SERVICE MANUAL PUMP S5AV 2-45
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Foreword Index Foreword... 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... 2 Preliminary operations... Disassembly... 4 Assembly... 7 Control mounting... 20 Through drive... 2 Testing procedure... 26 Storage and demolition... 29 S5AV 2-45 /0040/00 FOREWORD
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 98/7/EC and has been written following the guidelines of the UNI 089-2000 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 2-45 /0040/00
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 0mm a 4mm METRIC Allen Keys 2.5mm a 4mm Series of screwdrivers Series of Drivers / Punch Torque spanners Special tools DESCRIPTION CODE Threadlocking medium strength (allows disassembly) (commercial product) Grease (commercial product) S5AV 2-45 /0040/00 FOREWORD 5
Exploded views and part lists 6 5 5 9 8 48 28 27 45 26 24 4 5 6 4 44 4 42 44 5 8 9 8 29 7 6 7 8 2 0 5 50 7 4 4 2 40 20 47 4 0 2 2 9 22 25 6 5 2 4 46 6 TECHNICAL ILLUSTRATION S5AV 2-45 /0040/00
Exploded views and part lists Pos. Item Q.ty Tightening torques Nm [lbf ft] Pos. Item Q.ty Tightening torques Nm [lbf ft] SPLINED SHAFT S 42 ROTATION PLATE PARALLEL KEYED SHAFT C25 4 PUMP DATA PLATE 2 PORT COVER CW 44 RIVET UNI 9200-A 2.4x5 Al/Fe 4 2 PORT COVER C-CW 45 PLASTIC PLUG G/2 PUMP CASING 46 FLANGE PLUG SH5V /4 SAE 6000 4 SWASH PLATE CW 47 PLASTIC PLUG D=9 ( /2 SAE) 4 SWASH PLATE C-CW 48 KEY A 8x7x6 UNI 6604-69 5 CYLINDER BARREL 49 GRUB SCREW UNI 592 M8x45 4.9 6 PISTON 9 50 SCREW 4 7 PISTON SHOES RETAINING FLANGE 5 washer 4 8 SPHERICAL BUSHING 7 9 VALVE PLATE CW 9 VALVE PLATE C-CW 0 SWASH PLATE BUSHING 2 SWASH PLATE JOINT 2 COVER INNER CONTROL PISTON (SMALLER DIA.) 4 SEAT X CONTROL PISTON (SMALLER DIA.) 5 CONTROL PISTON (GREATER DIA.) 6 CONTROL ROD 7 FIXED ORIFICE M5x5 D=0.5 2 8 SPACER FOR SPRING 2 9 CYLINDER BARREL SPRING 20 SMALLER DIA. PISTON SPRING 2 GREATER DIA. PISTON SPRING 22 SEAL OR,78x5,76 22 PAPER GASKET 2 SEAL OR-2275.78x69.57 (2-9) (90Shore) 24 LIP SEAL BABSL AS 5x52x6/6.5 DIN 760 25 NEEDLE BEARING 26 STRAIGHT ROLLER BEARING 27 CIRCLIP X HOLE D=62 UNI747-62 28 CIRCLIP X SHAFT D=0 UNI745-0 29 CIRCLIP X HOLE D=5 UNI747-5 0 PIN UNI-EN 28-B 5X0 h8 PIN UNI-ISO 28-B-8x8-St 2 2 NEEDLE SOFT COPPER WASHER G/4 4 PLUG TCEI G./4 (DIN 908)-8.8 5 SOFT COPPER WASHER 2x27x.5 (/2 GAS) 2 6 PLUG TCEI G /2 DIN 908 2 7 GRUB SCREW UNI 592 M6x6 2 8 GRUB SCREW UNI 592 M8x50 4.9 9 SEAL LOCK NUT M8 2 40 S.H. SCREW M6X2 UNI59 0 [7.7] 4 S.H. SCREW UNI 59 M4x40-8.8 4 5 [00] S5AV 2-45 /0040/00 TECHNICAL ILLUSTRATION 7
Exploded views and part lists Pos. Item Q.ty Tightening torques Nm [lbf ft] SAE A through drive (pag 20) SAE A FLANGE 2 COUPLING O-RING 4 O-RING 5 SCREWS 4 SAE B through drive (pag 2) SAE B FLANGE 2 COUPLING O-RING 4 O-RING 5 COUPLING 6 SCREWS 4 7 SEEGER GR 2 through drive (pag 22) GR 2 FLANGE 2 COUPLING CENTERING RING 4 O-RING 5 O-RING 6 O-RING 7 SCREWS 2 8 WASHER 2 9 SEEGER 0 COUPLING SEEGER 2 GR through drive (pag 2) GR FLANGE 2 COUPLING O-RING 4 COUPLING 5 SCREWS 2 6 WASHER 2 7 SCREWS 2 8 SEEGER TANDEM through drive (pag 24) GR FLANGE 2 COUPLING O-RING 4 SCREWS 2 5 SCREWS 2 6 WASHER 2 8 TECHNICAL ILLUSTRATION S5AV 2-45 /0040/00
Ports and settings Min. displacement setting M8x50 grub screw + M8 seal lock nut By unscrewing the screw, displacement decrease (S5AV 2 di,95 cc/turn S5AV 45 di 5,40 cc/turn) Working pressure gauge port G /4 M R Case drain port G /2 Screw slot Ø4 Pressure port /4 SAE 6000 Modulated pressure gauge port G /4 A B M2 Case drain port G /2 T2 Holes for through drive options M2 Suction port /2 SAE 000 S Case drain port G /2 T Holes for control M5 Max. displacement setting M8x50 grub screw + M8 seal lock nut By screwing the screw, displacement decrease (S5AV 2 di,95 cc/turn S5AV 45 di 5,40 cc/turn) Air bleed-bearing flushing R2 CW rotating pump CCW rotating pump S5AV 2-45 /0040/00 TECHNICAL ILLUSTRATION 9
Ports and settings Controls CLS+TP Port CLS /8 G-BSPP Port Y remote /8 G-BSPP Port CLS /8 G-BSPP Port Y remote /8 G-BSPP Pressure control adjustament standby pressure (approx 0 bar/turn) By screwing the screw, pressure setting increase. Pressure control adjustament cut-off pressure (approx 50 bar/turn). Regolazione controllo pressione. By screwing the screw, pressure setting increase. CW rotating pump CCW rotating pump 0 TECHNICAL ILLUSTRATION S5AV 2-45 /0040/00
Ports and settings Control CTP Pressure control adjustament CTP (approx 50 bar/turn) By screwing the screw, pressure setting increase CW rotating pump CCW rotating pump S5AV 2-45 /0040/00 TECHNICAL ILLUSTRATION
Troubleshooting Hydrostatic transmission components Check points & instruments Transmission does not operate in any direction Engine Tacho-meter. Pump drive coupling Pump Ga, Gb ports 0-600 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/80 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. 2 TECHNICAL ILLUSTRATION S5AV 2-45 /0040/00
Preliminary operations Introduction Before removing the pump 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 pump 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 pump 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 pump by the means of lifting straps or eyebolts. Make sure you apply the straps firmly to the pump before you move it to prevent an accidental fall and damage of objects and / or injury to persons. S5AV 2-45 /0040/00 DISASSEMBLY
Disassembly 45 6 5 4 2 2 4 40 4 5 6 4 44 42 44 Fig. Fig. 2 4 2 Fig. Fig. 4 22 Fig. 5 Fig. 6 4 DISASSEMBLY S5AV 2-45 /0040/00
Disassembly 5 5 7 2 8 7 6 Fig. 7 Fig. 8 5 5 9 8 9 8 29 4 8 9 Fig. 9 Fig. 0 7 7 4 4 Fig. Fig. 2 S5AV 2-45 /0040/00 DISASSEMBLY 5
Disassembly 0 5 50 Fig. 24 26 28 27 Fig. 4 2 4 0 20 9 2 2 25 5 6 Fig. 5 Fig. 6 6 DISASSEMBLY S5AV 2-45 /0040/00
Assembly 24 5 26 8 28 27 29 8 9 Lubricate shaft seal s lip (24) with grease. Push it fully home and mount circlip (27). Fig. 7 Fig. 8 5 5 7 2 8 7 6 Lubricate pistons (6) with oil. Fig. 9 Fig. 20 7 Swash plate joint side Swash plate joint side 4 Check that orifices (7) are not clogged. CW pump CCW pump Fig. 2 Fig. 22 S5AV 2-45 /0040/00 ASSEMBLY 7
Assembly 7 2 4 4 20 25 Mount grub screws (7) using Loctite 50 on the thread. Fig. 2 Fig. 24 CCW pump CW pump 0 9 2 2 5 6 Lubricate with a few grease the steel face of the valve plate (9) and mount it into position into its seat in the port cover (2). Fig. 25 Fig. 26 Thread locking medium strength 5 9 0 5 4 Fig. 27 50 Lubricate with grease the bushings (0). Fig. 28 8 9 Screw (8) should be turned CW until blocking swash plate (4) during the following mounting steps. Screw (8) will later by set to allow correct tilting of the swash plate (4). 8 ASSEMBLY S5AV 2-45 /0040/00
Assembly 22 Fig. 29 Fig. 0 2 5 Nm [00 lbf ft] 4 Fig. Fig. 2 45 6 5 4 4 2 2 0 Nm [7.7 lbf ft] 40 4 5 6 4 44 42 44 Fig. Fig. 4 S5AV 2-45 /0040/00 ASSEMBLY 9
Control mounting CLS+TP control mounting procedure 7 Nm [5.6 lbf ft] CTP control mounting procedure 7 Nm [5.6 lbf ft] 20 ASSEMBLY S5AV 2-45 /0040/00
Through drive SAE A through drive 4 2 2 40 Lubricate O-ring (4) with grease. Fig. 5 Fig. 6 5 20 Nm [88.50 lbf ft] 2 Lubricate O-ring () with grease. Fig. 7 S5AV 2-45 /0040/00 THROUGH DRIVE 2
Through drive SAE B through drive 4 2 2 40 Lubricate O-ring (4) with grease. Fig. 8 Fig. 9 6 20 Nm [88.50 lbf ft] 2 5 7 Lubricate O-ring () with grease. Fig. 40 22 THROUGH DRIVE S5AV 2-45 /0040/00
Through drive GR 2 through drive 4 2 2 40 Lubricate O-ring (4) with grease. Fig. 4 Fig. 42 8 0 Nm [7.7 lbf ft] 7 20 Nm [88.50 lbf ft] Fig. 4 5 6 2 9 0 Lubricate O-ring (6) with grease. S5AV 2-45 /0040/00 THROUGH DRIVE 2
Through drive GR through drive 4 2 2 40 Lubricate O-ring (4) with grease. Fig. 44 Fig. 45 6 5 0 Nm [7.7 lbf ft] 7 20 Nm [88.50 lbf ft] 2 8 4 Fig. 46 Lubricate O-ring (6) with grease. 24 SETTING S5AV 2-45 /0040/00
Through drive TANDEM through drive 4 2 2 40 Lubricate O-ring (4) with grease. Fig. 47 Fig. 48 5 20 Nm [88.50 lbf ft] 7 6 2 Fig. 49 Lubricate O-ring () with grease. S5AV 2-45 /0040/00 SETTING 25
Testing procedure - TESTING ON THE TEST RIG A) Mounting the pump on the test bench (see example of test layout). Place the coupling and flange on the test bench. 2. If necessary, clean the pump s front cover from oil and/or dirt, in order to evaluate any eventual oil leakage after the test.. Fit the coupling on the pump s shaft. 4. Mount the pump on the test bench, having the control upward. Secure the pump with at least two screws (opposed). 5. Fit the coupling flanges on the suction port and on the pressure ports. 6. Connect the suction hose and the pressure hose to the respective flanges. 7. Open the oil suction and fill the pump casing with oil. 8. Set the desired rotation (CW / CCW). B) Testing procedure - Displacement setting (VgMax - VgMin). Check on order form any eventual displacement limitation of the pump. Set the stand-by screw approx half way of its setting field. 2. Running-in of the pump must be done at 500 rpm and 0 bar for approx. 2.5 min. and at 500 rpm and 00 bar for approx. 2.5 min.. Check/set MAXIMUM DISPLACEMENT: 500 rpm, 0 bar. When the throttle valve is fully open, the pump is swivelled to the maximum displacement, thus the delivered flow rate must be the pump s maximum nominal flow rate. Turn the maximum displacement adjustment screw until the nominal maximum flow rate is delivered (see tab.). If any maximum displacement limitation have to be set, the nominal flow rate is: 500 [rpm] Vg [cm /rev] Q [l/min] = 000 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. Unscrew completely the pressure cut-off setting screw. Check/set MINIMUM DISPLACEMENT: 500 rpm. Close the throttle valve on the pressure line until the pump swivel to the minimum displacement. The minimum displacement setting screw must then be adjusted until the pressure starts to increase. From this point, unscrew (turn counter-clockwise) the screw /2 turn (80 ). 6. Lock the minimum displacement adjustment screw with nut and locking nut (with their two washers). 7. By acting on the throttle valve, check the maximum and minimum displacement just set. Any difference with the expected values must be corrected repeating the procedure from point. or point 6. 8. Close the throttle valve and set the stand-by pressure by the means of the setting screw. Setting field 8-5 bar. 9. Screw completely the pressure cut-off setting screw to keep the pump at the maximum displacement during the high pressure tests. 0. Using an appropriate solvent, clean the pump from any oil trace, in order to check any oil leak during the following high pressure test.. Check the OUTPUT FLOW RATE. 250 bar, 500 rpm. The acceptable values can be seen on tab. 2. Increase the working pressure until the requested pressure cutoff value is reached. Acting on the cutoff pressure setting screw, turn it until the flow rate start to decrease. Lock the said screw into position with nut.. Increase and decrease the working pressure several times, in order to check the control functioning. If necessary, repeat the procedure from point 2. 4. Check for any oil leak. Stop the pump. 5. Fill the pump test form with the required data C) End test. Open the lower drainage port on the pump casing and to discharge the oil. 2. Remove the pump from the test bench.. Set the eventu Table - control settings Vgmax [cm /rev] Vgmin [cm /rev] Qmax (*) [l/min] Q250 (**) [l/min] Displacement variation for screw turn (ΔVg) Screw S5AV 2 2 0 48 45.95 c.c./turn M8 S5AV 45 4. 0 65 6 5.40 c.c./turn M8 (*): 500 rpm, 0 bar (**): 500 rpm, 250 bar (minimum acceptable output flow rate) 26 TESTING PROCEDURE S5AV 2-45 /0040/00
Testing procedure Example of test bench layout Throttle valve Pressure gauge LS Pressure gauge Y G P M Qmin Qmax M S T R 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. 28. 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.. 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.. 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 80 (/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 5 S5AV 45 X measure (mm) 2.5 (M8x50 screw) 2.5 (M8x50 screw) WARNING: in S5AV 2 and 45 the QMAX displacement setting screw is in the control side. X Q max S5AV 2-45 /0040/00 TESTING PROCEDURE 27
Testing procedure 8. Lock the screw with locking nut and cap. B) Stand-by pressure setting. 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.. Adjust the stand-by pressure setting screw until the required value is reached. Optimum setting field is 8-5 bar. We do not recommend to exceed 8 bar. 4. Lock the screw with its locking nut. 5. Stop the engine or moto. C) Cut-off pressure setting. 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 /4 hose). 2. Unscrew completely the cut-off valve setting screw (turn it counter-clockwise).. 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 50-50 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 Pressure port must be closed LS Pressure gauge Y G P M Qmin Qmax M S T R T2 R2 M2 Layout for on the field cut-off pressure setting Pressure port must be closed Pressure gauge LS Y G P M Qmin Qmax M S T R T2 R2 M2 28 TESTING PROCEDURE S5AV 2-45 /0040/00
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 2-45 /0040/00 STORAGE AND DEMOLITION 29
Brevini Fluid Power S.p.a. Via Moscova n 6 4224 Reggio Emilia (ITALY) Tel. +9-0522-748700 Fax.+9-0522-748750 e-mail: info@brevinifluidpower.com web-site: www.brevinifluidpower.com 0 S5AV 2-45 /0040/00