HPVSerMan (Page 1) - Continental Hydraulics UK Ltd
Contents
1. Figure 15 HPV Side Port Parts Identification 20 Form No R92 00 Rev 10 03 PARTS LIST continued P ipin Code 7 Remote Pressure i eym Code 19 Load Sensing 7 NE YA Uu a e g i D a i Tae l 1 oe jJ hoh 4 gi Fr i o amp LI i l F i Kg l i oi A i i i zi k s 5 l a z 1 a fa E For Lia A Code 18 Load ny Figure 16 Code 7 and Code 19 Pressure Compensator Parts Identification Code 26 Horsepower Limiting Compensator _ Orifice not shown S See pump exploded view and paris bet Figure 17 Code 26 Horse Power Limiting Pressure Compensator Parts Identification Form No R92 00 Rev 10 03 21 22 y Continental Hydraulics 12520 Quentin Avenue South CONTINENTAL Savage MN 55378 U S A HYDRAULICS Phone 952 895 6400 Fax 952 895 6444 www continentalhydraulics com Because Continental Hydraulics is continually improving its products specifications and appearance are subject to change without notice Form No R92 00 Rev 10 03 2003 Continental Hydraulics Printed in U S A T 01270 898594 F 01270 897662 E oliver continentalhydraulics co uk _ www continentalhydraulics co uk Building 1 Radway Green Business Centre Radway Green Cheshire CW2 5PR England2. CONTINENTAL HYDRAULICS SERVICE MANUAL HPV Axial Piston Pumps CAUTION Before performing any service operation on any pump be sure that all pressure has been relieved from the system CAUTION Before performing any service operation on any pump disconnect or lock off power supply CAUTION Before starting any pump be sure that any resulting machine function will not endanger persons or eguipment PRODUCT IDENTIFICATION Each HPV Piston Pump has a Model Code stamped on its escutcheon plate See Figure 1 for the location of the Model Code B Design Series GENERAL SPECIFICATIONS MOUNTING Any unrestricted mounting position acceptable Horizontal mounting preferred The mounting hub and two bolt mounting flange conform to SAE mounting standards Continental Hydraulics does not recommend direct rigid connection of piston pumps to the Prime Mover Use of a flexible coupling a coupling that allows for minor misalignment is recommended If the shaft connection to the Prime Mover is rigid the mounting face diametric concentricity and squareness must be within 001 inch 0 03 mm T I R for a flange mounted pump The HPV Piston Pump is designed for in line drive Angle drive creates side loads on the shaft and is not acceptable SHAFT INFORMATION Splined The coupling interface must be lubricated Continental Hydraulics recommends lithium molydisulfate or similar grease The
3. 5 Visually inspect components for possible contamination and for proper operation Pay special attention to wipers on cylinder rods Be sure that the rods are free of nicks and scratches 6 Flush the reservoir using pressurized solvent Use clean dry lint free cloths to ensure a clean interior Inspect the filler breather if used and the suction sirainer for cleanliness 7 Install a new filter with a 10 micron or better element and low Beta ratio If the machine does not have a filter install one that meets these specifications 8 Fill the reservoir with new FILTERED oil of the recommended type Be certain to monitor the fluid level since the entire system not just the reservoir must be filled 9 Re install all system lines Visually inspect to make sure they are clean and free of contamination Be sure that all inlet fittings are tight and clean 10 Install the new pump 11 Follow the start up procedures given on pages 2 and 3 of this manual 12 Cycle all cylinders and operate all motors at normal operating speeds for 20 minutes While operating observe the reservoir fluid level since all components will be filling with hydraulic fluid 13 Replace the filter element and check the fluid level Add new clean filtered oil if required To assure that your replacement pump performs at the same level as the original pump check daily for proper fluid level filter condition and leaks Change fluid at re
4. At Minimum At Rated Series Outlet Continuous Pressure Pressure HPV 6 6 0 7 1 22 7 26 9 5 9 Min 22 3 HPV 10 9 5 10 3 36 0 39 0 8 7 Min 32 9 HPV 15 15 0 16 6 56 8 62 8 14 4 Min 54 5 HPV 20 20 0 21 4 75 7 81 0 18 6 Min 70 4 HPV 29 28 0 30 4 106 0 115 1 26 6 Min 100 7 3 Case Drain flow at maximum rated continuous pressure and zero flow is as follows Series Case Drain Flow at Zero Flow HPV 6 93 GPM 3 5 Ipm Max HPV 10 98 GPM 3 7 Ipm Max HPV 15 1 06 GPM 4 0 Ipm Max HPV 20 1 60 GPM 6 1 Ipm Max HPV 29 1 90 GPM 7 2 Ipm Max Pressure Compensator Test Control Option Adjustment Procedures Standard Compensator 1 With a pump running at deadhead no flow adjust the compensator pressure to 3500 35 PSI 241 2 5 bar 2 The following flow rates should be achieved Flow Rate GPM Ipm Series Pressure PSI bar Flow GPM LPM HPV 6 3325 229 3 5 9 22 3 Min HPV 10 3325 229 3 8 7 32 9 Min HPV 15 3325 229 3 14 4 54 5 Min HPV 20 3325 229 3 18 6 70 4 Min HPV 29 2850 196 5 26 6 100 7 Min 3 The pump shall return to a stable condition with no loss of conttrol within one 1 second after being cycled from full flow to zero flow 4 Cycle the pump from zero flow to full flow to zero flow The zero pressures shall not vary more than 30 psi 2 bar Form No R92 00 Rev 10 03 15 PUMP ASSEMBLY continued 5 Th
5. 31 9 28 Attach rebuilt pressure compensator to pump cover 2 Pressure compensator assembly procedures are listed below and on the next page 29 Install the thread seal 54 and hex nut 45 on the adjusting screw 22 then screw into the hole in the pump cover 2 Finger tighten until the adjusting screw bottoms against the plunger Adjust to desired volume Series No of Turns Full to Zero Vol HPV 6 8 5 HPV 10 8 5 HPV 15 8 5 HPV 20 9 7 HPV 29 10 5 30 Using a lever or hub rotate the shaft several times in the direction indicated by the arrow on the escutcheon plate 61 Confirm that the pump rotates freely and smoothly 31 With the palm of your hand cover the port on the side on which the compensator is mounted Rotate the input shaft If air is forced out of the piping port the pump is working properly 32 Screw the case drain plug 58 into the pump body Seal other openings with plastic cap seals 33 Clean the outside of the pump and re install onto the original equipment If the pump will be stored before re installation coat all unpainted surfaces with a light coating of oil and store in a sealed plastic bag STANDARD PRESSURE COMPENSATOR CONTROL 28 ASSEMBLY 1 Carefully clean the compensator body 28 1 and spool 28 2 Soak in clean hydraulic fluid 2 Check O rings 28 8 and 28 9 for deformation or wear Replace as needed Assemble O ring 28 8 to cap 28 3 Ass
6. Cover Rear Port LH Kit 261191 SAE 261192 SAE 261193 SAE 261194 SAE 261195 SAE BSPP Con CHD BSPP Con CHD BSPP Con CHD BSPP Con CHD BSPP Con CHD 261774 SAE 261776 SAE 261778 SAE 2 Cover Side Port RH Kit 4 BSPP Con CHD BSPP Con CHD BSPP Con CHD WD 261762 261775 SAE 261777 SAE 261779 SAE Cover Side PBL BSPP Con CHD BSPP Con CHD BSPP Con CHD 261781 261785 SAE Con CHD SAE Con CHD Cover Tandem RH Kit N A BSPP Con CHD BSPP Con CHD Contact CHD 264609 I SAE Con CHD SAE Con CHD Cover Tandem LH Kit N A BSPP Con CHD BSPP Con CHD Contact CHD 264325 3 Barrel 1 552078 550876 552035 552021 550868 4 Port Plate RH 550910 550877 550898 550897 550867 Port Plate LH 552041 550939 550962 550947 550927 5 Piston and Shoe Ass y 9 258093 258094 258095 258096 258097 Keyed Shaft 550766 550879 550893 550894 550866 8 Splined Shaft i 550901 550883 550891 550895 550904 Tandem Shaft N A 550903 Splined 550846 Splined 552007 Splined 552008 Splined 552005 Keyed 552006 Keyed 550847 Keyed 550905 Keyed 9 Hanger 1 550885 550880 550884 550890 550864 10 Trunnion 2 258943 258985 258909 14 Guide ball 1 258098 258099 258100 258101 258102 15 Guide Plate 1 450700 450696 450698 450699 450721 16 Wear Plate 1 259025 258944 258986 258989 258912 18 Spring Barrel 1 258166 258167 258168 2588169 258170 19 Spring Hanger 1 258302 258303 258304 258305 258306 20 Spring Seat Hanger 1 259019 259499 258983 258991 25891
7. used trunnion shaft turned down to a slip fit simplifies hanger installation Slip the modified trunnion into one side to hold it in place while the working trunnion is press fit into the opposite side See Fig 8 page 12 for trunnion assembly tool specifications 15 Lightly coat the trunnions with teflon based sealing paste Avoid putting sealing paste on the section of the trunnion that will be held in the hanger Press them through the pump body and into the hanger NOTE Be certain the hanger bores are correctly aligned with the pump body After the trunnions have been installed confirm that the hanger moves freely on them Form No R92 00 Rev 10 03 13 PUMP ASSEMBLY continued 16 Place the barrel 3 on a clean working surface Insert the washers 27 and spring 18 into the center hole The washers 27 should be located on both ends of the spring 17 Compress the spring 18 using a mechanical press Secure the spring with the retaining ring 40 18 Place the barrel 3 on a clean sheet of paper or cloth Insert the three dowels 56 into the holes located outside of the spline hole Place the guide ball 14 on top 19 Compress manually and confirm spring 18 force 20 Hold the guide plate 15 horizontal with one hand and insert the nine piston assemblies 5 into the guide plate bores The piston shoes should move freely on the pistons 21 Support the guide plate horizontally and insert the
8. 30mm goto50mm Figure 7 not to scale Figure 8 not to scale 12 Form No R92 00 Rev 10 03 ASSEMBLY TOOLS continued Trunnion Removal Tool Series A B C D E F DIA DIA THD DIA HPV 6 In 1 75 1 50 56 4 25 1 2 13 2 50 HPV 10 mm 44 5 38 1 14 2 108 63 5 In 2 00 1 75 81 4 50 2 75 HPV 15 mm 50 8 44 5 20 6 114 2410 69 8 HPV 20 In 2 25 2 00 81 4 75 3 4 10 3 00 HPV 29 mm 57 15 50 8 20 6 121 76 2 Material Item Material 1 Sleeve Steel 2 Spacer Steel 3 Nut Hardened Steel GR 5 4 All Thread Rod Hardened Steel GR 5 ASSEMBLY PROCEDURES Pump Assembly Piston Pump assembly must be done more carefully than disassembly The working environment must be clean All parts must be clean and inspected for wear or damage in accordance with the Inspection Procedures listed on pages 7 through 11 1 Compare the disassembled parts with the exploded view shown in Fig 14 or 15 on page 20 for missing parts or irregularities 2 Inspect retaining rings Replace if deformed 3 Place the pump body 1 in a press with the mounting flange facing up 4 Apply grease between the lips of the shaft seal Grease should not protrude above the tip of the lip and should fill approximately 80 of the space 5 Use a press and the tool shown in Fig 5 o
9. 6 ASSEMBLY See Figure 17 1 For initial assembly follow steps 1 through 5 of the Standard Pressure Compensator Assembly listed above 2 To install the seat 26 15 insert the open end into the bore and press into place Install plug 26 20 and tighten 3 Fit the washer 26 23 and spring 26 7 onto the adjusting screw 26 18 Fit the cone 26 16 into the spring and assemble into the body 4 Set the adjusting screw to the measurement taken at disassembly and lock into place with nut 26 12 Cover with acorn nut 26 22 5 Place the ball 26 17 into the body atop the orifice 6 Insert the pin 26 24 into the fitting assembly 26 27 and tighten in the valve body 7 Install O ring 26 21 onto the fitting 26 29 and screw into the compensator 8 Install the O rings 82 Assemble the compensator to the pump cover TEST PROCEDURES AND SPECIFICATIONS Pump Performance Test 1 With the operating speed at 1750 35 rpm record delivery flow rate drain flow rate and fluid temperature at minimum outlet pressure and maximum rated continuous pressure Series Max Rated Continuous Pressure HPV 6 3500 PSI 241 bar HPV 10 3500 PSI 241 bar HPV 15 3500 PSI 241 bar HPV 20 3500 PSI 241 bar HPV 29 3000 PSI 207 bar 2 Rate of flow at minimum outlet pressure and maximum rated continuous pressure should fall within the following range Flow Rate At GPM Ipm
10. 7 21 Plunger 1 259027 258938 258982 258988 258918 258959 Rear 258959 Rear 259411 Rear 259411Rear 258919 Rear 22 Adjustment Screws 1 258959 Side 258959 Side 259411 Side 259411 Side 258919 Side N A 258959 Tandem 258584 Tandem 258581 Tandem 259141 Tandem 24 Gasket 1 258426 258425 258424 258423 258422 27 A Washer Barrel 2 258108 258109 258110 258111 258112 Pressure Compensator Kit 261097 Buna N Standard 261098 Viton Remote Pressure SAE 260199 Buna N SAE 261100 Viton Compensator Kit Code 7 BSPP 261101 Buna N BSPP 261102 Viton Remote Load Sensing SAE 261103 Buna N SAE 261104 Viton Compensator Kit Code 19 BSPP 261105 Buna N BSPP 261106 Viton 28 1 SAE 261107 Buna SAE 261111 Buna SAE 261115 Buna SAE 261119 Buna SAE 261127 Buna Rear BSPP 261109 Buna BSPP 261113 Buna BSPP 261117 Buna BSPP 261121 Buna BSPP 261129 Buna Power Limitet Port SAE 261108 Viton SAE 261112 Viton SAE 261116 Viton SAE 261120 Viton SAE 261128 Viton Control Kit UNE BSPP 261110 Viton BSPP 261114 Viton BSPP 261118 Viton BSPP 261122 Viton BSPP 261130 Viton Code 26 SAE 262120 Buna SAE 261111 Buna SAE 261115 Buna SAE 261123 Buna SAE 261131 Buna Side Tandem BSPP 262122 Buna BSPP 261113 Buna BSPP 261117 Buna BSPP 261125 Buna BSPP 261133 Buna Port s SAE 262121 Viton SAE 261112 Viton SAE 261116 Viton SAE 261124 Viton SAE 261132 Viton BSPP 262123 Viton BSPP 261114 Viton BSPP 261118 Viton BSPP 261126 Viton BSPP 261134 Viton 001512 Buna N 32 Compen
11. Cone Series A Bt C D E In 1 00 0 75 2 24 1 65 1 57 ae 25 4 19 1 56 9 41 9 39 9 In 1 00 0 875 2 68 2 08 2 00 REU 25 4 22 2 68 1 52 8 50 8 In 1 20 0 875 2 68 2 08 2 00 PPVS 30 5 22 2 68 1 52 8 50 8 In 1 40 1 25 2 68 2 08 2 00 HPV 20 35 6 31 8 68 1 52 8 50 8 in 1 40 1 25 268 2 08 2 00 35 6 HPV 29 31 8 68 1 52 8 50 8 Material Teflon preferred or steel heat treated to Rc40 or Rc45 and chromium plated 004 in 102 mm _ 008 in 203 mm 004 in 102 mm Trunnion Assembly Tool Series A B C In 1 75 997 996 HPV 6 mm 44 45 25 32 25 30 1 2 13 UNC X 3 4 DP In 1 75 997 996 HPV 10 mm 44 45 25 32 25 30 1 2 13 UNC X 3 4 DP In 2 00 1 247 1 246 HPV 15 mm 50 80 31 67 31 65 3 4 10 UNC X 1 DP In 2 25 1 497 1 496 HPV 20 mm 57 15 38 02 38 00 3 4 10 UNC X 1 DP In 2 25 1 497 1 496 HPV 29 mm 57 15 38 02 38 00 3 4 10 UNC X 1 DP Material Steel or rework trunnion to B diameter S099 R 1 mm Figure 6 not to scale D F J 4 150 15 y a J Y vo I y sy A R T S s AS 5mm oR BLEND RADIUS g n v 195 11610197 i mmj 5 mm
12. E 251248 Buna N 259414 Buna N 259138 Buna N 58 9 1 259831 Viton 259415 Viton 258264 Viton Plug Case Drain BSPP 258525 Buna N 258526 Buna N 9 260662 Viton 260309 Viton 61 Escutcheon Blank 1 261163S 62 Screw 2 250597 64 Guide Sleeve 1 259026 258940 258984 258990 258920 65 Needle Bearing 1 258127 258128 258129 258130 258131 66 Pin Cover 1 258336 258337 258338 258339 67 Expander Plug 1 259176 Retaining Ring 68 Shaft Bearing 2 258290 258291 258292 69 Ball Bearing 1 258191 258192 258193 258194 70 Key 1 126225 101580 001396 259001 71 Screw Soc Cap 4 199233 Standard 199086 Codes 7 19 26 83 Threaded Rod 2 N A 259691 84 Nut Hex Jam 2 N A 199127 Included in Cover Kit KIT LIST DESCRIPTION HPV 6 HPV 10 HPV 15 HPV 20 HPV 29 Seal Kit Buna N 258076 258077 258078 258079 258080 Seal Kit Viton 258294 258295 258296 258297 258298 Rotating Group Kit CW Rotation 258132 258133 258134 258135 258136 Rotating Group Kit CCW Rotation 258181 258182 258183 258184 258185 Keyed Shaft Kit 258122 258123 258124 258125 258126 Splined Shaft Kit 258259 258261 258262 258278 258279 Tandem Shaft Kit Keyed N A 259938 259939 259940 259941 Tandem Shaft Kit Splined N A 259934 259935 259936 259937 Form No R92 00 Rev 10 03 19 PARTS LIST continued Shipping Item For Use With orsepo Limiting Control Only Figure 14 HPV Pump and Standard Pressure Compensator Parts Identification
13. commended intervals Good fluid maintenance is especially important when using other than mineral based fluids not the cause of the problem The following general guide is offered to help you locate and eliminate the cause of problems by studying their effects Problem Possible Cause Look For Noisy Pump Air in fluid Leak in suction line Leak in shaft seal Low fluid level Turbulent fluid Return lines above fluid level Gas leak from accumulator Excessive pressure drop in the inlet line from a pressurized reservoir Cavitation in pump rotating group Fluid too cold too viscous or too heavy Shaft speed too high Suction line too small or collapsed Suction line strainer dirty or too small Continued on Page 4 Form No R92 00 Rev 10 03 3 TROUBLESHOOTING GUIDE Problem Possible Cause Look For Noisy Pump Misaligned shaft Faulty installation Distortion in mounting Axial interference Faulty coupling Mechanical fault in pump Piston and shoe loose or failed Bearing failure Incorrect port plate selection or index Eroded or worn parts in displacement control Erosion on barrel and port plate Air in fluid Refer to above Cavitation Refer to above High wear in pump Excessive loads Reduce speed or pressure setting Contaminant particles in fluid Improper filter maintenance Filter too coarse Dirty fluid introduced to the system R
14. e pressure ripples at zero flow and partial flow shall not exceed 50 psi 3 5 bar 6 Case drain flow shall be stable Control Option Adjustment Procedures Remote Compensator 1 Be sure the pin 24 is not in the compensator spool See Figure 16 2 Attach a vent line with needle valve into the vent line between the compensator and tank Upper Pressure Linn tit Adjusters rimuir Pressure Adjuatenent Figure 11 3 Close the valve in the vent line 4 Start the pump and adjust the load to deadhead no flow If there is a check valve installed before the pressure gauge allow some flow in the circuit up to 10 of full flow 5 Open the vent valve and set the minimum pressure adjustment screw see Fig 11 to 250 25 psi 17 1 7 bar 6 Close the vent valve Set the upper pressure limit adjustment to the maximum desired compensator setting See Figure 11 for adjuster location 7 Open and close the vent port several times When the valve is open discharge pressure should drop to the differential setting of 250 25 psi 17 1 7 bar When it is closed discharge pressure should go to the maximum compensator setting Cycle the pump from deadhead to full flow with the compensator vented or unvented 8 If flow is within accepted limits and no leaks are detected remove the needle valve from the vent port 9 The pump is now ready for remote control Control Option Adjustment P
15. ed limits and no leaks are detected the compensator is ready for operation Control Option Adjustment Procedures Horse Power Limiting Compensator 1 Be sure the proper orifice is installed in the pump discharge port 2 Install the sense line into the circuit High Flow Pressure sw bul jumtrraerrt Compansasar Overrice Ad usiment s High Praami y EZ Fira Adjustment Figure 13 16 Form No R92 00 Rev 10 03 3 Using the High Pressure Flow Adjustment Fig 13 preload the spring 4 Back out the High Flow Pressure Adjustment Fig 13 until there is no resistance 5 Start the pump 6 Using the Compensator Override Adjustment Fig 13 set the compensator 500 psi 34 5 bar above the desired pressure P1 Note if the pump is not at zero flow adjust the relief valve until zero flow is achieved 7 Adjust the relief valve to the desired pressure P1 8 Adjust the High Pressure Flow Adjustment Fig 13 to achieve full flow at 95 of the desired pressure P1 Note if the discharge pressure drops below the desired value readjust it using the relief valve 9 Adjust the relief valve to the desired pressure P1 plus 1 2 turn 10 Using the Compensator Override Adjustment set the pump at the desired pressure P1 Note the pump should be at zero flow 11 Adjust the pump to the desired flow F2 At the same time use the High Flow Pressure Adjustment to set the discharge pr
16. emble O ring 28 9 to spring seat 28 4 3 Carefully insert the spool 28 2 into the compensator body 28 1 4 Fit the spring seats 28 4 and 28 5 onto both ends of the spring 28 6 Assemble into the compensator body 5 With the adjusting screw 28 11 and nut 28 12 set on the cap place the cap on the spring seat 28 4 and screw into the threaded hole in the compensator body Tighten until the edge surface is flush Screw 28 11 adjustment rate approximately 650 psi 45 bar per turn 14 Form No R92 00 Rev 10 03 PUMP ASSEMBLY continued 6 Check O rings 32 for deformation and wear Replace as needed Install the O rings REMOTE PRESSURE Code 7 AND LOAD SENSING CONTROL Code 19 ASSEMBLY See Figure 16 1 For initial assembly follow steps 1 through 5 of the Standard Pressure Compensator Assembly listed above For Load Sensing Control Code 19 only install the pin 28 24 into the spool 2 To install the seat 28 15 insert the open end into the bore and press into place Install plug 28 20 and tighten 3 Fit the washer 28 23 and spring 28 7 onto the adjusting screw 28 18 Fit the cone 28 16 into the spring and assemble into the body 4 Set the adjusting screw to the measurement taken at disassembly and lock into place with nut 28 12 Cover with acorn nut 28 22 5 Install the O rings 32 Assemble the compensator to the pump cover HORSEPOWER LIMITING CONTROL Code 2
17. embly coat the internal parts with a film of clean oil and protect them from dirt and moisture 7 Prior to disassembly measure and record the length of the protruding part of adjusting screws 22 and 28 11 from Figure 14 and if necessary 18 from Figure 16 or 17 This will simplify resetting the pump after reassembly HPV REPAIR PROCEDURES DISASSEMBLY INSPECTION and REASSEMBLY GENERAL Disassembly in the field by other than an Authorized Repair Center technician whether for repair or modification will void warranty NOTE Certain steps in this procedure require special tools and the application of great force Care should also be taken to contain residual oil during disassembly Before beginning read this section through to make sure that you are prepared for the job General Disassembly Procedure 1 Drain pump body 1 via Case Drain Ports Figure 4 2 Position the pump with Case Drain Ports up 3 Remove four compensator screws 71 and then remove remove compensator 28 and O rings 32 4 Remove four cover retaining screws 46 Loosen two diagonally positioned screws first Then loosen the remaining two diagonally positioned screws Remove the screws and carefully separate the cover 2 from the pump body If the gasket holds the cover in place tap the cover lightly with a fiber hammer on the side opposite the compensator NOTE The port plate 4 may cling to the cover 2 due to oil
18. ent Readjust as required Repair or replace as required Deteriorating pump performance Worn compensator Change compensator PISTON PUMP DISASSEMBLY Precautions CAUTION Before performing any service operation on any pump be sure that all pressure has been relieved from BOTH SIDES of the system CAUTION Before performing any service operation on any pump disconnect or lock off power supply CAUTION Do not attempt to remove the Barrel Spring The Barrel Spring is assembled under high compression Any attempt to remove the Barrel Spring will cause sudden decompression and may inflict serious personal injury The Barrel Spring is NOT field serviceable Should the Barrel Spring require service the pump must be returned to Continental Hydraulics or an Authorized Repair Center 1 Please refer to the exploded view Figure 14 through 17 for proper names and locations of all parts PP gt Form No R92 00 Rev 10 03 2 Pump disassembly for inspection and repair should be undertaken only in the following cases Malfunction or leakage due to damage or wear When troubleshooting procedures contained in this manual do not solve a problem 3 Disassembly should be done only as far as necessary to replace or repair worn parts 4 Perform assembly and disassembly in a clean environment 5 Avoid dropping damaging or contaminating the machined parts of the pump and compensator 6 After disass
19. eservoir or breather cap open to atmosphere Improper line replacement Improper fluid Fluid too thick or too thin for operating temperature range Fluid breakdown due to age temperature or shearing effects Incorrect additives in new fluid Reduced additive effectiveness due to chemical aging Improper repair Incorrect parts procedures dimensions or finishes Unwanted water in fluid Condensation Faulty breather strainer Heat exchanger leaking Faulty clean up practice Water in makeup fluid Pressure shocks Cogging or erratic load movement Mechanical considerations Slow acting relief valve Replace with fast acting relief valve Worn relief valve Repair or replace as needed Worn compensator Repair or replace as needed Insufficient line capacitance line volume line stretch accumulator effects Increase line size or length Fluid overheats Excessive pump leakage Recheck case drain flow repair as needed Fluid too thin minimum operating viscosity 60 SUS 10Cst Improper assembly Faulty relief valve Set too low compared to load or compensator Instability caused by back pressure or worn parts Faulty compensator Set too high compared to relief Worn parts Faulty heat exchanger Water turned off or insufficient flow Ambient water temperature too high Fan clogged restricted or inoperative Mud or scale buildup Intermitten
20. essure to the corresponding full flow pressure P2 12 Check the flow at 95 of P1 If it is not as desired adjust it by using the High Flow Pressure Adjustment STANDARD SETTINGS Series HP P1 P2 F1 F2 HPV 6 8 3500PSI 1700 PSI 2 4 GPM _ 5 9 GPM HPV 10 12 3500 PSI 1700 PSI 4 0 GPM 8 7 GPM HPV 15 19 3500 PSI 1700 PSI 6 0 GPM 14 4 GPM HPV 20 24 3500 PSI 1700 PSI 8 0 GPM 18 6 GPM HPV 29 29 3000 PSI 1700 PSI 13 0 GPM 26 6 GPM 13 Adjust system pressure from high pressure to low pressure while observing HP draw If draw is not as desired repeat steps 10 and 11 14 If HP draw is within accepted limits and no leaks are detected the compensator is ready for operation Form No R92 00 Rev 10 03 17 PART AND ASSEMBLY IDENTIFICATION The following chart and Figures 14 17 may be used to identify individual parts and assemblies in Piston Pumps PARTS LIST DESCRIPTION QTY HPV 6 HPV 10 HPV 15 HPV 20 HPV 29 1 Pump Body i 550745 SAE 550750 SAE 550754 SAE 550759 SAE 550764 SAE 550748 BSPP 550749 BSPP 550756 BSPP 550757 BSPP 550758 BSPP Cover Rear Port RH Kit 260293 SAE 260294 SAE 260295 SAE 260296 SAE 260297 SAE BSPP Con CHD BSPP Con CHD BSPP Con CHD BSPP Con CHD BSPP Con CHD
21. female coupling should be hardened to 27 45 Rc and must conform to ANSI B92 1 Class 5 Fillet or Flat Root Side Fit Keyed High strength heat treated keys must be used Date Replacement keys must be hardened to 27 34 Rc Code sa Key corners must be chamfered 030 040 inch 75 1 0 mm at 45 to clear radii in the keyway Model MER T an PLUMBING Code Bare Connect inlet and outlet lines to the pump s cover HPV fluid connections are SAE straight thread SAE Figure 1 flange or BSPP This Service Booklet applies to products with Model MODEL REAR PORT SIDE PORT Codes like the sample in Figure 2 HPV 6 SAE 12 or 3 4 BSPP SAE 16 or 1 BSPP HPV 10 SAE 20 or 1 1 4 BSPP SAE 20 or 1 1 4 BSPP f HPV 15 SAE 20 or 1 1 4 BSPP SAE 20 or 1 1 4 BSPP Basic Pump HPV 6B35 RF O 1R HPV 20 SAE 20 or 1 1 4 BSPP SAE1 1 4 Flange Rotation A HPV 29 SAE 20 or 1 1 4 BSPP SAE1 1 2 Flange Seal Type Per Code 62 Per Code 61 Ports Maximum case pressure is 10 psi 0 70 bar Case pressure must never exceed inlet pressure by more than 15 psi 1 0 bar To prevent fluid drain down from the pump when idle make certain that case drain plumbing passes above the highest point of the pump before entering the reservoir Or install a 5 psi 3 bar case pressure check valve to assure that the pump is always filled with hydraulic fluid The case drain line must be big eno
22. film between parts DO NOT ALLOW THE PLATE TO FALL AND BE DAMAGED 5 Gently remove the port plate 4 from the barrel 3 face 6 Place the pump on a work bench with the shaft in a horizontal position Remove the barrel 3 with piston assembly 5 guide ball 14 guide plate 15 and dowel pins 56 as a unit 7 Place the barrel 3 on a clean cloth or plastic film Hold the side of the guide plate 15 and gently remove the piston assembly 8 Remove the guide ball 14 and dowel pins 56 9 Place the pump body 1 shaft down on a fixture designed to keep it from toppling Protect with a dust proof plastic film 10 Place the cover 2 with the assembled guide sleeve 64 plunger 21 and needle bearing 65 on a work bench The guide sleeve must face up Protect the parts with a dust proof plastic film NOTE Following completion of disassembly procedure steps 1 through 10 necessary pump inspection can be performed Further disassembly may be required if the following inspection steps reveal specific problems 11 1 When the barrel 3 is laid flat the dowel pins 56 must protrude slightly If otherwise or if the dowel pins are easily pushed in replace the barrel Figure 4 11 2 If the hanger 9 has little or no inclination against the shaft 8 or if it can easily be moved by hand go to steps 12 through 15 11 3 If shaft seal leakage or excessive ball bearing play is apparent go to ste
23. inued on Page 10 9 INSPECTION PROCEDURES Continued Part Item No Inspection Procedure Corrective Action Key Inspect for wear on side surface 70 A Discoloration A Remove discoloration with emery cloth Reuse key B Stepped wear B Replace key if worn over 0002 in or 005 mm When coupling hub to shaft fit is loose replace the coupling Recheck alignment with prime mover Check for excessive pressure or side load Correct as needed Guide Plate Visually inspect contact surface between guide plate Re use as is 15 and piston shoe If brightly polished Inspect contact surface for indentations If stepped or indented Replace guide plate Wear Plate Check face condition for 16 A Polish over all or part of the surface A Re use as is B Scratches wear or metal transfer B Replace wear plate Flush reservoir and circuit Check hydraulic fluid type temperature rise and excessive pressure Correct as needed Spring Measure free heights Correct heights are 18 A HPV 6 1 36 or 34 5 mm Replace when height B HPV 10 1 57 or 40 mm is decreased more C HPV 15 1 79 or 45 5 mm than 5 from the D HPV 20 1 97 or 50 mm given heights E HPV 29 2 05 or 52 mm Spring Measure free height Correct heights are 19 A HPV 6 2 44 or 62 mm Replace when height B HPV 10 2 60 or 66 mm is decreased more C HPV 15 3 00 or 76 mm than 3 from the D HPV 20 3 00 or 76 m
24. ll not endanger persons or eguipment PREVENTIVE MAINTENANCE This pump is self lubricating Preventive maintenance is limited to keeping the system fluid clean by changing filters regularly Since filtering needs can vary depending on applications filters used with this pump should be eguipped with indicators that show when changes are needed Do not operate the pump in a system with clogged or bypassing filters Keep all fittings and screws tight Do not operate this pump at pressures or speeds in excess of stated limits If the pump does not operate properly check the Trouble Shooting Section of this manual before attempting to overhaul the pump Overhauls are relatively simple and are covered in the Repair Procedures Section of this manual Note It is especially important to keep suction or inlet piping and fittings tight and in good repair Air drawn into the system through loose or damaged intake fittings can cause the pump to fail START UP PROCEDURE FOR NEW INSTALLATION 1 Read and understand the Service Manual Identify components and their functions 2 Visually inspect system components and lines for possible damage 3 Check reservoir for cleanliness Drain and clean as reguired 4 Check reservoir fluid level and fill as reguired with filtered fluid that Figure 3 meets or exceeds ISO 18 16 13 cleanliness level Fill pump through either Case Drain Port Figure 3 5 Check drive alignme
25. luid Operating Temperature Operating temperature should be determined by the viscosity characteristics of the fluid used Fluid temperature in the reservoir during operation should be kept between 100 F and 130 F 88 C and 54 C Because high temperature degrades seals reduces service life and creates hazards fluid temperature should not exceed 180 F 82 C at the case drain CAUTION Fluid temperatures in excess of 120 F 49 C can cause serious burns and scalding Allow fluid to cool before performing any repairs or maintenance Fluid Cleanliness Control particle contamination by changing or cleaning all filter elements periodically BEFORE they become clogged and start to by pass Fluid must be cleaned before and continuously during operation to a cleanliness level of ISO 18 16 13 or better This level of cleanliness can usually be accomplished by use of 10 micron filters Better fluid cleanliness will significantly extend component life Since contaminant generation varies with each application each must be analyzed to determine proper filtration to maintain required cleanliness After Extended Shutdowns Some types of hydraulic fluids become tacky after long periods of non use If possible hand turn the pump several times after extended shutdowns to assure that all components move freely before powering up CAUTION Before hand turning any pump be sure that any resulting machine function wi
26. m given heights E HPV 29 3 19 or 81 mm Plunger Inspect contact pattern on spherical surface 21 A Wear pattern less than 0 2 in or 5 mm wide B Wear pattern over 0 2 in or 5 mm wide A Re use as is B Replace plunger In case of rapid wear check hydraulic fluid type temperature rise and excessive pressure Correct as needed Guide Sleeve 64 10 Inspect outer surface contact condition A Slight uneven wear on one side partial polishing B Distinct localized contact with strong bright polishing A Re use as is B Replace guide sleeve and cover 2 Measure guide sleeve outside diameter at several points If the difference is more than 0008 in or 020 mm replace guide sleeve and cover 2 Check fluid type temperature rise and pressure Correct as needed Visually inspect for signs of seizure scoring or discoloration Replace guide sleeve and cover 2 Check hydraulic fluid type temperature rise and excessive pressure Correct as needed Continued on Page 11 Form No R92 00 Rev 10 03 INSPECTION PROCEDURES Continued Part Item No Inspection Procedure Corrective Action Ball Bearing Inspect for radial play or sticking Replace ball bearing if 69 Rotate outer race by hand excessive play or sticking is felt or if unusual noise is heard Replace if obvious discoloration or pitting are observed Needle Visually inspect r
27. n page 11 slowly force the shaft seal into the pump body 1 until seated 6 Assemble a retaining ring 68 on the shaft end The sharp edge of the retaining ring must always be facing away from the part being retained 7 Using the ball bearing installation tool shown in Fig 6 on page 12 press the ball bearing 69 onto the shaft Do not exceed the maximum pressing force guidelines listed as follows 8 Install the remaining retaining ring 68 Pressing Force Series Bearing Part No Lbs N HPV 6 258191 1330 5900 HPV10 258192 1500 6700 HPV10 258193 1690 7500 HPV10 258194 2200 9800 HPV10 258194 2200 9800 pa D Min Figure 9 not to scale 9 Rotate the bearing manually to check for unusual noise or binding 10 Fit the protective cone shown in Fig 7 on page 12 over the end of the shaft Apply a light coating of lithium grease to the outer surface of the cone Slide the protective cone and shaft through the shaft seal positioning the ball bearing in place 11 Assemble the retaining ring 41 into the pump body 12 Place the housing on a fixture with the shaft end facing down Insert the spring 19 and spring seat 20 into the pump body 13 Lightly coat the wear plate 16 with grease and mate to the hanger 9 Then fit into the pump body 14 Press the hanger 9 until approximately horizontal using a press if necessary Then install the trunnions NOTE A
28. nt 6 Check and activate oil cooler if included in circuit Check fluid temperature 7 Reduce relief valve pressure settings Make sure accurate pressure readings can be made at appropriate places 8 If the system includes solenoids check for proper actuation 9 Jog electric motor to confirm proper rotation Jogging the electric motor primes the pump and bleeds air from the system 10 Start pump drive Look for leaks and listen for excessive noise at the pump If leaks chattering or other noises are observed immediately turn the pump off Corrective actions are covered in the Trouble Shooting Section 11 Cycle unloaded machine at low pressure and observe actuation at low speed if possible 12 Increase pressure settings gradually Check for leaks in all lines especially in the pump inlet line 13 Adjust system pressure as needed 14 Gradually increase system speed to normal operating level Be alert for trouble as indicated by noise sound changes system shocks leaks or air bubbles in the reservoir 2 Form No R92 00 Rev 10 03 START UP PROCEDURE continued 15 When the system is running normally check fluid level and temperature at the reservoir Repeat these checks periodically Excessive fluid temperatures will damage the pump If fluid temperature does not stabilize at 140 F 60 C or less stop the system and take appropriate corrective action 16 System is operational Follow app
29. nts Check for excessive play between drive shaft 8 and needle bearing 65 Maximum radial play is 003 in or 076 mm Repair by lapping until Visually inspect the barrel face for uniform minute concentric nicks scratches are removed Do not exceed rework limits listed above Visually inspect for deep localized nicks Replace barrel Flush Barrel reservoir and circuit 3 Replace barrel Check for Visually inspect for signs of seizure scoring or discoloration correct hydraulic fluid type temperature rise excessive pressure Correct as needed Continued on Page 8 Form No R92 00 Rev 10 03 7 INSPECTION PROCEDURES Continued Part Item No Inspection Procedure Corrective Action Barrel Visually inspect the bores internal condition for the following 3 A Localized polishing at edge A Re use as is Continued B Minute longitudinal nicks B Re use as is C Localized longitudinal nicks C Replace part Flush reservoir and circuit D Localized seizure scoring discoloration D Replace barrel and all piston and shoe assemblies 5 Check for correct hydraulic fluid type temperature rise excessive pressure Correct as needed Inspect for bore wear as follows Wash the barrel bore Insert a If no resistance piston completely into a bore Cover the kidney shaped hole replace the barrel in the barrel and the center hole on the shoe Withdraw and piston assemblies the
30. olling surfaces Replace if obvious Bearing discoloration or pitting 65 are observed Gasket Replace whenever pump 24 is disassembled Shaft Seal Replace whenever shaft 38 is removed from pump Thread Seal Visually inspect for damage Replace thread seal 54 as needed ASSEMBLY TOOLS Shaft Seal Installation Tool Series A B CT D E F HPV 6 In 1 75 2 17 14851 5 0 1 25 79 mm 44 5 55 1 4 7 127 31 75 20 1 HPV 10 In 1 75 2 17 185 5 0 1 25 79 mm 44 5 55 1 4 7 127 31 75 20 1 HPV 15 In 1 95 2 36 197 5 0 1 25 79 mm 49 5 59 9 5 0 127 31 75 20 1 HPV 20 In 215 2 56 204 5 0 1 25 79 mm 54 6 65 0 5 2 127 31 75 20 1 HPV 29 In 2 15 2 56 204 5 0 1 25 79 mm 54 6 65 0 5 2 127 31 75 20 1 Material Steel 008 in 203 mm t 0 in 0mm 008 in 203 mm Figure 5 not to scale Form No R92 00 Rev 10 03 11 ASSEMBLY TOOLS continued Ball Bearing Installation Tool Series A B C D MENG ina 59 9 628 259 ai o apie mr Go 620 259 1148 ele ina 80 0 G13 31 0 iai yA Sasa mr 89 9 80 0 38 0 160 0 aes a a8 ain ise 0 deon Material Steel z 012 in 305 mm 004 in 102 mm Protective
31. or 005 mm measured by before and after depths of oil grooves on barrel face INSPECTION PROCEDURES Pistons 5 Measure each piston in four places including one at the shoe end where the piston doesn t enter the barrel Replace Piston if the difference in measurements exceeds 0006 in or 015 mm Shoe Piston Assembly Replace assemblies if end play exceeds 003 in or 076 mm Shoe Face May be lapped up to 004 in or 102 mm _ The difference in shoe flange thickness between the thinnest and thickest of nine shoes should not exceed 0012 in or 03 mm Port Plate 4 May be lapped 006 in or 152 mm Maintain flatness of 0002 in or 005 mm Wear Plate 16 Do not lap Replace if there are any indications of wear or bending Guide Plate 15 Do not lap Measure thickness at several places Replace if thickness varies more than 004 in or 102 mm Part Item No Inspection Procedure Corrective Action Check for cracks around tapped holes Pump Body Check for cracks around retainer ring groove Replace if cracked 1 Perform dye penetrant or magnetic particle inspection over entire housing when oil leakage is observed Visually inspect for obvious defects Check for excessive wear in guide sleeve 64 Axial scratches should not be detectable with a fingernail Diameter difference Cover must not exceed 001 in or 025 mm when measured at several Replace if defective 2 random poi
32. piston If there is resistance the bore is reusable Measure each bore in four places including one place deep Replace the barrel if the within the bore where the piston doesn t run difference in measurements exceeds 0004 in or 010 mm Port Plate Visually inspect the surface for uniform minute concentric Repair by lapping 4 scratches or deep scratches on the plate until scratch is removed Do not remove more than 006 in or 152 mm Maintain flatness of 0002 in or 005 mm Visually inspect for heat discoloration Use as is Lap if excessively discolored Do not remove more than 006 in or 152 mm Inspect for cavitation erosion between ports Repair by lapping until erosion is removed Do not remove more than 006 in or 152 mm Piston Inspect for shoe end play by pushing and pulling the shoe while Replace piston Assembly holding the piston If the shoe clicks or if movement can be 5 seen the piston assembly is excessively worn assemblies as a set Check circuit suction pressure If less than 5 in Hg raise fluid level in reservoir clean intake strainer and or correct faulty circuit design Visually inspect shoe face for localized polishing or random radial marks Repair by lapping assemblies as a set Shoes may be lapped up to 004 in or 102 mm Difference in shoe flange thickness between the thinnest and thickest of nine shoes should not exceed 0012 in or 03 mm Check circuit suc
33. piston assemblies 5 into the barrel bores 3 22 Place the pump body 1 so that the shaft 8 is horizontal Assemble the barrel 3 piston assemblies 5 guide ball 14 and guide plate 15 together onto the shaft CAUTION Do not force the shaft spline into the barrel groove Carefully rotate the parts and apply slight pressure to work them together Assembly is correct when the edge of the barrel is approximately 25 in below the edge of the pump body 23 Place the pump body with shaft end pointing down on a fixture and coat the face of the barrel with clean hydraulic fluid Place the gasket 24 on the pump body 24 Assemble the plunger 21 and port plate 4 onto the cover 2 25 Lightly coat the port plate 4 with grease Place the port plate on the cover 2 locating the U shaped slot over the pin 66 See Fig 10 ORGAATING AQTATION COUNTERCLOCKWISE VIEWED FRG SHAFT END OPERATING ROTATION CLOCK WIEBE WEWEO FROM SHAFT END LOCATING PIN LOCATING PIN Figure 10 26 Hold the cover so the plunger 21 does not fall off Then carefully place the cover on the pump body 27 Secure the cover 2 with socket head screws 46 tightened diagonally The final tightening torque should be as follows Series N m Lbs Ft Min Max Min Max HPV 6 5 4 6 9 4 0 5 1 HPV 10 7 8 9 8 5 8 7 3 HPV 15 21 6 25 5 16 0 18 9 HPV 20 39 2 43 1 29 0 31 9 HPV 29 39 2 43 1 29 0
34. ps 16 through 21 11 4 If compensator function is erratic go to steps 23 through 33 as required Hanger Removal 12 Place the pump body in a large vise or ona working surface adapted to hold the pump body firmly 13 Remove the trunnions 10 using the blind threaded holes and the appropriate trunnion removal tool See Figure 9 on page 13 for trunnion removal tool specifications CAUTION The hanger may be under tension and should be secured to prevent injury 14 Remove the hanger 9 spring seat 20 and spring 19 in this order 15 Proceed to HANGER INSPECTION and TRUNNION INSPECTION page 9 Shaft Removal and Disassembly 16 As required remove the key 70 Tap gently at the end of the key with a hammer or chisel if it is difficult to remove 17 Remove the retaining ring 41 with a snap ring pliers 18 Remove the shaft 8 Pull the shaft toward the cover Tap lightly with a fiber hammer on the end of the shaft if it is difficult to remove 19 Replace the ball bearing if it shows excessive wear or if noise is heard when rotating the outer race by hand 20 To replace the ball bearing remove retaining rings 68 and remove the ball bearing 69 with a hand press or by light hammering 21 If oil leaks are observed the shaft seal must be replaced Remove the shaft seal 38 from the pump body 1 Use a push rod of smaller diameter than the outside diameter of the shaft seal NOTE Do not reu
35. rocedures Load Sensing Compensator Upper Pressure Limhi Aidjustreert x Presswo du Dilherdr biel rr Figure 12 1 Make sure the pin 24 Fig 16 is in the compensator spool 2 Install a sense line between the load valve and the speed valve 3 Open the load valve 4 Back the upper pressure limit adjustment screw out two 2 turns Fig 12 page 16 5 Using a speed valve adjust the pump to zero flow deadhead Note if there is a check valve installed before the pressure gauge allow some flow in the circuit up to 10 of full flow 6 Adjust the pressure differential adjustment screw to A250 25 psi 17 1 7 bar Fig 12 7 Using the speed valve adjust the pump to partial flow 25 50 of full flow 8 Close the load valve 9 Set the upper pressure limit adjustment to the desired compensator setting 10 Open and close the load valve several times When the load valve is open discharge pressure should drop down to the pressure differential setting of A250 25 psi 17 1 7 bar When the load valve is closed discharged pressure should go to the maximum compensator setting 11 Using the load valve adjust the discharge pressure from 500 psi 34 5 bar to 2500 psi 172 4 bar The differential pressure should be at A250 25 psi 17 1 7 bar throughout the range 12 Using the speed valve cycle the pump from zero flow deadhead to full flow 13 If flow is within accept
36. ropriate maintenance procedures to assure fluid cleanliness and proper operating temperature REPLACEMENT PUMP INSTALLATION To prevent premature pump failure make A flushed completely clean before installing and operating a replacement pump system s filters is not enough to adequately clean the fluid Debris trapped in other components or lines may damage the components themselves or be system before installing a replacement pump voids the pump s warranty The following procedures checklist will help you provide satisfactory pump life 1 Determine the cause of the failure be sure you have found the cause and not simply a symptom 3 Drain the entire circuit including cylinders motors reservoirs control valves heat exchangers and filters a compatible solvent or clean filtered oil to remove contamination that may have entered the system when the pump failed Be certain that fluid has been sure that the entire hydraulic circuit is Simply draining the reservoir or relying on the drawn into the pump Failure to properly flush the replace a hydraulic pump with confidence that it will 2 Eliminate the cause of the failure 4 Remove system lines and components Flush with flushed from cylinders TROUBLESHOOTING GUIDE Component problems and circuit problems are often interrelated A poorly designed circuit may operate with apparent success but cause a component of the system to fail The component failure is the effect
37. sator O Ring 3 101194 Viton 38 Shaft Seal Buna N i 258081 258082 258083 Shaft Seal Viton 258299 258300 258301 40 Retaining Ring Barrel 1 258157 258158 258159 258160 258178 Retaining Ring 41 Bearing Housing 1 258330 258331 258332 258333 Retaining Ring 43 Shaft Seal 1 258327 258328 258329 45 Nut Hex 1 199127 199134 199136 melon Soc Cap Metric 199989 199911 199918 199717 199231 Rear Ports Screw Soc Cap Metric 198644 199985 199717 199234 Side Ports amp Tandem Codes 22 amp 23 1 120689 Buna N 439 BIg Codes 21 amp 31 2 NA 141714 Viton 18 Form No R92 00 Rev 10 03 PARTS LIST continued DESCRIPTION QTY HPV 6 HPV 10 HPV 15 HPV 20 HPV 29 50 O Rin Code 22 1 N A 144929 Buna N 144966 Viton 9 Code 23 N A 103999 Buna N 259659 Viton Code 21 N A 351354 351240 351394 351186 51 Coupling Code 22 1 N A 351355 351101 351393 351185 Code 23 N A 351392 351102 Code 31 N A 351355 351101 351393 351185 Code 21 N A 450634 Code 22 N A 450635 Be adapioi Code 23 N A 450672 Code 31 N A 450634 Code 22 2 53 Screw Soc Cap Code3il 6 N A 199682 54 Threadseal 1 258412 Buna N 258416 Buna N 258415 Buna N 258434 Viton 258419 Viton 258437 Viton 56 Dowel Pin Barrel 3 258103 258104 258105 258106 258107 Plug Case Drain SA
38. se seals See Parts List page 17 Item 38 for replacement part numbers 22 Proceed to SHAFT INSPECTION page 9 and BALL BEARING INSPECTION page 11 Compensator Disassembly 23 Loosen the hex nut 28 12 and remove the adjusting screw 28 11 from the end cap 28 3 24 Remove the end cap 28 3 25 Remove the spring 28 6 and spring seat 28 5 26 Remove the spool 28 2 Continue for Codes 7 19 and 26 compensators Item numbers refer to figures 16 and 17 page 20 27 Loosen the hex nut 12 and remove the adjusting screw 18 from the body 1 28 Remove the spring 7 and cone 16 29 Proceed to PRESSURE COMPENSATOR INSPECTION page 11 6 Form No R92 00 Rev 10 03 HPV REPAIR PROCEDURES continued NOTE If the cone is badly worn or damaged perform the following steps 30 For Code 7 or 19 compensators remove the plug 20 Using a rod tap the seat 15 out from the opposite end 31 For Code 26 compensators remove the fitting 27 and adjusting screw 18 as an assembly 32 Remove the dowel pin 24 and ball 17 33 Remove the fitting 29 Using a rod tap the seat 15 out from the opposite end Rework Limits for Wear Parts Barrel Bores Measure each bore in four places including one place deep within the bore where the piston doesn t run Replace the barrel if the difference in measurements exceeds 0004 in or 010 mm Barrel Face May be lapped no more than 0002 in
39. t hydraulic fluid flow through exchanger Form No R92 00 Rev 10 03 Continued on Page 5 TROUBLESHOOTING GUIDE continued continued Problem Possible Cause Look For Fluid Faulty reservoir Fluid level too low overheats Entrained air in fluid Improper or no baffles Poor air flow or ambient air temperature too high around reservoir Heat pick up from adjacent eguipment Decrease in Loose compensator adjusting screw set pressure Tighten adjusting screw No 11 in Fig 14 exploded view Defective function or relief valves Repair or replace relief valve Check relief valve setting Reservoir fluid level too low Replenish fluid Check drain below 5 of discharge at rated pressure Deteriorating pump performance Check pump internal components for wear repair or replace as needed Pressure Pump turning backward Change the rotating direction does not rise Reservoir fluid level too low Replenish fluid Relief valve or compensator set wrong Readjust and lock Relief valve or compensator defective Repair or replace Clogged suction line Inspect and clean suction strainers Open gate valve Deteriorating pump performance Check pump internal components for wear repair or replace as needed Insufficient Reservoir fluid level too low Replenish fluid flow Suction line not sealed Tighten fittings Improper pump stroke control adjustm
40. t to coupling hub Check alignment between prime mover and pump Correct as needed Visually inspect shaft seal surface for A Seal contact marks A Use as is B Bright polish B Use as is C Contact marks over 0 04 in or 1 mm wide can be felt with C Replace shaft fingernail Inspect and replace shaft seal as needed Visually inspect key groove bottom end for cracks If in doubt If cracked replace shaft check with dye penetrant or magnetic particle inspection Check alignment with prime mover Correct as needed Inspect needle bearing rolling contact surfaces for wear Replace shaft if difference between bearing contact and non contact surfaces is more than 0008 in or 020 mm Hanger Visually inspect the trunnion bore 9 Contact surface not excessively worn Reuse hanger as is Contact surface shows obvious wear uneven contact or Replace the hanger localized nicks when inside diameter difference is directionally more than 0008 in or 020 mm Visually inspect contact surface with the plunger 21 Wear marks up to 0 2 in or 5 mm wide Reuse hanger as is Wear marks over 0 2 in or 5 mm wide Replace hanger Adjust volume as needed Trunnion Visually inspect contact surface to hanger 9 10 Very slight wear Reuse trunnion as is Localized seizure scoring discoloration Replace the trunnion Also replace hanger 9 Check hydraulic fluid type temperature rise excessive pressure Form No R92 00 Rev 10 03 Cont
41. tion pressure If less than 5 in Hg raise fluid level in reservoir clean intake strainer and or correct faulty circuit design Form No R92 00 Rev 10 03 Continued on Page 9 INSPECTION PROCEDURES Continued Part Item No Inspection Procedure Corrective Action Piston Visually inspect the shoe flange for burrs or rolled edges If slight repair by lapping Assembly If severe replace part 5 Continued Inspect the piston outer diameter Measure each piston in four Replace Piston if the places including one at the shoe end where the piston doesn t difference in enter the barrel measurements exceeds 0006 in or 015 mm Visually inspect for slight discoloration or cross hatch trace Reuse as is Visually inspect for localized scratch marks running in Replace pistons a longitudinal direction as a set Flush reservoir and circuit Visually inspect for signs of seizure scoring or discoloration Replace piston and shoe assemblies 5 Replace barrel 3 Check for correct hydraulic fluid type temperature rise excessive pressure Correct as needed Shaft Visually inspect the shaft end outer surface 8 A If burnt brown spots are apparent over entire surface A Remove with emery paper B If uneven wear on key side surface B Check fit to coupling hub If loose replace Inspect for pitting or corrosion over all or part of shaft surface Replace shaft Check fi
42. ugh to prevent back pressure in excess of 10 psi 0 70 bar Figure 2 Form No R92 00 Rev 10 03 1 PLUMBING continued Hydraulic fluid from the case drain line should be returned to the reservoir below the fluid level and as far from the supply intake as possible All fluid lines whether pipe tubing or hose must be of adequate size and strength to assure free flow through the pump Do not tee return lines together SYSTEM RELIEF VALVES Although HPV series pumps have a very fast off stroke compensator response fast acting relief valves are recommended in all cases for safety They also help reduce transient pressure spikes RECOMMENDED FLUID Note The following fluid recommendations and specifications apply to HPV series pumps only Assure that all other components in the hydraulic system have compatible requirements Petroleum based and most phosphate esters Fluids should be designated by the manufacturer for use in hydraulic systems Fluids should be formulated with oxidation inhibitors anti rust anti foam and deaerating agents Other fluids may be acceptable but special O rings may be required Nitrile Buna seals are standard VISCOSITY Maximum at full power 750 SUS 160 Cst Optimum for maximum life 140 SUS 30 Cst Minimum at full power 60 SUS 10 Cst VISCOSITY INDEX 90 V I minimum Higher values extend the operating temperature range but may reduce fluid service life F
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