience and has had the required education or training to be able to carry out the maintenance work in a responsible and safe manner. Vehicle type The information in this maintenance manual has been updated until the time of printing and only relates to the vehicle series: SB(R) 4000+/SB(R) 230 Euro 4/5

0907

CONTENTS
SB(R) 4000+/SB(R) 230

Hydraulic fan drive PR-engine

Hydraulic fan drive PR-engine..................... 1-1 Hydraulic schematic diagram.......................... 1-1 operation of the hydraulic fan drive................. 1-2 Layout of the fan drives hydraulic system ...... 1-3 Specifications.................................................. 1-5 Temperature sensor........................................ 1-6 Electronic unit ................................................. 1-7 Proportional valve ........................................... 1-9 Thermostat valve .......................................... 1-11 Electrical system inspection.......................... 1-12 Hydraulic system inspection ......................... 1-14 Fan - engine speed ratio ............................... 1-15

1 2

Hydraulic fan drive MX-engine

Hydraulic fan drive MX-engine .................... 1-1 Hydraulic schematic diagram.......................... 1-1 operation of the hydraulic fan drive................. 1-2 Layout of the fan drives hydraulic system ...... 1-3 Specifications.................................................. 1-4 Temperature sensor........................................ 1-5 Electronic unit ................................................. 1-6 Axial piston pump............................................ 1-8 ED valve........................................................ 1-10 Electrical system inspection.......................... 1-12 Hydraulic system inspection ......................... 1-14 Fan - engine speed ratio ............................... 1-15

0907

DD007800

CONTENTS
SB(R) 4000+/SB(R) 230
Maindisclaimer 0907 VDL Bus & Coach bv, Eindhoven, The Netherlands. In the interest of continuous product development VDL Bus & Coach reserves the right to change specifications or products at any time without prior notice. No part of this publication may be reproduced and/or published by printing, by photocopying, in digital format or in any way whatsoever without the prior consent in writing of VDL Bus & Coach. This manual shall be governed by and applied in accordance with the laws of the Netherlands. Any dispute here under shall be referred to the decision of the District Court of s-Gravenhage in the Netherlands

1 2

DD007800

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230

HYDRAULIC FAN DRIVE PR-ENGINE

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive PR-engine

1.
1.1

HYDRAULIC FAN DRIVE PR-ENGINE

HYDRAULIC SCHEMATIC DIAGRAM

ILAj0127

1. 2. 3. 4. 5. 6. 7. 8.

Hydraulic reservoir Filter Hydraulic pump Proportional valve Hydraulic motor Heat exchanger Electronic unit Thermostat valve

0907

1-1

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine 1.2 OPERATION OF THE HYDRAULIC FAN DRIVE SB(R) 4000+/SB(R) 230

The hydraulic fan drive is infinitely variable by means of a proportional valve (4) and is controlled by an electronic unit (7). As a result, engine power is only taken when necessary.

The hydraulic oil is drawn out of the reservoir (1) by the hydraulic pump (3) and then pumped to the proportional valve (4). There is a branch before the proportional valve from where the hydraulic motor (5) with the fan is driven. The proportional valves opening determines the quantity of oil that can flow through the hydraulic motor (system pressure) and, therefore, the fans rotational speed. The proportional valve is controlled by an electronic unit that regulates the current sent to the proportional valve depending on the engines coolant temperature and whether the retarder is turned on or not. When the coolant is cold, the fan rotates slowly so that the engines air intake that flows through the intercooler is cooled. Coolant temperature < 86 C (< 72 C when the retarder is turned on) The proportional valve is fully open when the engine is cold. The hydraulic oil then flows from the pump to the thermostat valve (8) via the bypass in the proportional valve. The thermostat valve is open when the hydraulic oil temperature is < 45 C. As a result, the oil flows back to the reservoir through the thermostat valve. The hydraulic oil that flows back to the hydraulic reservoir (1) passes through a filter (2). The thermostat valve (8) closes when the hydraulic oil temperature is > 45 C. The oil then flows from the proportional valve (4) back to the reservoir (1) via the heat exchanger (6). Coolant temperature > 86 C < 92 C (> 72 C < 78 C when the retarder is turned on) The proportional valve (4) will partly close when the coolant temperature is > 86 C < 92 C (> 72 C < 78 C when the retarder is turned on). As a result, the system pressure in the direction of the hydraulic motor increases and the hydraulic motor starts to rotate at a faster speed. Coolant temperature > 92 C (> 78 C when the retarder is turned on) The proportional valve (4) is fully closed when the coolant reaches a temperature of 92 C (or 78 C when the retarder is turned on). As a result, the maximum system pressure builds up in the direction of the hydraulic motor and the hydraulic motor then rotates at the maximum speed. The system pressure is limited to 220 bar by a pressure relief valve.

1-2

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.3 LAYOUT OF THE FAN DRIVES HYDRAULIC SYSTEM Hydraulic fan drive PR-engine

ILAj0168

Situation 1: Proportional valve OPEN Thermostat valve OPEN 1. Hydraulic reservoir 2. Filter 3. Hydraulic pump 4. Proportional valve 5. Hydraulic motor 6. Heat exchanger 7. Thermostat valve

0907

1-3

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine SB(R) 4000+/SB(R) 230

ILAj0169

Situation 2: Proportional valve CLOSED Thermostat valve CLOSED 1. Hydraulic reservoir 2. Filter 3. Hydraulic pump 4. Proportional valve 5. Hydraulic motor 6. Heat exchanger 7. Thermostat valve

1-4

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.4 SPECIFICATIONS Hydraulic fan drive PR-engine

Temperature sensor (F568) Temperature range Resistance at 20 C Torque Time delay : : : : -30 C to + 130 C 1,000 Ohm 30 Nm 11 s

Electronic unit (D593) Supply voltage Output current Current limiter Time delay : : : : 11 - 36 V DC 0 - 1.1 A, load duration max. 50% output is limited to 1.1 A 3 sec. when retarder is operated due to excess pressure safety device

ILAj0126

Proportional valve (B158) Hydraulic Pressure regulating valve : 220 bar Nominal pressure (flow = 20 l/min) : 220 bar Max. flow : 200 l/min Electrical Duty cycle Electromagnet voltage Electromagnet current Coil resistance

ILAj0170

: : : :

100% 12 V 0.. 1.5 A 2.3 Ohm at 20 C Max. 3.65 Ohm

Static/Dynamic Hysteresis Torque

: < 4% : 100 +20 Nm

ILAj0128

0907

1-5

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine
Hydraulic pump Volume

SB(R) 4000+/SB(R) 230

: 19 cm3 / rev.

Hydraulic motor Volume

: 22,5 cm3 / rev.

1
Oil reservoir Capacity : 10 l Filter : Integrated Pressure relief valve : 3 bar

1.5

TEMPERATURE SENSOR

The temperature sensor (PTC type) is fitted in the radiator and measures the outgoing coolant temperature. The temperature sensors resistance varies under the influence of the coolant temperature according to the given characteristic. The PTC sensor gives an almost linear relationship between the temperature and the resistance value.
ILAj0125

ILAj0126

1-6

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.6 ELECTRONIC UNIT Hydraulic fan drive PR-engine

The single-channel electronic unit (D593) controls the proportional valve (B158) and, by doing so, also the speed of the fan. The coolant temperature value, which is used to control the proportional valve, is preprogrammed in the electronic unit as the nominal value: 86 C - 92 C retarder OFF. 72 C - 78 C retarder ON. The actual value is provided by the coolant temperature sensor (F568). The proportional valve and, therefore, the speed of the fan are controlled by the pulse-modulating current regulator, depending on the nominal/actual coolant temperature. When the retarder is turned on (relay G165 = open), the fan rotates faster at a lower coolant temperature. The relay (G165) is controlled via IOU 1.

ILAj0171

ILAj0172

B158 D593 E141 F568 G165

Proportional valve Electronic unit Fuse Temperature sensor Retarder relay

0907

1-7

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine SB(R) 4000+/SB(R) 230

ILAj0173

Electronic unit block diagram 1. Voltage supply 2. Sensor input 3. Magnetic valve voltage output 4. Voltage regulator 5. Current regulator with pulse-wide modulation 6. Nominal value 7. Retarder relay (contact open - retarder on)

1-8

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.7 PROPORTIONAL VALVE Hydraulic fan drive PR-engine

General information The proportional valve is a pressure regulating valve which opens proportionally. Operation When the engine is cold, the proportional valve is fully activated (Imax) and is open as far as possible. Almost all the oil from the hydraulic pump flows through the valve back to the reservoir (minimum system pressure). A small amount of the oil will flow via the hydraulic motor. The hydraulic motor/fan then runs at the minimum speed. In this way, the intercooler will be cooled. When the engine is warm, the proportional valve is not activated (I = 0 A) and is closed. All the oil from the hydraulic pump then flows to the hydraulic motor (maximum system pressure). When the proportional valve is in a position between fully open and fully closed, the fan rotates at a speed between the minimum system pressure and the maximum system pressure. If the current to the proportional valve is interrupted, the valve closes and the fan rotates at the maximum speed (safe mode).

ILAj0129

1. 2. A.

Proportional valve Hydraulic motor Hydraulic pump supply

0907

1-9

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine
Situation: Engine COLD Proportional valve fully OPEN

SB(R) 4000+/SB(R) 230

ILAj0132

ILAj0130

Situation: Engine WARM Proportional valve CLOSED

ILAj0133

ILAj0131

1 - 10

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.8 THERMOSTAT VALVE Hydraulic fan drive PR-engine

General information The thermostat valve is fitted in the line parallel to the oil cooler between the inlet and the outlet. The valve has a thermo-wax element and is completely open when the water temperature is below 45 C. The wax in the thermo-wax element is then hard. When the temperature exceeds 45 C, the wax becomes soft and the thermostat valve closes. The valve must be fully closed at 50 C. The thermostat valve ensures that the hydraulic oil becomes warm more quickly and prevents pressure peaks in the hydraulic system when the engine is cold. Operation When the hydraulic oil that flows through the thermostat housing (1) reaches a temperature of 45 C, the wax in the thermo-wax element (6) becomes soft and expands. The wax then pushes the pressure sleeve (4) to the left by means of a pin. Since the pressure sleeve (4) is part of the housing (5), the housing also moves to the right. The flow of oil gets increasingly throttled as the housing (5) gets closer to the sealing surface (A) up until the point that the housings conical surface completely closes the opening (55 C). No more oil then flows through the thermostat valve. The oil then flows back into the reservoir via the heat exchanger. If the temperature falls below 45 C, the wax contracts and the housing (5), together with the pressure sleeve (4), is gradually pushed back as far as possible to the left/right. As a result, the thermostat valve gradually opens as far as possible.

1
ILAj0123

ILAj0124

1. 2. 3. 4. 5. 6. A.

Thermostat housing Circlip Grille Pressure sleeve Housing, wax element Wax element Sealing surface

0907

1 - 11

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine 1.9 ELECTRICAL SYSTEM INSPECTION SB(R) 4000+/SB(R) 230

Perform the inspection twice. Once at a diesel engine speed of 1,450 rpm (A). Once at the max. diesel engine speed of 2,580 rpm (B).

Warning: Keep a safe distance from the rotating fan and the engine.

ILAj0175

1 - 12

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive PR-engine

ILAj0176

0907

1 - 13

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine 1.10 HYDRAULIC SYSTEM INSPECTION
* 78 C when the retarder is turned on.

SB(R) 4000+/SB(R) 230

ILAj0177

1 - 14

0907

HYDRAULIC FAN DRIVE PR-ENGINE

SB(R) 4000+/SB(R) 230 1.11 FAN - ENGINE SPEED RATIO Hydraulic fan drive PR-engine

ILAj0174

0907

1 - 15

HYDRAULIC FAN DRIVE PR-ENGINE

Hydraulic fan drive PR-engine SB(R) 4000+/SB(R) 230

1 - 16

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230

HYDRAULIC FAN DRIVE MX-ENGINE

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive MX-engine

1.
1.1

HYDRAULIC FAN DRIVE MX-ENGINE

HYDRAULIC SCHEMATIC DIAGRAM

ILAj0178

1. 2. 3. 4. 5. 6. 7.

Hydraulic reservoir Filter Axial piston pump ED valve (pressure regulating valve) Hydraulic motor Heat exchanger Electronic unit

0907

1-1

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.2 OPERATION OF THE HYDRAULIC FAN DRIVE SB(R) 4000+/SB(R) 230

The hydraulic fan drive is infinitely variable by means of an axial piston pump with a controllable stroke volume that is operated by an electro-hydraulic pressure regulating valve (ED valve) (4). The ED valve is controlled by an electronic unit (7). The axial piston pump only takes power from the engine when necessary, which saves fuel and also results in the hydraulic oil not becoming warm so quickly. The hydraulic oil is drawn from the reservoir (1) by the axial piston pump (3). The ED valve (4) controls the axial piston pumps (3) operating cylinder (3a). The operating cylinder places the axial piston pumps impact plate in a position that is dependent on the required stroke volume. The quantity of oil that flows through the hydraulic motor (stroke volume) determines the fans rotational speed. The ED valve is controlled by an electronic unit that controls the current sent to the ED valve depending on the engines coolant temperature and whether the retarder is turned on. When the coolant is cold, the fan rotates slowly so that the engines air intake that flows through the intercooler is cooled.

1-2

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 1.3 LAYOUT OF THE FAN DRIVES HYDRAULIC SYSTEM Hydraulic fan drive MX-engine

ILAj0179

1. 2. 3. 4. 5. 6. 7.

Hydraulic reservoir Filter Axial piston pump ED valve Hydraulic motor Heat exchanger Leak-off line 1-3

0907

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.4 SPECIFICATIONS SB(R) 4000+/SB(R) 230

Temperature sensor (F568) Temperature range Resistance at 20 C Torque Time delay : : : : -30 C to + 130 C 1,000 Ohm 30 Nm 11 s

Electronic unit (D593) Supply voltage Output current Current limiter Time delay : : : : 11 - 36 V DC 0 - 1.1 A, load duration max. 50% output is limited to 1.1 A 3 sec. when retarder is operated due to excess pressure safety device

ILAj0126

ED valve (B158) Hydraulic Pressure regulating valve Electrical Control range Max. duty cycle Operating voltage Max. current at Umax Nominal resistance Dither frequency

ILAj0170

: 250 bar

: : : : :

100 - 1,200 mA 100% 12 V 1.54 A 5.5 Ohm at 20 C Max. 3.65 Ohm : 100 - 200 Hz

ILAj0180

1-4

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230
Hydraulic pump Volume

Hydraulic fan drive MX-engine

: 19 cm3 / rev.

Hydraulic motor Volume

: 22,5 cm3 / rev.

Oil reservoir Capacity : 10 l Filter : Integrated Pressure relief valve : 3 bar

1.5

TEMPERATURE SENSOR

The temperature sensor (PTC type) is fitted in the radiator and measures the outgoing coolant temperature. The temperature sensors resistance varies under the influence of the coolant temperature according to the given characteristic. The PTC sensor gives an almost linear relationship between the temperature and the resistance value.
ILAj0125

ILAj0126

0907

1-5

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.6 ELECTRONIC UNIT SB(R) 4000+/SB(R) 230

The single-channel electronic unit (D593) controls the ED valve (B158) and, by doing so, also the speed of the fan. The coolant temperature value, which is used to control the ED valve, is preprogrammed in the electronic unit as the nominal value: 86 C - 92 C retarder OFF. 72 C - 78 C retarder ON. The actual value is provided by the coolant temperature sensor (F568). The ED valve and, therefore, the speed of the fan are controlled by the pulse-modulating current regulator, depending on the nominal/actual coolant temperature. When the retarder is turned on (relay G165 = open), the fan rotates faster at a lower coolant temperature. The relay (G165) is controlled via IOU 1.

ILAj0171

ILAj0172

B158 D593 E141 F568 G165

ED valve Electronic unit Fuse Temperature sensor Retarder relay

1-6

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive MX-engine

ILAj0173

Electronic unit block diagram 1. Voltage supply 2. Sensor input 3. Magnetic valve voltage output 4. Voltage regulator 5. Current regulator with pulse-wide modulation 6. Nominal value 7. Retarder relay (contact open - retarder on)

0907

1-7

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.7 AXIAL PISTON PUMP SB(R) 4000+/SB(R) 230

General information Piston pumps are often used for systems with high pressures or high capacities. The piston pump used here is an axial piston pump with a stationary impact plate and a rotating cylinder block. The cylinders are parallel to the drive shaft (1). The pistons (3) have hydrostatically lubricated sliding shoes so that there is minimum friction between the pistons and the impact plate. The cylinder block (4) is driven by the drive shaft (1). The rotating movement of the cylinder block makes the pistons move back and forth. The position (angle) of the impact plate (2) determines the stroke of the pistons (3) and, therefore, the pump's stroke volume. By making it possible to control the position of the impact plate, the stroke volume can be varied. The larger the impact plates angle, the greater the pumps stroke volume. When the impact plate is vertical, there is no piston stroke and the stroke volume is reduced to 0. The pumps runs, but does not deliver any oil - zero delivery. The impact plate is hydraulically adjusted by the integrated operating cylinder (5). This operating cylinder (5) is controlled by the ED valve (6).

ILAj0181

1. 2. 3. 4. 5.

Axle Impact plate Piston Cylinder block Impact plate operating cylinder

ILAj0182

1-8

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive MX-engine

ILAj0184

0907

1-9

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.8 ED VALVE SB(R) 4000+/SB(R) 230

General information The ED valve (electro-hydraulic pressure regulating valve) is a proportional pressure regulating valve. Operation The ED valve is controlled by the electronic unit by means of a variable magnetic current, which sets the ED valve to a certain pressure. If the pump pressure falls below the set pressure, the axial piston pump tries to increase the stroke volume (increase the volume flow) in order to meet the demand. Once the system pressure reaches the set pressure again, the pump automatically adjusts the stroke volume to the set system pressure. The variable magnetic voltage means that the system pressure is infinitely variable. If the voltage/magnetic current cuts out (I = 0), then the system pressure is limited to Pmax by the pressure regulating valve (safe mode).
ILAj0185

1 - 10

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230
Control valve

Hydraulic fan drive MX-engine

ILAj0186

The spring (2) can be set to a pre-tension by the adjusting screw (1). The spring force works against the control pressure and this sets the maximum system pressure (Pmax). When the magnetic valve (8) is activated, the piston (9) moves to the left against the force of the spring (2). This way, the control valves (9) opening pressure can be infinitely set depending on the control current. The control valve (9) controls the top piston gallery. The pump pressure is applied to the valve via a transverse bore (3) and a calibrated bore (6) in the main piston (4). The valve (12) is held back by the spring package (5). An internal control pressure is applied in the control chamber (7) via the calibrated bore. Depending on the control valve's (9) electronically set opening pressure, the main piston (4) is pushed to the right at the opening pressure (P). This causes port P to be connected to port A. The control cylinder (13) rotates the piston pumps impact plate until the set pressure is reached in P again. If the pressure in P falls, the main piston (4) is moved to the left by the compression spring (5) and ports A and T are connected. The piston pumps impact plate rotates until the set pressure is reached in P again.

0907

1 - 11

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.9 ELECTRICAL SYSTEM INSPECTION SB(R) 4000+/SB(R) 230

Perform the inspection twice. Once at a diesel engine speed of 1,450 rpm (A). Once at the max. diesel engine speed of 2,200 rpm (B).

2

Warning: Keep a safe distance from the rotating fan and the engine.

ILAj0187

1 - 12

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 Hydraulic fan drive MX-engine

ILAj0188

0907

1 - 13

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine 1.10 HYDRAULIC SYSTEM INSPECTION
* 78 C when the retarder is turned on.

SB(R) 4000+/SB(R) 230

ILAj0189

1 - 14

0907

HYDRAULIC FAN DRIVE MX-ENGINE

SB(R) 4000+/SB(R) 230 1.11 FAN - ENGINE SPEED RATIO Hydraulic fan drive MX-engine

ILAj0190

0907

1 - 15

HYDRAULIC FAN DRIVE MX-ENGINE

Hydraulic fan drive MX-engine SB(R) 4000+/SB(R) 230

1 - 16

0907