SERVICE MANUAL PUMP S5AV 75-90

Transcription

1 SERVICE MANUAL PUMP S5AV 75-90

2 Page Intentionally left Blank

3 Foreword Index Foreword... 3 Layout and use of this manual... 4 Notice... 4 Safety instructions... 4 Product identification and serial number... 5 Special tools... 5 Exploded views and part lists... 6 Ports and settings... 9 Troubleshooting Preliminary operations Disassembly Assembly Control mounting Through drive CLS+TP testing procedure CTP testing procedure PI+PC testing procedure NC+PI+PC testing procedure NC+PC testing procedure NC+LS+TP3 testing procedure Storage and demolition S5AV /0039/001 FOREWORD 3

4 Foreword Layout and use of this manual The purpose of this manual is to provide the user with all the information required to ensure the proper disassembly and assembly Brevini Fluid Power S.p.A. products. It contains information concerning technical matters, assembly, operation and safety. Before carrying out any operations, operators and qualified technicians must read the instructions contained in this manual very carefully. In the event of any doubts over the correct interpretation of the instructions, please contact our offices for clarification. The contents of this manual comply with Directive 98/37/EC and has been written following the guidelines of the UNI standard. It is forbidden to disclose, modify or use the contents of this manual for personal purposes. Notice Due to the continuous product developments, modifications and improvements Brevini Fluid Power S.p.A. will not be held responsible for any erroneous information or data that may lead to errors, indicated in catalogues, instructions, drawings, technical data and other data supplied by Brevini Fluid Power S.p.A.. Therefore, legal actions cannot be based on such material. Product development. Brevini Fluid Power S.p.A. reserves the right to make changes to its products, even for those already ordered, without notice. In preparing the manual some simple pictograms have been chosen with the purpose of drawing the reader s attention and making the consultation of the manual easier and more immediate. DANGER Failure to comply with the instructions could result in damage to persons and property. CAUTION Failure to comply with the instructions could lead to technical damage to the machine and/or system. Safety instructions The motor (or pump) may only be used or assembled on a machine by technicians who are adequately trained about its operation and the deriving dangers, using clothing and personal protective equipment appropriate. Variations to the functional parameters of the motor (or pump), pressure adjustments, demounting and refitting of parts not described in the operation and maintenance manual by unauthorized personnel shall relieve Brevini Fluid Power from all and every liability for deriving accidents or for failure to comply with the laws in merit. The motor (or pump) must be started in compliance with the specific instructions in the Installation and commissioning notes. Before proceeding with any operation on the motor (or pump), Stop the machine and let it cool. Never carry out any operation whilst the pump is running. Avoid release to the environment the oil contained in the motor housing (or pump housing) and in the circuit during disassembly. Moving the motor (or pump) only as described in the operations of predisassembly. Use the equipment listed in this manual to prevent damage to property and people. Tighten all components with the torque indicated in the table and in the early stages of assembly. During operation, the surface of the motor (or pump) can become dangerously hot. Avoid contact without gloves. 4 FOREWORD S5AV /0039/001

5 Foreword Product identification and serial number Product description X X X X X X X X X Each Brevini fluid power s product is supplied with an identification data plate. The full identification of the product is made only through the serial number. Every request of information must quote this number. YY/ M M - S S S S S S B B Do not remove, alter or damage the identification plate. Serial number YY = Year of production MM = Month of production SSSSSS = Batch number BB = Batch progressiv number Standard tools Standard tools METRIC Spanners 10mm a 41mm METRIC Allen Keys 2.5mm a 14mm Series of screwdrivers Series of Drivers / Punch Torque spanners Special tools DESCRIPTION CODE Threadlocking medium strength (allows disassembly) (commercial product) Grease (commercial product) S5AV /0039/001 FOREWORD 5

6 Exploded views and part lists TECHNICAL ILLUSTRATION S5AV /0039/001

7 Exploded views and part lists Pos. Item Q.ty Tightening torques Nm [lbf ft] Pos. Item Q.ty Tightening torques Nm [lbf ft] 1 SPLINED SHAFT S PLASTIC PLUG D= SPLINED SHAFT S 1 1 PARALLEL KEYED SHAFT DIAM SPLINED SHAFT S2 1 2 CIRCLIP x HOLE D=62 1 SOCKET HEAD ALLEN PLUG 1/4 G- 43 BSPP with SEAL 1 44 FLANGE PLUG 1 SAE 1 SOCKET HEAD ALLEN PLUG 1/2 G- 45 BSPP with SEAL 1 3 PUMP CASING 1 4 DISTRIBUTOR COVER - CW 1 4 DISTRIBUTOR COVER - C-CW 1 5 SWASH PLATE - CW 1 5 SWASH PLATE - C-CW 1 6 CYLINDER BARREL 1 7 PISTON 9 8 PISTON RETAINING FLANGE 1 9 SPHERICAL BUSHING 1 10 VALVE PLATE - CW 1 SOCKET HEAD ALLEN PLUG 3/4 G- 46 BSPP with SEAL 1 47 S.H. SCREW M18x PLASTIC PLUG (3/4 GAS) 1 49 FIXED ORIFICE M5x5 HOLE D= GRUB SCREW M6x NUT SEAL LOCK M GRUB SCREW M8x GRUB SCREW M8x70-12K 1 54 S.H. SCREW M6X VALVE PLATE - C-CW 1 11 STRAIGHT ROLLER BEARING 1 12 STRAIGHT ROLLER BEARING 1 13 DISPLACEMENT VARIATION JOINT 1 14 COVER 1 15 CONTROL PISTON (SMALLER AREA) 1 16 CONTROL PISTON (BIGGER AREA) 1 17 CONTROL ROD 1 18 SWASH PLATE BUSHING 2 19 SCREW 4 20 CYLINDER BARREL SPACER 2 21 CYLINDER BARREL SPRING 1 22 PISTON SPRING (SMALLER AREA) 1 23 PISTON SPRING (BIGGER AREA) 1 24 SEAL OR x CIRCLIP x HOLE D= CIRCLIP x SHAFT D= CIRCLIP x HOLE D= SEAL OR x69.57 (2-39) (90Shore) 1 29 SEAL OR x47.34 (2-32) 1 30 LIP SEAL AS 45x62x7/ PIN UNI-ISO 2338-B-6X12-St 1 32 WASHER 1 33 PIN UNI-ISO 2338-B-8x NEEDLES 3 35 SEAL OR C=1.78 INT (70 Shore) 2 36 ANTI-TAMPERING CAP M RIVET UNI 9200-A 2.4x5 Al/Fe 4 38 PUMP DATA PLATE 1 39 SPACER 1 40 SOCKET HEAD ALLEN PLUG 1/4 G- BSPP with SEAL 4 41 ROTATION PLATE 1 S5AV /0039/001 TECHNICAL ILLUSTRATION 7

8 Exploded views and part lists Pos. Item Q.ty Tightening torques Nm [lbf ft] SAE B through drive (pag 29) 1 SAE B FLANGE 1 2 COUPLING 1 3 O-RING 1 4 O-RING 1 5 COUPLING 1 6 SCREWS 4 7 SEEGER 1 GR 2 through drive (pag 30) 1 GR 2 FLANGE 1 2 COUPLING 1 3 CENTERING RING 1 4 O-RING 1 5 O-RING 1 6 O-RING 1 7 SCREWS 2 8 WASHER 2 9 SEEGER 1 10 COUPLING 1 11 SEEGER 2 GR 3 through drive (pag 31) 1 GR 3 FLANGE 1 2 COUPLING 1 3 O-RING 1 4 COUPLING 1 5 SCREWS 2 6 WASHER 2 7 SCREWS 2 8 SEEGER 1 SAE C/TANDEM through drive (pag 32) 1 SAE C FLANGE 1 2 TANDEM FLANGE 1 3 COUPLING 1 4 O-RING 1 5 O-RING 1 6 O-RING 1 7 SCREWS 4 8 SCREWS 4 8 TECHNICAL ILLUSTRATION S5AV /0039/001

9 Ports and settings Min. displacement setting M8x70 grub screw + M8 seal lock nut By unscrewing the screw, displacement decrease (S5AV 75 di 4,61 cc/turn - S5AV 90 di 5,76 cc/turn) Outlet pressure gauge port G 1/4 (controls NC - PI) M1 R1 Oil bleed port for first starting G 1/4 Holes for control M6 Outlet pressure gauge port G 1/4 (controls CTP - CLS) M1 Pressure port 1 SAE 6000 A B Fixing holes Ø21 Modulated pressure gauge port G 1/4 M2 Case drain port G 1/2 T1 Holes for throught drive options M12 Suction port 2 1/2 SAE 3000 S Case drain port G 1/2 T2 Modulated pressure gauge port G 1/8. Seat for flow restrictor M6 in case of Remote Control Max. displacement setting M8x60 grub screw + M8 seal lock nut By screwing the screw, displacement decrease (S5AV 75 di 4,61 cc/turn S5AV 90 di 5,76 cc/turn) Air bleed-bearing flushing G 1/4 R2 CW rotating pump CCW rotating pump S5AV /0039/001 TECHNICAL ILLUSTRATION 9

10 Ports and settings Controls CLS+TP Port CLS 1/8 G-BSPP Port Y1 remote 1/8 G-BSPP Port CLS 1/8 G-BSPP Port Y1 remote 1/8 G-BSPP Pressure control adjustament standby pressure (approx 10 bar/turn) By screwing the screw, pressure setting increase. Pressure control adjustament cutoff pressure (approx 50 bar/turn). Regolazione controllo pressione. By screwing the screw, pressure setting increase. CW rotating pump CCW rotating pump 10 TECHNICAL ILLUSTRATION S5AV /0039/001

11 Ports and settings Controls CTP Pressure control adjustament CTP (approx 50 bar/turn) By screwing the screw, pressure setting increase CW rotating pump CCW rotating pump S5AV /0039/001 TECHNICAL ILLUSTRATION 11

12 Ports and settings Controls PI+PC PI Pilot Pressure port G1/8 Deep 0.39 mm Screw M6x40 Minimum Pressure of the Setting Operation. Factory set, do not adjust Grub screw M10x1x35 UNI 5927 Pressure Control adjustment (approx 50 bar/turn) By screwing the screw, pressure setting increase Screw M5x16 Screw M6x55 G Control Boost Port G1/4 Deep 0.51 CW rotating pump CCW rotating pump 12 TECHNICAL ILLUSTRATION S5AV /0039/001

13 Ports and settings Controls NC+PI+PC Screw M5x40 PI Pilot Pressure port G1/8 Deep 0.39 Screw M6x40 Minimum Pressure of the Setting Operation. Factory set, do not adjust Grub screw M10x1x35 UNI 5927 Pressure Control adjustment (approx 50 bar/turn) By screwing the screw, pressure setting increase Grub screw M10x1x35 UNI 5927 Power Control adjustment. By screwing the screw, pressure setting increase Screw M6x85 G Control Boost Port G1/4 Deep 0.51 CW rotating pump CCW rotating pump S5AV /0039/001 TECHNICAL ILLUSTRATION 13

14 Ports and settings Controls NC+PC Screw M5x18 Grub screw M10x1x35 UNI 5927 Pressure Control adjustment. (approx 50 bar/turn) By screwing CW pressure setting increases Screw M6x45 Grub screw M10x1x35 UNI 5927 Power Control adjustment. By screwing CW, power setting increases G Control Boost Port G1/4 Deep 0.51 CW rotating pump CCW rotating pump 14 TECHNICAL ILLUSTRATION S5AV /0039/001

15 Ports and settings Controls NC+LS+TP3 Y1 Remot port G1/8 Load sensing port G 1/8 Grub screw M10x1x35 UNI 5927 Standby pressure adjustment. (approx 10 bar/turn) By screwing CW Δp setting increases Screw TCEI M6 Pressure Control adjustment. (approx 50 bar/turn) By screwing CW pressure setting increase Screw M5x40 Screw M6x45 Grub screw M10x1x35 UNI 5927 Power Control adjustment. By screwing CW, power setting increase CW rotating pump CCW rotating pump S5AV /0039/001 TECHNICAL ILLUSTRATION 15

16 Troubleshooting Hydrostatic transmission components Check points & instruments Transmission does not operate in any direction Engine Tacho-meter. Pump drive coupling Pump Ga, Gb ports bar manometer High pressure relief valve faulty or damaged (no pressure at port Ga, Gb). Boost pump Gs port 0-60 bar manometer. Wrong direction of rotation. Boost pump damaged. Suction line closed. Pump control Check the entire control mechanism from operator consolle to pump lever. The link might be faulty. Pump drain piping Motor Internal damage to motor. Check the drain flow. Motor output coupling Motor coupling damaged. Reservoir Oil level indicator. Low fluid level. Suction piping Disconnected or demaged pump suction. Suction filter Vacuum-meter. Suction filter plugged. Heat exchanger Heat exchanger by pass valve faulty. HYDROSTATIC TRANSMISSION TROUBLESHOOTING Transmission operates sluggishly or jerkily Engine overloading Low motor output torque Transmission operates hot (motor case temp. aboute 80 C/180 F) Low engine power. Engine damaged. Overloaded engine. The engine does not run at max. speed. Boost pressure relief valve damaged. Setting of high pressure relief valve is low. (check pressure at port Ga, Gb). Setting of high pressure relief valve low (check pressure at port Ga, Gb). Excessive operation at high pressure relief valve setting. Control line damaged or interrupted. Return lines directly connected to reservoir. Internal damage to motor. Check the drain flow. Internal damage to motor. Check the drain flow. Internal damage to motor. Check the drain flow. High oil temperature. Low fluid level in reservoir. Unsuitable oil. Suction filter plugged. Heat exchanger dirty. Low motor output speed The engine does not run at max speed. Internal damage to pump. Insufficient boost pressure or boost flow. Unsuitable gear ratio. Suction filter plugged. Check pressure at max speed. Heat exchanger by pass valve faulty. System is noisy Disaligned shaft. Check distorsion in mounting, axial interference, faulty installation, excessive overloading. Cavitation in the pump group. Mechanical fault in pump. Low fluid level in the reservoir. The diffuser of return lines in the reservoir aren t submerged below fluid level. Air in the system. Check for suction line air leaks. Air in suction line. Leakage from shaft seal Shaft seal damaged. Excessive pump leakage caused by internal damage to pump. Unsuitable drain hose. Shaft seal damaged. Unsuitable drain hose. 16 TECHNICAL ILLUSTRATION S5AV /0039/001

17 Preliminary operations Introduction Before removing the motor you need to take all precautions necessary to ensure safety. Stop the machine. Check that the system is not under pressure. Discharge or disconnect accumulators. Verify that there are no suspended loads connected to the machine. Before disconnecting the various pipes or hoses, clean the motor to avoid the accidental ingress of dirt. If there are electrical connections, check that they are not under tension. Remove the pressure, case drain and pilot lines and any electrical connections. CAUTION: The hydraulic circuit and the motor may be hot! Start the disassembly operations only after cooling. After removing the hoses, apply the protections at all the open port to prevent the ingress of foreign bodies. Move the motor by the means of lifting straps or eyebolts. Make sure you apply the straps firmly to the motor before you move it to prevent an accidental fall and damage of objects and / or injury to persons. S5AV /0039/001 DISASSEMBLY 17

18 Disassembly Fig. 1 Fig Fig. 3 Fig. 4 3 Fig Fig DISASSEMBLY S5AV /0039/001

19 Disassembly Fig. 7 Fig Fig. 9 Fig Fig. 11 Fig. 12 S5AV /0039/001 DISASSEMBLY 19

20 Disassembly Fig Fig Fig. 15 Fig DISASSEMBLY S5AV /0039/001

21 Assembly Lubricate shaft seal s lip (30) with grease. Push shaft kit fully home, mount circlip (25). Fig. 17 Fig Lubrificare i pistoni (7) con olio. Fig. 19 Fig. 20 Thread locking medium strength 49 Swash plate joint side Swash plate joint side 5 Check that orifices (49) are not clogged. Fig. 21 Do not use excessive thread locking agent in order not to clog the orifices Fig. 22 CW pump CCW pump S5AV /0039/001 ASSEMBLY 21

22 Assembly Fig. 23 Mount grub screws (50) after joint (13). Use Loctite 510 on both. Fig CCW pump CW pump Lubricate with a few grease the steel face of the valve plate (10) and mount it into position into its seat in the port cover Fig. 25 Fig Thread locking medium strength Fig. 27 Lubricate with grease the bushings (18). Fig. 28 After the swash plate (5) has been positioned screws (52-53) shoud be positioned in such away that the plate (5) is kept vertical (zero displacement). After this, unscrew the max displacement screw of 15 turns. 22 ASSEMBLY S5AV /0039/001

23 Assembly Fig. 29 Fig Nm [206 lbf ft] 47 Remove the tool used previously. Fig. 31 Fig Fig. 33 Fig. 34 S5AV /0039/001 ASSEMBLY 23

24 Control mounting CLS+TP control mounting procedure 12 Nm [8.85 lbf ft] 12 Nm [8.85 lbf ft] CTP control mounting procedure 12 Nm [8.85 lbf ft] 12 Nm [8.85 lbf ft] 24 ASSEMBLY S5AV /0039/001

25 Control mounting PI+PC control mounting procedure 12 Nm [8.85 lbf ft] Take care to insert the spring guide into the hole on control piston. 12 Nm [8.85 lbf ft] 6 Nm [4.42 lbf ft] S5AV /0039/001 ASSEMBLY 25

26 Control mounting NC+PI+PC control mounting procedure 12 Nm [8.85 lbf ft] Take care to insert the spring guide into the hole on control piston. 12 Nm [8.85 lbf ft] 6 Nm [4.42 lbf ft] 26 ASSEMBLY S5AV /0039/001

27 Control mounting NC+PC control mounting procedure 12 Nm [8.85 lbf ft] 6 Nm [4.42 lbf ft] S5AV /0039/001 ASSEMBLY 27

28 Control mounting NC+LS+TP3 control mounting procedure 12 Nm [8.85 lbf ft] 6 Nm [4.42 lbf ft] 28 ASSEMBLY S5AV /0039/001

29 Through drive SAE B through drive Lubricate O-ring (4) with grease. Fig. 38 Fig Nm [73.77 lbf ft] Lubricate O-ring (3) with grease. Fig. 40 S5AV /0039/001 THROUGH DRIVE 29

30 Through drive GR 2 through drive Lubricate O-ring (4) with grease. Fig. 41 Fig Nm [7.37 lbf ft] Nm [73.77 lbf ft] Fig Lubricate O-ring (6) with grease. 30 THROUGH DRIVE S5AV /0039/001

31 Through drive GR 3 through drive Lubricate O-ring (4) with grease. Fig. 44 Fig Nm [7.37 lbf ft] 7 Fig Nm [73.77 lbf ft] Lubricate O-ring (3) with grease. S5AV /0039/001 SETTING 31

32 Through drive SAE C/TANDEM through drive Lubricate O-ring (4) and O-ring (6) with grease. Fig. 47 Fig Nm [73.77 lbf ft] Nm [73.77 lbf ft] 8 7 Lubricate O-ring (5) with grease. 3 Fig. 49 Fig SETTING S5AV /0039/001

33 CLS+TP testing procedure Table - control settings Vgmax [cm 3 /rev] Vgmin [cm 3 /rev] Qmax (*) [l/min] Q250 (**) [l/min] Displacement variation for screw turn (ΔVg) Screw S5AV c.c./giro M8 S5AV c.c./giro M8 (*): 1500 rpm, 0 bar (**): 1500 rpm, 250 bar (minimum acceptable output flow rate) 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench (see example of test layout) 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Test procedure 1. Adjust the stand-by pressure setting screw to about half of the working stroke. 2. Running-in at 500 rpm for 5 min., Half with low pressure and half with pressure of 100 bar. 3. Check / adjustment DISPLACEMENT MAX: 1500 rpm, 0 bar. With the flow control valve fully open, the pump will stroke to maximum displacement. Unscrew the setting until the pump delivers the nominal flow for the unit in question (see table). If there are limitations to the maximum displacement, flow will read, nominally: Q [l/min] = 1500 [rpm] Vg [cm 3 /rev] 1000 The screw needs to be then adjusted until it reads the nominal flow rate. 4. Lock the maximum displacement screw with its nut. 5. Completely loosen the pressure cut-off setting screw. Check / adjustment MINIMUM DISPLACEMENT rpm. Close the flow control valve on the pump delivery to Swivel it to minimum displacement. Caution: if in closing the valve. Control the pressure increases excessively, unscrew minimum displacement setting screw! Adjust the minimum displacement setting until it is observed an increase in the system pressure. From this point unscrew off 1/4 turn. 6. Lock the minimum displacement screw with its nut 7. Check the flow with the pump unloaded at both the maximum and minimum displacement set, by acting on the flow control valve, towards the displacement minimum and back to maximum multiple times. Eventual errors must be corrected by repeating the procedure from step 3 or from step Close the flow control valve and, using the standby pressure setting screw, set the required value. Setting range 18 to 35 bar. Lock the screw with its nut. 9. Acting on the flow control valve, vary the opening of the same in steps, ie with variations almost instantaneous. The control should always maintain a constant Dp (pressure difference) before and after of the flow control valve, without jamming or response delays. 10. Adjust the pressure cut-off setting screw close to its maximum pressure position, in order to ensure that the pump remains on its maximum displacement. 11. Clean the pump with appropriate solvent until eliminating traces of oil. This in order to identify possible loss and / or leakage during the pressure test. 12. Check FLOW under LOAD rpm, 250 bar. The difference in flow rate of the pump must ensure that the volumetric efficiency remains within the 93% - see calculation. Q loaded/q unloaded =0.93 Or check the values in the table. If there are limitations of maximum displacement flow rate will be read, nominally: Q loaded/q unloaded = Increase system pressure up to a value higher than that provided for the required cut-off valve control pressure. Acting on the pressure cut-off valve adjusting screw, identify the point at which the controller begins to decrease the flow rate. Lock the screw above with nut. 14. Vary the pressure, increasing and decreasing many times, to check the correct operation of the regulator. If necessary, repeat the procedure from step Check for leaks and / or leakage. Then stop the pump. 16. Fill out the test with the required data. C) End test 1. Open the lower drainage port on the pump casing and disconnect the piloting line to discharge the oil. 2. Remove the pump from the test bench. 3. Check for leaks from the front cover and the shaft seal. S5AV /0039/001 TESTING PROCEDURE 33

34 CLS+TP testing procedure Example of test bench layout Throttle valve Pressure gauge LS Y1 Pressure gauge G P M1 Qmin Qmax M S T1 R1 T2 R2 M2 2 - ON THE FIELD TEST If the pump check and/or setting must be done with the pump already installed on the application, follow the procedure below. Check also layouts at page. 35. WARNING: during the procedure below moderate oil leakage from the pump will occur. Take actions to prevent contamination of the environment. A) Minimum and Maximum displacement setting. 1. The engine or motor must be STOPPED. If the pump is feeding a proportional valve, check that all the spools of the sections are CLOSED. If the flow is controlled with a throttle valve, completely CLOSE it. Disconnect the LS line from the pump LS port, in such a way that the pressure in LS port is vented. 2. Adjust the Stand-by setting screw approximately midway of its setting field. Unscrew (turn counterclockwise) completely the cutoff pressure setting screw. 3. Start the engine or the motor. The pump swivels to the minimum displacement at stand-by pressure. 4. Adjust the minimum displacement setting screw until the pressure on the M port starts to increase. From said position, turn the minimum displacement setting screw counter-clockwise 180 (1/2 turn). 5. Lock the screw with locking nut and cap 6. Open completely the proportional valve s spools (or the throttle valve) to reach the pump saturation flow. 7. Adjust the maximum displacement setting screw to reach the required flow. WARNING: if this operation is dangerous or impossible to achieve, it is possible to set the maximum displacement screw following the values in the table below: S5AV 75 S5AV 90 X measure (mm) 19.0 (M8x60 screw) 19.0 (M8x60 screw) X Q max 34 TESTING PROCEDURE S5AV /0039/001

35 CLS+TP testing procedure 8. Lock the screw with locking nut and cap. B) Stand-by pressure setting 1. The engine or motor must be STOPPED. If the pump is feeding a proportional valve, check that all the spools of the sections are CLOSED. If the flow is controlled with a throttle valve, completely CLOSE it. Disconnect the LS line from the pump LS port, in such a way that the pressure in LS port is vented. 2. Start the engine or the motor. 3. Adjust the stand-by pressure setting screw until the required value is reached. Optimum setting field is bar. We do not recommend to exceed 38 bar. 4. Lock the screw with its locking nut. 5. Stop the engine or moto. C) Cut-off pressure setting 1. The engine or motor must be STOPPED. If the pump is feeding a proportional valve, check that all the spools of the sections are CLOSED. If the flow is controlled with a throttle valve, completely CLOSE it. Connect the LS port of the pump with the M port of the pump (we recommend a 1/4 hose). 2. Unscrew completely the cut-off valve setting screw (turn it counter-clockwise). 3. Start the engine or motor. WARNING: if the operation of point 2 has not been properly performed, it might be impossible to start the engine or motor. 4. Adjust the pressure cut-off setting screw until the required pressure is reached. Setting field bar. 5. Lock the screw with its locking nut. 6. Stop the engine or motor 7. Restore all connections as per the original circuit layout. D) Final checks Perform the machine setting and test as per the manufacturer s specifications. Layout for on the field minimum displacement setting and Stand-by pressure setting LS Y1 1 Pressure port must be closed Pressure gauge G P M1 Qmin Qmax M S T1 R1 T2 R2 M2 Layout for on the field cut-off pressure setting LS Y1 Pressure port must be closed Pressure gauge G P M1 Qmin M Qmax S T1 R1 T2 R2 M2 S5AV /0039/001 TESTING PROCEDURE 35

36 CTP testing procedure 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench (see example of test layout) 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Test procedure 1. Running-in at 500 rpm for 5 min., Half with low pressure and half with pressure of 100 bar. 2. Check / adjustment DISPLACEMENT MAX: 1500 rpm, 0 bar. Unscrew the setting until the pump delivers the nominal flow for the unit in question (see table). If there are limitations to the maximum displacement, flow will read, nominally: 13. Fill out the test with the required data. C) End test 1. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench. 3. Check for leaks from the front cover and the shaft seal [rpm] Vg [cm 3 /rev] Q [l/min] = 1000 The screw needs to be then adjusted until it reads the nominal flow rate. 3. Lock the maximum displacement screw with its nut. 4. completely loosen the pressure cut-off setting screw. Check / adjustment MINIMUM DISPLACEMENT rpm. Close the flow control valve on the pump delivery to swivel it to minimum displacement. Caution: if in closing the valve control the pressure increases excessively, unscrew minimum displacement setting screw! Adjust the minimum displacement setting until it is observed an increase in the system pressure. From this point unscrew off 1/4 turn. 5. Lock the minimum displacement screw with its nut. 6. Check the flow with the pump at both the maximum and minimum displacement set, by varying the operating pressure towards the displacement minimum and back to maximum multiple times. Eventual errors must be corrected by repeating the procedure. 7. Adjust the pressure cut-off setting screw close to its maximum pressure position, in order to ensure that the pump remains on its maximum displacement. 8. Clean the pump with appropriate solvent until eliminating traces of oil. This in order to identify possible loss and / or leakage during the pressure test. 9. Check FLOW under LOAD rpm, 250 bar. The difference in flow rate of the pump must ensure that the volumetric efficiency remains within the 93% - see calculation. Q loaded/q unloaded = 0.93 Or check the values in the table. If there are limitations of maximum displacement flow rate will be read, nominally: Q loaded/q unloaded = Increase system pressure up to a value higher than that provided for the required cut-off valve control pressure. Acting on the pressure cut-off valve adjusting screw, identify the point at which the controller begins to decrease the flow rate. Lock the screw above with nut. 11. Vary the pressure, increasing and decreasing many times, to check the correct operation of the regulator. If necessary, repeat the procedure from step Check for leaks and / or leakage. Then stop the pump. 36 TESTING PROCEDURE S5AV /0039/001

37 PI+PC testing procedure 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Testing procedure 1. Check on orderform any eventual displacement limitation of the pump. 2. Running-in of the pump must be don e at 500 rpm and 0 bar for approx. 2.5 min. and at 500 rpm and 100 bar far approx. 2.5 min. 3. Verify/set MAXIMUM DISPLACEMENT: 1500 rpm, 0 bar. With no piloting pressure, the pump is swivelled to the maximum displacement, thus the delivered flow rate must be the pump s maximum nominai flow rate. Turn the maximum displacement adjustment screw until the nominai maximum flow rate is delivered. lf any maximum displacement limitation have to be set, the nominai flow rate is: 1500 [rpm] Vgmax [cm 3 /rev] Qmax [l/min] = 1000 The said screw must then be adjusted to obtain the calculated flow rate. 4. Lock the said adjustment screw with nut and locking nut (with their two washers). 5. Piloting pressure on PI port set ti 40 bar. 6. Verify/set MINIMUM DISPLACEMENT: 1500 rpm, 0 bar. The pump must not deliver any flow rate. Turn the minimum displacement setting screw until a zero flow rate is obtained. lf any displacement limitation have to be set, the nominai flow rate is: Qmin [l/min] = 1500 [rpm] Vgmin [cm 3 /rev] 1000 The sai d screw must then be adjusted in order to obtain the calculated flow rate 7. Lock the minimum displacement adjustment screw with nut and locking nut (with their two washers). 8. By changing PI pressure between 0 and 40 bar, verify the maximum and minimum displacementjust set. Any difference with the expected values must be corrected repeating the procedure from point 3. or point 7. 9.Screw Pressure Control screw completely in. 10. Using an appropriate solvent, clean the pump from any o il trace, in order to check any oil leak during the following high pressure test. 11. Verifythe DRAINAGE FLOW RATE. 250 bar, 1500 rpm. The drainage flow rate is obtained from the difference between the nominal maximum flow rate at 0 bar and the actual flow rate at 250 bar. 12. Verify INPUT TORQUE: On order form is reported the contrai requested torque. Raise the pressure until the contral starting pressure is reached, keeping the pump at 1500 rpm, then read the input torque value. The said torque must not be greater than the said values in the control setting tables. 13.Verifythe HYDRAULIC PILOTING STARTING AND ENDING PRESSURES. Fit the PI port pipe fitting on the top cap and connect the piloting pressure line. The40 bar boost pressure must act on port Y. Starting with a piloting pressure of 0 bar and with the pump at the minimum displacement, increase gradually said pressure to find the hydraulic control starting (the flow rate starts to increase ). Starting with a piloting pressure above 40 bar, decrease said pressure to find the hydraulic control ending pressure (the flow rate starts to decrease). Verify the control stability with intermediate hydraulic piloting pressures. Verify that the control can always reach the pre-set maximum and minimum displacements. The hydraulic piloting starting and ending pressures must be conveniently recorded on test form. 14. IMPORTANT: Should the pump function with a working pressure of less than 40 bar, the retum from Vgmax to Vgmin might be difficult or impossible, even with the 40 bar control boost pressure on top cap. lf, in such a case, the pump takes more than 5-10 sec. to restore from Vgmax to Vgmin or, even worse, it doesn t restore, try to operate several complete displacement variation cycles (Vgmax to Vgmin and vice versa) with higher working pressure, then repeat the low pressure test. lf, after all, the problem is still present, the pump must be overhauled. 15. Increase the working pressure until the requested pressure cutoff value is reached. Acting on the cutoff pressure setting screw (control CTP), turn it until the flow rate start to decrease. Lock the said screw into position with nut. 16. Increase and decrease the working pressure several times, in order to check the control functioning. 17. Verify the eventual presence of any oil leak. Stop the pump. 18. Fill the pump test form with the required data. C) End test 1. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench. 3. Verify the eventual oil leak from the front cover and the shaft seal. S5AV /0039/001 TESTING PROCEDURE 37

38 NC+PI+PC testing procedure 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Testing procedure 1. Check on orderform any eventual displacement limitation of the pump. 2. Running-in of the pump must be don e at 500 rpm and 0 bar for approx. 2.5 min. and at 500 rpm and 100 bar far approx. 2.5 min. 3. Verify/set MAXIMUM DISPLACEMENT: 1500 rpm, 0 bar. With no piloting pressure, the pump is swivelled to the maximum displacement, thus the delivered flow rate must be the pump s maximum nominai flow rate. Turn the maximum displacement adjustment screw until the nominai maximum flow rate is delivered. lf any maximum displacement limitation have to be set, the nominai flow rate is: 1500 [rpm] Vgmax [cm 3 /rev] Qmax [l/min] = 1000 The said screw must then be adjusted to obtain the calculated flow rate. 4. Lock the said adjustment screw with nut and locking nut (with their two washers). 5. Piloting pressure on PI port set ti 40 bar. 6. Verify/set MINIMUM DISPLACEMENT: 1500 rpm, 0 bar. The pump must not deliver any flow rate. Turn the minimum displacement setting screw until a zero flow rate is obtained. lf any displacement limitation have to be set, the nominai flow rate is: 1500 [rpm] Vgmin [cm 3 /rev] Qmin [l/min] = 1000 The sai d screw must then be adjusted in order to obtain the calculated flow rate 7. Lock the minimum displacement adjustment screw with nut and locking nut (with their two washers). 8. By changing PI pressure between 0 and 40 bar, verify the maximum and minimum displacementjust set. Any difference with the expected values must be corrected repeating the procedure from point 3. or point 7. 9.Screw Pressure Control screw completely in. 10. Screw in the contrai setting spring adjustment screw until close to the said spring s maximum preload, in order to keep the pump at the maximum displacement during the high pressure tests. 11.Using an appropriate solvent, clean the pump from any oil trace, in order to check any oil leak during the following high pressure test. 12.Verify the DRAINAGE FLOW RATE. 250 bar, 1500 rpm. The drainage flow rate is obtained from the difference between the nominai maximum flow rate at 0 bar and the actual flow rate at 250 bar. 13. Tuming the power control screw, find out the starting point of the control (when the control starts to swivel towards the minimum displacement, thus reducing the flow rate). Lock the pilot pushing screw into position with its locking screw. 14. Verify INPUT TORQUE: On order form is reported the contrai requested torque. Raise the pressure until the contral starting pressure is reached, keeping the pump at 1500 rpm, then read the input torque value. The said torque must not be greater than the said values in the control setting tables. 15.Verifythe HYDRAULIC PILOTING STARTING AND ENDING PRESSURES. Fit the PI port pipe fitting on the top cap and connect the piloting pressure line. The40 bar boost pressure must act on port Y. Starting with a piloting pressure of 0 bar and with the pump at the minimum displacement, increase gradually said pressure to find the hydraulic control starting (the flow rate starts to increase ). Starting with a piloting pressure above 40 bar, decrease said pressure to find the hydraulic control ending pressure (the flow rate starts to decrease). Verify the control stability with intermediate hydraulic piloting pressures. Verify that the control can always reach the pre-set maximum and minimum displacements. The hydraulic piloting starting and ending pressures must be conveniently recorded on test form. 16. IMPORTANT: Should the pump function with a working pressure of less than 40 bar, the retum from Vgmax to Vgmin might be difficult or impossible, even with the 40 bar control boost pressure on top cap. lf, in such a case, the pump takes more than 5-10 sec. to restore from Vgmax to Vgmin or, even worse, it doesn t restore, try to operate several complete displacement variation cycles (Vgmax to Vgmin and vice versa) with higher working pressure, then repeat the low pressure test. lf, after all, the problem is still present, the pump must be overhauled. 17. Increase the working pressure until the requested pressure cutoff value is reached. Acting on the cutoff pressure setting screw (control Power Control), turn it until the flow rate start to decrease. Lock the said screw into position with nut. 18. Increase and decrease the working pressure several times, in order to check the control functioning. 19. Verify the eventual presence of any oil leak. Stop the pump. 20. Fill the pump test form with the required data. C) End test 1. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench. 3. Verify the eventual oil leak from the front cover and the shaft seal. 38 TESTING PROCEDURE S5AV /0039/001

39 NC+PC testing procedure 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Testing procedure 1. Running-in at 500 rpm for 5 min., half with low pressure and half with pressure of 100 bar. 2. Unscrew the pressure valve control and the power control valve screws almost completely. 3. Close the flow control valve on the pump delivery to swivel it to minimum displacement. Caution: if in closing the valve control the pressure increases excessively, unscrew minimum displacement setting screw! Adjust the minimum displacement setting until it is observed an increase in the system pressure. From this point unscrew off 1/4 turn. If there are limitations to the maximum displacement, flow will read, nominally: Qmax [l/min] = The screw needs to be then adjusted until it reads the nominal flow rate. 4. Lock the minimum displacement screw with its nut. 5. Check / adjustment DISPLACEMENT MAX: 1500 rpm, 0 bar. With the flow control valve fully open, the pump will stroke to maximum displacement. Unscrew the displacement setting until the pump delivers the nominal flow for the unit in question. If there are limitations to the maximum displacement, flow will read, nominally: Qmin [l/min] = 1500 [rpm] Vgmax [cm 3 /rev] [rpm] Vgmin [cm 3 /rev] 1000 The screw needs to be then adjusted until it reads the nominal flow rate. 6. Lock the maximum displacement screw with its nut. 7. Check the flow with the pump unloaded at both the maximum and minimum displacement set, by acting on the flow control valve, towards the displacement minimum and back to maximum multiple times. Errors must be corrected by repeating the procedure from step Clean the pump with appropriate solvent until eliminating traces of oil. This in order to identify possible loss and / or leakage during the pressure test. 9. Adjust the pressure cut-off setting screw and the power setting screw close to the maximum position. Check FLOW under LOAD rpm, 250 bar. The difference in flow rate of the pump must ensure that the volumetric efficiency remains within the 93% - see calculation. 11. Acting on the pressure cut-off valve adjusting screw, identify the point at which the controller begins to decrease the flow rate. Lock the screw above with nut. 12. Vary the pressure, increasing and decreasing many times, to check the correct operation of the regulator. 13. Check / adjustment constant power control (NC). Set the pressure of the setting operation (P0) which is expected for the power value required calibration to 1500 rpm:: P0 [bar] = N [KW] 400 Vgmax [cm 3 /rev] 14. Acting on the NC control setting screw, identify the point at which the controller begins to decrease the displacement (the flow rate begins to decrease). Also check through reading the value of absorbed power. 15. Check of absorption of torque to the variation of the pressure: starting from pressure value corresponding to the start adjustment you may experience the values of flow rate, torque and power absorbed, to vary the operating pressure. This should be checked many times and by increasing or decreasing, the stair step, the operating pressure, for identify any problems of repeatability of the operation. 16. Lock the screw above with nut. 17. Check / adjustment pressure setting (PC). Increase system pressure up to a value higher than that provided for the required cut-off valve control pressure. Acting on the pressure cut-off valve adjusting screw, identify the point at which the controller begins to decrease the flow rate. Lock the screw above with nut. WARNING: During this adjustment could occur an intervention controller NC (before reaching the set pressure of the PC control the pump could limit, but do not reset the flow rate) which however does not compromises the calibration of the controller. 18. Vary the pressure, increasing and decreasing many times, to check the correct operation of the regulator. If necessary, repeat the procedure. 19. Check for leaks and / or leakage. Then stop the pump. 20. Fill out the test with the required data. C) End test 1. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench. 3. Verify the eventual oil leak from the front cover and the shaft seal. Q loaded/q unloaded = 0.93 Or check the values in the table. If there are limitations of maximum displacement flow rate will be read, nominally: Q loaded/q unloaded = Check / adjustment pressure setting (PC). Increase system pressure up to a value higher than that provided for the required cut-off valve control pressure. S5AV /0039/001 TESTING PROCEDURE 39

40 NC+LS+TP3 testing procedure 1 - TESTING ON THE TEST RIG A) Mounting the pump on the test bench 1. Place the coupling and flange on the test bench. 2.Ensure the output shaft area is clean and without any oil trace, so to spot any possible oil leakage after the test. 3. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, with the control upwards. 5. Connect the suction hose and the pressure hose to the respective flanges. 6. Open the oil suction and fill the pump casing with oil. 7. Set the desired rotation (CW / CCW). B) Testing procedure 1. Adjust the stand-by pressure setting screw to about half of the working stroke, and turn on the screws of the pressure valve control and the power control valve almost completely. 2. Running-in at 500 rpm for 5 min., half with low pressure and half with pressure of 100 bar. 3. Check / adjustment DISPLACEMENT MAX: 1500 rpm, 0 bar. With the flow control valve fully open, the pump will stroke to maximum displacement. Unscrew the setting until the pump delivers the nominal flow for the unit in question (see table). If there are limitations to the maximum displacement, flow will read, nominally: 1500 [rpm] Vgmax [cm 3 /rev] Qmax [l/min] = 1000 The screw needs to be then adjusted until it reads the nominal flow rate. 4. Lock the maximum displacement screw with its nut. 5. completely loosen the pressure cut-off setting screw. Check / adjustment MINIMUM DISPLACEMENT rpm. Close the flow control valve on the pump delivery to swivel it to minimum displacement. Caution: if in closing the valve control the pressure increases excessively, unscrew minimum displacement setting screw! Adjust the minimum displacement setting until it is observed an increase in the system pressure. From this point unscrew off 1/4 turn. 6. Lock the minimum displacement screw with its nut. 7. Check the flow with the pump unloaded at both the maximum and minimum displacement set, by acting on the flow control valve, towards the displacement minimum and back to maximum multiple times. Eventual errors must be corrected by repeating the procedure from step 3 or from step Close the flow control valve and, using the standby pressure setting screw, set the required value. Setting range 18 to 35 bar. Lock the screw with its nut. 9. Acting on the flow control valve, vary the opening of the same in steps, ie with variations almost instantaneous. The control should always maintain a constant Dp (pressure difference) before and after of the flow control valve, without jamming or response delays. 10. Adjust the pressure cut-off setting screw close to its maximum pressure position, in order to ensure that the pump remains on its maximum displacement. 11. Clean the pump with appropriate solvent until eliminating traces of oil. This in order to identify possible loss and / or leakage during the pressure test. 12. Check FLOW under LOAD rpm, 250 bar. The difference in flow rate of the pump must ensure that the volumetric efficiency remains within the 93% - see calculation. 13. Check / adjustment constant power control (NC). Set the pressure of the setting operation (P0) which is expected for the power value required calibration to 1500 rpm: N [KW] 400 P0 [bar] = Vgmax [cm 3 /rev] 14. Acting on the NC control setting screw, identify the point at which the controller begins to decrease the displacement (the flow rate begins to decrease). Also check through reading the value of absorbed power. 15. Check of absorption of torque to the variation of the pressure: starting from pressure value corresponding to the start adjustment you may experience the values of flow rate, torque and power absorbed, to vary the operating pressure. This should be checked many times and by increasing or decreasing, the stair step, the operating pressure, for identify any problems of repeatability of the operation. 16. Lock the screw above with nut. 17. CHeck / adjustment pressure cut-off (TP). Increase system pressure up to a value higher than that provided for the required cut-off valve control pressure. Acting on the pressure cut-off valve adjusting screw, identify the point at which the controller begins to decrease the flow rate. Lock the screw above with nut. WARNING: During this adjustment could occur an intervention controller NC (before reaching the set pressure of the PC control the pump could limit, but do not reset the flow rate) which however does not compromises the calibration of the controller. 18. Vary the pressure, increasing and decreasing many times, to check the correct operation of the regulator. If necessary, repeat the procedure from step Check for leaks and / or leakage. Then stop the pump. 20. Fill out the test with the required data. C) End test 1. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench. 3. Check for leaks from the front cover and the shaft seal. Q loaded/q unloaded = TESTING PROCEDURE S5AV /0039/001

41 Storage and demolition Storage Fill with oil all the ports and the casings and apply protective plastic caps on the open parts of the motor (or pump) to avoid the entry of foreign bodies. Store in a dry place and protect from dust or rain. (eg: plastic bag). Demolition Do not dispose outdoors but hand the motors (or pumps) over to specialised waste collection centres. S5AV /0039/001 STORAGE AND DEMOLITION 41

42 Brevini Fluid Power S.p.a. Via Natta N Reggio Emilia (ITALY) Tel Fax info@brevinifluidpower.com web-site: 42 S5AV /0039/001