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Sany Original Compound Pump Set HP5V76L+HP5V76L-ER2D2-T201 Sany Part Number: 150108010013A Applicable Models: SY1250, SY1350
Place of Origin:China
Brand Name:Sany
Model Number:150108010013A
Minimum Order Quantity:1pcs
Price:Negotiable
Payment Terms:T/T,Western Union
Supply Ability:1-10000pcs
Product Description
Detailed Product Specification for Sany Original Compound Main Pump Assembly HP5V76L+HP5V76L-ER2D2-T201
I. Basic Material Information
Full Product Name: Sany Original Tandem Variable Displacement Piston Compound Main Pump Assembly (Fully Electronic Controlled Dual-Pump Merging Hydraulic Main Pump)
Model No.: HP5V76L+HP5V76L-ER2D2-T201
Sany Original Material Code: 150108010013A
Brand Attribution: Original matching main pump assembly for SANY hydraulic system, custom modified version of Hengli HP5V series high-pressure piston pump
Supply Status: In Stock, Wooden Case Packaging, Price Available in US Dollars and Negotiable
Applicable Models:
Sany Ultra-Large Mining Excavators SY1250H, SY1350H (120-ton heavy-duty mining excavators, matched with C ummins Q S K23 high-power engine)
Structure Form: Integrated tandem dual-pump structure with independent displacement control for left and right pumps, equipped with fully electronic E-P/P-V proportional regulator
II. Core Function Definition
This tandem piston compound pump serves as the power core of the entire hydraulic system for SY1250H/SY1350H excavators, supplying high-pressure oil to five executive mechanisms including boom, arm, bucket, travel and swing. Adopting independent displacement regulation plus merging oil supply mode for dual pumps, it matches engine output power in real time via electronic regulators to realize high-flow merging under heavy loads and energy-saving unloading with single pump under light loads. Cooperating with the machine’s fully electronic main control valve, it distributes flow precisely to improve smoothness of compound movements and digging breakout force, while restraining overflow loss and reducing fuel consumption under heavy-load mining conditions. Built-in logic of pressure cut-off, power limitation and negative flow control enables automatic pressure relief upon overload to protect the pump body and hydraulic components.
III. Overall Structure & Material Classification of Key Components
1. Overall Structural Layout (From Input Shaft to Oil Outlet)
Engine Connecting Flange → Main Through Input Shaft → Cylinder Block, Piston & Valve Plate Assembly of Front Pump (HP5V76L) → Cylinder Block, Piston & Valve Plate Assembly of Rear Pump (HP5V76L) → Dual Swashplate Displacement Mechanism → ER2D2 Electronic Proportional Regulator Assembly → T201 Integrated Valve Block Housing → Main Oil Inlet, Independent Oil Outlets for Dual Pumps, Pilot Control Oil Port, Drain Port, Oil Drain & Air Vent Plugs
2. Material & Heat Treatment Process for Core Components
- Pistons, Cylinder Blocks, Valve Plates: High-toughness carburized bearing steel with integral carburizing quenching and mirror finishing. Surface hardness: HRC60~64. Resistant to high-pressure high-speed friction, cavitation and eccentric wear, suitable for continuous long-term operation under 32MPa high pressure and wear resistant to impurities in dusty hydraulic oil from mining sites.
- Swashplates, Retainer Plates, Shoe Assemblies: High-strength quenched and tempered alloy steel with copper-based sintered wear-resistant lining. Excellent load-bearing and anti-impact performance, sensitive swashplate angle adjustment, jamming-free displacement response and no deformation under long-term alternating loads.
- Pump Housing: Precisely integrally cast with high-strength cast aluminum / ductile iron, with sufficient pressure margin for high-pressure chambers, anti-hydraulic impact, vibration and noise reduction. High housing rigidity prevents deformation and oil leakage under high pressure.
- Spools & Sleeves of Electronic Regulator: Precisely matched nitrided alloy pairs with micron-level clearance, fast response, minimal internal leakage, high temperature resistance and anti-coking anti-jamming performance for hydraulic oil.
- Complete Sealing System: Combination of imported fluororubber and PTFE encapsulated oil seals, resistant to high pressure, high-temperature hydraulic oil and aging, eliminating leakage on housing, end covers and regulating mechanisms under high and low temperature conditions.
- Main Drive Bearing Assembly: Matched heavy-duty double-row angular contact bearings and tapered roller bearings, capable of bearing alternating axial and radial impact forces, delivering stable high-speed operation and long service life.
IV. Precise Technical Parameters
Theoretical Displacement per Pump: 76mL/r, Total Displacement of Tandem Pump: 152mL/r
Control Mode: ER2D2 fully electronic dual-mode E-P+P-V displacement control, with T201 integrated pressure cut-off valve group
Rated Working Pressure: 320bar (32MPa)
Instantaneous Peak Pressure: 350bar (35MPa)
Rated Matching Rotational Speed: 2400r/min, Maximum Permissible Rotational Speed: 3000r/min
Maximum Output Flow per Pump @ 2400rpm: 182.88L/min; Total Flow of Tandem Pump: 365.76L/min
Power Control Modes: Composite regulation including constant power, pressure cut-off, negative flow and electronic proportional flow
Matched Engine Power: Matching C ummins Q S K23 powertrain rated 567kW @ 1800rpm
Applicable Hydraulic Oil Temperature: -20℃ ~ +98℃, adaptable to extreme winter and summer temperatures for open-pit mining operations
Net Weight of Assembly: 278kg
Protection Class: IP54, dust-proof and splash-proof against muddy water intrusion
Compatible Fluid: 46#/68# anti-wear high-pressure hydraulic oil for construction machinery; required oil cleanliness: within NAS Class 8
V. Core Product Advantages
Precise Interchangeability with Original Factory Part Code
Exclusive Sany part code 150108010013A. Mounting flange, spline specification, oil port layout and regulator wiring harness interface are 100% compatible with SY1250H/SY1350H. No pipeline modification or power curve calibration required; direct assembly replacement with zero assembly tolerance.
Reinforced Design for Ultra-Large Heavy-Duty Mining Conditions
Optimized for heavy loading, hard rock breaking, continuous climbing and full-load truck loading scenarios of 120-ton mining excavators. Increased load margin for piston friction pairs improves impact resistance, cavitation resistance and fatigue resistance, solving common premature wear and excessive internal leakage under high flow and high pressure, suitable for intensive continuous mining operations.
Accurate ER2D2 Electronic Control Response & Energy Saving
Independent electronic displacement regulation for dual pumps realizes high pump-valve matching, excellent coordination for compound movements and responsive fine manipulation without lag. Automatic displacement reduction and unloading under no-load greatly cuts overflow loss, lowering overall machine fuel consumption by 5%~12%, conforming to Sany’s fully electronic hydraulic matching strategy for complete machines.
Integrated Layout of T201 Valve Block
Built-in integration of pressure cut-off, overload protection and damping throttling simplifies external pipelines, reduces leakage points of external hoses for compact structure and lower failure rate. Instant high-pressure cutoff upon overload protects costly hydraulic components including pump body, main control valve and cylinders.
Adaptive Oil Supply via Dual-Pump Merging & Flow Splitting
Dual-pump merging for large flow output with strong breakout force during heavy digging; independent single-pump supply for energy saving under light-load conditions such as single-side travel and swing. Balances working efficiency and fuel economy to meet multi-circuit compound movement demands of ultra-large excavators.
Convenient Maintenance & Modular Structure
Available for whole-unit replacement; separate disassembly and maintenance for wearing parts such as piston-cylinder assemblies, electronic regulators, oil seal kits and bearings to reduce overhaul costs. Drain ports and air vent plugs pre-reserved on housing for easy air bleeding and internal leakage inspection.
VI. Key Points for Installation & Replacement
- Pressure Relief Operation: Shut down the engine, actuate control levers repeatedly to release residual high pressure inside the system, disconnect the negative battery terminal and implement high-pressure safety protection measures.
- Pipeline Disassembly: Remove oil inlet hose, dual-pump high-pressure outlet hoses, pilot control hoses, electronic connectors of regulators and housing drain hose in sequence; mark pipeline positions to prevent reverse connection.
- Pump Removal & Installation: Loosen pump fixing bolts and lift out the old pump set steadily with special lifting tools. Clean oil stains and iron filings on the engine connecting flange end face and inspect wear condition of input splines.
- Alignment & Assembly: Apply sealant on the flange end face of new pump, align splines and insert smoothly, then fasten fixing bolts evenly in diagonal multiple passes to avoid shaft binding caused by eccentric load.
- Pipeline Reassembly: Restore all hydraulic pipelines according to marks, fit brand-new O-rings and gaskets, and tighten all pipe joints to prevent leakage.
- Oil Filling & Air Bleeding: Fill qualified hydraulic oil, loosen pump air vent plugs to exhaust air inside pump cavity and eliminate cavitation noise. Connect electronic wiring harness and run 30-minute low-idle running-in.
- Commissioning & Trial Operation: Cycle no-load movements to test single-pump and merging functions, inspect pressure, flow, abnormal noise and leakage. Connect Sany diagnostic instrument to match pump control parameters and calibrate constant power curve. The assembly is qualified if digging, travel and swing performances meet requirements under full-load test.
VII. Common Faults, Causes & Operational Hazards
Abnormal Pump Noise, Humming & Periodic Noise
Causes: Air intake and insufficient oil supply, piston/valve plate scratching by impurities from poor oil cleanliness, damaged bearings, loose worn splines.
Hazard: Long-term operation leads to cylinder scoring and direct scrapping of the entire main pump assembly.
Weak Machine Movements, Failed Pressure Build-Up & Insufficient Pressure Buildup Resistance
Causes: Excessive internal leakage from worn piston pairs, stuck regulator spool, premature tripping of pressure cut-off valve, insufficient swashplate swing angle due to stuck displacement mechanism.
Hazard: Sharp decline in digging force, slipping during heavy loading and drastic drop of overall working efficiency.
Oil Leakage on Pump Housing, End Covers & Pipe Joints
Causes: Aging seals, loose housing bolts, casting pinholes and cracks, failed oil seals from excessive oil temperature.
Hazard: Oil shortage and air intake accelerate internal wear, resulting in pump overheating and seizure.
Uneven Movement Speed, Stagnant Compound Movements & Flow Mismatch
Causes: Stuck ER2D2 electronic solenoid valve, poor contact or short circuit in wiring, coked regulator spool, unsynchronized displacement of dual pumps.
Hazard: Degraded operation feel and uncoordinated interference among digging, travel and swing actions.
Abnormally Rising Oil Temperature & System High-Temperature Alarm
Causes: Excessive pump internal leakage, stuck displacement mechanism maintaining full displacement overflow, clogged radiator, excessive return oil backpressure.
Hazard: Accelerated deterioration of hydraulic oil, rapid seal failure and cascading damage to complete hydraulic components including multi-way valves and motors.
Pump Vibration & Engine Speed Drop / Stalling Under Load
Causes: Unbalanced constant power matching, stuck swashplate displacement mechanism, poor oil suction from clogged inlet filter.
Hazard: Instant engine overload and stalling under heavy load; long-term impact damages crankshaft and powertrain assembly.
VIII. One-Stop Supporting Supply List (Complete Matching Parts for Hydraulic System)
- Same-model tandem main pump assembly, overhaul kits for pump piston & cylinder block
- ER2D2 electronic proportional regulator, solenoid coils, spool & sleeve accessories
- Complete oil seal kits, repair kits and end cover sealing kits for HP5V76L
- Hydraulic inlet filter, pilot filter, return filter and hydraulic oil maintenance consumables
- High-pressure main hoses, pilot hoses, pipe joints, shock-absorbing pipe clamps and sealing accessories
- Main multi-way valve, swing motor, travel motor, boom/arm/bucket cylinder assemblies for SY1250/SY1350
- Hydraulic oil temperature sensors, pressure sensors and complete pump control wiring harness assembly
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