HST-71, HST-90. Hydrostatic Transmissions. Service Manual
Contents
1. description identification quantity 3 Seal ring 009 013 25 2 2 national standard 1829 2 a Pressure relief safely vane 0PK 16 00003 5 Plg JHNS ORMIZXLSDINISO61492 2 6 Pump ___ LE Lo i 7 Charge pressure valve 4160 90 77 00140 oa 39 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Charge Pump 1 2 3 description identification S quantity 1 Screws M6x20 12 9 A3K ISO 4762 6 2 Pressure ring plate 4160 90 77 00099 oa 3 Coverplate 4160 90 77 00055 18 4 Sealring 098 102 25 2 2 national standard 18829 1 6 Thrustring RW45 DIN a oa 7 Wheel 4160 90 7700051 a 8 Gear J4160 90 7700052 oa 9 Ring 4160 90 77 00053 o a 10 Spacer 4160 90 77 00054 Ao 11 Pump sd 46 0 7 or 416 090 o a p12 Pin 3m6x32DIN6325 oa 13 Key cotter T A4x4x18 DIN 6885 Toa an 40 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Shaft Sealing description identification quantity amp pomp aerate ba 2 Sealring 082 088 36 2 2TOCT 18829 4160 90 77 00018 01 0127mm 6 65T 019 national standard 6402 6 6 Screw M6x20 12 9 A3K ISO 4762 6 Shaft Assembly description identification quantity rest Thrust nt ing o Aaron 2 Bearing S 76592708M I I 41 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e 406 0 712. HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Description of HST 90 Components e Series 416 Pumps Basic Components Series 416 variable displacement axial piston swash plate pumps Series 416 Pump General View serve to operate in closed hydraulic schemes Pump output flow is proportional to shaft speed and working volume The working volume is regulated steplessly from O to maximum point in all directions The direction of fluid supply may be reversed by changing the angle of swash plate right about of neutral position The hydraulic pumps have iron housings The round valve plate and steel embronze cylinder block are applied in the pumping unit of the hydraulic pump They allow to boost the maximum working pressure and to increase the resource The working volume of the pump is regulated by changing the angle of swash plate The maximum working volume in hydraulic pumps may be limited in all directions by regulating screws All connection dimensions are done according to ISO SAE standards e Components Series 416 Pump Sectional view The pump consists of the following basic components main pump end cap servo regulator control mechanism j i f a J Fi F f f F r i T LITER o A TP et Soy er a a i r Q HE x N ze mr k A er v ki Fi hy oes Fi y G e Main Pump The main pump has the iron housing in which the followi
3. 12 ISO 6149 1 Case Pressure M22x1 5 15 ISO 6149 1 NN Ordering code G Special features T1 T2 T2 Case Pressure 7 8 14UNF 2B ISO 11926 1 IN Ordering code G Special features M22x1 5 15 DIN 3852 1 RN Ordering code G Special features System Pressure Port A System Pressure Gauge Part B1 y M18x1 5 12 150 6149 1 Charge Pressure Gauge Port Fe M18x1 5 12 150 6147 1 em Pressure Gauge Port A Case Drain Port T1 15 12 ISO 6149 1 Sr js 16 HST 71 HST 90 Hydrostatic Transmissions PSM rorauLics Service Manual Air Bleeding Port R Control Pressure Gauge Port X1 M12x1 5 14 150 6149 1 M12x1 5 14 150 0149 1 Control Pressure Gauge Port X2 System Pressure Port B M12x1 5 14 150 6149 1 17 HST 71 HST 90 Ng Hydrostatic Transmissions PSM HYDRAULICS Service Manual Trouble Shooting e The list of the main failures of series 416 pump and series 406 hydraulic motor Recommendations on trouble shooting Zero unavailability mechanical zero is not adjusted on the swash plate of To adjust zero with the help of axis on the servo the pump regulator Neutral on the control mechanism is not adjusted To adjust neutral on the control mechanism Control mechanism failure Change the control mechanism Servo regulator failure Change the pump Flash heat of the hydraulic system Hydraulic system overheating Low level of oil in the hydraulic reservoir Eliminate the cause
4. Turn the orifice out of servo regulator s housing Check the orifice hole for cleanliness Unplug in case of dirt Install the orifice into the servo regulator s housing Install the plug Torque 35 3Nm 35 i HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULIcS Service Manual e Basic Repair of Hydraulic Motors e Hydraulic Motor Shaft and Shaft Sealing Replacement Take the shaft assembly shaft bearing and seal plate out of the hydraulic motor housing Replace the seal for the new one Replace the seal ring of the seal plate for the new one Check the working area of shaft and seal surface contact Replace the shaft in case of wearing Install the shaft assembly into the hydraulic motor in case when the shaft replacement is not necessary Take the locking ring off the shaft Take the roller bearing off the shaft and install it on the new one Install the locking ring on the new shaft Install the new shaft assembly into the motor 36 HST 71 HST 90 Hydrostatic Transmissions Service Manual PSM HYDRAULICS Install the seal ring of the seal cover plate Set the tapered mandrel for seal fixing on the shaft Grease the following parts with working fluid before seal cover plate installation mandrel surface shaft surface in the area of seal contact cutting edge of the seal seal ring of the seal cover plate Install the seal cover pl
5. based on 2 proportional pressure reducing valves with electro control Each valve is installed in the control line of servo piston Getting the 12V or 24V signal the valve regulates proportionally the pressure value of servo control which effects the servo piston The angle of swash plate is proportional to the electric PWM signal rate only in case of constant pressure in the power line When the hydraulic drive loading changes the scheme of control changes too and the proportionality stays up 10 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Series 406 Hydraulic Motors Basic Components All series 406 hydraulic motors are designed and meant for closed loop hydraulic systems Series 406 hydraulic motor General view Series 406 hydraulic motor Sectional view Fixed displacement axial piston swash plate hydraulic motors The hydraulic motors convert the energy of working fluid into the mechanical energy of shaft rotation The direction of shaft rotation is defined by the direction of working fluid flow The shaft speed is defined by the volume of supplied fluid The torque on the motor s shaft is defined by working fluid pressure Hydraulic motors are done in iron housings Round valve plate and steel embronze cylinder block are applied in the pumping unit of hydraulic motor They allow to boost the maximum working pressure and to increase the resource The loop flushing valve is installed into the en
6. E C 4 bolts Recommended orientation of installation pump control mechanism is located above or on the side motor any orientation Hydraulic lines connection ports See Pressure Control e Technical Features Variable displacement pumps 4460 71 416 0 90 416 0 110 416 0 125 Displacement emre n 90 10 15 Shaft speed minimum nominal maximum peak Torque at Nom Vmaxs Pmax eo 85 785 Fixed displacement hydraulic motors oemei cere Te0m0 406 0110 406 0 128 125 Shaft speed minimum 2000 2000 1500 1500 nominal 3050 3050 3000 3000 maximum 3300 3300 3200 3200 peak Torque at Nom Vmax Pmax Weight kg 40 462 462 13 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Hydraulic Parameters Working pressure differential pressure Power fluid temperature Maximum working pressure Max constant temp 400 bar Max peak temp short time Maximum peak pressure 450 bar Min short time temp cold start Min working pressure 0 8 bar optimal constant 20 35 mm s cSt Min short time pressure t lt 5min Max starting 1500 mm s cSt cold start 0 5 bar Min short time 10 mm s cSt Max working pressure 2 5 bar 12 class of national standard 17216 71 Max short time pressure t lt 5min 5 bar 18 15 class of ISO DIN 4406 See the recommended working fluids and their basic characteristics in the catalogue of products or
7. HST 71 HST 90 Hydrostatic Transmissions Service Manual PSM Hydraulics Ekaterinburg 2009 HST 71 HST 90 Ng Hydrostatic Transmissions PSM HYDRAULICS Service Manual Introduction e Service Manual Application The given Manual provides the information and instructions on correct operation application and after sales service of series 416 hydraulic pumps and series 406 hydraulic motors making up together the group of hydrostatic transmissions The Manual includes the description of hydraulic units and their components the information on trouble shooting instructions on adjustment and repair Guarantee liabilities are valid in case the operation service repair regulation and adjustment are done in strict compliance with recommendations provided by the given Manual Disassembling of hydraulic units is not compulsory for some adjusting and service operations Nevertheless the hydraulic units should be accessed easily and cleaned thoroughly before starting up service adjusting or repair operations The working fluid pollution is the main cause of any hydraulic equipment breakdown The purity requirements should be observed strictly especially while filter elements replacing or adjusting and repairing For more detailed information see the web site www psm hydraulics com The Manual is not intended for overhauling of hydraulic units and their full disassembling Contact the authorized service network of PSM Hydraulics for overhau
8. air contact the producer or authorized service centers All repair works except shaft sealing replacement in hydraulic units should be agreed together with producer or authorized suppliers or authorized service center in order to keep the hydraulic unit s warranty Outwatch the sealing elements while making the repair procedures rubber rings and seal housings cutting edges of seals and shaft surface valves gates working surfaces and responsive edges done in the hydraulic units housings In order to avoid failures during assembling lubricate the seal rings and their seats in the housings before hydraulic components installation Avoid dirt contamination in the interior cavities and passages of hydraulic units Before dismantling any component of pump or hydraulic motor clean this component and surfaces around thoroughly Use cleaning fluids dry clean rag and pressed air Use only new seal rings and layings in order to prolong the mechanical life of the pump and hydraulic motor Always change all the general mechanical rubber goods and layings to the new parts even if the faults are not inspected out in any component of pump or hydraulic motor 28 4 lll FA HST 71 HST 90 WU aaa Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Basic Repair of Pump e Pump shaft and shaft sealing replacement Unscrew seal cover plate s six screws internal hex 6mm Take the seal cover plate out R
9. and 406 0 90 Fixed Displacement Hydraulic Motors The motors 71 and 90 ccm rev working volumes are designed with maximum unification The motors are distinguished by housings types 12 3 4 5 6 7 8 10 11 description identification 4060 90 20 00009 019 023 25 2 2 national standard 18829 5 Sealring 009 013 25 2 2 national standard 18829 3 6 Pug HN BOR M12x1 5 DIN ISO 6149 2 _ 3 7 Purgerelief vave 4160 90 77 00140 CT 1 8 Hydraulic motor 406 0 71 or 406 0 90 1 9 Sealring 085 090 30 2 2 national standardig829 1 10 Seal Simmering BABSL d50 D72 b7 _ _ 1 12 Thrustring JS90 DIN472 CC A 13 Spoo 310 3 56 19 01009 0 o Z 18 HHHH 42 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Shaft Assembly m description 1 Thrust ring 40x1 75 DIN 471 Bearing sanm ooo Shaft 23T 16 32 pitch ANSI B92 3 Shaft 21T 16 32 pitch ANSI B92 i 43
10. angeout in the power tubes to provide productive working temperature range in the hydraulic system and the constant opportunity of closed circuit cleaning Getting to the insignificant pressure fall at its ends the spool effects bushing compresses spring and displaces aside In this case the lower pressure line drain tube together with the drain line connects to the housing of hydraulic motor through purge relief valve The springs of spool are adjusted by plugs Loop Flushing Valve Sectional View Purge Relief Valve Sectional View The purge relief valve serves to support the charge pressure in hydraulic system when the loop flushing valve operates Getting to the adjusting pressure the effort on the edge of the valve compresses spring and connects bleeding line together with drain line through loop flushing valve supporting the charge pressure The setting of purge relief valve is made by spring compressing with the help of valve thread casing 12 HST 71 HST 90 Ng Hydrostatic Transmissions PSM HYDRAULICS Service Manual Features e Main Features Connection ports of power tubes Variable displacement axial piston swash plate pumps SAE 3000 psi and fixed displacement axial piston swash plate hydraulic SAE 6000 psi motors Mounting flanges Direction of shaft rotation pumps SAE C 4 bolts SAE C C 6 bolts pumps clockwise or counterclockwise SAE D 4 bolts SAE D D 6 bolts motors reverse motors SA
11. arge pressure by turning the valve casing by the wrench Valve casing clockwise rotation increases the charge pressure One complete revolution of charge pressure valve casing increases the pressure up to 4 0 5bar approx The pressure should be controlled by the manometer Torque the lock nut 50Nm holding the valve casing by the wrench 20 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Pressure Relief Safety Valves Checking the system pressure setting Connect the two manometers to the system pressure gauge ports Al and B1 on the end cap of the pump for checking the system pressure It is admissible to connect the manometers to the system pressure gauge ports Al and B1 on the end cap of hydraulic motor The limit of measured pressure of the manometer is to be up to 600bar and not lower Connect the manometer to the charge pressure gauge port Fe on the end cap of the pump The limit of measured pressure of the manometer is to be up to 60bar and not lower WARNING Exclude the cut off valve out of operation in case of its availability in the construction of the pump In order to exclude the cut off valve ease off the lock nut on the cut off valve turn the adjusting screw of the valve against the clock on two complete revolutions One complete revolution corresponds to the changing of pressure setting up to 60 5bar Block the output shaft of the hydraulic motor Activat
12. ate into the motor housing Install the locking ring 37 HST 71 HST 90 LO Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Purge Relief Valve Replacement It is recommended to mark the lock nut position relating to end cape and valve casing before the replacement of purge relief valve Install the valve in accord with the mark and set the pressure in case when the purge relief valve replacement is not required Ease off the lock nut of purge relief valve external hex 27mm Turn the valve out of the end cap of motor external hex 13mm Check the sealing edge in the end cap of the motor seat for cleanliness and defects Install the new valve Torque the lock nut of the valve 50Nm Adjust the valve e Loop Flushing Valve Replacement Unscrew the two plugs closing the spool external hex 27mm Take the two springs out Take the spool out two bushing Check the spool hole in the end cap of hydraulic motor for defects and cleanliness Install the new spool Install the bushing Install the springs and plugs Torque the plugs 100 10Nm 38 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Parts Catalogue e 416 0 71 and 416 0 90 Variable Displacement Pumps The pumps 71 and 90 ccm rev working volumes are designed with maximum unification The pumps are distinguished by servo regulators types Built in valves
13. ch side cover of servo regulator in order to limit the maximum working volume The maximum possible working volume of the pump is adjusted by limit screws The working volume in each direction may be limited to zero m PSM HYDRAULICS e Control Mechanisms e Proportional Mechanical Servo Control Servo control mechanism serves to convert the basic mechanical Signal into intense servo hydraulic signal by servo regulator which angles the swash plate 209 with linear scaling of working volume corresponding to the special position of the control lever The proportionality of swash plate angle to the control lever angle is provided by mechanical feedback between servo piston and servo control mechanism e Proportional Hydraulic Control Mechanism of hydraulic control serves to convert the input hydraulic Signal into the intense servo hydraulic signal by servo regulator controlling the angle of pump s swash plate The spool of control mechanism controls the servo piston directly and has the mechanical feedback to it The feedback provides the angle of swash plate proportionally to the hydraulic signal control pressure variance e Proportional Electro Control Mechanism of proportional electro control is similar to mechanism of proportional hydraulic control Instead of hydraulic signal the electric signal 12 and 24V is used Electric PWM signal effects on 2 proportional electric solenoids which convert the signal in
14. d bushings with necessary type of splines e Filtration There are 2 types of working fluid filtration for series 416 pumps Using outer suction filter installed in the suction line of charge pump The parameters and type of filter are defined by the consumers Using pressure filter installed on the end cap of the pump in the pressure line of charge pump Filter is an integral part of the pump The parameters and type of filter are defined by producer e Servo Regulator Servo regulator serves to convert the input hydraulic signal delivered from control mechanism into the intense servo hydraulic signal controlling the angle of pump s swash plate Servo piston installed in the iron housing is the main component of servo regulator Servo piston delivers the effort to the swash plate through sliding block moving freely in the servo piston s channel Servo piston has the mechanical feedback to the spool of control mechanism Servo regulator enables the axis springs and taps group installed on the axis In case of no signal from control mechanism the springs return the servo piston into the initial position corresponding to zero delivery of the pump The initial position of servo piston and zero delivery of central pump is defined by the axis position The axis has threaded joint with one of the side covers of servo regulator The position of axis is fixed by the screw Working volume limitation The limit screw is installed on ea
15. d cap of hydraulic motor All connection dimensions are done according to ISO SAE standards e Components Hydraulic motor consists of the following basic components main motor end cap e Main Motor The main hydraulic motor has the iron housing in which the following parts are located shaft coming through the motor The front support of the shaft is a roller bearing fixed in the housing The end support of the shaft is a sliding bearing fixed in the end cap pumping unit of hydraulic motor driving through splined joint of cylinder block and shaft Piston heels of the pumping unit are retained to the inclined support in the housing and they slide on it during pumping unit rotation seal plate fixed in the motor s housing at mounting flange side The seal is installed in the seal carrier 11 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e End Cap Different types of end caps are applied in the series 406 hydraulic motors End cap includes loop flushing valve purge relief valve End cap type defines the configuration of high pressure lines connection ports WARNING Removing of the end cap cancels the motor warranty e Loop Flushing Valve and Purge Relief Valve The loop flushing valve is built into the end cap of hydraulic motor The construction and operating principles of loop flushing valve are showed at the picture The spool serves to assist fluid ch
16. e the pump Set the shaft speed on the pump up to 1500 rpm The temperature of working fluid in the drain cavity of the pump should be up to 45 50 C Set the pump control signal slowly Control the pressure relief safety valve setting with the help of manometers Repeat the procedure for the second system line second pressure relief safety valve The pressure relief safety valves operation setting is the difference of gauges reading pumping pressure charge pressure Pressure Relief Safety Valve Adjustment Remove the valve from the pump Get the internals out of the valve bushing Ease off the lock screw internal hex 3mm lock screw Set the required pressure holding the valve by the wrench external hex 10mm turning the plunger external hex 14mm Torque the lock screw 6 0 5Nm The plunger s clockwise turning increases the pressure setting of the valve One complete revolution of the plunger increases the pressure up to 40 5bar approx HST 71 HST 90 Hydrostatic Transmissions Service Manual Install the spring of return valve into the valve bushing Install the internals into the valve bushing Install the valve seat Install the pressure relief safety valve into the end cap of the pump Torque the valve 200 15Nm 22 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Cut off Valve Checking the cut off pressure setti
17. eplace the seal for the new one Replace the seal ring of the seal cover plate for the new one Check the working area of shaft and seal cover plate surface contact Replace the shaft in case of wearing Install the seal cover plate in case when the shaft replacement is not necessary Take the ring out Take the shaft out of the pump 29 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Take the locking ring off the shaft Take the roller bearing off the shaft and install it on the new one Install the locking ring on the new shaft Install the shaft assembly into the pump Grease the following parts with working fluid before seal cover plate installation shaft surface in the area of seal contact cutting edge of the seal seal ring of the seal cover plate Install the seal cover plate into the pump housing Set the seal cover plate six screws Torque the screws 12 2Nm e Charge Pressure Valve Replacement It is recommended to mark the lock nut position relating to end cap of the pump and valve casing before the replacement of charge pressure valve Install the valve in accord with the mark and set the pressure in case when the charge pressure valve replacement is not required Ease off the lock nut of charge pressure valve external hex 27mm Turn the charge pressure valve out of the end cap of pump external hex 13mm Check the seali
18. he adjusting screw by the wrench 23 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Adjustment of Displacement Limitation Limit screws are installed into servo regulator in order to limit the maximum working volume of the pump The maximum working volume supply of the pump may be limited on each direction Ease off the lock nut of adjusting screw Adjust the required working volume by screw turning Torque the lock nut 25Nm holding the adjusting screw by the wrench The clockwise turning limits the working volume of the pump One complete revolution of the screw corresponds to AV 10 4 cm r approx adjusting screws internal hex 4mm vu i 24 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Proportional Servo Control Neutral is set by neutral adjustment screw on the Servo Control Servo Control top view neutral en external hex 17mm Lock screw internal hex 2 5mm Connect the manometers in order to set neutral on the Servo Control to the control pressure gauge ports X1 and X2 of on the servo regulator casing to the charge pressure gauge port Fe of on the end cap of the pump The limit of measured pressure of the manometers should be up to 60bar Activate the pump Set the pump s shaft speed up to 1500 rpm Ease off the lock screw Set neutral by turning adjustment screw The setting should be co
19. heck valves serve to deliver the working pressure to the cut off valve see HST scheme The cut off valve s functioning is based on regulating principle The pressure in the delivery pumping line increases up to the given level and the valve spool moves and connects the control line with drain line Upon that the control line pressure falls to the level of drain line pressure causing the return of servo piston into zero position therefore the working volume is reduced to zero The orifice separating charging and control lines doesn t allow charging line pressure fall to the level of drain line pressure Cut off valve s pressure setting should be lower at 10 30bar than pressure relief valve s pressure setting The cut off valve prevents the pressure relief valves reaction operation in speed up and slowdown excluding overheating of the hydraulic system as a result of pressure relief valves operation The pressure relief valves are opened only at pressure jumps therefore the heat releases at a minimum level as the period when the valves are opened is short Cut off Valve Structure nut housing tap spring tap spool sleeve pin HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Auxiliary Mounting Pads The tandem function is available on every type of series 416 pumps Tandem function is realized by installing the auxiliary mounting pad on the end cap of the pump and using spline
20. in out together Install the new pump WARNING Do not confuse the pin s location and the direction of charge pump delivery while installing the new gerotor type charge pump The charge pump parts orientation depending on the direction of central pump s shaft rotation is shown at the picture Counterclockwise rotation pump Clockwise rotation pump 32 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Install spacer and pin Install the ring Install the key of the new charge pump into the splined bushing Install the gear on splined bushing Install splined bushing on the shaft of central pump Install the wheel Lubricate the seal ring on the cover plate of charge pump Install the cover plate of charge pump Install the pressure ring plate and torque the six screws 8 82 9 8Nm WARNING Hold the torque urgently Torque the screws in accordance with the picture Pressure ring plate communicates only with the cover plate of gerotor type charge pump Some space should be left between pressure ring plate and the end cap of main pump Keep the screw torque urgently In case of disregard of the given instructions the misuse failure of charge pump and main pump elements is possible 33 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Replacement of Proportional Servo Control Disconnect the charge pipeline external he
21. ing Valve Shaft Ve r it 7 Y a el gt Check Valves Rotary Group Rotary Group e Description of Hydrostatic Transmission HST 90 Hydrostatic transmission is a closed hydraulic system consisting of hydraulic pump and hydraulic motor Hydrostatic transmission serves to deliver the mechanical energy from drive motor to the operating unit of the product Basic Closed Circuit Basic ports of the pump are connected to basic ports of hydraulic motor through hydraulic lines The working fluid flows in different directions from pump to hydraulic motor returning back to the pump in the given closed circuit Each hydraulic line may be under high pressure In operating mode the position of swash plate defines the direction of the working fluid flow and also points which of the hydraulic lines is under high pressure Drain Line and Heat Exchange Drain lines are necessary for pump and hydraulic motor in order to aspirate the hot fluid from drain cavities The hydraulic motor is to be connected to the drain line through drain port located in the upper point to guarantee the filling up of hydraulic motor s drain cavity It is recommended to connect the hydraulic motor s drain line to the bottom drain port of the pump The bleed off to the hydraulic reservoir comes through upper drain port of the pump The heat exchanger serves to cool the bleeding working fluid before it gets into the hydraulic reservoir
22. lean the valve Pressure relief safety valve failure Change the valve Internal faults of the pump Change the pump 18 HST 71 HST 90 Ng Hydrostatic Transmissions PSM HYDRAULICS Service Manual HST doesn t operate in both directions Low level of oil in the hydraulic reservoir Eliminate the cause of oil bleeding Top up the oil into the hydraulic reservoir Control mechanism failure Change controlling mechanism Orifice in control lines is choked Clean the orifice Charge pump failure Change the charge pump Charge pressure unavailabili Low speed starting and delays Air remains in hydraulic system Eliminate the leakage of the hydraulic system connections Low charge pressure See above Orifice are choked Clean the orifice Defective details in the pumping unit of pump and Change the pump or hydraulic motor hydraulic motor Low efficiency of hydrostatic transmission Low level of oil in hydraulic reservoir Eliminate the cause of oil bleeding Top up the oil into the reservoir Rotary Group wear Change pump or hydraulic motor Low charge pressure Fluctuations of pump supply flow in case of controlling unavailability Charge pressure valves are adjusted similarly Adjust the charge pressure valves on the pump and hydraulic motor correctly Zero of hydraulic pump swash plate cradle is not Change the pump adjusted Leak flow on the shaft of the product Sealing failure Change the seal Defective spindle
23. ling PSM Hydraulics authorized service network provides repairs of any complexity level Contact our service centers for more details and information or our company directly Sibirsky trakt 1km 8 620100 Ekaterinburg Russia tel fax 7 343 2646650 e mail trade psmural ru web www psm hydraulics com See the list of our service centers network on www psm hydraulics com e Safety Precautions Follow the common safety Precautions during hydrostatic transmissions operating and after sales service e The working fluid is under high pressure Be careful during working fluid under pressure operating Bleedings of working fluid under pressure as a result of hydrostatic transmissions failure may be injurious to personnel s health Getting to the skin the working fluid may burn it The working fluid may also penetrate under the skin causing serious infections and other negative consequences therefore medical aid should be provided immediately e Cleaning and degreasing solvents Some solvents are highly inflammable Avoid keeping close to the open fire springs e Blocking of vehicle moving technological equipment Some procedures of service and operation may require the following additional security measures lifting up of driving wheels disconnecting of drive gear on the driving wheels driving axle To prevent any possible injuries of personnel PSM HYDRAULICS Content Introduction Safety Precautions General Info
24. ng Connect the two manometers to the system pressure gauge ports Al and B1 on the end cap of the pump for checking the cut off pressure It is admissible to connect the manometers to the system pressure gauge ports Al and B1 on the end cap of hydraulic motor The limit of measured pressure of the manometer is to be up to 600bar and not lower Connect the manometer to the charge pressure gauge port Fe on the end cap of the pump The limit of measured pressure of the manometer is to be up to 60bar and not lower Block the output shaft of the hydraulic motor Activate the pump Set the shaft speed on the pump up to 1500 rpm The temperature of working fluid in the drain cavity of the pump should be up to 45 50 C Set the pump control signal slowly Control the pressure setting of cut off valve with the help of monometers Repeat the procedure for the second pumping line The pressure of cut off valve s operation setting is the difference of gauges reading pumping pressure charge pressure Cut off pressure setting adjusting screw internal hex 4mm valve casing external hex 22mm The cut off pressure is set by adjusting screw on the cur off valve Holding the cut off valve casing by the wrench ease off lock nut Set the required cut off pressure by turning the adjusting screw Control the pressure by the manometer Torque the lock nut 25Nm holding t
25. ng edge in the end cap of the pump seat for cleanliness and defects Install the new valve Torque the lock nut of the valve 50 Nm Adjust the valve e Pressure Relief Safety Valve Replacement Take the pressure relief safety valve out of the end cap plate of the pump external hex 30mm Check the sealing surface in the end cap of the pump for defects Install the new valve into the rear plate Lubricate the seal rings of the valve before installation Torque the valve 200 15Nm 30 P HST 71 HST 90 F u u m m m UL Tr Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Cut off Valve Replacement a5 Turn the cut off valve out of the end cap of the pump external hex 22mm Install the new cut off valve lubricate the seal ring of the valve and the seat in end cap before installation Torque the valve 100 10Nm e Check Valves Replacement Turn the check valve out Install the new check valve Set the plug Torque 35 3Nm Replace the second valve on the other side 31 HST 71 HST 90 Hydrostatic Transmissions Service Manual PSM HYDRAULICS e Charge Pump Replacement Unscrew the pressure ring plate s six screws internal hex 6mm and take the ring plate of charge pump off Take the cover plate of the charge pump out Take the splined bushing with installed key and gear out Take the gear out Take the ring spacer and p
26. ng units are located swash plate supported by two roller bearings fixed on each side of the housing shaft coming through the pump The front support of the shaft is a roller bearing fixed in the housing The end support of the shaft is a sliding bearing fixed in the end cap pumping unit driving through splined joint of cylinder block and shaft Piston heels of the pumping unit are retained to the swash plate and they slide on it during pumping unit rotation seal carrier fixed on the pump housing at mounting flange side The seal is installed in the seal carrier les PSM HYDRAULICS e End Cap HST 71 HST 90 Hydrostatic Transmissions Service Manual Series 416 pumps are equipped with end caps of different types End Cap consists of the following parts gerotor type charge pump charge pressure valve 2 pressure relief safety valves cut off valve 2 check valves filter End Cap type defines the configuration of high pressure lines connection ports the configuration of suction line s connection port availability non availabililty of cut off valve availability non availabililty of filter WARNING Removing of the end cap cancels the pump warranty e Charge Pump Charge pump is a gerotor type fixed displacement pump It is installed into the end cap Charge pump drives by the shaft of main pump Gerotor type charge pump serves to compensating of bleeding in the main lo
27. ntrolled by manometers reading in gauge ports X1 and X2 The readings should be similar Torque the lock screw 6 0 5Nm holding the neutral adjustment screw by the wrench e Proportional Hydraulic Control Neutral is set by neutral adjustment screw on the Hydraulic Control Lock screw internal hex 4mm fom H E u no Eq E mn CI HD neutral adjustment screw screwdriver slot Connect the manometers in order to set zero on the Hydraulic Control to the control pressure gauge ports X1 and X2 of on the servo regulator casing to the charge pressure gauge port Fe of on the end cap of the pump The limit of measured pressure of the manometers should be up to 60bar Activate the pump Set the pump s shaft speed up to 1500 rpm Ease off the lock screw Set neutral point by turning adjustment screw The setting should be controlled by manometers reading in gauge ports X1 and X2 The readings should be similar Torque the lock screw 6 0 5Nm holding the neutral adjustment screw by the wrench 25 i HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Proportional Electro Control Neutral is set by neutral adjustment screw on the Electro Control Lock screw internal hex 4mm Hi ff E I Neutral adjustment screw screwdriver slot Connect the manometers in order to set zero on the mechanism to the control pressure gauge
28. of oil bleeding Top up the oil into the hydraulic reservoir Oil cooler failure Clean repair or change oil cooler Low level of pressure relief safety valves adjustment Adjust the safety valves to the higher level Excessive load of HST Lower the operating conditions of HST Low charge pressure Charge pump heating Filter in the suction line is choked Change the filter element The suction line of the pump is choked Eliminate the choking Charge pressure valve is not adjusted Adjust the charge pressure valve Charge pressure valve failure Change the valve U ss Low level of oil in the hydraulic reservoir Eliminate the cause of the oil bleeding Top up the oil into the hydraulic reservoir Air remains in the suction line Eliminate the leakage of suction line Charge pump failure Change the charge pump Charge pressure unavailability Charge pump failure Change charge pump Charge pressure valve failure Central pump drive failure Repair the drive of central pump Unwanted sounds during hydrostatic transmission operation Air remains in hydraulic system Eliminate the leakage of hydraulic system connections Pump or motor internal faults Change pump or hydraulic motor HST operates only in one direction Control mechanism failure Change the control mechanism Orifice is choked in the control line Clean the orifice One of the check valves is defective Change the check valve Pressure relief safety valve is choked C
29. ol without Feedback Series 406 Hydraulic Motors Purge Relief Valve Basic Repair Instructions Basic Repair of Pumps Pump shaft and shaft sealing Replacement Charge Pressure Valve Replacement Pressure Relief Valve Replacement Cut off Valve Replacement Check Valves Replacement Charge Pump Replacement Replacement of Proportional Servo Control Replacement of Proportional Electro Control Replacement of 3 Positioning Discrete Electro Control Replacement of Proportional Electro Control without Feedback Replacement of Proportional Hydraulic Control without Feedback Throttle checking Basic Repair of Hydraulic Motors Hydraulic Motor Shaft and Shaft Sealing Replacement Purge Relief Valve Replacement Loop Flushing Valve Replacement Catalogue of Details 416 0 71 and 416 0 90 Variable Displacement Pumps Charge Pump Shaft Sealing Shaft Assembly 406 0 71 and 406 0 90 Fixed Displacement Motors Shaft Assembly 34 34 35 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual General Information e Hydraulic Scheme of Hydrostatic Transmission Reservoir Heat Exchanger B DE us suction line echanical Servoco I charge line dai EH control line e EH high pressure line WE case drain line Charge Pressure Relief Valve Purge Relief Valve 406 series Motor Charge Pump mann pP 416 series Pum Loop Flush
30. ometer shows the pressure of charge pressure valve setting on the pump The charge pressure is a difference of gauges reading charge pressure drain pressure The charge pressure is up to 23 1bar upon 1500rpm of the pump s shaft and working fluid temperature in the drain cavity of the pump 45 50 C Charge pressure setting valve casing external hex 13mm lock nut external hex 27mm Ro gt re E EE A E Goo bol 77 U U U U A 5 Sn ae a zu TG bes Ma oer erie ie FIRE E Wl The charge pressure is adjusted by purge relief valve Ease off the lock nut Set the required charge pressure by turning the valve casing Valve casing clockwise rotation increases the charge pressure One complete revolution of charge pressure valve casing increases the pressure up to 4 0 5bar approx The pressure should be controlled by the manometer Torque the lock nut 50Nm holding the valve casing by the wrench 27 HST 71 HST 90 Ng Hydrostatic Transmissions PSM HYDRAULICS Service Manual Basic Repair Instructions The examples of minimum repairs of series 416 pumps and series 406 hydraulic motors are described in the given section The following procedures may be done directly on the equipment except shaft and sealing replacement and do not require pump or hydraulic motor disassembling For more complicated rep
31. on the shaft of the pump Change the shaft of the pump and the sealinc 19 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Checking and Adjusting Checking and adjusting of pumps and hydraulic motors are described in the given section It is necessary to read thoroughly the given section before starting the after sales service of hydrostatic transmission s components Follow the above mentioned sections if necessary in order to define the correct port and its parameters for connecting the gauges e Series 416 pumps e Charge Pressure Valve Checking the charge pressure setting For checking the charge pressure setting connect the manometer to the charge pressure gauge port Fe on the end cap of the pump The limit of measured pressure of the manometer should be up to 60bar and not lower Connect the other manometer to the drain pressure gauge port in the pump Activate the pump in the neutral delivery mode and measure the charge pressure The charge pressure is a difference of gauges reading charge pressure drain pressure The charge pressure is up to 27 1 bar upon 1500 rpm of the pump s shaft and working fluid temperature in the drain cavity of the pump 45 50 C Charge pressure setting Valve casing external hex 13mm Safety nut external hex 27mm The charge pressure is adjusted by charge pressure valve casing Ease off the lock nut Set the required ch
32. on the web site www psm hydraulics com e Hydraulic Schemes Bed Pc 35MP Variable displacement pump with proportional servo control Fixed displacement hydraulic motor 14 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual Pressure Control Pressure control ports locations and their description The following procedures may be done applying the standard set of tools and keys In case when a special tool is required its code is pointed according to the rules of PSM Hydraulics The applying gages and other measuring tools should be checked and calibrated e Fixed Displacement Hydraulic Motor Function Gauge Size and Fitting gt Z o S System Pressure M12x1 5 12 ISO 6149 1 Xi Charge Pressure M12x1 5 12 ISO 6149 1 o S O Tam Cerro as 28 SO AI PIN dera code peal tues T1 T2 T2 Case Pressure 1 Case Urain Port 11 Lose Drain Port 13 system Pressure Port System Pressure Port B ssure Gauge Port B1 SU 6149 1 Charge Pressure Gauge Port X M12x1 5 12 ISO 6149 1 system Pressure Gauge Port Al M12x1 5 12 ISO 6149 1 15 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Variable Displacement Pumps Gauge Size and Fitting O00 O AL Bi System Pressure M12x1 5 12 ISO 6149 1 Po o Charge Pressure M12x1 5 12 ISO 6149 1 IT Los Control Pressure M12x1 5 12 ISO 6149 1 RO Air Bleeding M12x1 5
33. op of HST The bleeding appears as a result of leak flows in the rotary groups of pump and motor creating and keeping of necessary pressure in suction line of the main pump for suction conditions improvement creating and keeping of necessary pressure in control line e Charge Pressure Valve The pressure produced by charge pump should be constant in all operating modes in order to avoid the failure of hydrostatic transmission The charge pressure is produced and controlled by charge pressure valve overflowing the working fluid from charge pump line to the drain cavity of main pump The charge pressure valve adjustment is set on the nominal revolutions of the pump at the swash plate neutral position The charge pump releases when the swash plate angles aside The interior arrangement charge pump and charge pressure valve locations are shown at the sectional drawing HST 71 HST 90 Hydrostatic Transmissions PSM rorauLics Service Manual e Pressure Relief Safety Valves The two bilateral pressure relief valves serve to limit the overshoot pressure in the working tubes and to supply working fluid from charge pump to the suction line of main pump Each valve is installed on one of the power lines OS E o yj N Pressure Relief SafetyyValves Structure body plunger spring bushing saddle sleeve valve spring bolt e Cut off Valve and Check Valves The two c
34. ports X1 and X2 of on the servo regulator casing to the charge pressure gauge port Fe of on the end cap of the pump The limit of measured pressure of the manometers should be up to 60bar Activate the pump Set the pump s shaft speed up to 1500 rpm Ease off the lock screw Set neutral point by turning adjustment screw The setting should be controlled by manometers reading in gauge ports X1 and X2 The readings should be similar Torque the lock screw 6 0 5Nm holding the neutral setting by the wrench e 3 Position Discrete Electro Control Adjustment and settings are not required m 6 e Proportional Electro Control without Feedback Adjustment and settings are not required Adjustment and settings are not required 26 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Series 406 Hydraulic Motors e Purge Relief Valve Checking the charge pressure setting For checking the purge relief valve setting connect the manometer to the charge pressure gauge port X1 on the end cap of the motor The limit of measured pressure of the manometer should be up to 60bar and not lower Connect the other manometer to the drain pressure gauge port in the motor Activate the supply of working fluid from the pump and measure the charge pressure The working fluid flow direction is not necessary WARNING When the pump is not in the neutral delivery mode the man
35. rmation Hydraulic Scheme of Hydrostatic Transmission Description of Hydrostatic Transmission HST 90 Description of HST 90 Components Series 416 Pumps Basic Components Components Main Pump End Cap Charge Pump Charge Pressure Valve Pressure Relief Safety Valves Cut off Valve Check Valves Auxiliary Mounting Pads Filtration Servo Regulator Control Mechanisms Proportional Mechanical Servo Control Proportional Hydraulic Control Proportional Electro Control 3 Position Discrete Electro Control Proportional Hydraulic Control without Feedback Proportional Electro Control without Feedback Series 406 Hydraulic Motors Components Main Motor End Cap Loop Flushing Valve Purge Relief Valve Features Main Features Technical Features Hydraulic Parameters Hydraulic Schemes Pressure Control Tools and Equipment Ports and Control Holes Location Fixed Displacement Motor Variable Displacement Pump Trouble Shooting A BR A DO O O O CO no oo NINO UW UI UI UI HST 71 HST 90 Hydrostatic Transmissions Service Manual Checking and Adjusting Series 416 Pumps Charge Pressure Valve Pressure Relief Valves Cut off Valve Adjustment of Displacement Limitation Proportional Servo Control Proportional Hydraulic Control Proportional Electro Control 3 Position Discrete Electro Control Proportional Electro Control without Feedback Proportional Hydraulic Contr
36. to the mechanical effect of control spool moving Therefore mechanism of electro control converts the electric PWM signal into the hydraulic control signal by servo piston HST 71 HST 90 Hydrostatic Transmissions Service Manual The spool of electro control mechanism is connected to the servo piston by mechanical feedback The feedback provides the swash plate angle proportionally to the electric PWM signal variance e 3 Position Discrete Electro Control The control mechanism is the electro driven sleeve valve During signal 12V or 24V sending to one of the electric solenoids the spool moves from the initial position to the max position turning the pressure of servo control into the appropriate servo piston s cavity Servo piston angles the swash plate of the pump to the maximum angle Deenergizing the control signal on the electric solenoid the spool returns back to the initial neutral position HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Proportional Hydraulic Control without Feedback The control hydraulic signal effects the servo piston which angles the swash plate The angle of swash plate is proportional to the rate of hydraulic control signal only in case of constant pressure in the power line When the hydraulic drive loading changes the scheme of control changes too and the proportionality stays up e Proportional Electro Control without Feedback The control mechanism is
37. x 17mm Turn the four screws out internal hex 5mm and take the Servo Control off Install the new laying Install the new Servo Control Check the finger sphere of mechanism s reaction matching with servo piston s dog hole Torque the 4 screws 10 2Nm Install the fitting into the new Servo Control Torque 20 2Nm Install the charge pipeline in the fitting Torque the pipeline s screw 20 2Nm eThe same above mentioned procedures are used for replacing the following mechanisms proportional hydraulic control proportional electro control without feedback 3 position discrete electro control proportional electro control 34 HST 71 HST 90 Hydrostatic Transmissions PSM HYDRAULICS Service Manual e Orifice control line orifice EP TT 7 two orifice of return lines o DAR u lo m RED E Dm l NI REA q IA MR PES Essas E X Control line orifice checking Disconnect the control line pipe external hex 17mm Turn the fitting out of the control mechanism external hex 17mm Unscrew the orifice out of the control mechanism s housing by the screwdriver Check the orifice hole for cleanliness Unplug in case of dirt Install the orifice into the control mechanism s housing Install the fitting Torque 20 2Nm Install the pipeline Torque 20 2Nm Return lines orifice checking Turn the plug out internal hex 6mm
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