P90 VARIABLE DISPLACEMENT PUMP

Transcription

1 P90 VARIABLE DISPLACEMENT PUMP S E R V I C E M A N U A L

2

3 POCLAIN HYDRAULICS Hydraulic Pumps CONTENT OVERVIEW 5 OPERATION 13 Operations OILS & FILTER / MAINTENANCE 19 Fluid Selection 19 Water content 22 START-UP PROCEDURE 25 PRESSURE MEASUREMENT 27 TROUBLESHOOTING 29 ADJUSTMENTS 33 MINOR REPAIRS 41 Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 3

4 POCLAIN HYDRAULICS Hydraulic Pumps 4 A19501W 08-OCT-2009

5 POCLAIN HYDRAULICS Hydraulic Pumps OVERVIEW This manual includes information for installation, maintenance, trouble shooting and minor repair of P90 axial piston closed circuit pump. Safety notice. This document also includes instructions essential for the operation of this product along with general information. They are displayed in the following manner: Essential instruction. Operations General information. Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance Recover used oil. 08-OCT-2009 A19501W 5

6 Hydraulic Pumps POCLAIN HYDRAULICS Warnings Before Installation Take all necessary safety precautions (people and machines) and comply with safety regulations in effect. Confirm that mobile equipment is immobilized. Confirm that the hydraulic systems energy generator (motor) is stopped and electric power is disconnected. Lay out a safety perimeter. Do not perform work on a hydraulic system that is hot or under pressure (discharge the accumulators). Oil that is hot or under pressure can cause serious burns and infection. Consult a physician in case of accident. During Installation Install the hydraulic system according to the specifications and processes appearing in this document. Support the components using a lifting device whose capacity is adequate for attaching the components to the chassis. During handling protect all sensitive surfaces from shocks (centerings, bolts, connectors, plugs, etc.). Confirm that the components centering and support surfaces on the chassis are clean (free of paint). Never heat hydraulic fluid which can ignite at high temperature. Some solvents are also inflammable. Do not smoke while working on the system. After Installation Consult repair documents for system and component maintenance and repair instructions. Do not over-size the safety valves. Wearing in the motors is not necessary; full performance is reached after a few hours of operation. 6 A19501W 08-OCT-2009

7 POCLAIN HYDRAULICS Hydraulic Pumps Component Identification B A C Component identification Operations A Part Number B Model code 90R075 SA2BC60 S3C6 C33 PEA C Serial number N Part number and serial number must be specified to order spare parts. Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing. A worldwide network of Poclain Hydraulics Authorized Service Centers (ASCs) is available for repairs. Poclain Hydraulics ASCs are trained by the factory and certified on a regular basis. You can locate your nearest ASC using the distributor locator at Hydraulics.com. Click on the Sales and Service link. General instructions Follow these general procedures when repairing P90 variable displacement closed circuit pumps. Remove the unit Prior to performing repairs, remove the unit from the vehicle/machine. Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the pump and fittings for damage. Cap hoses after removal to prevent contamination. Keep it clean Cleanliness is a primary means of assuring satisfactory pump life, on either new or repaired units. Clean the outside of the pump thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, all parts must be kept free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. If left unattended, cover the pump with a protective layer of plastic. Replace all O-rings and gaskets Use new O-rings and gaskets during reassembly. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Secure the unit For repair, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the pump while removing and torquing end covers, controls, and valves. Safety precautions Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system. Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 7

8 Hydraulic Pumps POCLAIN HYDRAULICS Unintended machine movement Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/ disconnect the mechanism while servicing. Flammable cleaning solvents Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present. Fluid under pressure Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic fluid. Personal safety Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times. 8 A19501W 08-OCT-2009

9 POCLAIN HYDRAULICS Hydraulic Pumps Symbols used in Poclain literature Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose. 08-OCT-2009 A19501W 9

10 Hydraulic Pumps POCLAIN HYDRAULICS Design Poclain Hydraulics P90 closed circuit piston pumps convert input torque into hydraulic power. Rotational force is transmitted through the input shaft to the cylinder block. The input shaft is supported by bearings at the front and rear of the pump and is splined into the cylinder block. A lipseal at the front end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one end by a ball joint. The slippers are held to the swashplate by a spring washer. The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. Via the valve plate, one half of the cylinder block is connected to low pressure and the other half to high pressure. As each piston cycles in and out of its bore, fluid is drawn from the inlet and displaced to the outlet thereby imparting hydraulic power into the system. A small amount of fluid is allowed to flow from the cylinder block/valve plate and slipper/swashplate interfaces for lubrication and cooling. Case drain ports return this fluid to the reservoir. The volume of fluid displaced into the system is controlled by the angle of the swashplate. The swashplate is forced into an inclined position (into stroke) by the servo piston. The pump control, by varying the pressure at the servo piston, controls the displacement of fluid in the system circuit. Cross section view Slider block Cradle hold down Servo piston Servo arm Servo valve Feed back Cradle bearing Charge pump Cradle leveler Swashplate Cradle guide P E The system circuit The basic closed circuit The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow. Basic closed circuit diagram 10 A19501W 08-OCT-2009

11 POCLAIN HYDRAULICS Hydraulic Pumps Case drain and heat exchanger The pump and motor require case drain lines to remove hot fluid from the system. The motor should be drained from its topmost drain port to ensure the case remains full of fluid. The motor case drain can then be con-nected to the lower drain port on the pump housing and out the top most port. A heat exchanger, with a bypass valve, is required to cool the case drain fluid before it returns to the reservoir. System circuit diagram Travel Control Joystick System Setup HHT System Setup PC Smart Drive Accumulateur Operations Potentiometer P1 Travel Pedal Pump swashplate Control handle Variable displacement pump Speed sensor Input shaft Pump swashplate Orificed check valve Servo control cylinder Servo control cylinder Displacement control valve High pressure relief valve Reservoir Charge pressure relief valve to pump case Charge pump High pressure relief valve Heat exchanger Vacuum gauge Heat exchanger bypass valve Pressure sensor Pressure sensor Loop flushing valve System loop (low pressure) System loop (high pressure) Control fluid Case drain / Suction / System return MOTOR Valving cover Cylinder-block Piston Cam Valving Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 11

12 Hydraulic Pumps POCLAIN HYDRAULICS Pump schematic S1 S2 12 A19501W 08-OCT-2009

13 POCLAIN HYDRAULICS Hydraulic Pumps OPERATIONS Charge pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmission. The charge pump is a fixed-displacement, gerotor type pump installed in the variable displacement pump and driven off the main pump shaft. Charge pressure is limited by a relief valve. The standard charge pump will be satisfactory for most applications. How-ever, if the charge pump sizes available for the given main pump size are not adequate, a gear pump may be mounted to the auxiliary mounting pad and supply the required additional charge flow. Pump charge system Case drain line Input PV PF Charge relief valve Charge pump System check valves Operations Charge relief valve Inlet filter Tank The charge relief valve on the pump serves to maintain charge pressure at a designated level. A direct-acting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1500 rpm. This nominal setting assumes the pump is in neutral (zero flow); in forward or reverse charge pressure will be lower. The charge relief valve setting is specified on the model code of the pump. Charge pressure relief valve Charge pressure P E P E Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 13

14 Hydraulic Pumps POCLAIN HYDRAULICS High Pressure Relief Valves Cartridges The high pressure relief valves cartridge incorporates the system check valve, the high pressure relief valve the bypass valve in a replaceable cartridge. These functions are described separately. There are two high pressure relief valve cartridges in each P90 pump to handle functions in either direction. See corresponding Sections for adjustments and repairs. High Pressure Relief Valve cartidge High pressure adjustment screw Valve housing High pressure lock nut High pressure relief / check valve poppet Check valve poppet Bypass actuator High pressure valve poppet Bypass High pressure relief valve "For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by cross-porting system flow to the low pressure side of the loop. Circuit diagram showing pressure control mechanism To control High pressure relief valve Port "A" Bypass adjustment Port "B" High pressure relief valve Charge pressure relief valve System check valves The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level. This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the high pressure relief valves assembly. Bypass valves The bypass valves can be operated when it is desired to move the vehicle or mechanical function when the pump is not running. The valve is opened by manually resetting the valve position. The bypass valves are built into the high pressure relief valves. Speed sensors An optional speed sensor can be installed on P90 pumps to provide unit speed information. The sensor reads a magnetic ring wrapped about the unit s cylinder. See the corresponding section to locate, install and adjust the speed sensor. 14 A19501W 08-OCT-2009

15 POCLAIN HYDRAULICS Hydraulic Pumps Filtration options P90 pumps may be equipped with provisions for either suction or charge pressure filtration to filter the fluid entering the circuit. Suction filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump. When suction filtration is used, a reducer fitting is placed in the charge pressure gauge port (M3). Filtration devices of this type are provided by the user. Full flow suction filtration Reservoir Filter To low pressure side of loop and servo control Charge pressure filtration The pressure filter may be integrally mounted directly on the pump or a filter may be remotely mounted for ease of servicing. The filter is situated in the circuit after the charge pump. Use a 125 µm screen, located in the reservoir or the charge inlet line, when using this filtration option. To low pressure side of loop and servo control Charge relief valve To pump case Full flow pressure filtration Reservoir To pump case Charge relief pump Strainer Strainer Charge pump P001603E Filter with bypass Charge pump P001605E Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 15

16 Hydraulic Pumps POCLAIN HYDRAULICS PH SA displacement control The POCLAIN-HYDRAULICS smart drive box connected to the PH SA displacement control manages displacement and flow direction of the pump to obtain vehicle performance as required by the driver. Drivers intents are acquired through cab sensors (travel pedal, brake pedal etc ) with vehicle performance checked trough system sensors (pressure, engine speed, etc ). Pump displacement and flow direction are controlled through two contamination resistant solenoid valves S1 & S2, A sensor linked to the swash plate monitors permanently the actual displacement setting P1. S2 S1 Size 55 S1 S2 Size S2 S1 S1 S2 Internal diagram 1 2 Feedback sensor P1 Solenoid S2 Solenoid S S2 S1 s2 s1 s1-s2 T p P C B A s1 s2 T S1 S2 16 A19501W 08-OCT-2009

17 POCLAIN HYDRAULICS Hydraulic Pumps Operating parameters This section defines the operating parameters and limitations for P90 pumps with regard to input speeds and pressures. For actual parameters, refer to the operating parameters for each displacement. Input speed Minimum speed is the lowest input speed recommended during engine idle condition. Operating below minimum speed limits the pump s ability to maintain adequate flow for lubrication and power transmission. Continuous speed is the highest input speed recommended at full power condition. Operating at or below this speed should yield satisfactory product life. Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed limit under any operating conditions. When determining speed limits for a particular application see Poclain Hydraulics publication BLN-9984 Pressure and speed limits. System pressure System pressure is the differential pressure between system ports A and B. It is the dominant operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life. System pressure must remain at or below continuous pressure during normal operation to achieve expected life. Continuous pressure is the average, regularly occurring operating pressure. Operating at or below this pressure should yield satisfactory product life. Maximum pressure is the highest intermittent pressure allowed. Maximum machine load should never exceed this pressure. For all applications, the load should move below this pressure. Charge pressure An internal charge relief valve regulates charge pressure. Charge pressure supplies the control with pressure to operate the swashplate and to maintain a minimum pressure in the low side of the transmission loop. Minimum charge pressure is the lowest pressure allowed to maintain a safe working condition in the low side of the loop. Minimum control pressure requirements are a function of speed, pressure, and swashplate angle, and may be higher than the minimum charge pressure shown in the Operating parameters tables. Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment, and which provides normal component life. Elevated charge pressure can be used as a secondary means to reduce the swashplate response time. The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the pump in neutral, operating at 1800 min-1 [rpm], and with a fluid viscosity of 32 mm2/s [150 SUS]. The charge pressure setting is referenced to case pressure. Charge pressure is the differential pressure above case pressure. Charge inlet pressure Unintended vehicle or machine movement hazard Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss. All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop pressure from gauge readings to compute the differential. At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure. Minimum charge inlet pressure is only allowed at cold start conditions. In some applications it is recommended to warm up the fluid (for example in the tank) before starting the engine and then run the engine at limited speed until the system fluid temperature is raised to an acceptable level. Possible component damage or leakage Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings, causing external leakage. Performance may also be affected since charge and system pressure are additive to case pressure. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 17

18 Hydraulic Pumps POCLAIN HYDRAULICS Temperature and viscosity Temperature The high temperature limits apply at the hottest point in the transmission loop, which is normally the motor case drain. The system should generally be run at or below the quoted rated temperature. The maximum intermittent temperature is based on material properties and should never be exceeded. Cold oil will generally not affect the durability of the transmission components, but it may affect the ability of oil to flow and transmit power; therefore temperatures should remain 16 C [30 F] above the pour point of the hydraulic fluid. The minimum temperature relates to the physical properties of component materials. Size heat exchangers to keep the fluid within these limits. Poclain Hydraulics recommends testing to verify that these temperature limits are not exceeded. Viscosity For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range. Minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation. Maximum viscosity should be encountered only at cold start. 18 A19501W 08-OCT-2009

19 POCLAIN HYDRAULICS Hydraulic Pumps OIL & FILTER / MAINTENANCE Fluid Selection General Recommendations Poclain hydraulics recommends the use of hydraulic fluids defined by the ISO and ISO standards. For temperate climates, the following types are recommended. HM 46 or HM 48 for fixed installations. HV 46 or HV 68 for mobile installations. HEES 46 for mobile installations. These specifications correspond to category 91H of the CETOP standard, parts 1, 2 and 3 of the DIN standard, and grades VG32, VG 46 and VG68 of the ISO standards. It is also possible to use ATF, HD, HFB, HFC or HFD type hydraulic fluid upon Poclain Hydraulics specific approval of the components operating conditions. Standardized designations for the fluids HM : Mineral fluids having specific antioxidant, anticorrosion and antiwear properties (HLP equivalent to DIN parts 1 and 2). HV : HM mineral fluids providing improved temperature and viscosity properties (DIN part 3). HEES :Biodegradable fluids based on organic esters. It is also possible to use a fluid that meets the biodegradability criteria and is compatible in the event of accidental food contact. The BIOHYDRAN FG 46 fluid designed by the company Total has undergone testing of its properties and performance on our test benches. Since this type of fluid has not yet been categorized, it is the responsibility of machine manufacturers to validate its compatibility with all of the components used in order to guarantee that the intended functions will be fulfilled (specifically the brakes' hold on a slope and emergency braking) and this for the desired life time of all equipment items. Class32 (ISO VG 32) : Viscosity of 32 cst at 40 C. Class46 (ISO VG 46) : Viscosity of 46 cst at 40 C. Class68 (ISO VG 68) : Viscosity of 68 cst at 40 C. For biodegradable fluids, consult your Poclain Hydraulics' application engineer. During operation, the temperature of the circuit must be between 0 C [32 F] and 80 C [176 F]; the minimum and maximum temperatures may be exceeded momentarily by ± 20 C [± 68 F] for a duration of less than 30 minutes. The viscosity must always be between 9 and 500 cst, otherwise check over the cooling system, the design, or the oil rating. For all applications outside these limits, please consult with your Poclain Hydraulics application engineer. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 19

20 Hydraulic Pumps POCLAIN HYDRAULICS Extract of the NF ISO Standard HM Category Tests Test Methods or Standards Viscosity Grade Units Kinematic viscosity at 40 ISO mm² / s Minimum viscosity index (a) ISO Acidity index, maximum (b) ISO 6618 (c) (c) (c) (c) (c) mg KOH / g Water context, maximum ASTM D 1744 DIN mg / kg DIN (d) Flash point Cleveland in open-cup, min. ISO C Foaming at 24 C, max. 150/0 150/0 150/0 150/0 150/0 ISO C, max. 75/0 75/0 75/0 75/0 75/0 ml Deaeration at 50 C, maximum ISO min Copper blade corrosion at 100 C, 3 h maximum ISO Grading Anti-rust power, method A ISO 7120 Pass Pass Pass Pass Pass Anti-wear property, FZG A/8, 3/90, minimum DIN (e) Deterioration Level Flow point, maximum ISO C Aptitude to separate from water: Time needed to obtain 3 ml of emulsion at 54 C, max. ISO min HV Category Tests Test Methods or Standards Viscosity Grade Units Kinematic viscosity at 40 ISO mm² / s Minimum viscosity index (a) ISO Acidity index, maximum (b) ISO 6618 (c) (c) (c) (c) (c) mg KOH / g Water context, maximum ASTM D 1744 DIN mg / kg DIN (d) Flash point Cleveland in open-cup, min. ISO C Foaming at 24 C, max. 150/0 150/0 150/0 150/0 150/0 ISO C, max. 75/0 75/0 75/0 75/0 75/0 ml Deaeration at 50 C, maximum ISO Copper blade corrosion at 100 C, 3 h maximum ISO Grading Anti-rust power, method A ISO 7120 Pass Pass Pass Pass Pass Anti-wear property, FZG A/8, 3/90, minimum DIN (e) Deterioration Level Flow point, maximum ISO C Aptitude to separate from water: Time needed to obtain 3 ml of emulsion at 54 C, max. ISO 6614 (c) (c) (c) (c) (c) (a) (b) (c) (d) (e) These limits should only be taken into consideration for fluids made from hydrocracked or hydro-isomerized mineral oils. Both base fluids and additives contrubute to the initial acidity index. The behavior criteria or the values of properties must be the subject of negotiation between the supplier and the end user. The DIN standard applies in cases where interference caused by certain chemical compounds must be avoided. Free bases, oxidizing or reducing agents, mercaptans, some nitrogenous products or other products that react with iodine interfere. Not applicable to ISO 22 viscosity grade. 20 A19501W 08-OCT-2009

21 POCLAIN HYDRAULICS Hydraulic Pumps Extract of the ISO Standard HM Category Tests Test Methods or Standards Viscosity Grade Units Kinematic viscosity at 40 ISO mm² / s Minimum viscosity index (a) ISO Acidity index, maximum (b) ISO 6618 (c) (c) (c) (c) mg KOH / g Water context, maximum ASTM D 1744 DIN mg / kg DIN (d) Flash point Cleveland in open-cup, min. ISO C Foaming at 24 C, max. 150/0 150/0 150/0 150/0 ISO C, max. 75/0 75/0 75/0 75/0 ml Deaeration at 50 C, maximum ISO min Copper blade corrosion at 100 C, 3 h maximum ISO Grading Anti-rust power, method A ISO 7120 Pass Pass Pass Pass Anti-wear property, FZG A/8, 3/90, minimum DIN (e) Deterioration Level Flow point, maximum ISO C Aptitude to separate from water: Time needed to obtain 3 ml of emulsion at 54 C, max. ISO 6614 (c) (c) (c) (c) min HV Category Tests Test Methods or Standards Viscosity Grade Units Kinematic viscosity at 40 ISO mm² / s Minimum viscosity index (a) ISO Acidity index, maximum (b) ISO 6618 (c) (c) (c) (c) mg KOH / g Water context, maximum ASTM D 1744 DIN mg / kg DIN (d) Flash point Cleveland in open-cup, min. ISO C Foaming at 24 C, max. 150/0 150/0 150/0 150/0 ISO C, max. 75/0 75/0 75/0 75/0 ml Deaeration at 50 C, maximum ISO min Copper blade corrosion at 100 C, 3 h maximum ISO Grading Anti-rust power, method A ISO 7120 Pass Pass Pass Pass Anti-wear property, FZG A/8, 3/90, minimum DIN (e) Deterioration Level Flow point, maximum ISO 3016 (c) (c) (c) (c) C Aptitude to separate from water: Time needed to obtain 3 ml of emulsion at 54 C, max. ISO 6614 (c) (c) (c) (c) min (a) These limits should only be taken into consideration for fluids made from hydrocracked or hydro-isomerized mineral oils. (b) Both base fluids and additives contrubute to the initial acidity index. (c) The behavior criteria or the values of properties must be the subject of negotiation between the supplier and the end user. (d) The DIN standard applies in cases where interference caused by certain chemical compounds must be avoided. Free bases, oxidizing or reducing agents, mercaptans, some nitrogenous products or other products that react with iodine interfere. (e) Not applicable to ISO 22 viscosity grade. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 21

22 Hydraulic Pumps POCLAIN HYDRAULICS Temperature and Viscosity The best performance is obtained by havng the system operate in the regimes shaded gray. ZONE D ZONE B ZONE E ZONE A ZONE C Temperature Zone A Zone of maximum efficiency. In this zone, temperature variations have a weak effect on the response time, efficiency and life expectancy of the components. Poclain Hydraulics components can operate at all speeds, pressures and powers specified in their technical documentation. Zone B High speeds can lead to vibrations and drops in mechanical efficiency. The booster pump can cavitate if the intake conditions are too tight but without risk for the system as long as the pump remains boosted. The Poclain Hydraulics components can operate at the pressures specified in their documentation but it is not advisable to use the pumps at full displacement. In a translation circuit, a rapid rise in the pump speed from zone B is allowed, but ordering the translation when the temperature has reached zone A is recommended. Zone C The efficiency is less and the use of effective antiwear additives is required. The Poclain hydraulics components can temporarily operate at a power under 20 to 50% of that stated in the technical documentation, or during 20% of the operating time at the stated power. Zone D The stated restrictions for zone B likewise apply to zone D. Further, the pumps must startup at low speed and no displacement. They must not be used in their normal operating conditions as long as the booster pressure has not stabilized and the hydraulic fluid temperature in the reservoir has not come up to zone B. Zone E The efficiency is reduced and the risk of wear on the pump and hydraulic fluid is increased. The system can operate in zone E at low-pressure and during short periods. The temperature of the hydraulic fluid in the power circuit must not be more than 10 C above the temperature of the hydraulic fluid in the reservoir, and must not be more than 20 C warmer than the hydraulic fluid in the components cases. Water content The ISO standard calls for a water content 0.05%. Poclain Hydraulics components tolerate up to 0.1%. Checking Water Content Visual Inspection The oil appears cloudy once it has a water concentration greater than or equal to 1%. 22 A19501W 08-OCT-2009

23 POCLAIN HYDRAULICS Hydraulic Pumps We suggest two possible verification methods: 1- Quick Elementary Check The crackle test. Step Action Make a small cup using household aluminum foil. Put a drop of oil to test in the bottom of the cup. Heat it by placing it over a flame using tongs. Operations Step 4 Action 2- Laboratory analysis To determine the exact water content of the fluid, we recommend a laboratory analysis. Filter recommendations To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when servicing. Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid immediately if these conditions occur. Correct the problem immediately. Inspect vehicle for leaks daily. Change the fluid and filter per the vehicle/machine manufacturer s recommendations or at these intervals: Change fluid after first 500 hours. Fluid and filter change interval If bubbles appear, the water content of the fluid exceeds 0.05%. If bubbles do not appear, the water content in the fluid is less than 0.05%. Poclain Hydraulics performs laboratory analyses of water content in fluids. Contact us for further information. Reservoir type Sealed Breather Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance Max oil change interval 2000 hours 500 hours 08-OCT-2009 A19501W 23

24 Hydraulic Pumps POCLAIN HYDRAULICS High temperatures and pressures will result in accelerated fluid aging. More frequent fluid changes may be required. Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater than the recommended maximum. Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid. Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter. Replace all fluid lost during filter change. 24 A19501W 08-OCT-2009

25 POCLAIN HYDRAULICS Hydraulic Pumps START-UP PROCEDURE General Follow this procedure when starting-up a new pump installation or when restarting an installation in which the pump has been removed. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/ disconnect the mechanism while servicing. Prior to installing the pump, inspect for damage incurred during shipping. 1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and heat exchanger) are clean and free of any foreign material. 2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened and there are no air leaks. 3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3. 4. Fill the housing by adding filtered oil in the upper case drain port. Open the case plug in the top of the control to assist in air bleed. 5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron reservoir filler filter. Ensure inlet line from reservoir to pump is filled. 6. Disconnect the pump control input signal. After start-up the oil level in the reservoir may drop due to filling of the system components. Check the level in the reservoir to maintain a full oil level throughout the start-up. Damage to hydraulic components may occur if the oil supply is not maintained. 7. Use a common method to disable the engine to prevent the engine from starting. Crank the starter for several seconds. Do not to exceed the engine manufacturer s recommendation. Wait 30 seconds and then crank the engine a second time as stated above. This operation helps remove air from the system lines. Refill the reservoir to recommended full oil level. 8. When charge pressure begins to appear, enable and start engine. Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at all line connections and listen for cavitation. Check for proper fluid level in reservoir. Air entrapment in oil under high pressure may damage hydraulic components. Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered. 9. When adequate charge pressure is established (as shown in model code), increase engine speed to normal operating rpm to further purge residual air from the system. 10. Shut the off engine. Connect the pump control signal. Start the engine, checking to be certain the pump remains in neutral. Run the engine at normal operating speed and carefully check for forward and reverse control operation. 11. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop. Normal charge pressure fluctuation may occur during forward and reverse operation. 12. Check that the reservoir is full. Remove charge pressure gauge. The pump is now ready for operation. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 25

26 Hydraulic Pumps POCLAIN HYDRAULICS 26 A19501W 08-OCT-2009

27 POCLAIN HYDRAULICS Hydraulic Pumps PRESSURE MEASUREMENT Required tools The service procedures described in this manual for P90 pumps and motors can be performed using common mechanic s tools. Special tools, if required are shown. Pressure gauges should be calibrated frequently to ensure accuracy. Use snubbers to protect pressure gauges. Port locations and gauge installation The following sections list the ports for each type of hydraulic unit. The fitting size and recommended pressure gauge are also specified. The following table and drawings show the port locations and gauge sizes needed. Port information Port Pressure obtained Gauge size Port size identifier M1, M2 System pressure 1000 bar [ psi] 9/16-18 M3 (M6) Charge pressure 50 bar [1000 psi] 9/16-18 M4, M5 Servo pressure 50 bar [1000 psi] L1, L2 Case pressure 10 bar [100 psi] X3 External control pressure 50 bar [1000 psi] 9/16-18 S System pressure gauge port M2 Charge inlet pressure System pressure gauge port M1 Charge pump inlet port S Charge pump inlet Case drain port L1 System pressure port B System pressure port A Vacuum gauge, Tee into inlet line Servo / displacement cylinder pressure gauge port M4 Servo / displacement cylinder pressure gauge port M5 Case drain port L2 Speed sensor 055 7/ / / / / / / / /2 SAE-split flange Charge pressure gauge port M3 External control pressure supply port X3 Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 27

28 Hydraulic Pumps POCLAIN HYDRAULICS Pump with side port end cap and remote pressure filtration Pump with side port end cap and integral pressure Charge pressure gauge port M6 (before the filter) Port E (from filter) Port D (to filter) Charge pressure gauge port M3 (after the filter) Charge pressure gauge port M3 (after the filter) P E 28 A19501W 08-OCT-2009

29 POCLAIN HYDRAULICS Hydraulic Pumps TROUBLESHOOTING This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced. Always observe the safety precautions listed in the Introduction section and related to your specific equipment. Neutral difficult or impossible to find Input to pump control Item Description Action Pump displacement control System operating hot Input to control module is operating improperly Control linages are not secure, control orifices are blocked, and so on Check control input and repair or replace as necessary Adjust, repair, or replace control module as necessary Operations Item Description Action Oil level in reservoir Heat exchanger Charge pressure Charge pump inlet vacuum System relief pressure settings For internal leakage in motor System pressure Insufficient hydraulic fluid will not meet cooling demands of system Heat exchanger not sufficiently cooling the system Low charge pressure will overwork system Transmission operates normally in one direction only Input to pump control High inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow If the system relief settings are too low, the relief valves will be overworked Leakage will reduce low side system pressure and overwork the system High system pressure will overheat system Fill reservoir to proper level Check air flow and input air temperature for heat exchanger. Clean, repair, or replace heat exchanger Measure charge pressure. Inspect and adjust or replace charge relief valve. Or repair leaky charge pump Check charge inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions Verify settings of pressure limiters and high pressure relief values and adjust or replace high pressure relief valves as necessary Monitor motor case flow without loop flushing in the circuit (use defeat spool). If flow is excessive, replace motor Measure system pressure. If pressure is high, reduce loads Item Description Action Pump displacement control Interchange system pressure limiters, high pressure relief valves, and system check valves Charge pressure Input to control module is operating improperly Control linkages are not secure, control orifices are blocked, and so on Interchanging the high pressure relief valves will show if the problem is related to the valve functions contained in the high pressure relief valves. If charge pressure decays in one direction, the loop flushing valve may be sticking in one direction Check control input and repair or replace as necessary Repair or replace control module as necessary Interchange high pressure relief valves. If the problem changes direction, repair or replace the valve on the side that does not operate Measure charge pressure in forward and reverse. If pressure decays in one direction, inspect and repair the motor loop flushing valve Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 29

30 Hydraulic Pumps POCLAIN HYDRAULICS System will not operate in either direction Item Description Action Oil level in reservoir Insufficient hydraulic fluid to supply system loop Fill reservoir to proper level Input to pump control Input to control module is operating improperly Check control input and repair replace as necessary Pump displacement control Ensure bypass valve(s) are closed Charge pressure with pump in neutral Charge pressure with pump in stroke Pump charge relief valve Low motor output torque Control linkage is not secure, control orifices are blocked, etc. If bypass valve(s) are open, the system loop will be depressurized Low charge pressure insufficient to recharge system loop Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set A pump charge relief valve that is leaky or set too low will depressurize the system Repair or replace control module as necessary Close bypass valves. Replace high pressure relief valves if defective Measure charge pressure with the pump in neutral. If pressure is low, go to Pump charge relief valve; otherwise continue with Charge pressure with pump in stroke. Measure charge pressure with pump in stroke. If pressure is low, adjust or replace motor charge relief valve, otherwise go to Charge pumps check Adjust or replace pump charge relief valve as necessary Charge pump inlet filter A clogged filter will undersupply system loop Inspect filter and replace if necessary Charge pumps Pump displacement control System pressure System high pressure relief valves A malfunctioning charge pump will provide insufficient charge flow Control linkages are not secure, control orifices are blocked, and so on Low system pressure will not provide power necessary to move load Defective high pressure relief valves will cause system to pressure to be low Repair or replace the charge pump. Repair or replace control module as necessary Measure system pressure. Continue to next step Repair or replace high pressure relief valve(s) Item Description Action System pressure at motor Motor stuck at minimum displacement Internal leakage Low system pressure at the motor will reduce torque Minimum motor displacement yields low output torque Internal leakage will reduce system pressure Measure system pressure at motor. If pressure limiter setting is low, increase setting Check control supply pressure or repair displacement control. Check motor control orifices Check for leakage in O-rings, gaskets and other fittings. Repair unit as required, or replace leaking unit Improper motor output speed Item Description Action Oil level in reservoir Pump output flow Motor displacement control Internal leakage Insufficient hydraulic fluid will reduce motor speed Incorrect outflow will affect output speed. Incorrect output flow indicates the swashplate is out of position If the motor displacement doesn't change correctly, the motor displacement change spool may disfunction. Internal leakage will reduce system pressure Fill oil to proper level Measure pump output and check for proper pump speed. Ensure the pump is in full stroke If the displacement change spool of the motor is not responding, check the pilot pressure circuit. If the pilot pressure is correct at the motor; inspect the motor displacement change spool. Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit 30 A19501W 08-OCT-2009

31 POCLAIN HYDRAULICS Hydraulic Pumps System noise or vibration Item Description Action Oil in reservoir Insufficient hydraulic fluid will lead to cavitation Fill reservoir to proper level Air in system Pump inlet vacuum Shaft couplings System response is sluggish Safety precautions Air bubbles will lead to cavitation High inlet vacuum causes noise. A dirty filter will increase the inlet vacuum A loose shaft coupling will cause excessive noise Shaft alignment Misaligned shafts cause noise Align shafts Oil level in reservoir Look for foam in reservoir. Check for leaks on inlet side system loop and repair. Afterwards, let reservoir settle until foam dissipates. Run system at low speed to move system fluid to reservoir. Repeat Inspect and replace filter as necessary. Check for proper suction line size Replace loose shaft coupling or replace pump or motor Item Description Action high pressure relief valves pressure settings Pump inlet vacuum Prime mover speed Charge and control pressures System internal leakage Insufficient hydraulic fluid causes sluggish response. Incorrect pressure settings affects system reaction time. High pump inlet vacuum reduces system pressure. Low engine speed reduces system performance. Incorrect charge or control pressures affects system performance. Internal leakage reduces system pressure. Fill reservoir to proper level. Adjust or replace high pressure relief valves. Measure charge inlet vacuum. If high, replace inlet filter. Adjust engine speed. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/ disconnect the mechanism while servicing. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/ disconnect the mechanism while servicing. Contamination can damage internal components and void the manufacturer s warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines Measure charge and control pressures and correct if necessary. Check for leakage in O-rings, gaskets, and other fittings. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 31

32 Hydraulic Pumps POCLAIN HYDRAULICS 32 A19501W 08-OCT-2009

33 POCLAIN HYDRAULICS Hydraulic Pumps ADJUSTMENTS Standard procedures, inspections, and adjustments Before working on the pump, clean all dirt and grime from the outside of the pump. 1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump. 2. If removing the pump, tag each hydraulic line connected to the pump. If hydraulic lines are disconnected, plug each open port, to ensure that dirt and contamination do not get into the pump. 3. Ensure the surrounding areas are clean and free of contaminants such as dirt and grime. 4. Inspect the system for contamination. 5. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge, or small metal particles. 6. If there are signs of contamination in the hydraulic fluid, all filters must be replaced and the hydraulic system must be drained and filled with the correct hydraulic fluid. 7. Flush the lines before replacing the hydraulic fluid. Warranty Performing adjustments and minor repairs according to the procedures in this manual will not affect your warranty. Major repairs requiring the removal of a unit s rear cover, servo sleeves or front flange voids the warranty unless done by a Poclain Hydraulics Global Service Partner. Adjustments This section offers instruction on inspection and adjustment of pump components. Read through the entire related section before beginning a service activity. Refer to Pressure measurements, pages 23, 24 and 25, for location of gauge ports and suggested gauge size. Charge pressure relief valve adjustment Contamination can damage internal components and void the manufacturer s warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines The following procedure explains how to check and adjust the charge pressure relief valve. 1. Install a 50 bar [1000 psi] pressure gauge in the pump charge pres-sure gauge port (M3). Install a 10 bar [100 psi] gauge to measure case pres-sure (tee into L1 or L2 or use servo gauge port). Operate the system with the pump in neutral (zero displacement) when measuring pump charge pressure. 2. The table shows the acceptable pump charge pressure range for some nominal charge relief valve settings (see sample model code at right). These pressures assume 1500 pump rpm and a reservoir temperature of 50 C [120 F], and are referenced to case pressure. The following procedure may require the ve-hicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and by-standers. Take necessary safety precau-tions before moving the vehicle/machine. Operations Minor repairs Adjustments Troubleshooting Pressure Start-up Oils & filter measurement procedure Maintenance 08-OCT-2009 A19501W 33