LPV Closed Circuit Variable Pumps Service Manual
Contents
1. T 5 M022 M023 f High pressure T04 relief valve End cover screw h J06 H Loop flushing valve plug 2 K02 i a Neutral return NHH pivot T X B K08 Ss RIA LL Neutral return seal nut L01 s03 Jo4 Bypass valve O ring plug 1 1 16 12 Endcap screw P106 323E Fastener size and torque chart Item Fastener Wrench size Torque H01 Charge relief valve plug lin 81 203 Nem 60 150 Ibf ft J04 Endcap screw 8 mm internal hex 54 Nem 40 Ibf ft J06 Loop flushing valve plug 11 16 in 45 Nem 33 Ibf ft K02 Neutral return pivot 1 4 in N A K08 Neutral return seal nut 13 mm 22 Nem 16 Ibf ft L01 Bypass valve 11 16 in 20 Nem 15 Ibf ft M022 M023 High pressure relief valve 5 16 in internal hex 81 Nem 60 Ibf ft N03 N07 Trunnion cover screw 13 mm 33 Nem 24 Ibf ft T04 End cover screw 9 16 in 44 Nem 32 Ibf ft Plug size and torque chart Item O ring plug Wrench size Torque S03 S04 11 16 12 15 mm internal hex 69 Nem 51 Ibf ft 11004904 Rev 0100 July 2015 35 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohyd2. Port information Port Port size Wrench size Pressure obtained Gauge size bar identifier psi Case drain 1 1 16 12 UNF 2B 15 mm internal hex Case drain 10 100 Port A Port B 1 1 16 12 UNF 2B N A System pressure 600 10 000 Charge inlet 7 8 14 UNF 2B N A Charge pressure 50 1000 Port locations 7 8 14 SAE straight thread O ring boss 11 16 12 3 SAE straight thread charge inlet O ring b r H case dien H T3 7 8 14 ia SAE straight thread l p O ring boss Sy ide 11 6 12 SAE straight thread a O ring boss system portA Tu TET N 11 16 12 SAE straight thread O ring boss case drain alternate 11 16 12 SAE straight thread O ring boss system port B P106 323E 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Troubleshooting Overview System operating hot This section provides general steps to follow if undesirable system conditions are observed Follow the steps listed until the problem is solved Some of the items will be system specific For areas covered in this manual a
3. E101 438E 11004904 Rev 0100 July 2015 25 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Input shaft removal 1 Remove retaining ring S09 using retaining ring pliers 2 Pull shaft E01 with bearing S07 out of the pump If necessary tap on the shaft to dislodge it from the internal pump components e Caution If the shaft is to be replaced without complete pump disassembly do not move or rotate the pump once the shaft is removed This may dislodge internal components making reassembly impossible 3 Remove retaining ring S08 using retaining ring pliers 4 Press bearing off the shaft using the inner race 5 Remove retaining ring S06 from the shaft using retaining ring pliers Shaft inspection Check to see that the shaft E01 and its splines are straight and free of damage or heavy wear Inspect the shaft surface where it meets the shaft seal Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic fluid out of the unit Clean the sealing area with a nonabrasive material if necessary Lubricate the shaft with a light coat of hydraulic fluid before re assembly Inspect shaft P106 291E 26 11004904 Rev 0100 July 2015 Danfoss Service Manual LPV Closed Circuit Axial Piston Pumps Minor rep
4. Personal Safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Hazardous Material A Warning Hydraulic fluid contains hazardous material Avoid prolonged contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11004904 Rev 0100 July 2015 5 Service Manual LPV Closed Circuit Axial Piston Pumps Introduction Symbols used in Danfoss literature Al WARNING may result in injury d Tip helpful suggestion CAUTION may result in damage to product or P Lubricate with hydraulic fluid property A Reusable part Apply grease petroleum jelly m Non reusable part use a new part dd Apply locking compound a Non removable item re Inspect for wear or damage w Option either part may exist p Clean area or part Superseded parts are not interchangeable A Be careful not to scratch or damage T Measurement required g Note correct orientation 7 Flatness specification Z Mark orientation for reinstallation 7 Parallelism specification z Torque specification 5 External hex head i Pressin press fit Internal hex head Eg Pull out with tool press fit e Torx head Cover splines with installation sleeve
5. Check that inlet line is not restricted and is proper size Cold oil If oil is under cold conditions it may be too viscous for proper function and pump cavitates Allow the oil to warm up to its normal operating temperature with engine at idle speed Pump inlet vacuum High inlet vacuum causes noise cavitation Check that inlet line is not restricted and is proper size Check filter and bypass valves if present Shaft couplings Shaft alignment A loose shaft coupling will cause excessive noise Misaligned shafts creates noise Replace loose shaft coupling Replace pump or motor Align shafts Charge system relief valves Unusual noise may indicate sticking valves Possible contamination Clean replace valves and test pump May be a normal condition Sluggish system response Item Description Action Oil level in reservoir High pressure relief valves Low oil level will cause sluggish response Incorrect pressure settings will affect system reaction time Fill reservoir Adjust or replace high pressure relief valves Low prime mover speed Low engine speed will reduce system performance Adjust engine speed Air in system Air in system will produce sluggish system response Fill tank to proper level Cycle system slowly for several minutes to remove air from system Pump inlet vacuum Inlet vacuum is too high resulting in reduced system
6. O ring boss port O Pressure measurement gauge location or specification The symbols above appear in the illustrations and text of this manual They are intended to communicate helpful information at the point where it is most useful to the reader In most instances the appearance of the symbol itself denotes its meaning The legend above defines each symbol and explains its purpose Design LPV represents a family of hydrostatic pumps for low to medium power applications with maximum pressures up to 345 bar 5000 psi These pumps can be applied with other products in a system to transfer and control hydraulic power LPV pumps provide an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation LPV pumps come in three displacements 25 cm3 1 53 in3 30 cm3 1 83 in3 and 35 cm3 2 32 in3 LPV pumps are compact high power density units All models use the parallel axial piston slipper concept in conjunction with a tiltable swashplate to vary the pump s displacement Reversing the angle of the swashplate reverses the flow of fluid from the pump reversing the direction of rotation of the motor output LPV pumps are provided with an internal neutral return mechanism for ease of installation and are available with optional loop flushing for circuit flexibility LPV pumps are designed to receive charge flow from an auxiliary circuit or from a gear pump mounted on the auxil
7. 5 16 in ED 9 5 16in E101441E Inspection 1 Inspect plug and cartridge Replace O rings before reassembly 2 Inspect internal parts of cartridge If internal parts are worn or damaged replace entire cartridge Reassembly 1 Lubricate and install new O rings M022 and M023 onto each system check relief valve M10 and M20 2 Install the system check relief valves in their original location as noted during disassembly 3 Use a 5 16 in internal hex wrench to torque valves to 81 Nem 60 Ibf ft 30 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Charge pressure relief valve Removal 1 Using a 1 in hex wrench remove the charge pressure relief valve plug H01 Discard O ring HO1A 2 Charge relief valve shim kit HO6 remains in plug HO1 Remove shims by tapping the plug on the workbench 3 Use a magnet to remove the spring H07 4 Use a magnet to remove the charge relief poppet H08 Charge pressure relief valve H01 EM cy tit H06 8 H07 OE NS H08 S gt AX N E101 440E Inspection 1 Inspect charge relief valve plug for wear or damage Replace O ring before reassembly 2 Inspect shim kit 3 Inspect the spring Replace spring if it is warped or bent 4 Inspect charge relief valve
8. Remove the unit and refer to Sauer Danfoss Global Service Partner for repairs Leveling swashplate with pump installed on machine Leveling the swashplate adjusting neutral return mechanism with the pump installed on the machine is the same procedure as adjusting on the test stand A cam allows precise zero displacement adjustment Block wheels off the ground Disconnect control linkage from pump trunion If machine creeps loosen locknut and turn adjusting screw until creep is eliminated If neutral adjustment is not possible pump teardown is necessary See your nearest Danfoss Global Service Provider It may be necessary to disconnect the control linkage to eliminate possible linkage drag 24 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Input shaft and seal Shaft seal removal 1 Orient pump with the shaft pointing up 2 Remove retaining ring D03 using retaining ring pliers to release the shaft seal components Discard retaining ring o Caution Do not damage the housing bore shaft or bearing when removing the shaft and shaft seal 3 Remove the seal support washer D02 Use a small hook if necessary 4 Install a special fitting with air chuck into a case drain port 5 Use air pressure to push out shaft seal D01 Discard seal 6 Remove special fitting and replace with original plug Remove shaft seal bearing ZA a _ D03 i _ D02
9. System pressure Frequent or long term operation over system relief setting will create heat in system Measure system pressure If pressure is too high reduce loads Transmission operates normally in one direction only Item Description Action Control linkage Control linkage operating improperly Repair replace control linkage Interchange high pressure relief valves Interchanging the high pressure relief valves will show if the problem is related to the valve function If the problem changes direction replace the valve that does not operate correctly Ensure bypass valve is closed Open bypass will cause both directions to be inoperative Close repair bypass function System will not operate in either direction Item Description Action Ensure bypass valve is closed If bypass valve is open the system loop will be depressurized Close bypass valve Charge pressure with pump in neutral Low charge pressure insufficient to recharge system loop Measure charge pressure with the pump in neutral If pressure is low go to Pump charge relief valve 18 11004904 Rev 0100 July 2015 Zonen Service Manual LPV Closed Circuit Axial Piston Pumps Troubleshooting Item Description Action Charge pressure with pump in stroke Low charge pressure resulting from elevated loop leakage Isolate pump f
10. an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Danfoss Power Solution representative nearest you Local address Danfoss Power Solutions Trading Danfoss Danfoss Shanghai Co Ltd Power Solutions GmbH amp Co OHG Power Solutions ApS Building 22 No 1000 Jin Hai Rd Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District DK 6430 Nordborg Denmark Phone 45 7488 2222 Shanghai China 201206 Phone 86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 11004904 Rev 0100 July 2015 www danfoss com Danfoss A S 2014
11. poppet Reassembly 1 Insert charge relief valve poppet H08 and spring H07 into endcap 2 Install shims H06 into charge relief valve plug H01 3 Lubricate and install a new O ring HO1A onto the charge relief valve plug 4 Install charge relief valve plug using a 1 in hex wrench Torque to 81 203 Nem 60 150 Ibf ft 11004904 Rev 0100 July 2015 31 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Loop flushing valve Removal 1 Using a 11 16 in hex wrench remove the loop flushing valve plugs 06 Discard Oring 06A 2 Use a magnet to remove springs J07 3 Use a magnet to remove loop flush spool J08 Disassemble loop flushing valve J06A M m DON In j RA J07 aum J06 T C 11 16 in Dus dl E101 442E Inspection 1 Inspect loop flushing valve plugs for damage or wear Replace O rings before reassembly 2 Inspect the springs Replace if warped or bent 3 Inspect loop flush spool If worn or damaged replace the loop flush spool Reassembly 1 Insert loop flush spool J08 and springs J07 into endcap 2 Lubricate and install new O rings JO6A onto loop flushing valve plug J06 3 Thread the loop flushing valve plugs into the housing 4 Torque to 45 Nem 33 Ibf ft using a 11 16 in hex wrench 32 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Ax
12. the working loop with charge oil Each side of the transmission loop has a dedicated HPRV valve that is non adjustable with a factory set pressure When system pressure exceeds the factory setting of the valve oil is passed from the high pressure system loop into the charge gallery and into the low pressure system loop via the charge check HPRV valve P106 273E The LPV contains a dedicated bypass valve The bypass function is activated when the bypass valve is mechanically backed out 3 full turns maximum The bypass function allows a machine or load to be moved without rotating the pump shaft or prime mover Bypass valve O P106 286E e Caution Excessive speeds and extended load vehicle movement must be avoided The load or vehicle should be moved not more than 2096 of maximum speed and for a duration not exceeding 3 minutes Damage to drive motor s is possible When the bypass function is no longer needed care should be taken to reseat the bypass valves to the normal operating position 11004904 Rev 0100 July 2015 Devt Service Manual LPV Closed Circuit Axial Piston Pumps Operation CPRV Charge pressure relief valve Loop flushing valve An internal charge relief valve regulates charge pressure Charge pressure is supplied to maintain a minimum pressure in the low side of the
13. titer etes diee elena te Serena y ete tese leben ERI 19 Sluggish SysSteEM Beo i A 19 Pump adj stMEnt ainese Standard procedures inspections and adjustments B Charge pressure relief valve ACjUSTIMENKS sssccssssccsssscrsseesessseesssscessusecesusecssssesesusecesseceessseesssseessuseecenseessaseeesanecesneeeesanees System check ls du Checking for proper HPRV valve OperatiOn sssssccsssssccsseccssesscsnsecssseesssusecssnseesssssecsasecssueesesuseessncessueecssueessneeesseeetse Loop fl shing valve riter tette tete eE a ES re uenisse bake tiene tee sereni esteso ete Neutraliret rn mechanism recette etnies tees tb se kde gri tbbekk ci dee pub bleue tipp bei better brains Leveling swashplate with pump installed on MACHINE eecsssssccsseessssseccsseceesecssseesesusecessseeccaecesnsecssnseecesecssneeessaseees 24 putha and seal isa rrt HE ERES PHE HP REM ENEEPURTEFRE ERE THEAR EH EAE EHE EPA EH USE Pee EE er FERRE ES 25 UEM 29 High Pressure Relief Valves tiet ett teet aiie ana ain dp eet Ree pede 30 Charge press re relief ValWes cc scccisssceassesessseacessgesasercosssscdesesavssedssavasdtagstcconsditesststaaasevesatetessitcasanctossscea otesesasedsaancdesaesonssevossiesnaas 31 Loop flushing valve 32 Bypass valve eee E 34 Fasteners and Plug ERR Fa
14. 00 July 2015 11 Service Manual LPV Closed Circuit Axial Piston Pumps Technical specifications Specifications General specifications Design Axial piston pump of trunion swashplate design with variable displacement Direction of rotation Clockwise counterclockwise pipe connections Main pressure ports SAE straight thread O ring boss Recommended installation position Pump installation recommended with control position on the top or side Consult Danfoss for non conformance to these guidelines The housing must always be filled with hydraulic fluid Physical properties Displacement Feature Unit 25 30 35 Maximum Displacement cm in 25 1 53 30 1 83 35 2 14 Flow at rated speed theoretical l min 85 2 104 9 137 0 US gal min 22 5 27 7 36 2 Input torque at maximum displacement theoretical N m bar 04 0 5 0 6 Ibf in 1000 psi 244 291 340 Mass moment of inertia of internal rotating components kg m 0 001670 0 001580 0 001530 slug ft 0 0012 0 00120 0 00113 Weight kg Ib 23 51 Rotation Clockwise Counterclockwise Mounting SAE B 2 bolt Auxiliary mounting SAE J744 A 9T SPCL 11T System ports type 1 1 16 12 UNF 2B ORB System ports location Twin radial Control types Direct displacement control Shafts Splined Splined SAE13 tooth 15 tooth Case drain port
15. 61E 28 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Trunion seal Removal 1 Remove four trunnion cover bolts N03 using a 13 mm hex wrench 2 Remove trunnion cover N01 Remove and discard O ring N04 3 Press the lip seal N02 out of the trunnion cover N01 discard N03 Omm N N01 E101 493E Inspection Inspect seal land on trunnion shaft and trunnion cover for rust wear or contamination Polish seal land on trunnion shaft if necessary Reassembly 1 Press new trunnion seal N02 into cover N03 2 Install new O ring N04 Retain with petroleum jelly 3 Cover the trunnion shaft with an installation sleeve or wrap with packaging tape to prevent damage to seal 4 Install trunnion cover and seal assembly N01 to housing 5 Install four trunnion cover bolts using a 13mm hex wrench Torque to 33 Nem 24 Ibf ft 11004904 Rev 0100 July 2015 29 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair High Pressure Relief Valves Removal 1 Mark the location of each system check relief valve for proper reassembly 2 Using a 5 16 internal hex wrench remove system check relief valves M10 and M20 3 Remove and discard O rings M022 and M023 Disassemble system check relief valves M023 3 M022 pe M20
16. MAKING MODERN LIVING POSSIBLE Denfs Service Manual Closed Circuit Axial Piston Pumps LPV powersolutions danfoss com Service Manual LPV Closed Circuit Axial Piston Pumps Revision history Table of revisions Date Changed Rev July 2015 Danfoss layout 0100 November 2006 First printing A 2 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Contents Introduction Operation Technical specifications MI 4 Warranty 4 General instructions 4 Safety Precautions ss 5 Symbols used in Danfoss literature 6 Pio e 6 Direct displacement drive SYSteM sssssccsscscsssccsssseccssecsssssecsusecsssssescsnecesueesssseeessscessnseeesuseessasececanecesuseeesuseessuscessueeessuseessaseesees 8 LPV Pump schematic Giagrar sssscssssscsssssecssessesnsecsssecccsecesnssessssecsssueessssecesssecessuseccssecessucesssuecessseecenueessuesesueccsneeessueesssaseeste 8 HPRV High pressure relief valve Fluid and filter recommendations Startup procedures Pressure measurements Troubleshooting Adjustments Minor repair Torque chart Bypass function sss CPRV Charge pressure relief ValVe ccssseccssseccsssssssssecsssecccssecesssecsssseccssseccsssecesssecssnseeccasecesusecssasecesasec
17. air Shaft bearing inspection Clean bearing with a solvent and lubricate with hydraulic fluid Inspect for wear or pitting Replace bearing if cleaning exposes wear or damage to bearing Inspect shaft bearing 4 P106 292E Shaft and seal reassembly au fFWN Orient pump with the shaft end pointing up Install first bearing retaining ring S06 using retaining ring pliers Lubricate bearing S07 with hydraulic fluid Press bearing onto shaft by applying force to inner race Install second bearing retaining ring S09 using retaining ring pliers For protection cover end of shaft with installation sleeve or packaging tape Install shaft S01 with bearing into housing It may be necessary to tap the shaft to seat the bearing o Caution Do not damage the housing bore shaft or bearing when installing the shaft and shaft seal Using retaining ring pliers install first seal retaining ring S09 11004904 Rev 0100 July 2015 27 ones Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair 8 Lubricate the seal D01 using hydraulic fluid Press seal into housing until it bottoms out Press evenly to avoid binding and damaging the seal 9 Install the seal support washer D02 10 Install the second seal retaining ring D03 using retaining ring pliers Install shaft seal bearing E101 4
18. d motor speed Pictorial circuit diagram Reservoir Heat exchanger bypass Filter Heat exchanger Cylinder block assembly Charge relief valve OMS 2 orbital motor Bypass valve O O D Output shaft O Charge pump Suction flow haft dE ae HPRV valves Loop flushing valves E Charge pressure isplacement pump Servo pressure Bl High pressure CI Case flow P100 586E The diagram shows an LPV pump driving an OMR motor The system shown uses an external charge pump and external filter Charge pressure relief valves high pressure relief valves and loop flushing valves are shown separated from the pump to provide clarity to the hydraulic system LPV Pump schematic diagram Charge pressure inlet Li P106 287E 8 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Operation HPRV High pressure relief valve Bypass function LPV pumps are equipped with a combination high pressure relief and charge check valve The high pressure relief function is a dissipative with heat generation pressure control valve for the purpose of limiting excessive system pressures The charge check function acts to replenish the low pressure side of
19. e all fluid lost during filter change A Warning Hazardous material Hydraulic fluid contains hazardous material Avoid contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations Hazardous material A Warning W Warning Hydraulic fluid contains hazardous material Avoid contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11004904 Rev 0100 July 2015 15 Service Manual LPV Closed Circuit Axial Piston Pumps Startup procedures General Start up procedure Follow this procedure when starting up a new pump installation or when restarting an installation in which the pump has been removed and re installed on a machine Ensure pump has been thoroughly tested ona test stand before installing on a machine A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Prior to installing the pump inspect for damage that may have occurred during shipping w Ensure that the machine hydraulic oil and system components reservoir hoses valves fittings and heat exchanger are clean and free of any foreign material Install new system filter element s if necessary Check that inlet line f
20. ect hydraulic fluid 7 Flush the lines before replacing the hydraulic fluid 8 Before re installing the pump perform a leakage test per Sauer Danfoss leakage test HPP 112 Charge pressure relief valve adjustments The following procedure explains how to check proper operation of the charge pressure relief valve Correct charge pressure is the measured pressure minus case drain pressure 20 11004904 Rev 0100 July 2015 Danfoss Service Manual LPV Closed Circuit Axial Piston Pumps Adjustments 1 Validate that external charge pump is operating properly 2 Install a 50 bar 1000 psi pressure gauge tee in charge pressure inlet port Install a 10 bar 100 psi gauge at one of the case pressure ports Operate the system with the pump in neutral zero displacement when measuring charge pressure 3 Verify correct charge pressure per model code Pressure measurements assume 5 Gal US Min charge flow a reservoir temperature of 50 C 120 F and are referenced to case pressure Charge pressure relief valve O 1in Z 81 Nem L7 HOIA CO 60 Ibf ft Pressure listed in model code assumes a charge flow of 19 l min 5 Gal US Min At higher charge flows the charge pressure will rise over the rated setting 4 If measured pressure is not correct disassemble valve and look for signs of wear or contamination Refer to Charge pressure relief valve on page 31 for wrenc
21. ent cm in 25 1 53 30 1 83 35 2 14 Viscosity Minimum mm 2 s SUS 7 47 Recommended range 12 60 66 278 Maximum 1600 7500 Temperature Range Minimum C F 40 40 Rated 82 180 Maximum intermittent 100 212 Filtration Cleanliness per ISO 4406 22 18 13 Efficiency charge pressure filtration B ratio B15 20 75 B102 10 Efficiency suction filtration B35 45 75 B102 2 Recommended inlet screen mesh size um 100 125 2At the hottest point normally case drain port Mounting flange allowable overhung parameters Continuous load moment M Shock load moment M Nem Ibf in Nem Ibf in 361 3200 617 5470 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Technical specifications Mounting flange G factors for sample applications Application Continuous vibratory Maximum shock acceleration acceleration G G Skid steer loader 6 10 Trencher 6 8 rubber tires Asphalt paver 6 6 Windrower 6 5 Aerial lift 6 4 Turf care vehicle 6 4 Vibratory roller 6 10 Applications experiencing extreme resonant vibrations may require additional pump support Refer to LPV Technical Information 520L0954 for information concerning mounting flange loads 14 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Fluid and filt
22. ents eo Caution Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered When adequate charge pressure is established increase engine speed to normal operating rpm to further purge residual air from the system Shut off engine Connect pump control Start engine checking to be certain pump remains in neutral Run engine at normal operating speed and carefully check for forward and reverse control operation Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop Normal charge pressure fluctuation may occur during forward and reverse operation Check that the reservoir is full Remove charge pressure gauge The pump is now ready for operation 16 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Pressure measurements Required tools The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown When testing system pressures calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges Port locations and gauge installation The following table and drawing show the port locations and gauge sizes needed
23. er recommendations Fluid and filter recommendations To ensure optimum life perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Inspect vehicle for leaks daily Fluid and filter change interval Reservoir type Max oil change interval Sealed 2000 hours Breather 500 hours Change the fluid and filter per the vehicle machine manufacturer s recommendations or at these intervals First fluid change recommended at 500 hours o Caution High temperatures and pressures will result in accelerated fluid aging More frequent fluid changes may be required Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater than the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replac
24. h sizes and torque settings 5 If valve is worn replace entire valve 6 Valve may be adjusted using available shim kit 7 When the desired charge pressure setting is achieved remove the gauges 11004904 Rev 0100 July 2015 21 Devt Service Manual LPV Closed Circuit Axial Piston Pumps Adjustments System check and HPRV Loop flushing valve Whenever an HPRV valve has been replaced or opened the pump should be operated in its full range of functions to ensure proper machine operation The HPRV valves are pre set at the factory no adjustment is possible Checking for proper HPRV valve operation For suspected HPRV valve malfunction replace valve with identical relief setting and test operation of pump HPRV valves HPRV valves P106 333E The loop flushing valve in not adjustable If loop flushing malfunction is suspected disassemble valve and check for worn damaged or scored components Replace parts if necessary Refer toLoop flushing valve on page 32 for disassembly procedures Loop flushing valve Loop flushing valve P106 335E 22 11004904 Rev 0100 July 2015 Danfoss Service Manual LPV Closed Circuit Axial Piston Pumps Adjustments Neutral return mechanism The neutral return mechanism is designed to mechanically return the pump to zero displacement A cam allows precise zero displacement adjustment If pump does not return to neutral loosen l
25. ial Piston Pumps Minor repair Bypass valve Removal Using a 5 8 in hex wrench remove the bypass valve cartridge L01 Discard Oring 1003 and backup ring 1002 Bypass valve 5 8 in E101 443E Inspection 1 Inspect plug and cartridge Replace O rings before reassembly 2 Inspect internal parts of cartridge If internal parts are worn or damaged replace entire cartridge Reassembly 1 Install new O ring 1003 and backup ring 1002 2 Install the bypass valve cartridge L01 using a 5 8 in hex wrench 3 Torque to 20 Nem 15 Ibf ft 11004904 Rev 0100 July 2015 33 Service Manual LPV Closed Circuit Axial Piston Pumps Minor repair Coupling Removal 1 Position pump so endcap is on top 2 Remove coupling T03 Use a small hook if necessary E101 439E Inspection Check coupling for abnormal or excessive wear Look for cracks that indicate coupling fatigue If wear or damage is found replace coupling Reassembly Lubricate and install coupling T03 34 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Torque chart Fasteners and plugs N03 N07 Trunnion cover screw S04 O ring plug 1 1 16 12 H01 Charge relief valve plug
26. iary mounting pad LPV pumps feature an SAE A auxiliary mounting pad to accept auxiliary hydraulic pumps for use in complementary hydraulic systems LPV pumps include a trunnion style direct displacement control 6 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Introduction LPV cross section NKCAN Trunion X Tapered roller bearing Cylinder block N Valve plate LZ e A 1 v JY Ball bearing ld ZZ cn LAE 2 e St ZICICIZICM RS AWA E A j A Input shaft __ Y iz d P Needle bearing Piston Swashplate M P106 271E Cylinder block spring Slipper 11004904 Rev 0100 July 2015 Devt Service Manual LPV Closed Circuit Axial Piston Pumps Introduction Direct displacement drive system The direct displacement control varies the swashplate angle Swashplate angle determines pump flow an
27. ittings are properly tightened and there are no air leaks Install the pump Install a 50 bar 1000 psi gauge in the charge pressure gauge port M3 4 Fill the housing by adding filtered oil in the upper case drain port 10 11 12 Fill the reservoir with hydraulic fluid of the recommended type and viscosity Use a 10 micron reservoir filler filter Ensure inlet line from reservoir to pump is filled Disconnect the pump from control After start up the oil level in the reservoir may drop due to filling of the system components Check the level in the reservoir to maintain a full oil level throughout the start up A Warning Damage to hydraulic components may occur if the oil supply is not maintained Use acommon method to disable the engine to prevent the engine from starting Crank the starter for several seconds Do not to exceed the engine manufacturer s recommendation Wait 30 seconds and then crank the engine a second time as stated above This operation helps remove air from the system lines Refill the reservoir to recommended full oil level When charge pressure begins to appear enable and start engine Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system Check for leaks at all line connections and listen for cavitation Check for proper fluid level in reservoir e Caution Air entrapment in oil under high pressure may damage hydraulic compon
28. l procedures when repairing Series LPV variable displacement closed circuit pumps Remove the unit A Prior to performing major repairs remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses after removal to prevent contamination Keep it clean Z Cleanliness is a primary means of assuring satisfactory pump life on either new or repaired units Clean the outside of the pump thoroughly before disassembly Take care to avoid contamination of the system ports Cleaning parts by using a clean solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the pump with a protective layer of plastic Lubricate moving parts p b During assembly coat all moving parts with a film of clean hydraulic oil This assures that these parts will be lubricated during start up Replace all O rings and gaskets iil 11004904 Rev 0100 July 2015 Danfoss Service Manual LPV Closed Circuit Axial Piston Pumps Introduction Safety Precautions It is recommended that all O ri
29. ngs be replaced Lightly lubricate all O rings with clean petroleum jelly prior to assembly Secure the unit E For major repair place the unit in a stable position with the shaft pointing downward It will be necessary to secure the pump while removing and torquing the endcap bolts Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system Unintended Machine Movement A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable Cleaning Solvents A Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid Under Pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid
30. ocknut and turn adjusting screw until creep is eliminated Torque locknut to 22 Nm 16 Ibf ft If neutral adjustment is not possible pump teardown is necessary See your nearest Danfoss Global Service Provider Neutral return adjustment z 9 O Neutral AB return we adjustment P106 336E Neutral return adjusting screw Adjusting cam UN Lock seal nut X 77 X w Neutral return mechanism Swashplate E P Shaft bg i ESQ e N Neutral gt turn TEE aN re arm Adjusting cam WJ P106 278E 11004904 Rev 0100 July 2015 23 Service Manual LPV Closed Circuit Axial Piston Pumps Adjustments Neutral return adjustment 1 For propel applications raise the wheels off the ground and secure the vehicle so you can operate it safely Other applications take necessary steps to ensure you can operate the machine safely during this procedure 2 Remove the control linkage and check for creep If the wheels mechanism move while the control linkage is disconnected loosen the locknut and turn the adjusting screw clockwise or counterclockwise You will achieve maximum adjustment with only 1 4 turn in either direction 3 If creep is eliminated by adjustment torque the locknut to 22 Nem 16 Ibf ft while holding the adjustment screw secure If creep cannot be eliminated then the pump requires major repair
31. pressure Measure charge inlet vacuum Inspect line for proper sizing Replace filter Confirm proper bypass operation 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Adjustments Pump adjustment This section offers instruction on inspection and adjustment of pump components Read through the entire topic before beginning a service activity Refer to Pressure measurements on page 17 for location of gauge ports and suggested gauge size Standard procedures inspections and adjustments Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 1 With the prime mover off thoroughly clean all dirt and grime from the outside of the pump 2 If removing the pump tag each hydraulic line connected to the pump If hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not get into the pump 3 Ensure the surrounding areas are clean and free of contaminants such as dirt and grime 4 Inspect the system for contamination 5 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles 6 If there are signs of contamination in the hydraulic fluid all filters must be replaced and the hydraulic system must be drained and filled with the corr
32. raulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors PLUS 1 GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Comatrol www comatrol com Schwarzm ller Inverter www schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 D 24539 Neum nster Germany Phone 49 4321 8710 Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Danfoss Your Strongest Partner in Mobile Hydraulics Go to www powersolutions danfoss com for further product information Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with
33. rom motor by blocking system ports With pump in partial stroke and engaged for only a few seconds check pump charge pressure Low charge pressure indicates a malfunctioning pump Continue to next step Good charge pressure indicates a malfunctioning motor or other system component Check motor charge relief operation if present Pump charge relief valve A pump charge relief valve that is leaky or contaminated or set too low will depressurize the system Adjust or replace pump charge relief valve as necessary Charge pump inlet filter Charge pump A clogged filter will under supply system loop A malfunctioning charge pump will provide insufficient charge flow Inspect filter and replace if necessary Repair or replace the charge pump System pressure Low system pressure does not provide enough power to move load Measure system pressure Continue to next step System relief valves Defective high pressure relief valves cause system pressure to below Repair or replace high pressure relief valves System noise or vibration Item Description Action Reservoir oil level Low oil level leads to cavitation Fill reservoir Aeration of the oil pump inlet vacuum Air in system decreases efficiency of units and controls Air in system is indicated by excessive noise in pump foaming in oil and hot oil Find location where air is entering into the system and fix
34. s 1 1 16 12 SAE ORB Operating parameters Displacement Rating Units 25 30 35 Input speed minimum min rpm 500 500 500 continuous 3400 3500 3600 maximum 3950 4150 4300 Working pressure continuous bar psi 210 3045 175 2540 140 2030 maximum 345 5000 External shaft loads External moment Me Nem lbf in 7 7 68 Thrust in Tin out Tout N Ibf 750 169 Bearing life max at 210 bar 3045 psi B10 hours 120 000 63 000 37 000 swashplate angle and max continuous speed Charge pressure minimum bar psi 6 87 maximum 20 300 12 11004904 Rev 0100 July 2015 Service Manual LPV Closed Circuit Axial Piston Pumps Technical specifications Operating parameters continued Case pressure rated bar psi 2 29 maximum 6 87 Sound levels dB A 100 bar 1450 psi 200 bar 2900 psi 300 bar 3451 psi Displ cm in 1000 min rpm 1000 min rpm 1000 min rpm 25 1 53 62 66 68 35 2 14 61 66 69 Sound levels dB A 100 bar 1450 psi 200 bar 2900 psi 300 bar 3451 psi Displ cm in 3000 min rpm 3000 min rpm 3000 min rpm 25 1 53 70 74 76 35 2 14 71 75 80 Sound data was collected in a semi anechoic chamber Values have been adjusted 3 dB to reflect anechoic levels Fluid specifications Feature Unit Displacem
35. section is referenced Always observe the safety precautions listed in Safety precautions and related to your specific equipment A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Item Description Action Oil level in reservoir Insufficient hydraulic fluid will not meet cooling demands of system Fill reservoir to proper level Heat exchanger Heat exchanger not sufficiently cooling the system Check air flow and input air temperature for heat exchanger Clean repair or replace heat exchanger Charge pressure Low charge pressure will overwork system Measure charge pressure Inspect and adjust or replace charge relief valve Inspect charge pump Repair or replace charge pump Charge pump inlet vacuum High inlet vacuum will overwork system A dirty filter will increase the inlet vacuum Inadequate line size will restrict flow Check charge inlet vacuum If high inspect inlet filter and replace as necessary Check for adequate line size length or other restrictions System relief pressure settings If the system relief valves are worn contaminated or valve settings are too low the relief valves will be overworked Verify settings of high pressure relief valves and replace valves as necessary
36. ssnseessasecsenseessaeeessaee 10 Loop flushing valve risa er E E FO E ER ee EH Rc ve a eee Crede eed eH US Rete gh 10 Neutral return MeChanisi ssssesscscsssssscessesscsecssseseseessssessessseseseesssessesnsseeseesssseseesnseseseessssesecessseesecsssessseessesssecsnseeseessessessensess 11 SPECIFICATIONS n 12 Fluid and filter recoMMendations essssssesssecsssessecsssesseeessneeseessssessssssseeseesssetsessssnseceessneeesssssssecssssneesesssseseesessnsesssssneseeseseee 15 K m 16 Start Up PrOCeC UNG eet 16 PRECIO TO Se sccssccssesscaceces cazgnstscapeassccovsis es 17 Port locations and gauge installation cssssssccsssscssssecssssssccseccssseeessseccssueecssuseessseesssusecssnecssueeessuecessueesssaseessneeessueeseaseessee 17 Overview 18 System operating NOt esccssescccseecssseccsteccsneeeecnteeseseesses 18 Transmission operates normally in one direction ONLY ssssscccsseccsseccseecssssecssseesssseecssuecessueeccsnseessuecessuseccsneesesueeessnees 18 System will not operate in either Airection scssssseccsseccssseccssssessseessssseccsseceesusecssseeessueeessnecessuccessuseessucesesueccsueesesneeesenees 18 Syst m noise OF Vibration ciet ettet tree
37. stener size and torque chart a Pl g size and TORUS ear qu 11004904 Rev 0100 July 2015 3 Service Manual LPV Closed Circuit Axial Piston Pumps Introduction Overview Warranty General instructions This manual includes information for the installation maintenance and minor repair of the LPV pump It includes a description of the unit and its individual components troubleshooting information and minor repair procedures Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Danfoss Global Service Partners is available for major repairs Danfoss Global Service Partners are trained by the factory and certified on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www sauer danfoss com Click on the Sales and Service link Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring the removal of a unit s rear cover or front flange voids the warranty unless done by a Danfoss Global Service Partner Follow these genera
38. transmission loop CPRV valve yT Case pressure Charge pressure P106 274E Minimum charge pressure is the lowest pressure allowed to maintain a safe working condition in the low side of the loop Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment and which provides normal component life The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the pump in neutral operating with 5 gpm of charge flow The charge pressure setting is referenced to case pressure Charge pressure is the differential pressure above case pressure LPV pumps incorporate an optional integral loop flushing valve which removes heat and contaminants from the main loop at an increased rate Loop flushing valve P106 276E 10 11004904 Rev 0100 July 2015 Denpi Service Manual LPV Closed Circuit Axial Piston Pumps Operation Neutral return mechanism The neutral return mechanism is designed to mechanically return the pump to zero displacement A cam allows precise zero displacement adjustment Neutral return adjusting cam Adjusting cam mE Lock seal nut h Ni P106 277E SS Neutral return mechanism Swashplate Shaft Neutral return arm Adjusting cam P106 278E 11004904 Rev 01
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