EX3600 Hydraulic Pump Assembly
2 month ago
Product details
The EX3600 Hydraulic Pump Assembly is a core component of large-scale hydraulic excavators (e.g., Hitachi EX3600-6/E-6 models), designed for ultra-heavy-duty mining and quarrying operations. Below is a structured breakdown of its technical details, functionality, and industry significance.
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1. Key Technical Specifications
【表格】
Parameter Details
Model Compatibility Hitachi EX3600-6, EX3600E-6 (360-ton class excavators)
Engine Matching Cummins QSK60/QSKTA60-CE (1,450 kW @ 1,800 RPM)
Pump Configuration 8 × Variable-Displacement Axial Piston Pumps
- Max Flow Rate 500 L/min per pump (Total: ~4,000 L/min)
- Relief Pressure 29.4 MPa (4,264 PSI)
Operational Weight 362,000–366,000 kg (depending on configuration)
Bucket Capacity 21.0–24.0 m³ (ISO standard)
Max Digging Depth 4,160 mm
Max Reach 15,470 mm
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2. Core Functions & Working Principle
• Role:
Converts mechanical energy from the engine into hydraulic pressure/flow to power the excavator’s hydraulic cylinders (boom, arm, bucket, swing).
• Technical Breakdown:
• Axial Piston Pump Design:
• Rotating pistons inside a swash plate generate hydraulic flow.
• Variable Displacement: Adjusts stroke length (via swash plate angle) to match load demands, optimizing energy use.
• Closed-Loop Circuit: Maintains consistent pressure even under varying loads (e.g., digging vs. swinging).
• Load-Sensing System:
• Dynamically adjusts pump output based on operator input, reducing energy waste.
• Analogy:
Think of the pump as a “hydraulic heart”—it pumps fluid (like blood) under pressure to activate muscles (cylinders) for movement.
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3. Structural Components & Durability
• Key Parts:
• Pump Body & Cover: High-strength alloy steel for pressure resistance.
• Rotor & Pistons: Hardened steel with wear-resistant coatings.
• Inlet/Outlet Ports: High-flow, corrosion-resistant fittings.
• Cooling System: Integrated heat exchangers to prevent overheating.
• Design Features:
• Modular Assembly: Individual pumps can be replaced without dismantling the entire system.
• Sealing Technology: Triple-lip seals and labyrinth designs to prevent fluid leaks.
• Vibration Dampening: Rubber mounts to reduce stress on the pump housing.
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4. Critical Applications
• Mining:
• Used in large open-pit mines (e.g., coal, copper, iron ore) for overburden removal.
• Matched with 100-ton haul trucks (e.g., Komatsu 930E, Caterpillar 797F) for efficient material transport.
• Heavy Construction:
• Dredging, large-scale earthmoving, and infrastructure projects.
• Performance Example:
• Hitachi EX3600E-6:
• 95%+ operational uptime in Chinese mines.
• Loads 3–4 buckets per haul truck cycle (21–24 m³ per bucket).
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5. Maintenance & Longevity
• Key Checks:
• Daily:
• Fluid levels (hydraulic oil, coolant).
• Leaks or abnormal noise.
• Weekly:
• Filter changes (every 250 hours).
• Inspection of couplings and belts.
• Monthly:
• Pressure tests (ensure relief valves function at 29.4 MPa).
• Seal integrity checks.
• Common Failures & Fixes:【表格】
Issue Cause Solution
Low Flow Rate Worn pistons/valves Replace affected components
Overheating Clogged heat exchanger Flush with cleaning solution
Excessive Noise Air in system Bleed air, check pump mounts
• Pro Tips:
• Use OEM-approved hydraulic oil (e.g., Shell Tellus S4 M 46).
• Avoid overloading (exceeding bucket capacity reduces pump lifespan by 30–40%).
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6. Market Impact & Competitive Edge
• Dominance in Heavy Mining:
• The EX3600 series holds40%+ global market sharein the >120-ton excavator segment.
• Competitors: Komatsu PC8000, Liebherr R 9800 (but Hitachi leads in reliability).
• User Feedback Highlights:
• Reliability: “Runs 12-hour shifts for 6+ years with minimal downtime.”
• Efficiency: “Fuel savings of 15% vs. older models due to load-sensing pumps.”
• Support: “Global dealer network ensures parts availability within 48 hours.”
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7. Future Upgrades & Trends
• Electrification:
• The EX3600E-6 model uses electric drives (6,000 VAC), reducing emissions by 30% vs. diesel.
• IoT Integration:
• Sensors monitor pump health in real time, predicting failures before they occur.
• Material Innovations:
• Ceramic-coated pistons (under development) to withstand higher pressures (up to 35 MPa).
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