B20 Maintenance

Transcription

B20 Maintenance

INTERNATIONAL
A DIVISION OF ATLAS COPCO CANADA INC.
Operators Maintenance Manual
B20 Underground Drill
Serial Number 2920025-47
JKS BOYLES INTERNATIONAL
A Division of Atlas Copco Canada Inc.
P.O. Box #197
640 Mckeown Ave.
North Bay, Ontario, P1B 8H2
Tel: (705) 472-3320 Fax: (705) 472-6843
Doc. 2920025-47-5 Rev. 2
Printing Date: 06/21/00
B-2
Contents
Foreword ............................................................................................................................. B-7
General Information.............................................................................................................................. B-7
How to Order ..................................................................................................................................... B-7
Terms and Conditions ........................................................................................................................... B-8
Terms ................................................................................................................................................. B-8
General Information.............................................................................................................................. B-8
Standard Terms Of Sale ....................................................................................................................... B-9
Conditions Of Sale ............................................................................................................................ B-9
Maintenance ...................................................................................................................... B-11
OIL AND GREASE LUBRICATION ............................................................................................... B-11
Lubrication Instructions ................................................................................................................... B-11
Lubricant Specifications .................................................................................................................. B-11
HYDRAULIC OIL .......................................................................................................................... B-13
Checking of Hydraulic Fluid Level ................................................................................................. B-14
Hydraulic Filters .................................................................................................................................. B-14
Pressure Filters: ............................................................................................................................... B-14
Main Return Filter: .......................................................................................................................... B-14
Breather on Tank ............................................................................................................................. B-14
Lube Oil Filter on Drillhead ............................................................................................................ B-14
Manufacturers Part Numbers for Filter Elements .......................................................................... B-15
Hydraulic Pumps ................................................................................................................................. B-15
Three Year Warranty on Hydraulic Pumps ..................................................................................... B-16
Warranty Conditions........................................................................................................................ B-16
Recommended Hydraulic System Maintenance ............................................................................... B-16
Hydraulic Oil Analysis Service........................................................................................................... B-17
Electric Motor Specifications .......................................................................................... B-21
Motor Starter ....................................................................................................................................... B-23
Pump Maintenance (PVWH) ........................................................................................... B-27
Purpose of Instructions ....................................................................................................................... B-27
Preparation and Installation .............................................................................................................. B-27
A. Mounting .................................................................................................................................... B-27
B. Piping and Fittings ...................................................................................................................... B-27
C. Power .......................................................................................................................................... B-28
D. Drive ........................................................................................................................................... B-28
E. Filtration ...................................................................................................................................... B-28
F. Fluid Cooling ............................................................................................................................... B-29
G. Air Breather ................................................................................................................................ B-29
H. Fluid Filling and Starting Recommendations ............................................................................. B-29
Construction .................................................................................................................................... B-30
Malfunctions and Causes .................................................................................................................... B-30
A. Unresponsive or Sluggish Control .............................................................................................. B-30
B. Insufficient Pump Volume .......................................................................................................... B-31
C. Irregular or Unsteady Operation ................................................................................................. B-31
Doc. 2920025-47-5 Rev. 2
B-3
D. Loss of Pressure .......................................................................................................................... B-31
E. Excessive or High Peak Pressure ................................................................................................ B-31
F. Excessive Noise ........................................................................................................................... B-31
G. Excessive Heating ....................................................................................................................... B-31
Principle of Operation ......................................................................................................................... B-32
Specifications ........................................................................................................................................ B-34
Testing and Adjusting ......................................................................................................................... B-34
A. Piston Pump ................................................................................................................................ B-34
B. Control ........................................................................................................................................ B-35
Disassembly .......................................................................................................................................... B-35
A. General ........................................................................................................................................ B-35
B. Preparation .................................................................................................................................. B-35
C. Control Group ............................................................................................................................. B-35
D. Valve Plate Group ....................................................................................................................... B-36
E. Rotating Group ............................................................................................................................ B-36
F. Driveshaft Group ......................................................................................................................... B-36
G. Swashbock Group ....................................................................................................................... B-37
Inspection ............................................................................................................................................. B-37
A. Control Group ............................................................................................................................. B-37
B. Valve Plate Group ....................................................................................................................... B-37
C. Rotating Group ........................................................................................................................... B-37
D. Swashblock Group ...................................................................................................................... B-38
E. Driveshaft Group ......................................................................................................................... B-38
Assembly ............................................................................................................................................... B-38
A. Swashblock Group ...................................................................................................................... B-38
B. Driveshaft Group ........................................................................................................................ B-39
E. Control Group ............................................................................................................................. B-40
After Sales Service ............................................................................................................................... B-45
STAY-ON-STREAM SERVICE ................................................................................................. B-45
SERVICE SCHOOLS ..................................................................................................................... B-45
SPARE PARTS AVAILABILITY .................................................................................................. B-45
Oilgear Exchange Service ............................................................................................................... B-45
Pump Maintenance (PVG) ............................................................................................... B-47
Purpose of Instructions ....................................................................................................................... B-47
Preparation and Installation .............................................................................................................. B-47
A. Mounting .................................................................................................................................... B-47
B. Piping and Fittings ...................................................................................................................... B-47
C. Power .......................................................................................................................................... B-48
D. Drive ........................................................................................................................................... B-48
E. Filtration ...................................................................................................................................... B-48
F. Fluid Cooling ............................................................................................................................... B-48
G. Air Breather ................................................................................................................................ B-49
H. Fluid, Filling and Starting Recommendations ............................................................................ B-49
Construction ......................................................................................................................................... B-49
Specifications ........................................................................................................................................ B-50
Doc. 2920025-47-5 Rev. 2
B-4
Malfunctions and Causes .................................................................................................................... B-50
A. Unresponsive or Sluggish Control .............................................................................................. B-50
B. Insufficient Pump Volume ......................................................................................................... B-51
C. Irregular or Unsteady Operation ................................................................................................. B-51
D. Loss of Pressure .......................................................................................................................... B-51
E. Excessive or High Peak Pressure ................................................................................................ B-51
F. Excessive Noise ........................................................................................................................... B-51
G. Excessive Heat ............................................................................................................................ B-51
Principle of Operation ......................................................................................................................... B-51
Testing and Adjusting ......................................................................................................................... B-54
A. Piston Pump ................................................................................................................................ B-54
Disassembly .......................................................................................................................................... B-54
A. Preparation .................................................................................................................................. B-54
B. Control Group ............................................................................................................................ B-55
C. Valve Plate Group ....................................................................................................................... B-55
D. Rotating Group ........................................................................................................................... B-55
E. Driveshaft Group ......................................................................................................................... B-56
F. Swashblock Group ...................................................................................................................... B-56
Inspection ............................................................................................................................................. B-56
A. Control Group ............................................................................................................................. B-56
B. Valve Plate Group ....................................................................................................................... B-56
D. Swashblock Group ...................................................................................................................... B-57
Assembly ............................................................................................................................................... B-57
A. Swashblock Group ...................................................................................................................... B-57
B. Driveshaft Group ........................................................................................................................ B-57
E. Control Group ............................................................................................................................. B-58
Parts List .............................................................................................................................................. B-59
High Speed Motor ............................................................................................................. B-65
Introduction ......................................................................................................................................... B-65
Ordering of Parts ................................................................................................................................. B-65
ORDERING EXAMPLE ................................................................................................................. B-66
Technical Data ..................................................................................................................................... B-66
Fluid Recommendations .................................................................................................................. B-66
Operating Viscosity Range .............................................................................................................. B-66
Viscosity Limits ............................................................................................................................... B-66
Operating Temperature Range ......................................................................................................... B-66
Built-On Flushing Valve ................................................................................................................. B-67
Installation Position ......................................................................................................................... B-68
Fluid Cleanliness Levels .................................................................................................................. B-68
Filtration ............................................................................................................................................... B-68
Direction of Flow............................................................................................................................. B-68
Operating Pressure Range ............................................................................................................... B-68
Speed Range .................................................................................................................................... B-69
Case drain pressure .......................................................................................................................... B-69
Table of Values ................................................................................................................................ B-70
Doc. 2920025-47-5 Rev. 2
B-5
Output Drive .................................................................................................................................... B-71
Speed, Displacement, Pressure, Torque .......................................................................................... B-72
Speed Sensor (D) ............................................................................................................................. B-72
Hydraulic Control ............................................................................................................................... B-73
HD Pilot Pressure Related ............................................................................................................... B-73
Variation: Constant Pressure Control (D) ....................................................................................... B-74
Hydraulic Two-Position Control ..................................................................................................... B-75
Electrical Two-Position Control EZ with Switching Solenoid ....................................................... B-76
Electrical Control EP with Proportional Solenoid ........................................................................... B-76
Variation: Constant Pressure Control (D) ....................................................................................... B-77
Automatic Control High Pressure Related ...................................................................................... B-78
Variation: ......................................................................................................................................... B-79
Pressure Override ................................................................................................................................ B-79
Control Description ......................................................................................................................... B-79
Adjustment Procedure ..................................................................................................................... B-79
Installation ............................................................................................................................................ B-80
Motor Flushing .................................................................................................................................... B-81
Filtration .......................................................................................................................................... B-81
Pre-Start Procedure............................................................................................................................. B-82
Start-Up Procedure ............................................................................................................................. B-82
Begin of Stroke Adjustment, Gauge Method .................................................................................... B-87
Preparation for Adjustment ............................................................................................................. B-87
Adjustment Procedure for the HD Control ...................................................................................... B-88
Adjustment Procedure for the HA Control ...................................................................................... B-88
Adjustment Procedure for the EP Control ....................................................................................... B-89
Swivel Angle (Speed) Adjustment ...................................................................................................... B-89
Shaft Seal Replacement ....................................................................................................................... B-92
Routine Maintenance .......................................................................................................................... B-93
Renewal of Filter Elements ............................................................................................................. B-93
Hydraulic Fluid Change................................................................................................................... B-93
Leakage Inspection .......................................................................................................................... B-94
Cleanliness Inspection ..................................................................................................................... B-94
Fluid Level Inspection ..................................................................................................................... B-94
Hydraulic Fluids .................................................................................................................................. B-94
Port Information .................................................................................................................................. B-95
Chuck Assembly Drawing................................................................................................ B-97
Rod Clamp Assembly Drawing ....................................................................................... B-98
Electrical Schematic ......................................................................................................... B-99
Hydraulic Schematic ...................................................................................................... B-102
Block Schematic .............................................................................................................. B-104
Doc. 2920025-47-5 Rev. 2
B-6
Foreword
(Reference: Plate 1797a)
Thank you for choosing JKS Boyles Equipment.
For your convenience, the manual is divided into sections for quick reference. Please familiarize yourself
with the detailed index, which will assist you in locating any particular item you may wish to find.
JKS Boyles, playing its role as leading supplier to the diamond drilling industry, has pioneered development
of new equipment since 1895. This experienced organization is your assurance of quality products with
reliable service. The quality of JKS Boyles equipment can meet and solve the challenges of todays worldwide exploration drilling markets.
JKS Boyles is actively engaged in metallurgical research, engineering design, and improved manufacturing
techniques geared toward developing and field testing new ideas and products for the future...all to help you
reduce your drilling costs. Drilling equipment, specifically designed for the mining and construction industry, is our business.
For all your drilling requirements, call your nearest JKS Boyles sales representative.
General Information
Your own purchase order is satisfactory.
How to Order
Please list: quantity, part number, description, prices, shipping address and preferred routing.
When ordering MAJOR ASSEMBLIES
Please furnish complete description on power unit, sprocket ratios, swivelhead, chuck jaws and other standard optional equipment desired.
PUMPS - Please furnish complete description on power unit, sprocket - state size, liners - state bore, specify
whether transmission, chain or belt drive with or without gear reduction.
Where To Send Order
Mail or fax orders to any of the Sales/Service locations listed in this catalogue, or to:
P.O. Box #197
640 Mckeown Ave.
North Bay, Ontario, P1B 8H2
Tel: (705) 472-3320
Fax: (705) 472-6843
Doc. 2920025-47-5 Rev. 2
B-7
Terms and Conditions
Ter ms
DOMESTIC - Net 30 days on approved credit.
EXPORT - Confirmed irrevocable letter of credit.
DELIVERY
Most items are available from stock and you will receive a confirmed order acknowledgement specifying
shipment date. Shipments will be routed by the most direct means of transportation unless otherwise specified and your order should indicate if partial orders are acceptable.
RETURN OF MATERIAL
No goods should be returned without written permission from JKS BOYLES. Goods returned are subject to
15% restocking charges and special equipment is not returnable.
General Information
Prices and specifications listed are subject to change at any time without notice.
All prices are f.o.b. factory.
Federal and provincial taxes where applicable are not included.
Export bowing charges are 4% of list price.
Doc. 2920025-47-5 Rev. 2
B-8
Standard Terms Of Sale
The following pages outlines JKS BOYLES standard terms of sale for their equipment.
Conditions Of Sale
All sales by JKS Boyles International Inc., of products offered and sold by them shall be subject to the following conditions which shall be deemed incorporated into all orders and offers to purchase submitted to JKS
Boyles International Inc., for acceptance and into all their acceptances and contracts of sale.
1. Disclaimer of Liability for Consequential Damage
JKS Boyles International Inc., shall not be liable in any event for any loss of income, goodwill, increased
costs or any special, indirect, incidental or consequential damages arising out of or in connection with this
sale.
2. Warranties
There are no warranties Express or implied made by JKS Boyles International Inc., except for their following
standard warranty; JKS Boyles International Inc., warrants new and unused core drilling machines and
accessory equipment of our own manufacture against defects in material and workmanship caused by normal
use and service, for a period of 90 days from date of original use, but not to exceed 6 months from the date
of shipment from our premises. The obligation under this warranty is limited to the replacement or repair of
such parts deemed by us to have been defective at the time of sale. Any alterations or changes to the product
design by the customer invalidates any warranty claims. We reserve the right to inspect any defective part
claims. Before such parts are returned to our premises, our written approval must be obtained and the parts
then returned at the customers expense. Product not manufactured by us are subject to the original manufacturers warranty only.
3. Diamond Recovery From Used Diamond Set Products
As a service to their customers and to facilitate the rotation of diamonds, JKS Boyles International Inc., will
accept usable stones recovered from used items as a credit only against subsequent orders for new items in
the same product line. Where the value of diamonds set in the new items ordered does not equal the value of
diamonds recovered from used items, JKS Boyles International Inc., will hold any excess of usable diamonds
in safekeeping for their customers and subject to their customers orders.
JKS Boyles International Inc., do not obligate themselves at any time to purchase or take back new or used
diamonds for credit.
This credit has been issued for use as detailed in our Conditions of Sale. The amount noted may not be
applied against the purchase of any non-diamond or diamond impregnated product. Nor may it be used
against setting charges associated with surface set products, or as a cash valuation.
4. Prices
Prices apply to quantities and specifications requested by the buyer or as outlined in price lists published by
JKS Boyles International Inc.
JKS Boyles International Inc., reserves the right to change their prices without notice.
Prices on written quotations will remain firm within the validity period specified in each quotation.
Doc. 2920025-47-5 Rev. 2
B-9
5. Delivery
JKS Boyles industries Inc., shall not be liable for any delay in manufacturing or delivering any of the products, if such delay shall be due to one or more of the following causes:
fire; destruction of premises; strike; lockout; acts of God; accident; delay in transportation war (whether
declared or undeclared); riot; insurrection; blockade; embargo; acts; demands; or requirements of Canada or
the country in which or through which delivery is to be made; or of any province, state or territory thereof or
of any governmental subdivision thereof; decrees or restraining orders of any court or judge; or any other
cause whether similar or dissimilar to those herein before enumerated, beyond the reasonable control of JKS
Boyles International Inc.
6. Terms of Payment
Standard terms are net 30 days from date of invoice unless otherwise stated. Products are sold F.O.B. JKS
Boyles International Inc., premises unless otherwise stated. JKS Boyles International Inc., reserve the right
to apply finance charges to overdue accounts at 2 % above the prime rate charged by the chartered banks in
Canada.
7. Title and Risk of Loss
Full risk of loss (including transportation delays and losses) shall pass to the buyer upon delivery of products
there under to the F.O.B. point. However, JKS Boyles International Inc., retain title, for security purposes
only to all products until payment in full is received.
8. Taxes
Any sales, use, or similar taxes imposed on this sale or on the transaction are not included in the price. Such
taxes shall be shown separately on applicable invoices and paid for by the buyer. If applicable, JKS Boyles
International Inc., will accept a valid exemption certificate from the buyer, however, if an exemption certificate previously accepted is not recognized by the government taxing authority, and JKS Boyles International
Inc., is required to pay the taxes covered by such exemption certificate, buyer agrees to promptly reimburse
JKS Boyles International Inc., for the taxes paid on the buyers behalf.
9. Claims by Buyer
Claims for any shortages or product quality made by the buyer against JKS Boyles International Inc., shall be
made in writing to JKS Boyles International Inc., within ten (10) days after receipt of the shipment. Claims
covered under warranty will be reported as outlined in paragraph 2.
10. Return of Saleable Product
No product may be returned to JKS Boyles International Inc., without their prior authorization. Product
authorized for return must be shipped PREPAID and will be subject to a restocking charge.
Setting charges on unused products are non-refundable.
11. Cancellation of Orders
After an order has been accepted, no cancellation by the buyer shall be binding on JKS Boyles International
Inc., without their prior within consent and subject to such conditions as will indemnity of JKS Boyles
International Inc., against loss for commitments made and in process and completed custom work.
Doc. 2920025-47-5 Rev. 2
B-10
Maintenance
(Reference Plate 2047)
(B20 Underground Drill)
OIL AND GREASE LUBRICATION
Lubrication Instructions
See Table 3.1 for lubrication points and servicing frequencies.
Lubricant Specifications
The following specifications apply to the lubricants:
I. GEAR CASE OIL
The drillhead and pump drive oil must meet the following specification:
Automotive Gear Oil
Grade 80W90 Viscosity Grade
Meets API GL4 or GL5
It is recommended the gearcase oil be a recognized brand name from an international oil company, such as
ESSO (EXXON in USA), SHELL, TEXACO, BP etc.. This will ensure consistent quality.
The drills are shipped from the factory filled with Esso GX 80W90. Check with your supplier that the oil
you use is equivalent to this oil. Consult with the factory if there is any doubt about the suitability of gear
case oils available locally.
II. BEARING GREASE
The bearing grease must meet the following specifications:
High quality grade Lithium soap base containing Molybdenum Disulphide penetration meeting NGLI #2
It is recommended the bearing grease be a recognized brand name from an internationally known oil company, such as ESSO (EXXON in the USA) SHELL, TEXACO, BP etc.. This will ensure consistent quality.
The drills are shipped from the factory greased with ESSO Lonax Moly. Check with your supplier that the
grease you use is equivalent to this grease.
CHECKING OIL LEVEL IN FMC W1122BCD MUD PUMP
The mud pump requires 4 quarts of SAE 30 (non-detergent) oil in the crankcase. The level should be
checked weekly and the oil should be changed every 6 months. Another area of the pump requiring lubrication is the 3 fittings on the plunger oil seal holders. These fittings should be greased twice a year.
CAUTION: Do not over grease fittings to the plunger oil seal holders or damage could occur to oil seal and
holders.
Doc. 2920025-47-5 Rev. 2
B-11
To check the oil level, remove the petcock on the end of the pump. The oil level should be even with the
petcock opening. If not, add oil until it reaches that level. Filling oil past this point will damage seals.
To change oil, remove the magnetic drain plug. Examine the used oil. Should the oil have a milky appearance, water is leaking past the plunger rod seals in the pump. The plunger rod seals should be checked and
replaced if necessary. After draining all oil, clean and replace the drain plug and add oil through the oil fill
opening.
PRESSURE FILTERS
The pressure filters are located in the outlet line of each of the three pumps. The filters have high collapse
elements (3000 psi collapse pressure) with no bypass. When the pressure drop across the element reaches 72
psi, a differential pressure switch will cause the diode light on the filter switch electrical connection to go off.
CHECKING OIL LEVEL IN DRILL HEAD AND PUMP DRIVE OIL
The initial fill should be changed after 150 hours. Thereafter follow changing frequency in Table 3.1, or
whenever the oil level shows traces of dirt, water contamination or the effects of high temperature, evidenced
by discoloration or strong odour. Oil should be drained while the unit is still warm and the used oil examined for contamination or metal particles. After draining the oil, clean the magnetic drain plug before replacing.
Checking oil level in Drillhead Housing (for models built after November 1989). There is one oil level
plug (item 60) for uphole, downhole and angle drilling.
NOTE:
Make sure breather plug on cover is switched with oil filler plug for uphole and downhole drilling.
The drill must be set up in drilling position before checking the oil level as the volume of oil required varies
for up-hole, down-hole and angle drilling.
DRILL COMPONENT
LUBRICANT
OIL LEVEL CHECK
FREQUENCY
OIL CHANGE
FREQUENCY
GREAS ING
FREQUENCY
1. POWER PACK
Pu mp Drive Gear Bo x
(Where Ap p licab le)
Electric mo to r Bearings
Gear Case Oil
Weekly
6 Mo nths
-
Bearing Grease
-
-
Yearly
2. DRILL UNIT
Drill Head Gearb o x
C hu c k
Fo o t Clamp
Drill Head Carriage Ro llers
Feed Frame Pivo t Po ints
Gear Case Oil
Bearing Grease
Bearing Grease
Bearing Grease
Bearing Grease
Weakly
-
1000 Ho u rs
-
Every Shift
Every Shift
Every Shift
Weekly
3. WATER PUMP
FMC W1122BCD
G ear C as e
Plu nger Oil Seal Ho lders
Sea 30 Oil
Bearing Grease
Weekly
-
6 Mo nths
-
Twice Yearly
4. WIRELINE HOIST
Levelwind Screw
Chain Drive
Bearing Grease
Sea 30 Oil
-
-
Every Week
Every Week
Doc. 2920025-47-5 Rev. 2
B-12
HYDRAULIC OIL
Hydraulic Oil (Petroleum Based Fluid)
The hydraulic fluid must be a high-grade petroleum based fluid meeting the Denison HF-0 standard. The
viscosity range recommended for underground operation is ISO VG 46. The list of acceptable fluids is
shown below. Consult factory for other fluid suppliers.
APPROVED S UPPLIER
FLUID
AMOCO
RY K ON 46
RY K ON MV 46
AW 4 6
CASTROL
AWS-AD 46
CHEVRON
AW 4 6
EXXON
N UT O 4 6
UNIVIS 46
PETRO CANADA
HARMONY AW 46
SHELL
TELLUS 46
TEXACO
RANDO HD 46
The table below give the operating temperature ranges for ISO VG 46 hydraulic fluid
IS O VIS COS ITY GRADE (OR FLUID)
IS O VG 46
MINIMUM COLD START TEMPERATURE
25 DEG F
MINIMUM FULL POWER TEMPERATURE
75
OPTIMUM RUN TEMPERATURE
120
MAXIMUM RUN TEMPERATURE
170
Please contact the factory with any questions on fluids as we can verify HF-O approval and if given start-up,
running and ambient temperatures, can assist in selecting the proper viscosity.
Automatic transmission fluids (ATF) are not HF-O approved and must not be used in JKS Boyles hydraulic
systems. Drill performance and component life will not be satisfactory when using these ATF fluids. Use of
these ATF fluids voids the JKS Boyles warranty.
NOTE:
1)
2)
3)
4)
Extreme care should be taken when adding or changing hydraulic oils so as not to contaminate the
system. Only add fluid to the tank with the fill pump provided on the drill. The experience of hydraulic
system designers and maintenance supervisors has shown that about 75% of the downtime on hydraulically operated machinery is caused by dirt in the hydraulic fluid.
Check the hydraulic oil level daily prior to starting the unit. If the oil level is low, add approved hydraulic oil as required
Adjust cooling water flow (or cooler bypass ball valve on air cooled units) to obtain optimum operating
temperature
Particular care should be taken when disconnecting and reconnecting the quick disconnects on the
hydraulic system. The plastic caps and plugs provided must be used. If dirt has entered the quick
Doc. 2920025-47-5 Rev. 2
B-13
5)
disconnect, it must be carefully cleaned. Always ensure that any plastic and the quick disconnects that
are lost are promptly replaced.
Every 12 months, or when oil analysis indicates (whichever comes sooner), the hydraulic oil should be
changed. At that time it is recommended that the tank also be cleaned.
Checking of Hydraulic Fluid Level
Check the hydraulic oil level daily prior to starting the unit. If the oil level is low, add approved hydraulic
oil as required.
Hydraulic Filters
The drill is equipped with the following filters:
Ø
Pressure Filters at the outlet of each the three hydraulic pumps.
Ø
Main return filter with dirt and water removal elements
Ø
Breather on Tank
Ø
Lube Oil Filter on Drillhead
Pressure Filters:
The pressure filters are located in the outlet line of each of the three pumps. The filters have high collapse
elements (3000 psi collapse pressure) with no bypass. When the pressure drop across the element reaches 72
psi, a differential pressure switch will cause the diode light on the filter switch electrical connection will go
off. At the same time, on computer controlled drills, a message will come up on the screen and on the conventional B20 drills, a red light will come on the electrical panel. At that time, the filter elements should be
changed. If the elements are not changed, the increasing pressure drop will lead to loss of performance of the
drill. It is recommended that the filter elements be changed a minimum of every 6 months to prevent unnecessary pressure drop through the filters and hence power loss.
Main Retur n Filter :
The main return filter filters all of the oil returning to the tank except for the case drain lines. It has three
elements. Two are dirt-holding elements and the third one is a water removal element. The oil flows through
the three elements in parallel. When the water removal element becomes plugged, more oil will flow through
the dirt removal elements. When the pressure drop across the filter reaches 27 psi, a differential pressure
switch will cause the diode light on the filter switch electrical connection to go off. At the same time, on
computer controlled drills, a message will come up on the screen and on the conventional B20 drills, a red
light will come on the electrical panel. At that time, the filter elements should be changed immediately since
the filter will start bypassing at a pressure drop of 30 psi across the filter. It is recommended that the filter
elements be changed a minimum of every 6 months to keep flow going through all three elements.
If conditions such as varying ambient temperatures and the presence of humidity, can cause condensation,
the water should be drained out of the tank daily and the filters changed more frequently to prevent the water
removal element from clogging.
Breather on Tank
The tank breather prevents dirt from entering the hydraulic tank. It should be changed every 6 months or
more often in dusty conditions.
Lube Oil Filter on Drillhead
The lube oil filter is located on the suction side of the lube oil pump. It should be changed every 1000 hours
or 2 months.. If the lubrication oil is dirty or discoloured, the filter should be changed more often.
Doc. 2920025-47-5 Rev. 2
B-14
The filter element change frequencies are summarised in the table below
FILTER
ELEMENT PART NUMBER
CHANGE
FREQUENCY
Main Pu mp Pressu re Filter Element
(Cartridge Ty p e)
5204295
By Indicato r o r a Minimu m o f
Every 6 Mo nths
Au xiliary Pu mp #1
(Feed, Chu ck, Clamp )
5204297
Every 6 Mo nths
Au xiliary Pu mp #2
(Water Pu mp )
5204295
Every 6 Mo nths
Main Retu rn Filter
5204208 (Qty 2)
5204207 (Qty 1)
Every 6 Mo nths
Mo re Often if Water is
Co ndensing in the Tank
Tank Breather Filter
(Sp in-On Ty p e)
5204209
A Minimu m o f Every 6 Mo nths
Mo re Often in Du sty
Co nditio ns
Drillhead Lu b e Oil Filter
(Sp in-On Ty p e)
5203074
Every 1000 Ho u rs o r a Minimu m
o f Every Two Mo nths
Mo re Often if Lu b e Oil
is Dirty o r Disco lo u red
COMMENTS
Manufacturers Par t Numbers for Filter Elements
The filter elements have been carefully chosen to give suitable combinations of flow capacities, dirt removal
efficiencies and economy of purchase. It is important that the customer does not use substitute filters since
this can cause malfunction of the hydraulic system There are cases where customer substitution of element
with unsuitable specifications has led directly to hydraulic pump failure. In order to help prevent customer
substitution of filter elements, the manufacturers part number for the filter elements are given in manual
description of the element part number as well as in the table below.
FILTER
FILTER ELEMENT
RATING
JKS BOYLES
PART NUMBER
MANUFACTURE'S
PART NUMBER
Main Pu mp Pressu re Filter Element (Cartridge Ty p e)
Beta 10 = 100
5204295
Hy dac
0280D010B H 3H C
Au xiliary Pu mp #1
(Feed, Chu ck, Clamp )
Beta 10 = 1000
5204297
Hy dac
0240D 0053H 3H C
Au xiliary Pu mp #2
(Water Pu mp )
Beta 10 = 100
5204295
Hy dac
0280D010B H 3H C
Main Retu rn Filter
Beta 10 = 100
N /A
5204208 (Qty 2)
5204207 (Qty 1)
Schro eder K S7
Schro eder K W
Tank Breather Filter (Sp in-On Ty p e)
3 Micro n No minal
5204209
Schro eder ABF3/10
Drillhead Lu b e Oil Filter (Sp in-On Ty p e)
N /A
5203074
Vickers 573-082
Hydraulic Pumps
Servicing Instructions for the hydraulic pumps are attached. The following types of pumps are used:
Main Pump:
# 1 Auxiliary Pump (Feed, Chuck, Clamp):
#2 Auxiliary Pump (Water Pump):
PVG100 (Load sense control axial piston type)
PVWH15 (CN -pressure compensated control axial piston
type)
PVWH34 ( CF -load sense control axial piston type)
Full-bore valves are provided for ease of servicing the pumps. Use of these valves avoids the need for draining the reservoir when servicing the pumps.
Doc. 2920025-47-5 Rev. 2
B-15
CAUTION
Be sure the valves in the suction lines are locked in the open position when operating the pumps. Failure to
do so will damage the pump.
Three Year Warranty on Hydraulic Pumps
The Oilgear company has made available to JKS Boyles and its customers, a three year warranty against
defects in material and workmanship on the hydraulic pumps used in this drill. A copy of the warranty is
attached.
This warranty is available on this drill because the it is equipped with a pressure filtration, water removal
elements, and other hydraulic circuit features and performance specifications recommended by the Oilgear
company for application of its hydraulic pumps.
.
War ranty Conditions
The warranty period is for a period of three years after shipment of the pumps from the factory. After receiving the drill, the customer is supplied with a letter stating the serial numbers of the pumps and the date the
pumps were shipped from the factory. The attached Oilgear warranty gives the conditions of the warranty.
The warranty conditions that relate to operation and maintenance are summarized as follows:
1.
2.
3.
4.
The hydraulic fluid must be on the list of approved fluids contained in the section on hydraulic fluids.
If the hydraulic oil that the customer wishes to use is not on the approved list, JKS Boyles must specifically approve the fluid.
The hydraulic fluid must be maintained at cleanliness level of ISO 20/18/15 or better.
The maximum allowable water content is 0.1%
No changes can be made to the factory pressure settings, components, or plumbing in the hydraulic
system.
Recommended Hydraulic System Maintenance
In order to ensure that the required cleanliness level is achieved and maintained, it is strongly recommended
that the customer perform the following maintenance and monitoring steps on the hydraulic system:
1.
2.
3.
4.
5.
Perform periodic checks on oil cleanliness using a recognized oil analysis service. This should be done
after the first month of operation and every 6 months thereafter. (See below for availability of this
service)
Change filters according to the schedule in the manual or as indicated by the electric switches located
on all of the filters, whichever is earlier. Use only the filter elements that are called up in Table 3.3.
They are available from JKS Boyles or can be purchased directly from the filter manufacturer using the
part numbers shown in the table.
Change the hydraulic oil at the frequencies recommended in the section on hydraulic oil. When changing the oil, also clean out the hydraulic tank.
Log the oil analysis results, filter changes, and purchase records of filter elements. This information
may be required in event of a warranty claim.
Once a year, have the complete drill, including the hydraulic system, checked out by a JKS Boyles
factory trained technician.
By following the above maintenance procedures, the customer will ensure that the machine is in top operating condition and prevent unnecessary down time due to oil or water contamination.
Doc. 2920025-47-5 Rev. 2
B-16
Hydraulic Oil Analysis Ser vice.
In Canada, oil analysis service available from:
Hydac Corporation
14 Federal Road
Welland Ontario
L3B 3P2
Telephone: 905-714-9322
Fax: 905-714-4664
The sample bottles are also available from JKS Boyles under part 5204170.
In the United States, customers can also send the Hydac sample bottle to Welland, Ontario, Canada for
Analysis.
Alternatively, a hydraulic oil analysis service is available from Vickers, using sample bottle Vickers Part #
894277. This kit is available from any Vickers Hydraulics dealer.
Doc. 2920025-47-5 Rev. 2
B-17
Doc. 2920025-47-5 Rev. 2
B-18
Doc. 2920025-47-5 Rev. 2
B-19
Doc. 2920025-47-5 Rev. 2
B-20
Electric Motor Specifications
Doc. 2920025-47-5 Rev. 2
B-21
Doc. 2920025-47-5 Rev. 2
B-22
Motor Starter
Doc. 2920025-47-5 Rev. 2
B-23
Doc. 2920025-47-5 Rev. 2
B-24
Doc. 2920025-47-5 Rev. 2
B-25
Doc. 2920025-47-5 Rev. 2
B-26
SERVICE INSTRUCTIONS
OILGEAR TYPE PVWH PUMPS
Pump Maintenance (PVWH)
(Reverence: Plate 1783)
Purpose of Instructions
These instructions are written to simplify your work when installing, operating and maintaining these Oilgear
pumps. Your acquaintance with the construction, principle of operation and characteristics of these units will
help you attain satisfactory performance, reduce down-time and increase the units life. Some units have been
modified from those described in this bulletin and other changes may be made without notice.
Figure 1738.1 - Typical Oilgear PVHW Open Loop Pump
Preparation and Installation
A. Mounting
PUMP WITHOUT RESERVOIR:
The pump may be mounted in any position. But, for convenience recommended mounting position is with
the driveshaft axis on a horizontal plane and with case drain Port 1 to the top side. Secure the unit to a
rigid mounting surface. See section B on Pipe and Fittings.
PUMP WITH RESERVOIR:
These units are usually fully piped and equipped, although it may be necessary to connect to supercharge
circuit when used. Mount reservoir on level foundation with reservoir bottom at least six (6) inches above
floor level to facilitate fluid changes.
B. Piping and Fittings
See reference Piping Information bulletin and individual circuit diagram before connecting pump to system.
For PVWH and PVW Pumps using 150-300 SSU VISCOSITY FLUIDS, an inlet strainer is not required.
Inlet should be unrestricted and have a minimum of fittings. See reference Specification Bulletin for
minimum inlet psia requirements at selected input rpm. If suction line is used, it should reach within 1 to 2
Doc. 2920025-47-5 Rev. 2
B-27
times its diameter from the bottom of reservoir - do not bottom-out tubes in reservoir.
Arrange case drain line so case remains full of fluid (non-siphoning) at less than 25 psi (1,7 bar) and case
pressure must not be 10 psi (0,7 bar) greater than inlet pressure. Each drain line must be separate, unrestricted, full sized and connected directly to the reservoir below the lowest fluid level. Drain tubing should
not incorporate a suction break. Provisions for opening this line without draining (siphoning) reservoir
should be made.
WARNING:
Running pump in Neutral position (zero delivery) for long periods of time without supercharge (or a case
bleed thru circuit) can damage the pump.
System and pump must be protected against over-loads by separate high pressure relief valves. Install bleed
valve(s) at highest point(s) in system. Consult The Oilgear Company for other recommendations.
C. Power
Power is required in proportion to volume and pressure used. Motor size recommendations for specific
applications can be obtained from The Oilgear Company. Standard low starting torque motors are suitable
for most applications.
CAUTION:
Never start or stop unit under load unless system is approved by The Oilgear Company. It may be
necessary to provide delivery bypass in some circuits.
D. Drive
See rotation direction plate on units housing. Units are available for left hand (CCW) or right hand (CW)
rotation but are not reversible. Use direct drive. Size and install coupling per manufacturers instructions.
CAUTION:
Do not drive coupling onto pump driveshaft. If fit is too tight, it may be necessary to heat coupling
(see manufacturers instructions).
Misalignment of pump shaft to driveshaft should not exceed 0.005 (0, 13 mm) Total Indicator Read-out
(TIR) in any plane.
E. Filtration
To assure long life from your hydraulic system, keep fluid clean at all times. See reference bulletins on
Filtration Recommendations and Contamination Evaluation. Oilgear recommends the use of a filter in
an auxiliary (pilot) pump circuit. Replace filter element(s) when filter condition indicator reaches change
area at normal fluid temperature. Drain and thoroughly clean filter case.
For 150-300 SSU Viscosity Fluid, use of ten micron filtration (Beta 10 of four or better) in pressure or
return line is recommended.
For 27-30 SSU Viscosity Fluid, use of ten micron filtration (Beta 10 of fifteen or better) in pressure or
return line is recommended. Continuous filtration is required.
Doc. 2920025-47-5 Rev. 2
B-28
F. Fluid Cooling
When pump is operating continuously at rated pressure or frequently at peak load, auxiliary cooling of fluid
may be necessary. Fluid temperature should not exceed limits specified in referenced bulletin on Fluid
Recommendations.
G. Air Breather
On most installations, an oil bath type air breather is mounted on top of fluid reservoir. It is important for the
breather to be of adequate size to allow air flow in and out of reservoir as fluid level changes. Keep breather
case filled to the fluid level mark. About once every six months, remove cover, wash screens in solvent,
clean and refill case to fluid level mark and install dry screen. See manufactures recommendations.
H. Fluid Filling and Starting Recommendations
PVWH and PVW Pumps use 150-300 SSU Viscosity Fluids, meeting or exceeding lubricating specifications of SAE IOW API Engine Service Classifications - SC, CC or SE (or ISOVG32 thru 68) is recommended, viscosity range 150-300 SSU at 100oF (37,7oC). For fire resistant fluids, phosphate ester hydraulic
fluids can be used in accordance with manufacturers recommendations.
Refer to instruction plate on unit, reservoir, machine and/or referenced Fluid Recommendations bulletin.
Pump all fluid into reservoir thorough a clean (see Section E for Beta ratings) filter. Fill reservoir to, but not
above, high level mark on sight gage with hydraulic fluid. Remove case drain line at the pump and fill
pump case with hydraulic fluid.
Turn driveshaft a few times by hand with a spanner wrench to be sure parts are free.
TORQUE TO TURN SHAFT
SIZE UNIT
11, 15, 20
APPROXIMATE TORQUE TO TURN SHAFT
foot pounds
N.m.
2.9 - 3.3
4,0 - 4,5
Figure 1738.1 - Torques to Turn Shaft.
With the pump under no load, or with pump control at neutral turn drive unit on and off several times before allowing pump
to attain full speed. The system can usually be filled by running the pump and operating the control. Watch the fluid level in the
reservoir and stop pump if the level reaches low level mark.
Add fluid and start again. With different (cylinder) systems fluid must not be above high level when ram is retracted or below
low level when extended. Bleed air from the system by opening air bleed petcocks at highest point in the system. Close
connections or petcocks tightly when solid stream of fluid appears.
Doc. 2920025-47-5 Rev. 2
B-29
Figure 1783.2 - Cross Section of Typical PVWH Pump From Right Side
Construction
Refer to Figures 2, 10 and 11. A driveshaft runs throng the centre line of pump housing (5), saddle block (8)
and valve plate (22). Pump cylinder barrel (18) is splined to driveshaft. A bearing (3) supports the outboard
end of the driveshaft and a bushing integral with the valve plate supports the inboard end. The pump cylinder barrel is carried in a journal type hydrodynamic cylinder bearing (12). The valve plate (22) has two
crescent shaped ports. Pumping piston/shoe assemblies (15) in the cylinder barrel are held against a
swashblock (11) by a shoe retainer (14). The shoe retainer is held in position by a fulcrum ball (16) which is
forced outward by shoe retainer spring (17). The spring acts against the pump cylinder barrel forcing it
against the valve plate while also forcing the piston shoe against the swashblock (11). The semi-cylinder
shaped swashblock limits the piston stroke and can be swivelled in arc shaped saddle bearings (10A and
10B) which are pinned (9) into the saddle (8). The swashblock is swivelled by a control (covered in referenced material).
For PVWH Pumps (only), the (pressure side) saddle bearing is force lubricated. A small hole in the face
of the swashblock (11) provides porting for the hydrostatic balance fluid [of the piston/shoe assembly (15)]
through the swashblock to a rectangular shaped groove milled in one of the two arc shaped swashblock faces,
to lubricate the face of the mating saddle bearing.
Malfunctions and Causes
1.
2.
3.
4.
5.
6.
A. Unresponsive or Sluggish Control
See reference control instruction material.
Low control input (pilot) pressure for R and V volume type controls only.
Swashblock saddle bearings (IOA & IOB) worn or damaged.
Worn or grooved cylinder barrel (1 8) and/or valve plate (22) matching surfaces.
Worn piston/shoe assemblies (15) or piston bores in cylinder (18).
Worn or damaged piston shoe or swashblock (11).
Doc. 2920025-47-5 Rev. 2
B-30
1.
2.
3.
B. Insufficient Pump Volume
Delivery limited by faulty control (see appropriate control instruction material).
Obstructed suction circuit or insufficient supercharge volume.
Insufficient drive motor speed.
C. Ir regular or Unsteady Operation
1.
2.
3.
4.
5.
Faulty control.
Fluid level in reservoir is low or supercharge is insufficient.
Air entering hydraulic system.
Worn axial piston pump.
Faculty output circuit components (cylinder, motors, valves, etc.).
1.
2.
3.
4.
5.
Worn piston pump.
Worn or grooved cylinder barrel (18) and/or valve plate (22) matching surfaces.
Worn piston/shoe assemblies (15) or piston bores in cylinder.
Faulty output circuit components.
Faulty control.
1.
Faulty output circuit components (pay particular attention to relief valves). The use of a spike relief
valve (fast acting) is recommended.
1.
2.
3.
4.
5.
Pump incorrectly being stopped or started under load.
Low fluid level in reservoir or insufficient supercharge resulting in cavitation.
Fluid too cold or viscosity to high.
Suction line problem i.e.; obstruction in line, line too long, line diameter too small, too many bends
and/or loops in line.
Broken or worn piston/shoe assembly (15).
Pump rotating in wrong direction.
6.
7.
1.
2.
3.
4.
5.
6.
7.
D. Loss of Pressure
E. Excessive or High Peak Pressure
F. Excessive Noise
G. Excessive Heating
Operating pump above rated or peak pressure.
Low fluid level in reservoir or insufficient supercharge.
Worn piston pump.
Worn or grooved cylinder barrel (I 8) and/or valve plate (22) matching surfaces.
Faulty output circuit components (continuous blowing relief valve or shp through valves, cylinder,
etc).
Insufficient cooling provision or clogged coolers.
Doc. 2920025-47-5 Rev. 2
B-31
Figure 1738.3 - Type PVWH Pumping Mechanism
Figure 1738.4 - Position A Swashblock Set For Full
Delivery Port A
Figure 1738.5 - Position A/2 Swashblock Set For
Partial Delivery From Port A
Principle of Operation
A one-way pump driven counter clockwise (left hand) is described.
See Figure 1738.3. Turning the driveshaft rotates the splined cylinder barrel (18) which contains pumping
pistons with swivel shoes (15). A shoe retainer (14), backed up by a spring (17) loaded fulcrum ball (16),
holds piston shoes against a swashblock (11).
See Figure 1738.4 - Position A. When the control positions the swashblock for full delivery from Port A, the
swashblock face is at maximum angle (to the cylinder face). When cylinder is rotated, the piston move in
and out of their bores as the shoes ride against the angled swashblock.
As the cylinder rotates, the individual piston bores are connected alternately to the lower (Port B) and upper
(Port A) crescent shaped ports in the valve plate. While connected to the lower (suction) Port B, each piston
moves outward, drawing fluid from Port B into the piston bore until its outermost stroke is reached. At that
point, the piston bore passes from the lower crescent port to the upper crescent port.
While rotating across the upper crescent, each piston moves across the angled swashblock face. Thus, each
piston is forced inward. Each piston displaces fluid through the upper crescent port to Port A until its innermost stroke is reached.
Doc. 2920025-47-5 Rev. 2
B-32
See Figure 1738.5 - Position A/2. A study of the diagram will show that the degree od swashblock angle
determines the length of the piston stroke (difference between outermost and innermost position). thereby
determining the amount of delivery from the pump.
See Figure 1738.4 - Position A. When the control positions the swashblock for full delivery from Port A, the
swashblock face is at maximum angle (to the cylinder face). When cylinder is rotated, the piston move in
and out of their bores as the shoes ride against the angled swashblock.
As the cylinder rotates, the individual piston bores are connected alternately to the lower (Port B) and upper
(Port A) crescent shaped ports in the valve plate. While connected to the lower (suction) Port B, each piston
moves outward, drawing fluid from Port B into the piston bore until its outermost stroke is reached. At that
point, the piston bore passes from the lower crescent port to the upper crescent port.
While rotating across the upper crescent, each piston moves across the angled swashblock face. Thus, each
piston is forced inward. Each piston displaces fluid through the upper crescent port to Port A until its innermost stroke is reached.
See Figure 1738.5 - Position A/2. A study of the diagram will show that the degree od swashblock angle
determines the length of the piston stroke (difference between outermost and innermost position). thereby
determining the amount of delivery from the pump.
Figure 1738.6 - Position N, Swashblock Positioned For Neutral
See Figure 1738.6 - Position N. Neutral position results when the control centres the swashblock. The
swashblock angle is now zero and swashblock face is parallel to cylinder face. Therefore, no inward or
outward motion of the pump piston exist as piston shoes rotate around the swashblock face. The lack of
inward and outward motion results in no fluid being displaced from the piston bores to the cresents in the
valve plate and conseuently no delivery from pump ports.
Doc. 2920025-47-5 Rev. 2
B-33
Specifications
See referenced material, pump control material and individual application circuits for exceptions.
"PVWH" AND "PVW" PUMPS WITH 150-300 S S U VIS COS ITY FLUID
UNIT
SIZE
THEORETICAL
MAXIMUM
DISPLACEMENT
RATED
CONTINUOUS
PRESSURE
MAXIMUM
PRESSURE
FLOW RATE
at 1880 rp m,
rated co ntinu o u s
p ressu re & 14.7
p sia (1b ar abs)
inlet co nditio n
MINIMUM INLET PRESSURE
p sia (b ar abs)
MAXIMUM
SPEED
POWER
INPUT
at rated
co ntinu o u s
p ressu re and
1800 rp m.
in3/rev
ml/rev
p si
b ar
p si
b ar
gp m
l/min
1200
rp m
1500
rp m
1800 rp m
rp m
hp
kw
11
1.55
25,4
5000
344,8
5800
400,0
10.9
41,3
7.0 (,48)
7.3 (,50)
8.2 (,57)
3000
36.5
27,2
15
2.06
33,8
350 0
241,4
400 0
275,9
14.7
55,7
7.0 (,48)
7.6 (,52)
8.4 (,58)
300 0
35.5
26,5
20
2.83
46,4
2500
172,4
3000
206,9
20.6
78,1
7.2 (,50)
7.9 (,54)
9.0 (,62)
2400
35.0
26,1
Table 1738.2 - Nominal Performance Data
70+65+<'
.'0)6*
9+&6*
*'+)*6
9'+)*6
Table 1738.3 - Nominal Weights and Dimensions
289*27/201/+0#.%#5'5.+28'4575*+)*24'5574'#6TRO
8+5%15+6+'51(
557
27/2
RUK
EKRO
RUK
NRO
EKRO
RUK
NRO
EKRO
RUK
NRO
EKRO
RUK
NRO
EKRO
NRO
0#
0#
0#
0#
0#
0#
0#
0#
0#
0#
Table 1738.4 - PVWH Pump Nominal Case Slip Versus High Pressure at 1800 rpm.
Testing and Adjusting
WARNING:
Shut pump off and release pressure from the system before disassembling components. Failure to comply
with these instructions could result in personal injury or death. Blocking pressure line before (up-stream
from) pump relief valve or system high pressure relief valve will result in damage and could result in serious
personal injury.
A. Piston Pump
To check for worn piston pump, measurement of the leakage can be made from the case drain while the
pump is under pressure, but pressure control (when used) is not unloading. After the unit is warm, either
install a flow meter in the drain line or have the flow from the drain line directed into a large container or
reservoir. The pump case must remain full of fluid during this test.
CAUTION:
Do not run a pump on stroke against a blocked output unless it is protected by a high pressure relief
valve and then run no longer than necessary to check slip. Limit discharge to prevent dropping reserDoc. 2920025-47-5 Rev. 2
B-34
voir fluid below low level.
With an accurate high pressure gage in the pressure line, start pump, put it on stroke and stall (or block)
output device to raise system pressure to maximum (as set by system relief valve). Read the flow meter, or
time the case drain flow to fill a known size container and calculate the flow rate in terms of cubic inches per
minute (cipm). The leakage should conform with Table 1738.4 or 1738.5. Additional leakage indicates wear,
but does not become critical until it impairs performance.
B. Control
Refer to applicable (referenced) pump control instructions material.
Disassembly
A. General
Refer to Figures 1738.10 and 1738-11. It will be advantageous to tag similar parts (particularly screws, plugs
and orings) during disassembly to be certain they dont become confused with similar parts and to assure
they will be returned to original location. Do not remove (locator) roll pins unless they are deformed or
otherwise in need of replacement.
B. Preparation
For disassembly and assembly, a crane and/or sling capable of handling 200 lb. loads will be useful.
When disassembling or assembling unit, we recommend choosing an area where no traces of dust, sand or
other abrasive particles, which could damage the unit, are in the air. We also recommend not working near
welding, sand blasting, grinding benches and the like. Place all parts on a clean surface. To clean parts
which have been disassembled, it is important to use clean solvents. All tools and gages should be clean
prior to working with these units and new clean lint free rags used to handle and dry parts.
WARNING:
Never attempt to remove or install any components or assemblies while unit and system is running.
Always stop the pump, shut-off power and release pressure from the system before servicing or testing. Be sure provisions have been made so case drain line can be disconnected from unit without
causing the line to drain (siphon) the reservoir.
Disconnect pump from drive motor and piping. Usually, it is necessary to remove the pump from its mounting before the case can be drained.
After removing pump from mounting, but before disassembly, cap or plug all ports and clean the outside
thoroughly to prevent entry of dust into the system.
Refer to Figure 1738.10 and 1738.11. Depending upon what part or parts are to be inspected, it may not be
necessary to completely take apart all assemblies.
C. Control Group
See reference material for applicable information on the control your unit is equipped with. Remove four
hex. head cap screws and lift the control group assembly, with control pin, straight up from the top of the
pump assembly. Control pin may or may not remain in the swashblock (11). Remove control gasket and
orings from pump housing.
Doc. 2920025-47-5 Rev. 2
B-35
D. Valve Plate Group
If another unit is coupled to thru shaft units, it will be necessary to remove coupling (half) (180 or 190)
before removing valve plate (22). Block unit on bench with driveshaft facing down. Remove valve plate
(22) by alternately removing four hex head screws (25) and lifting straight up. Remove valve plate gasket
(21) and oring (28).
E. Rotating Group
WARNING:
Extreme care must be taken not to damage cylinder wear surface (that matches against the valve
plate), bearing diameters or piston shoes. The use of a sling, and/or assistance from others and use of
proper lifting techniques are strongly recommended to prevent personal injury.
Place the pump in a horizontal position and remove the rotating group by turning shaft (1) slowly while
pulling the cylinder barrel (18) from the housing.
Figure 1738.7 - Rotating Group Disassembly
See Figure 1738.7. Lift out shoe retainer (14) with piston/shoe assemblies (15) and remove fulcrum ball (16)
and shoe retainer spring (17).
Remove retaining ring (13) and pull hydrodynamic cylinder bearing (12) from pump housing.
F. Driveshaft Group
Remove drive key (2) if used and driveshaft bearing retainer ring (29). Grasp outboard end of driveshaft (1)
and pull out from pump housing. Remove shaft retainer ring (4) and front driveshaft bearing (3). Remove
seal retainer (6) and shaft seal
(7) from housing only if necessary.
Doc. 2920025-47-5 Rev. 2
B-36
G. Swashbock Group
Reach inside the case and remove swashblock (I 1). Note which saddle bearing is in the upper (10A) position and which is in the lower (10B) position. Remove saddle bearings (IOA and IOB) from the saddle (8) if
necessary. If necessary, the saddle itself can be pulled out. On most units, the saddle is located by pin (20)
and can be pulled from the housing. On early units, the saddle is located in the case by two dowel pins (not
shown) and the saddle is secured to the case by two nylock socket head cap screws (not shown) which will
have to be removed before the saddle can be withdrawn from the housing.
Inspection
Clean all parts thoroughly. Inspect all seals, and orings for hardening, cracking or deterioration and replace
if necessary. Check all locating pins for damage and spring for cracking or signs of fatigue.
WARNING:
Always wear safety goggles when using solvents or compressed air. Failure to wear safety goggles
could result in serious injury.
Figure 1738.8 - Rotating Group Inspection
A. Control Group
See applicable reference material on pump controls. Be sure to carefully check control pin for cracks and/or
signs of fatigue. Check fit of control pin in swashblock. It should be a slip fit
without side-play.
B. Valve Plate Group
Inspect the valve plate (22) surface that mates with the cylinder barrel (18) for excessive wear or scoring.
Remove minor defects by lightly stoning the surface with a hard stone that is flat to within 0.00 1
(0,03mm). Be sure to stone lightly. Any excessive stoning will remove the hardened surface. If wear or
damage is extensive, replace the valve plate (as part of Valve Plate Assembly Kit No. 79L or 79R) and
cylinder barrel (18).
C. Rotating Group
Inspect cylinder barrel (18) piston bores and the face that mates with valve plate for wear or scoring. Remove minor defects by lightly stoning the surface with a hard stone that is flat to within 0.00 I (0,03 mm).
Be sure to stone lightly. Any excessive stoning will remove the hardened surface. If defects can not be
removed by this method, replace the cylinder barrel as part of Rotating Group Kit No. 73. Inspect hydrodynamic cylinder bearing (12) and matching cylinder barrel surface for galling, pitting, roughness, damage and
replace if necessary.
Doc. 2920025-47-5 Rev. 2
B-37
Figure 1738.9 - Rotating Group Inspection
See Figure 1738.9. Piston shoes must pivot smoothly, but end play should not exceed 0.006" (0.152 mm).
Check end play as follows: Place square end of piston on bench and hold down firmly. Pull on end of shoe
with other hand and note end play. The shoe must rotate and pivot on the piston ball. Inspect each shoe face
for nicks and scratches. Measure shoe thickness [the part held between shoe retainer (14) and swashblock
(11)]. All shoes must be equal within 0.001" (0,025 mm). If a single piston/shoe assembly needs to be
replaced, all piston/shoe assemblies must replaced. Replace as part of Piston/Shoe Kit No. 87 . When installing a new rotating group kit, make sure pistons are free in bores.
D. Swashblock Group
Inspect the swashblock (11) for wear or scoring. In the case of size 60 units, inspect the swashblock
wearplate (11 A). If damage is extensive, replace the swashblock and/or wearplate as part of Swashblock Kit
No. 82.
Compare saddle bearing (10A and 10B) thickness in worn area to thickness in an unworn area. Replace
saddle bearings if difference is greater than 0.008 in (0,2mm). Check mating surface of swashblock for
cracks or excessive wear. Swashblock movement in saddle bearings must be smooth. Replace as part of
Saddle Bearing Kit No. 85.
E. Driveshaft Group
Check shaft seal (7) for deterioration or cracks. Replace if necessary. Examine the sealing area of the shaft
(1) for scoring or wear. Inspect shaft bearing (3) for roughness, galling, pitting or binding. Check shaft and
splines for wear. If driveshaft is bent, scored or worn excessively or if bearing is bad, replace as part of Shaft
and Bearing Kit No. 74K or 74S. Inspect bushing in valve plate (22). If replacement is necessary, the bushing is not available as a loose item, it is included when ordering Valve Plate Assembly Kit No. 79L or 79R.
Assembly
Refer to Figures 1738.10 and 1738.11. The procedure for assembling the pump is basically the reverse order
of disassembly. During assembly , install new gaskets and o-rings (Kit No. 77). Apply a thin film of clean
grease or hydraulic fluid to sealing components to ease assembly. If a new rotating group (Kit No. 73) is
used, lubricate thoroughly with clean hydraulic fluid. Apply fluid generously to all wear surfaces.
A. Swashblock Group
If removed, press shaft seal (7) into front of pump housing (5) and then place housing on bench with mounting flange side down. Place saddle block (8) into housing - centre properly [a locating hole in the saddle and
a pin (20) in the housing must match]. On early units, two dowel pins (not shown) locate the saddle and
saddle is secured to housing by two nylock socket head cap screws.
Doc. 2920025-47-5 Rev. 2
B-38
The saddle bearings (10A and 10B) and swashblock (11) can now be installed. Check the swashblock faces
that mate with the saddle bearings (10A and 10B). One of these faces has a rectangular groove cut into it.
The groove should be on the control (upper) side of the swashblock for left hand driven pumps and on the
(lower) side for right hand driven pumps.
For all sizes of PVW Pumps only, both bearings are the same. It is recommended they be put back in their
original locations. If replacement saddle bearings are used - it makes no difference which is placed in which
location.
NOTE:
Install saddle bearings on size 04 thru 20 with notched corners toward shaft and bearing.
Place the swashblock into the case and be sure the swashblock swivels in the saddle bearings. With new
bearings, swivelling may be stiff (not always smooth).
Position the hydrodynamic bearing (12) into the case so the pin (in the bearing) will fit (per Table 6) a corresponding slot in the housing. The bearing should fit into place with little difficulty and be square to the axis
of the pump. Tap bearing into place if necessary, using extreme care not to damage the bearing. Insert
retaining ring (13) to hold bearing in place.
61437'6167405*#(6
5+<'70+6
#2241:+/#6'61437'6167405*#(6
HQQVRQWPFU
0O
Table 1738.5 - Hydrodynamic Bearing Location Pin Position
B. Driveshaft Group
Place housing on its side with axis horizontal and then install seat retainer (6). Place front driveshaft bearing
(3) onto driveshaft (1) and lock in place with shaft retaining ring (4). Lubricate shaft seal (7) and shaft, then
insert driveshaft and bearing assembly into pump housing (5) and lock in place with driveshaft bearing
retainer ring (29).
C. Rotating Group
See Figure 1738.7. Place the cylinder barrel (18), wear surface down, on a clean cloth. Place the shoe retainer spring (17) in the centre of the barrel with the, fulcrum ball (16) on top of it. Insert the pistons/shoe
assemblies (15) into the shoe retainer (14). As a unit, fit the pistons into their bores in the cylinder barrel. Do
Not Force. If aligned properly, the pistons will fit smoothly.
WARNING:
Assistance from others and proper lifting technique is strongly recommended to prevent personal
injury while assembling larger sized pump rotating groups into the pump.
The rotating group can now be carefully installed over the tail of the driveshaft (1) and into the pump housing (5). When installing the rotating group, support the weight of the cylinder barrel (18), as cylinder spline
is passed over the tailshaft, to avoid scratching or damage. Push cylinder forward until the cylinder spline
reaches the driveshaft spline and rotate the cylinder slightly to engage shaft splines. Continue to slide cylinder forward until it encounters the hydrodynamic cylinder bearing (12). Lifting the tailshaft slightly helps
Doc. 2920025-47-5 Rev. 2
B-39
cylinder barrel (18) and cylinder bearing (12) engagement. Continue pushing cylinder forward until the
piston shoes contact the swashblock. At this point, the back of the cylinder should be located slightly outside
the back of the pump housing.
Place pump housing on bench with open end facing up. Install new oring (28) and gasket (21) on housing.
Make sure the tail end of shaft engages bushing while positioning the valve plate (22) on pins (19) and
housing. Finger tighten hex head cap screw (25) closest to oring (28) first and then alternately tighten other
cap screws per Table 1738.2. On thru shaft units connected to another pump or device, install coupling half.
61437'5
5+<'70+6
8#.8'2.#6'
%10641.
(V.DU
0O
(V.DU
0O
Table 1738.6 - Torques
E. Control Group
See reference material for applicable information on the control your unit is equipped with. See appropriate
control reference for control
Doc. 2920025-47-5 Rev. 2
B-40
26 27
28
23, 24 19 18
15
(REFERENCE
CONTROL
PIN)
11A, 11C, 11B
(SIZE 60 ONLY)
17 1416
20
29
10A
21
22C
22D
39
1D, 1E
2
40
41
4
25
1A
22A
22B
3
5
OPTIONAL
THRUSHAFT
COVER
&
VALVE PLATE FOR
KEYED SHAFT
1312 11 10B * 9
8 7
6
* ROLL PINS TO EXTEND
0.600+/- 0.01 (1,5 +/-0.25)
FROM SURFACE SADDLE
185184182180 183 187
REAR
PUMP
ASSEMBLY
FRONT
PUMP
ASSEMBLY
1A
22A or 22B
* REAR PUMP-TO-ADPTER MOUNTING BOLTS
(189) AND LOCK WASHERS (190) ARE NOT
SHOWN. WHEN FRONT PUMP IS SIZE 06 OR 10,
STUDS (191), NUTS (192) AND LOCK WASHER (190)
ARE USED INSTEAD OF MOUNTING BOLTS (188
& 189).
INTEGRAL VALVE PLATE BUSHING IS
USED WITH TYPE TK (KEYWAY DRIVEN)
DRIVE SHAFTS
Doc. 2920025-47-5 Rev. 2
B-41
185184 191192 183 187
FRONT
PUMP
REAR
PUMP
* REAR PUMP-TOADPTER MOUNTING BOLTS (189)
AND LOCK WASHERS (190) ARE NOT
SHOWN.
WHEN
FRONT PUMP IS
SIZE 06 OR 10, STUDS
(191), NUTS (192)
AND
LOCK
WASHER (190) ARE
39
40
1B
41
1B
22A
OR
22A OR 22
188 & 190
THRU SHAFT VALVE
PLATE
FOR SPLINED SHAFT AND
DUAL PUMP ADAPTER AS-
INTEGRAL VALVE PLATE THRU SHAFT VALVE
BUSHING IS USED WITH PLATE FOR SPLINED
TYPE TK (KEYWAY
Figure 1738.11 - Parts Drawing Showing Driveshaft w/SAE Spline Shaft (Side Ports) DS-SW-8A
Parts used in this assembly are per Oilgear Specifications. Use oilgear parts to ensure compatibility with
assembly requirements. When ordering replacement parts, be sure to include pump type and serial number.
To assure seal and packing compatibility, specify type of hydraulic fluid used.
Parts Lists
+6'/
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+6'/
&'5%4+26+10
#
& 4 +8 ' 5 * # (6 9 +6 * - ' ; 9 # ; 5 +& ' 21 4 6 # 5 5 ' / $ . ; 2+5 6 1 0 5 * 1 '
$
& 4+8 ' 5 * # (6 9 +6 * 5 # ' 5 2. +0 ' 5 * # (6 5 +& ' 21 4 6 $ # . . (7 . % 4 7 /
&
& 4+8 ' 5 * # (6 9 +6 * - ' ; 9 # ; 4 ' # 4 21 46 5 24+0 ) 5 * 1 ' 4' 6 # +0 ' 4
'
& 4 +8 ' 5 * # (6 9 +6 * 5 # ' 5 2. +0 ' 4 ' # 4 21 4 6 $ # 44 ' . % ; . +0 & ' 4
- ' ; & 4 +8 ' 5 * # (6
2+0 4 1 . .
$ ' # 4 +0 ) (4 1 0 6 & 4 +8 ' 5 * # (6
2+0 5 # & & . ' . 1 % # 6 +0 )
4 +0 ) 5 * # (6 4 ' 6 # +0 ' 4
) # 5 - ' 6 8 # . 8 ' 2. # 6 '
* 1 7 5 +0 ) 27 / 2
#
8 # . 8 ' 2. # 6 ' 5 +& ' 21 4 6 4 ' # 4 5 * # (6 . *
4 ' 6 # +0 ' 4 5 ' # .
$
8 # . 8 ' 2. # 6 ' 5 +& ' 21 4 6 4 ' # 4 5 * # (6 4 *
5 ' # . 5 * # (6
%
8 # . 8 ' 2. # 6 ' 4' # 4 21 4 6 . *
$ . 1 % - 5 # & & . ' +6 ' / 5 5 1 . & # 5 # 0
&
8 # . 8 ' 2. # 6 ' 4' # 4 21 4 6 4*
#5 5'/$. ; 2+0 4 1 . . +6 ' / 5 5 1 . & # 5 # 0 # 5 5 ' / $ . ;
5 ' # . 1 4 +0 )
#
$ ' # 4 +0 ) 7 22' 4 5 # & & . '
2. 7 ) 5 # ' * 1 . . 1 9 * ' :
$
$ ' # 4 +0 ) . 1 9 ' 4 5 # & & . '
5 % 4 ' 9 * ' : * ' # &
$ ' # 4 +0 ) % ; . +0 & ' 4 * ; & 4 1 & ; 0 # / +%
0 # / ' 2. # 6 ' +& ' 0 6 +(+% # 6 +1 0
5 9 #5 * $ . 1 % -
5 % 4' 9 & 4 +8 '
#
9 ' # 4 2. # 6 ' 5 9 # 5 * $ . 1 % - 5 +< ' 1 0 . ; 5 ' # . 1 4 +0 )
$
2+0 4 1 . . 5 +< ' 28 9 * 1 0 . ; 4 +0 ) & 4 +8 ' 5 * # (6 $ ' # 4 +0 ) 4 ' 6 # +0 ' 4
%
5 ' # . 1 4 +0 ) 5 +< ' 28 9 * 1 0 . ;
) #5 - ' 6
4 +0 ) 4 ' 6 # +0 ' 4
%1 8 '4
4' # 6 # +0 +0 ) 5 * 1 '
5 % 4' 9 * ' : * ' # & % # 2
Table 1738.7 - Parts List
Doc. 2920025-47-5 Rev. 2
B-42
&7#.27/2#&#26'4#0&%172.+0)-+6
5+<'6*417)*
+6'/
&'5%4+26+10
%172.+0)(4106
-';%172.+0)
%172.+0)4'#4
)#5-'6#&#26'4
#&#26'4
5'#.14+0)
4+0)5*#(64'6#+0'4
4+041..
5%4'9*':*'#&%#2
5%4'9*':*'#&%#2
0165*190
.1%-9#5*'4
0165*190
%172.+0)52.+0'
2+041..
$
$'#4+0).19'45#&&.'
Table 1738.8 - Dual Pump Adapter and Coupling Kits
14+0)5+<'5
#4270+(41/5+<'07/$'4
9+6*&741/'6'4
+6'/
27/25+<'
%1051.6(#%614;
Table 1738.9 - ORing Sizes
Doc. 2920025-47-5 Rev. 2
B-43
It is recommended that spare or replacement parts be ordered as part of the following kits.
*175+0)2+05-+607/$'4
8#.8'2.#6'-+607/$'4
+6'/
&'5%4+26+10
+6'/
&'5%4+26+10
*175+0)27/2
)#5-'68#.8'2.#6'
5'#.5*#(6
8#.8'2.#6'
2+041..
5'#.14+0)
2+05#&&.'.1%#6+0)
2.7)*1..19*':
5%4'9*':*'#&
5'#.14+0)
416#6+0))4172-+607/$'4
+6'/
&'5%4+26+10
4'6#+0'45*1'
#55'/$.;2+56105*1'
+6'/
&'5%4+26+10
$#..(7.%47/
-';&4+8'5*#(6
524+0)5*1'4'6#+0'4
5%4'9*':*'#&
$#44'.%;.+0&'4
5%4'95-';6#)-+607/$'4
5*#(6$'#4+0)-+607/$'4
&'5%4+26+10
&4+8'5*#(6
+6'/
-';&4+8'5*#(6
$'#4+0)(4106
&4+8'5*#(6
4+0)(4106&4+8'5*#(6
4'6#+0'45'#.
5%4'9&4+8'
416#6+0))4172$'#4+0)-+607/$'4
+6'/
0#/'2.#6'
+&'06+(+%#6+10
4+0)&4+8'5*#(6
$'#4+0)4'6#+0'4
)#5-'65'#.-+607/$'4
&'5%4+26+10
$'#4+0)%;.+0&'4
*;&41&;0#/+%
4+0)4'6#+0'4
59#5*$.1%--+607/$'4
+6'/
&'5%4+26+10
59#5*$.1%-
5#&&.'-+607/$'4
+6'/
&'5%4+26+10
+6'/
&'5%4+26+10
5'#.5*#(6
$.1%-5#&&.'
)#5-'68#.8'2.#6'
2+041..
5'#.14+0)
#
$'#4+0)722'45#&&.'
5'#.14+0)
$
$'#4+0).19'45#&&.'
5#&&.'$'#4+0)-+607/$'4
+6'/
&'5%4+26+10
#
$'#4+0)722'45#&&.'
$
$'#4+0).19'45#&&.'
Table 1738.10 - Spare Parts Kits
Doc. 2920025-47-5 Rev. 2
B-44
After Sales Ser vice
Oilgear builds products that last. However, it is the nature of this type of machinery to require proper maintenance regardless of the care that goes into its manufacture. Oilgear has several service programs to help
you.
STAY-ON-STREAM SERVICE
By signing up for Oilgears Stay-On-Stream program you can prepare for problems before they happen.
Certain field tests such as fluid testing, slip testing and electronic profile recording comparisons can be
performed by our field service people or your own trained personnel. These tests can indicate problems
before they become down-time difficulties.
SERVICE SCHOOLS
Oilgear holds schools to train your maintenance personnel. A general hydraulic or electronic school is
conducted in our Milwaukee plant on a regular basis. Custom schools, specifically addressing your particular hydraulic and electrohydraulic equipment can be conducted in your plant.
SPARE PARTS AVAILABILITY
Prepare for future needs by stocking Oilgear original factory parts. Having the correct parts and necessary
skills in-plant enables you to minimize down-time. Oilgear has developed parts kits to cover likely future
needs. Oilgear field service technicians also stand ready to assist your maintenance people in trouble-shooting and repairing equipment.
Oilgear Exchange Ser vice
Standard replacement pumps and motors are available to users of Oilgear equipment where comparable units
will be returned in exchange. When standard replacements must be modified to replace units which are
special, shipment will depend on availability of parts, assembly and test time necessary.
To obtain this service, place an order for an exchange unit and provide the serial number and type designation. The replacement unit will be shipped F.O.B. our factory. Milwaukee, Wisconsin. User retains the
replacement and returns the worn unit prepaid to The Oilgear Company for reconditioning and test. When
the unit is reconditioned or stocked, the user is billed the cost of reconditioning or a flat rate exchange price
if one has been applied to that particular type of unit.
THE OILGEAR COMPANY
2300 So. 51st. Street
Milwaukee, WI 53219
Doc. 2920025-47-5 Rev. 2
B-45
Doc. 2920025-47-5 Rev. 2
B-46
SERVICE INSTRUCTIONS
OILGEAR TYPE PVG PUMPS
Pump Maintenance (PVG)
(Reference: Plate 1971)
Purpose of Instructions
These instructions are written to simplify your work of installing, operating and maintaining Oilgear type
PVG pumps. Your acquaintance with the construction, principle of operation and characteristics of these
units will help you attain satisfactory performance, reduce shut-down and increase the units life. Some units
have been modified from those described in this bulletin and other changes may be made without notice.
Figure 1971.1- Typical Oilgear-PVG Open Loop Pump.
Preparation and Installation
A. Mounting
PUMP WITHOUT RESERVOIR:
The pump may be mounted in any position. But, for convenience the recommended mounting position is
with the driveshaft on a horizontal plane and with case drain port I on the top side. Secure the unit to a rigid
mounting surface. See section B on Piping Information.
PUMP WITH RESERVOIR:
These units are usually fully piped and equipped although it may be necessary to connect to supercharge
circuit when used. Mount reservoir on level foundation with reservoir bottom at least six (6) inches above
floor level to facilitate fluid changes.
B. Piping and Fittings
See referenced Piping Information bulletin and individual circuit diagram before connecting pump to
system. Inlet velocity must not exceed 5 fps (1,5 mps). Inlet should be unrestricted and have a minimum of
fittings. An inlet strainer is not recommended.
Arrange line from case drain so case remains full of fluid (nonsiphoning). The PVG-l00 case to inlet
differential pressure must be less than 60 psi (4,1 bar) for speeds of 1200 and 1800 rpm .The PVG-130 case
to inlet differential pressure must be less than 60 psi (4.1 bar) for 1200 rpm and less than 50 psi (3,4 bar) for
1800 rpm. Case to inlet differential pressure can be described as (case pressure minus inlet pressure). Special
shaft seals will be required for case pressure above 25 psi (1,7 bar). For speeds above 1800 rpm, contact our
Doc. 2920025-47-5 Rev. 2
B-47
factory. Each drain line must be a separate line, unrestricted, full sized and connected directly to the reservoir
below lowest fluid level. Provisions for opening this line without draining (siphoning) reservoir should be
made.
WARNING:
Running pump in Neutral position (zero delivery) for long periods of time without supercharge can
damage the pump.
System and pump must be protected against overloads by sperate high pressure relief valves. Install
bleed valve(s) at highest point(s) in system
C. Power
Power is required in proportion to volume and pressure used. Motor size recommendations for specific
applications can be obtained from The Oilgear Company. Standard low starting torque motors are suitable
for most applications.
CAUTION:
Never start or stop unit under load unless system is approved by Oilgear. It may be necessary to provide delivery bypass in some circuits.
D. Drive
See rotation direction plate on units housing. Clockwise units should not be driven counter-clockwise nor
counter-clockwise units driven clockwise. Use direct drive coupling. Size and install coupling per manufactures instructions.
CAUTION:
Do not drive coupling onto pump driveshaft. If it is too light, it may be necessary to heal coupling (see
manufactures instructions).
Misalignment of pump shaft to drivers shaft should not exceed 0.005" (0,13mm) Total Indicator
Read-out (TIR) in any plane.
E. Filtration
To assure long life from your hydraulic system, keep fluid clean at all times. See reference bulletin on Filtration Recommendations and on Contamination Evaluation. Oilgear recommends use of a filter in the
pressure or return line. Replace Filter element(s) when filter condition indicator reaches change area at
normal fluid temperature. Drain and thoroughly clean filter case. Use replacement element(s) of same beta 10
ratio (normally a ratio of 4 with hydraulic oils).
F. Fluid Cooling
When pump is operated continuously at rated pressure or frequently at peak load, auxiliary cooling of fluid
may be necessary. Fluid temperature should not exceed limits specified in referenced Oilgear bulletin on
Fluid Recommendations.
Doc. 2920025-47-5 Rev. 2
B-48
G. Air Breather
On most installations, an air breaths is mounted on top of fluid reservoir. It is important for the breather to be
of adequate size to allow air flow in and out of reservoir as fluid level changes. Keep breather case filled to
the fluid level mark. About once every six months, remove cover, wash screen in solvent, clean and refill
case to level mark and install screen. See manufacturers recommendations.
H. Fluid, Filling and Star ting Recommendations
Refer to instruction plate on the unit, reservoir, machine and/or referenced Fluid Recommendations bulletin. Fire resistant fluids and phosphate ester fluids can be used in accordance with fluid manufactures recommendations.
Pump all fluid into reservoir through a clean (beta 10 ratio of 4 or more) filter. Fill reservoir to, but not
above, high level mark on sight gage. Remove case drain line and fill pump case with hydraulic fluid.
S IZE UNIT
100 130
APPROXIMATE TORQUE TO TURN DRIVE SHAFT - FOOT
POUNDS
24
NM
32
Table 1971.1 Torque to Turn Shaft
With pump under no load, or with pump control at neutral, turn drive unit on and off several times
before allowing pump to attain full speed. The system can usually be filled by running the pump and operating the control. Watch the fluid level in the reservoir and stop pump if the level reaches low level mark.
Add fluid and start again. With differential (cylinder) systems, fluid must not be above high level when
ram is retracted or below low level when extended. Bleed air from the system by loosening connections or
opening petcocks at the highest point in the system. Close connections or petcocks tightly when solid stream
of fluid appears.
Construction
Refer to Figures 1971.2, 1971.9 and 1971.10. A driveshaft (301) runs through the centre line of pump housing (001) and valve plate (401) with pump cylinder barrel (101) splined to it. A bearing (306) supports the
outboard end of the driveshaft and a bushing (402 is part of valve plate assembly) supports the inboard end.
The pump cylinder barrel is carried in a polymerous (journal type) cylinder bearing (202). The valve plate
(401) has two crescent shaped ports. Pumping piston/shoe assemblies (102) in the cylinder barrel are held
against a swashblock (201) by a shoe retainer (104). The shoe retainer is held in position by the fulcrum ball
(103) which is forced outward by shoe retainer spring (105). The spring acts against the pump cylinder barrel
forcing it against the valve plate while also forcing the piston shoes against the swashblock. The semi-cylindrical shaped swashblock limits the piston stroke and can be swivelled in arc shaped saddle bearings (204).
The swashblock is swivelled by a control (covered in referenced material).
Doc. 2920025-47-5 Rev. 2
B-49
Figure 1971.2 -Cross Section of Typical PVG Pump
Specifications
See reference material, pump control material and individual application circuit for exceptions.
Unit
Theo retical
Max imum
Displacement
Rated
Co ntinuo us
Pressure
Max imum
Pressure
Flo w Rate
At 1899
Rpm, Rated
Co ntinuo s
Pressure
and 14.7
Psia (bar abs)
Inlet
Co nditio n
in3/rev
ml/rev
p si
b ar
p si
b ar
gp m
l/min
PVG 100
6.00
98 3
5000
344,8
5800
400,0
42.4
PVG 130
7.94
130 2
3750
258,6
4250
293,1
57.6
Minimum Inlet
Pressure Psia (bar abs)
1200
rp m
1500
rp m
Max imum
S peeds
Po wer
Input
1800 rp m
rp m
hp
kw
160,5
9.5 (,66) 10.3 (,71) 11.2 (,77)
2400
150
111,9
218,0
8.6 (,59)
1800
150
111,9
9.2 (,63)
10.8 (,74)
Table 1971.2 - Nominal Performance Date with 150 - 330 SSU Viscosity Fluids
UNIT
FACE
MOUNT ING
LENGT H
WIDT H
HEIGHT
WEIGHT
in.
mm.
in.
mm.
in.
mm.
lb s.
kg.
100
13.0
330,5
8.4
212,9
7.3
185,7
110
50
SAE "C" Bo lt
300
13.0
330,5
8.4
212,9
7.3
185,7
110
50
SAE "C" Bo lt
Table 1971.3 - Nominal Dimensions and Weights
See Installation drawings for more detailed dimensions and port configurations.
Malfunctions and Causes
1.
2.
3.
A. Unresponsive or Sluggish Control
See referenced control instruction material.
Low control input (pilot) pressure - for R and V volume type controls only.
Swashblock saddle bearings (204) worn or damaged.
Doc. 2920025-47-5 Rev. 2
B-50
1.
2.
3.
4.
5.
6.
B. Insufficient Pump Volume
Delivery limited by faulty control (see appropriate control instruction material).
Obstructed suction circuit or insufficient supercharge volume.
Insufficient drive motor speed.
Worn piston/shoe assemblies (102) or piston bores in cylinder (101).
Worn or damaged piston shoe or swashblock (201).
C. Ir regular or Unsteady Operation
1.
2.
3.
4.
5.
Faulty control.
Fluid level in reservoir is low or supercharge is insufficient.
Worn axial piston pump.
Faulty output circuit components (cylinders, motors, valves, etc.).
1.
2.
3.
4.
Worn piston pump.
Worn or grooved cylinder barrel (101) and/or-valve plate (401) matching surfaces.
Worn piston/shoe assemblies (102) or piston bores in cylinder.
Faulty output circuit components.
D. Loss of Pressure
E. Excessive or High Peak Pressure
1.
Faulty output circuit components (pay particular attention to relief valves).
1.
2.
3.
4.
5.
Pump incorrectly being stopped or started under load.
Low fluid level in reservoir or insufficient supercharge resulting in cavitation.
Fluid too cold or viscosity too high.
Suction line problem i.e.; obstructions in line, line too long, line diameter too small or too many bends
and/or loops in line.
Broken or worn piston/shoe assembly (102).
Pump rotating in wrong direction.
6.
7.
1.
2.
3.
4.
5.
6.
7.
F. Excessive Noise
G. Excessive Heat
Operating pump above rated or peak pressure.
Low fluid level in reservoir or insufficient supercharge..
Worn piston pump.
Faulty output circuit components (continuous blowing relief valves or slip through valves, cylinder,
etc.)
Insufficient cooling provision or clogged coolers.
Principle of Operation
A two-way pump, driven clockwise (right hand), is described. Diagrams are shown from top (plan) view.
See Figure 1971.3. Rotating the driveshaft clockwise turns the splined cylinder, which contains the pumping
pistons. When the cylinder is rotated, the pistons move in and out of their bores as the shoes ride against
the angled swashblock.
Doc. 2920025-47-5 Rev. 2
B-51
As the cylinder rotates, the individual piston bores are connected, alternately, to upper (Port A) and lower
(Port B) crescent shaped ports in the valve plate. While connected to the upper side (suction) Port A, each
piston moves outward, drawing fluid from Port A into the piston bore until its outermost stroke is reached.
At that point, the piston bore passes from upper crescent port to the lower crescent port.
While rotating across the lower crescent, each piston moves across the angled swashblock face. Thus each piston is
forced inward. Each piston displaces fluid thru the lower crescent to Port B until its innermost stroke is reached. At
that point, the piston bore passes from the lower to the upper crescent again and the operating cycle is repeated.
Figure 1971.3 Position B Plan View
See Figure 1971.4. A study of the diagram will show that the degree of swashblock angle determines the
length of piston stroke (difference between outermost and innermost position) thereby determining the
amount of delivery from the pump. In this case, the stroke angle is one-half of the former stroke angle.
Therefore, the piston stroke is one half the former and pump delivery is one half the former delivery.
Figure 1971.4 - Position B/2 Plan View
See Figure 1971.5. Neutral position results when the control centres the swashblock. The swashblock angle
Doc. 2920025-47-5 Rev. 2
B-52
is now zero and swashblock face is now parallel to cylinder face. Therefore, no inward or outward motion of
the pump pistons exist as piston shoes rotate around the swashblock face. The lack of inward and outward
motion results in no fluid being displaced from the piston bores to the crescents in the valve plate and consequently no delivery from pump ports.
Figure 1971.5. - Position N Plan View
See Figure 1971.6. For two-way pumps, the direction of swashblock angle determines which port is inlet or
outlet. If swashblock angle is reversed (From Position B), the pistons will stroke outward during the lower
half revolution and draw fluid from Port B. During the upper half revolution, the pistons, stroke inward
and deliver fluid to Port A.
It should be noted that when a two-way pump reverses flow direction - the rate of delivery is decelerated as
the swashblock moves toward neutral position - flow is stopped as it crosses neutral position - flow rate
accelerates from the other port as the swashblock moves in that direction. Thus, flow reversal is cushioned
by the pump itself. The degree of cushion is determined by the rate (speed) of swashblock position reversal.
Figure 1971.6 - Position A Plan View
Doc. 2920025-47-5 Rev. 2
B-53
Testing and Adjusting
WARNING:
Shut pump off and release pressure from the system before disassembling components. Failure to
comply with these instructions could result in personal injury or death. Blocking pressure line between
pump and system (or pump) high pressure relief valve will result in damage and could result in serious
personal injury.
A. Piston Pump
To check for worn piston pump, measurement of the leakage can be made from the case drain while pump is
under pressure. After the unit is warm, either install a flow meter in the drain line or have the flow from the
drain line directed into a large container or reservoir. The pump case must remain full of fluid during this
test.
CAUTION:
Do not run a pump on stroke against a blocked output unless it is protected by a high pressure relief
valve and then run no longer than necessary to check slip. Limit discharge to prevent dropping reservoir fluid below low level.
With an accurate high pressure gage in the pressure line. Start the pump and stall (or block) output device to
raise system pressure to maximum (as set by system relief valve). Read the flow meter or time the case drain
flow used to fill a known size container and calculate the flow rate in terms of cubic inches per minute
(cipm). The leakage should conform with Table 1971.4. Additional leakage indicates wear, but does not
become critical until it impairs performance.
PUMP S IZE
CAS E S LIP at FULL S TROKE and INDICATED PRES S URE
500 psi
1000 psi
2000 psi
3000 psi
100 cipm
190
250
400
1 pm
3,1
4,1
130 cipm
300
1 pm
4,9
3750 psi
4000 psi
5000 psi
600
900
1200
6,5
9,8
14,7
19,7
400
600
1000
1400
NA
NA
6,6
9,8
16,4
22,9
NA
NA
Table 1971.4 - Nominal Case Slip vs. High Pressure at 1800 rpm (Viscosities of 90-110 SSU)
Disassembly
A. Preparation
When disassembling or assembling unit, we recommend choosing an area where no traces of dust, sand or
other abrasive particles, which could damage the unit, are in the air. We also recommend not working near
welding, sandblasting, grinding benches and the like. Place all parts on a Clean surface. To clean parts which
have been disassembled, it is important to use Clean solvents. All tools and gages should be clean prior to
working with these units and new, Clean threadless rags used to handle and dry parts.
WARNING:
Never attempt to remove or install any component or assembly while unit and system is running.
Always stop the pump, shut-off power and release pressure from the system before servicing or testing. Be sure provisions have been made so case drain line can be disconnected from the unit without
causing the line to drain (siphon) the reservoir.
Doc. 2920025-47-5 Rev. 2
B-54
Disconnect case drain line from Port 1 or 1A and drain pump case through the remaining (Port l or
1A) on bottom of case. If plugs are inaccessible, it may be necessary to remove pump from mounting (and
drive motor) before draining it.
After removing pump from mounting, but before disassembly, cap or plug all ports and clean the outside of
unit thoroughly to prevent entry of dust into the system.
Refer to Figures 1971.9 and 1971.10. Depending upon what part or parts are to be inspected, it may not be
necessary to completely take apart all assemblies.
B. Control Group
See reference material for applicable information on the control your unit is equipped with. Some force is
required to remove the control housing. Remove four socket head cap screws and lift the control group
assembly, with control pin, straight up from the top of the pump assembly. Control pin may or may not
remain in the swashblock (201). Remove control gasket and orings from pump housing.
C. Valve Plate Group
If another unit is coupled to thru shaft units, it will be necessary to remove coupling (half) before removing
valve plate. Block unit on bench with driveshaft facing down. Remove valve plate (401) by removing four
hex head cap screws (403) and lifting straight up. Remove valve plate gasket (41 1) and oring (404).
D. Rotating Group
WARNING:
Size 100 and 130 rotating group weigh approximately 15 lbs. (7 kg). Extreme care must be taken not to
damage cylinder wear surface (that matches against the valve plate), bearing diameters or piston
shoes. Assistance from others and use of proper lifting techniques are strongly recommended to prevent personal injury.
On thru shaft units, the tailshaft bushing assembly (307, 308, 309) or a coupling will have to be removed (a
jacking screw can be used) before rotating group can be disassembled. Place the pump in a horizontal
position and remove the rotating group by turning shaft (301) slowly while pulling the cylinder barrel (101)
from the housing.
Mark (number) each pump piston shoe assembly (102) and its respective bore in cylinder barrel (101) and
shoe retainer (104). See Figure 1971.7. Lift out shoe retainer (104) with pistons (102) and remove fulcrum
ball (103) and shoe retainer spring (105).
Figure 1971.7 - Rotating Group Disassembly
Doc. 2920025-47-5 Rev. 2
B-55
Remove retaining ring (208) and pull the hydrodynamic bearing (202) and roll pins, if necessary, (205) from
the housing
E. Driveshaft Group
Remove drive key (303) if used and driveshaft bearing retainer ring (305). Grasp outboard end of driveshaft
(301) and pull out from pump housing. Remove shaft retaining ring (304) and bearing (306). Remove shaft
seal retainer (302) and shaft seal (007) from housing only if necessary.
F. Swashblock Group
Remove flat head screws (206) and guide plate (203). Reach inside the case and remove the swashblock
(201) and saddle bearings (204).
Inspection
Clean all pans thoroughly. Inspect all seals and orings for hardening, cracking or deterioration and replace if
necessary. Check all locating pins for damage and springs for cracking or signs of fatigue.
WARNING:
Always wear safety goggles when using solvents or compressed air. Failure to wear safety goggles
could result in serious personal injury.
A. Control Group
See applicable reference material on pump controls. Be sure to carefully check control pin for cracks and/or
signs of fatigue. Check fit of pin in swashblock. It should be a slip fit without side-play.
B. Valve Plate Group
Inspect the valve plate (401) surface that mates with the cylinder barrel (101) for excessive wear or scoring.
Remove minor defects by lightly stoning the surface with a hard stone that is flat to within 0.001" (0,03 mm).
Be sure to stone lightly. Any excessive stoning will remove the hardened surface. If wear or damage is
extensive, replace the valve plate.
C. Rotating Group
Inspect cylinder barrel (101 ) piston bores and the face that mates with valve plate for wear and scoring.
Remove minor defects on the face by lightly stoning or lapping the surface. If defects can not be removed by
this method, replace the cylinder barrel.
Inspect cylinder bearing (202) for damage and replace if necessary. Check all piston and shoe assemblies (
102) to be sure they ride properly on the swashblock.
Figure 1971.8 - Piston and Shoe Inspection
Doc. 2920025-47-5 Rev. 2
B-56
See Figure 1971.8. Check each shoe face for nicks and scratches. Check the shoe for smooth pivot action on
the piston. If one or more piston/shoe assembly needs to be replaced, replacement of all piston/shoe assemblies is necessary. When installing new piston/shoe assemblies or rotating group, make sure pistons are free
in their respective bores.
D. Swashblock Group
Inspect the swashblock (201) for wear and scoring. If defects are minor, stone the swashblock lightly. If
damage is extensive, replace the swashblock. Check the very small holes in the face of the swashblock.
These holes provide porting for the hydrostatic balance fluid (of the piston/shoe assembly) to be channelled through the swashblock to the face of the saddle bearing (providing pressure lubrication).
Compare saddle bearing (204) thickness in worn area to thickness in an unworn area. Replace saddle bearings if difference is greater than 0.015 in. (0,4 mm). Check mating surface of swashblock for cracks or excessive wear. Swashblock movement in saddle bearings must be smooth. Replace if necessary.
Assembly
Refer to Figures 1971.9 and 1971.10. The procedure for assembling the pump are basically the reverse order
of disassembly procedures. During assembly, install new gaskets, seals and orings. Apply a thin film of
CLEAN grease or hydraulic fluid to sealing components to ease assembly. If a new rotating group is used,
lubricate thoroughly with CLEAN hydraulic fluid. Apply fluid generously to all wear surfaces.
A. Swashblock Group
If removed, press shaft seal (007) into front of pump housing and then place housing on bench with mounting flange side down. If replaced or removed, press two roll pins (207) into the pump housing so pins extend
0.050 to 0.065 inches (1,3 to 1,6 mm) from case. Grease back side of saddle bearing (204) and place on the
pin to locate the bearing in pump case. Be sure the pin does not protrude.
Partially insert swashblock (201) into pump housing. Insert guide plate (203) into the case so flat head cap
screws (206) can be used to fasten the guide plate (203) to the housing. Place the swashblock (201) on the
guide plate (203) making sure the guide plate (203) is in the groove of the swashblock (201). Once in place,
be sure swashblock swivels in the saddle bearings. With new bearings, swivelling may be stiff (not always
smooth).
Be sure the two roll pins (205) are inserted into the cylinder bearing (202). Position the cylinder bearing so
the pins are located nearest the control facing the outboard end of driveshaft (301 ). The bearing should fit
into place with a little difficulty and be square to the axis of the pump. Tap bearing into place if necessary
using extreme care not to damage the bearing. Insert retaining ring (208) to hold bearing in place.
B. Driveshaft Group
Place housing on its side with the axis horizontal and then install seal retainer (302). Place front driveshaft
bearing (306) onto driveshaft (301) and lock in place with shaft retaining ring (304). Lubricate shaft seal
(007) and shaft, then insert driveshaft (301) and bearing assembly into housing and lock in place with
driveshaft bearing retainer ring (305).
C. Rotating Group
See Figure 1971.7. Place the cylinder barrel (101), wear surface down, on a clean cloth. Place the shoe
retainer spring (105) in the centre of the barrel with the fulcrum ball (103) on top of it. Insert the (numbered
on disassembly) pistons (102) into their corresponding (numbered) holes of the shoe retainer (104). As a unit,
Doc. 2920025-47-5 Rev. 2
B-57
fit the pistons into their corresponding (numbered) bores in the cylinder barrel. Do Not Force. If aligned
properly, the pistons will fit smoothly
WARNING:
The assembled rotating group weighs approximately 15 lbs. (7 kg). Assistance from others and proper
lifting techniques is strongly recommended to prevent personal injury.
The rotating group can now be carefully installed over the tail of the driveshaft (301) and into the pump
housing (001). When installing the rotating group, support the weight of the cylinder barrel (101), as cylinder
spline is passed over the tailshaft, to avoid scratching or damage. Push cylinder forward until the cylinder
spline reaches the driveshaft spline and rotate the cylinder slightly to engage shaft splines. Continue to slide
cylinder forward until it encounters the cylinder bearing (202). Lifting the tailshaft slightly helps cylinder
(101) and cylinder bearing (202) engagement. Continue pushing cylinder forward until the piston shoes
contact the swashblock. At this point, the back of the cylinder should be located approximately 0.4 in. (10,2
mm) outside the back of the pump housing. On thru shaft units without another pump or device connected to
them, install roll pin (309) into spline cover (307), slide assembly onto shaft (301) and secure in place with
socket head shoulder screw (308).
Place pump housing on bench with open end facing up. Install new oring (411) and gasket (407) on housing.
Make sure the tail end of shaft engages bushing (in rear ported valve plates) while positioning valve plate
(401) on pins (005) and housing. Finger tighten hex head cap screw (403) closest to oring (404) First then
alternately tighten the other cap screws. On thru shaft units connected to another pump or device, install
coupling (half).
E. Control Group
See reference material for applicable information on the control your unit is equipped with. See appropriate
control reference for control group mounting.
Doc. 2920025-47-5 Rev. 2
B-58
Parts List
Parts used in this assembly are per Oilgear specifications. Use Oilgear parts to insure compatibility with
assembly requirements. When ordering replacement parts, be sure to include pump type and serial number,
bulletin number and item number. To assure seal and packing compatibility, specify type of hydraulic fluid.
ITEM NUMBER
DES CRIPTION
ITEM NUMBER
DES CRIPTION
300
DRIVES HAFT AS S EMBLY GROUP
000
HOUS ING AS S EMBLY GROUP
001
Ho u sing, Pu mp
301A
Driveshaft With K ey way (Side Po rt)
003
Name Plate, Identificatio n
301B
Driveshaft With SAE Sp line (Side Po rt)
004
Plu g, SAE
301D
Driveshaft With K ey way (Rear Po rt)
005
Pin, Ro ll
301E
Driveshaft With SAE Sp line (Rear Po rt)
006
Pin, Ro ll
302
Retainer, Seal
007
Seal, Shaft
303
K ey , Driveshaft
008
Screw
304
Ring, Shaft Retainer
010
Seal, O'Ring
305
Ring, Driveshaft Bearing Retainer
306
Bearing, Fro nt Driveshaft
100
ROTARY AS S EMBLY GROUP
307
Co ver, Sp line
101
Barrel, Cy linder
308
Screw, So cket Head Cap Sho u lder
102
Assemb ly , Pisto n / Sho e
309
Pin, Ro ll
103
Ball, Fu lcru m
104
Retainer, Sho e
400
VALVE PLATE AS S EMBLY GROUP
105
Sp ring, Sho eRetainer
401A
V alve Plate, Side Po rt / Rear Po rt
401E
V alve Plate, Side Po rt, No Rear Shaft
401I
V alve Plate, Rear Po rt
201
S WAS HBLOCK AS S EMBLY
GR O UP
Swashb lo ck
402
Bu shing (Pan o f V alve Plate)
202
Bearing, Cy linder
403
Screw, Hex Head
203
Plate, Gu ide
404
Seal, O'Ring
204
Bearing, Saddle
405
Seal, O'Ring
205
Pin, Ro ll
406
Seal, O'Ring
206
Screw, So cket Head Cap
407
Seal, O'Ring
207
Pin, Ro ll
408
Plu g, SAE
208
Ring, Retainer
409
Plu g, SAE
410
Plu g, SAE
411
Gasket, V alve Plate
412
Co ver, Rear Shaft
413
Seal, O'Ring
414
Screw, So cket Head Cap
200
Table 1971.5 - Oilgear Type PVG Pumps Parts List
Doc. 2920025-47-5 Rev. 2
B-59
ITEM NUMBER
ARP 568 UNIFORM
S IZE NUMBER WITH
DUROMETER
ITEM NUMBER
ARP 568 UNIFORM
S IZE NUMBER WITH
DUROMETER
010
912-70
406
903-90
404
013-90
407
904-90
405
902-90
413
138-70
Table 1971.6 - ORing Sizes
Doc. 2920025-47-5 Rev. 2
B-60
101
105
104
202
204
207
206, 203
006
207
302
305
004, 010
303
304
103
411
001
102
208
404
005
407, 410 406, 409 403
307
308
309
412, 413, 414
401
008, 003
* 205
007
306
301
* NOTE:
Pins shown out of position. Hydrobearing, Item 202, to be assembled with scarf cuts positioned top
and bottom with pins, Item 205, which locate on top of internal cast boss.
Figure 1971.10 - Cross Section and Plan View Parts Drawing
Doc. 2920025-47-5 Rev. 2
B-61
NOTE:
* - Two pins used only on size 130 units
** - Size 100 and 130 only
Figure 1971.10 - Exploded Parts Drawing
Doc. 2920025-47-5 Rev. 2
B-62
305
304
301-d
306
007
406,
302
407,
303
301-
301307
308
*205
004, 010
309
**206
401-e
403
001
301-B
407,
005
**203
411
404
401-I
008
208
201
403
207
405,
204
006
003
202
104
105
406, 409
103
401412, 413
204
407, 410
005
102
403
414
101
After Sales Ser vices
Oilgear builds products that last. However, it is the nature of this type of machinery to require proper maintenance regardless of the care that goes into its manufacture. Oilgear has several service programs to help you.
Stay-on-Stream Ser vice
By signing up for Oilgears Stay-On-Stream program you can prepare for problems before they happen.
Certain field tests such as fluid testing, slip testing and electronic profile recording comparisons can be
performed by our Field service people or your own trained personnel. These tests can indicate problems
before they become down-time difficulties.
Ser vice Schools
Oilgear holds schools to train your maintenance personal. A general hydraulic or electronic school is
conducted in our Milwaukee plant on a regular basis. Custom schools, specifically addressing your particular hydraulic and electrohydraulic equipment can be conducted in your plant.
Spare Par ts Availability
Prepare for future needs by stocking Oilgear original factory parts. Having the correct parts and necessary
skills in-plant enables you to minimize down-time. Oilgear has developed parts kits to cover likely future
needs. Oilgear field service technicians also stand ready to assist your maintenance people in troubleshooting
and repairing equipment.
Oilgear Exchange Ser vice
Standard replacement pumps and motors are available to users of Oilgear equipment where comparable units
will be returned in exchange. When standard replacements must be modified to replace units which are
special, shipment will depend on availability of parts, assembly and test time necessary.
To obtain this service, place an order for an exchange unit and provide the serial number and type designation. The replacement unit will be shipped F.O.B. our factory. Milwaukee, Wisconsin. User retains the
replacement and returns the worn unit prepaid to The Oilgear Company for reconditioning and test. When the
unit is reconditioned and stocked, the user is billed the cost of reconditioning or a flat rate exchange price if
one has been applied to that particular type of unit.
Doc. 2920025-47-5 Rev. 2
B-63
Doc. 2920025-47-5 Rev. 2
B-64
APPLICAT IONS & S ERVICE INS T RUCT IONS
REXROT H VARIAB LE DIS PLACEMENT MOT OR
Mo del AA6VM, S ize 160
High Speed Motor
Introduction
This manual is intended to provide the information required to successfully start up, adjust, trouble shoot and
service the Rexroth Variable Displacement Motor, Model AA6VM.
The adjustment and disassembly procedures described herein may be performed in clean conditions without
affecting the warranty. Dismantling the units beyond the stages described in this manual without the express
permission of Rexroth may void the warranty.
When performing any type of service or conversion to these motors, the utmost cleanliness of work area,
tools, cleaning rags, and the components is required. Dirt and contamination introduced during assembly and
service is a major cause of failure in high-pressure piston equipment. Therefore, the importance of cleanliness cannot be over emphasized.
Ordering of Parts
For Rexroth to supply the correct parts for your unit, please include all of the following information along
with your parts order.
Ø
Model Code
Ø
Serial Number
Ø
Unit Number
Ø
Part Name
Ø
Part Number
Due to modifications and improvements to our products, minor changes can occur to the parts, even though
the type code may not necessarily reflect these changes. The type number and serial number will guarantee
that the correct parts for your unit are supplied
Doc. 2920025-47-5 Rev. 2
B-65
ORDERING EXAMPLE
To order a replacement viton shaft seal for an AA6VM variable displacement motor having the above nameplate, the following information would be required:
+ Model Code
AA6VM55HD1/63W-VSC520B
+ Serial Number
1127809
+ Unit Number
5621-004-014
* Part Name
Shaft Seal
* Part Number
5000-076-026
+ This information is taken from the nameplate on the motor
* This information is taken from the replacement parts section in this manual.
Technical Data
Fluid Recommendations
The AA6VM motor in the standard design, should be used with good quality, petroleum oil based, anti-wear
hydraulic fluids. More detailed information regarding the selection of hydraulic fluids and their application
limits can be found in our Data Sheets RA 90220 (Petroleum Oil), RA 90221 (Biodegradable Fluids) and RA
90223 (Type HF-Fire Resistant/Synthetic Fluids).
When operating with environmentally compatible fluids (Biodegradable) or fire resistant fluids (Type HF
synthetic) possible reduction of the operating specifications may be required. Please consult us and your fluid
supplier.
Operating Viscosity Range
(See Selection Diagram)
In order to obtain optimum efficiency and service life we recommend that the operating viscosity (at normal
operating temperature) be selected from within the range.
Optimum Viscosity (Vopt) 80-170 SUS (16-36 mm²/s)
Viscosity Limits
The limiting values for viscosity are as follows
Maximum Viscosity (Vmax) 7400 SUS (1600 mm²/s)
Only for short periods during cold start up
(tmin= 40ºF/C)
Absolute Minimum Viscosity (Vmin) 42 SUS (mm²/s)
Operating Temperature Range
Min operating temp
-13ºF (-25ºC)
Absolute min temp
-40ºF (-40ºC)
Max operating temp for short duration 240ºF(115ºC)
Please note that applications with low start-up temperatures -40 -15ºF (-40 -25ºC) may require special installation positions, please consult us.
Doc. 2920025-47-5 Rev. 2
B-66
Selection Diagram
Notes on Hydraulic Fluid Selection
In order to select the correct fluid, it is necessary to know the normal operating temperature in the circuit in
relation to the ambient temperature; in an open circuit the reservoir temperature and in a closed circuit, the
loop temperature.
The hydraulic fluid should be selected so that, within the operating temperature range, the fluid viscosity is
within the optimum range Vopt (see shaded area in the fluid selection diagram) We recommend that the higher
viscosity grade is selected in each case.
Example: At an ambient temperature of Xº, the operating temperature in the reservoir is 140ºF (60ºC). In the
optimum operating viscosity range Vopt, (shaded area), this corresponds to viscosity grades VG46 or VG68,
VG68 should be selected.
Important:
The leakage fluid (case drain fluid) temperature is influenced by pressure and speed and is typically
higher than the circuit temperature However, maximum temperature at any point in the system must
be less than 240ºF (115ºC).
If it is not possible to comply with the above conditions because of extreme operating parameters or high
ambient temperature, please consult us.
Built-On Flushing Valve
The built-on flushing valve is set at a fixed pressure of 230 psi* (16 bar) and serves to maintain the minimum
boost pressure. A quantity of hydraulic fluid, determined by the orifice fitted (see table), is drawn off from
the low pressure side and passed into the motor housing, from where it is led off to tank together with the
leakage fluid. The fluid thus taken from the circuit must be replaced with cooled oil by means of the boost
pump.
Different flushing volumes can be selected by means of orifices.
Doc. 2920025-47-5 Rev. 2
B-67
Set primary charge relief valve accordingly.
FLUSHING VOLUME
VO LUME
O RIFICE NUMBER
2.6 gpm (10 L/min)
HU09419697/503.12.01.01
Values given for charge pressure Dp = 360 psi (25 bar)
When ordering please state required orifice in clear text.
Installation Position
Optional: The unit may be mounted in any horizontal position (drive shaft axis). Other mounting orientations
(Ex. drive shaft vertical) are possible, see data sheet RA 90270 for further installation information.
The housing must be filled prior to start-up, and must always remain full of fluid. Therefore, the case drain
line should be connected to the highest case drain port.
The case drain line, or hose should be sized to accept the full flow of the charge pump at the maximum
anticipated drive speed with minimal pressure drop.
Fluid Cleanliness Levels
In order to ensure proper and reliable operation, the hydraulic fluid must be maintained at a minimum cleanliness level of 18/15 (according to ISO/DIS 4406; SAE J1165) Axial piston component life is directly dependent on the cleanliness of the fluid in the system.
TEMPERATURE RANGE
- 40 - 195 DEGREES F
- 40 - 90 DEGREES C
195 - 240 DEGREES F
90 - 115 DEGREES C
Cleanliness Recommendations
Class
Class
ISO /DIS 4406 (SAE J1165)
18/15
17/14
NAS 1638
9
8
SAE
6
5
Filtration
Many factors influence the selection of a filter to achieve the desired cleanliness level, including dirt ingression rate, required cleanliness level, and system complexity. We have found the following filter Beta (b)
ratios (ISO 4572) to be satisfactory b20 b30 á 100
Direction of Flow
CLOCKWISE ROTATION
COUNTER- CLOCKWISE ROTATION
A to B
B to A
Operating Pressure Range
Maximum pressure at port A or B
Nominal pressure pn 5800 psi (400 bar)
Peak pressure pmax
6525 psi (450 bar)
The sum of the pressures at ports A and B must not exceed 10 000 psi (700 bar). Individual pressure per side
of 6525 psi (450 bar) is not to be exceeded. This summation pressure is for intermittent duty only. Consult us
for applications where continuous summation pressure greater than 7250 psi (500 bar) exists.
Doc. 2920025-47-5 Rev. 2
B-68
Speed Range
There is no limitation on minimum speed Nmin. If smooth shaft rotation is required (no cogging) then the
minimum speed Nmin should not be allowed to fall below 50 rpm.
The maximum flow from the pump and the minimum displacement of the variable motor together determine
the maximum output speed. The minimum displacement is mechanically limited by means of an adjustment
screw, so that the maximum permissible speed (of the variable motor or driven unit) are not exceeded.
Adjustment range from Vg 0 to Vg max.
Minimum displacement (Vgmin) is factory set and secured by a tamper proof cap. For special applications, the
AA6VM series 63 is capable of zero displacement operation.
Case drain pressure
Maximum shaft seal life is achieved with low case pressures and low motor speeds. The values shown in the
diagram are the maximum permissible case pressure and speed conditions and should not be exceeded.
Exceeding these values will result in decreased shaft seal life. For short periods (t < 5 min ) case pressures up
to 75 psi (5 bar) regardless of drive speed are permissible and up to 90 psi (6 bar) at low speeds.
RGTOKUUKDNGRTGUUWTG
RUK
DCT
2
UK\G
Z
C
O
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D
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URGGFKPTRO
Special operating conditions may require limitations of these values
NOTE:
Maximum permissible motor speeds are given below.
Max permissible case pressure pabs 90 psi (6 bar)
The pressure in the housing must be the same or greater than the external pressure on the shaft seal.
Doc. 2920025-47-5 Rev. 2
B-69
Table of Values
(Theoretical Values Rounded)
AA6VM
Disp lacement
Variab le Mo to r
Vg max
S IZE 55
S IZE 80
S IZE 160
cm3/rev
54.8
80
160
in /rev
3.34
4.88
9.76
cm3/rev
0
0
0
in3/rev
0
0
0
rp m
4200
3750
3000
rp m
4600
4100
3300
rp m
6300
5600
4500
cm3/rev
37
54
107
in3/rev
2.26
3.3
6.53
rp m
7100
6300
5000
L/min
230
300
480
gp m
60.8
79.3
126.8
Nm/b ar
0.87
1.27
2.54
lb -ft/p si
0.04
0.06
0.13
Nm
348
510
1016
lb -ft
256.7
376.2
749.4
Kw
153
200
320
hp
205.2
268.2
429.1
K gm2
0.0042
0.0080
0.0253
lb -ft2
0.100
0.190
0.600
kg
26
34
64
lb s
57.3
75.0
141
3
Vg01)
Sp eed
max. rp m at Vg max
n
max co nt
max. rp m at Vg max
n
max intermittent
2
)
max. rp m at Vg < Vg.1
Vg.1
max. rp m at Vg0
Flo w
To rqu e Co nstant
To rqu e
at nmax cont and Vg max
at Vg max
at Vg max (D p = 400
b ar)
Qmax
Tk
T
max
p si)
Po wer
b ar)
P max
p si)
Mo ment o f Inertia (Ab o u t Drive Axis)
Weight (Ap p ro ximate)
1.
2.
J
m
The minimum displacement Vgmin is infinitely adjustable between Vg0 and 0.8 * Vg max. Indicate in the
order: Vgmin = cm³
Intermittent max. speed: overspeed at high-idle and over-running travel operation, t< 5 sec. and Dp <
2200 psi (150 bar).
Doc. 2920025-47-5 Rev. 2
B-70
Output Drive
AA6VM
S IZE 55
S IZE 80
S IZE 160
in
0.59
0.69
0.89
mm
15
17.5
22.5
lb f
2347
1911
4568
N
10440
8500
20320
+ F ax max
112
160
252
- F ax max
112
160
252
+ F ax max
500
710
1120
- F ax max
500
710
1120
a
Fq max
6F ax max
lb f
N
6F ax perm./p si
lb f/p si
0.12
0.15
0.23
6F ax perm./b ar
N / b ar
7.5
9.6
15.1
(S
(CZ
C
a
= distance from Fq from shaft shoulder
Fq max
= max. perm. radial force at distance a (at a intermittent operation)
6Fax max
= max. perm. axial force when stationary or when axial pistion unit is running at zero pressure
6Fax perm./psi = perm. axial force/psi operating pressure
6Fax perm./bar = perm. axial force/bar operating pressure
- Fax max
= increased bearing life
+ Fax max
= increased bearing life
8$GNV&TKXG
)GCT&TKXG
$K FKTGEVKQPCN
4QVCVKQP
u
V
wQR
wQR
V
u
$K FKTGEVKQPCN
4QVCVKQP
u
V
R
Q
w
wQ
RV
u
%QWPVGT%NQEMYKUG
%NQEMYKUG
%NQEMYKUG
%QWPVGT%NQEMYKUG
4QVCVKQP
4QVCVKQP
4QVCVKQP
4QVCVKQP
2TGUUWTGCV2QTV$
2TGUUWTGCV2QTV#
2TGUUWTGCV2QTV#
2TGUUWTGCV2QTV$
Doc. 2920025-47-5 Rev. 2
B-71
Speed, Displacement, Pressure, Torque
8
I
IOCZ
P
OCZ
P
CV 8
0)
8
IOCZ
2TGUUWTGR
DCT
D
I
2TGUUWTGR
RUK
D
8
8
Diagram 1
IOCZ
EO
6QTSWG/
0O
6QTSWG/
.DHV
Diagram 2
Example
Given:
Required:
Size 107
Maximum Permanent Displacement
Speed n=3860
Torque
nmax at Vg max (See Table of Values)
Pressure Dp=4350psi (300 bar)
Solution:
Speed Ratio
n
nmax at Vg max
= 3860 = 1.17
3300
From Diagram 1:
Displacement Ratio
Vg
= 0.85
Vg max
Therefore displacement Vg = 0.85 . Vg max
= 0.85 . 107cm3 = 91cm3
Speed Sensor (D)
Version A6VM...d (with provisions for speed sensor) includes toothed collar on the rotary group.
A speed-proportional signal is produced by means of the rotating, toothed rotary group witch can be picked
up by a suitable sensor and fed back for evaluation.
The feed sensor can be screwed into the upper drain port. An additional adapter piece is necessary for the
drain ports in order to install the speed sensors (M18 x 1.5).
S IZE
55
80
107
160
Nu mb er o f Teeth
54
58
67
72
Length o f Thread (mm)
19.9
19.9
19.9
31.9
Doc. 2920025-47-5 Rev. 2
B-72
Hydraulic Control
HD Pilot Pressure Related
The pilot pressure related hydraulic control allows infinite variation of the motor displacement in relation to
a pilot pressure signal. The control function is proportional to the pilot pressure applied at port X.
HD1
Pilot pressure increase (Vg rnax - Vg 0) .... Dps = 145 psi (10 bar)
Start of control, adjustable....between 30-300 psi (2-20 bar)
Standard setting: start of control at 45 psi (3 bar)
end of control at 1 85 psi (1 3 bar)
HD2
Pilot pressure increase (Vg max - Vg 0) .... Dps = 360 psi (25 bar)
Start of control, adjustable.....between 70-725 psi (5-50 bar)
Standard setting: start of control at 145 psi (10 bar)
end of control at 500 psi (35 bar)
The required control oil is taken from the high pressure side; for this, a minimum operating pressure of 220
psi (15 bar) is necessary. If it is necessary to operate the control at an operating pressure of <220 psi (15 bar).
a boost pressure of minimum 220 psi (15 bar) must be applied at port G via an external check valve. Maximum permanent pilot pressure.....1450 psi (100 bar).
Doc. 2920025-47-5 Rev. 2
B-73
Standard Version :
Start of control at Vg max (maximum torque, minimum speed)
End of Control at Vg min (maximum torque, minimum speed)
Variation: Constant Pressure Control (D)
The constant pressure control is superimposed on the HD function. Should system pressure rise as a result of
the load torque or reduction of the motor swivel angle , when the setting of the constant pressure control is
reached the motor is swivelled out to a higher angle.
As a result of the increased displacement and constant pressure reduction, the control deviation is eliminated.
By increasing the displacement the motor produces a higher torque at a constant pressure.
Setting range of constant pressure control valve:
1160...5800 psi (80...400 bar)
Co ntro l Characteristics
Adju stab le range: p ilo t p ressu re at "X" fo r co ntro l b egin
Pilo t p ressu re increase (D p ) fo r disp lacement adju stment Vmax to V min
Maximu m allo wab le p ilo t p ressu re at "X"
Minimu m sy stem p ressu re requ ired at p o rt A, B o r G fo r co rrect co ntro l
fu nctio n
UNITS
HD1
HD2
HD1D
H2D2
p si
30
70
30
70
(b ar)
(2-20)
(5-50)
(2-20)
(5-50)
p si
145
360
145
360
(b ar)
(10)
(25)
(10)
(25)
p si
1450
1450
1450
1450
(b ar)
(100)
(100)
(100)
(100)
p si
220
220
220
220
(b ar)
(15)
(15)
(15)
(15)
Doc. 2920025-47-5 Rev. 2
B-74
Hydraulic Two-Position Control
The hydraulic two-position control allows the displacement to be set to Vg min or Vg max by applying or venting
pilot pressure at port X.
The required control oil is taken from the high-pressure side; for this, a minimum operating pressure of 220
psi (15 bar) is necessary. If it is necessary to operate the control at an operating pressure of < 220 psi (15
bar), a boost pressure of min. 220 psi (15 bar) must be applied at port G via an external check valve.
Standard version
Pilot pressure at port X = 0 psi motor set to Vg max
Pilot pressure at port X £ 145 psi (10 bar) motor set to Vg min
Doc. 2920025-47-5 Rev. 2
B-75
Electrical Two-Position Control EZ with Switching Solenoid
The electrical two-position control with switching solenoid allows the displacement to be set to Vg min or Vg
by energizing or de-energizing the solenoid.
max
Solenoid de-energized motor set to Vg max
Solenoid energized motor set to Vg min
EZ1, EZ3 switching solenoid 12 V DC, 26W (EZ1) 30W (EZ3)
EZ2, EZ4 switching solenoid 24 V DC, 26W (EZ2) 30W (EZ4)
psi (15 bar) is necessary. If it is necessary to operate the control at an operating pressure of < 220 psi (15
bar), a boost pressure of minimum 220 psi (15 bar) must be applied at port G via an external check valve
Electrical Control EP with Propor tional Solenoid
The electrical control with proportional solenoid allows infinite variation of the motor displacement in relation to an electrical signal. The control function is proportional to the electrical control current applied.
Standard version:
Start of control at Vg max (max torque, min. speed)
End of control at Vg min (min. torque, max. speed)
MODEL
CONTROL VOLTAGE (DC)
CONTROL CURRENT S TART - END OF CONTROL
EP1
12 V
400m A - 1200m A
EP2
24 V
200mA - 600mA
bar is necessary. If it is necessary to operate the control at an operating pressure of < 220 psi (15 bar), a boost
pressure of min. 220 psi (15 bar) must be applied at port G via an external check valve.
Adjustment of the control speed or limiting of the displacement (limiting of swivel) range by electrical
means is possible using the following control devices:
Proportional amplifier PV see RA 95023
Chopper amplifier CV see RA 95029
Proportional solenoid driver MDSD see RA 29864
Multi purpose controller EDA
Doc. 2920025-47-5 Rev. 2
B-76
Variation: Constant Pressure Control (D)
The constant pressure control is superimposed on the EP function. Should system pressure rise as a result of
the load torque or reduction of the motor swivel angle, when the setting of the constant pressure control is
reached the motor is swivelled out to a higher angle.
As a result of the increased displacement and consequent pressure reduction, the control deviation is eliminated. By increasing the displacement the motor produces a higher torque at a constant pressure.
Setting range of constant pressure control valve 1160 ... 5800 psi (80 ... 400 bar)
CONTROL CHARACTERIS TICS
UNITS
EP1
EP2
EP1D
EP2D
Co ntro l Vo ltage
Co ntro l Cu rrent Fo r Co ntro l Begin
Vdc
12
24
12
24
MA
400
200
400
200
Psi
-
-
1160-5800
1160-5800
(b ar)
-
-
(80-400)
(80-400)
Psi
220
200
200
200
(Bar)
(15)
(15)
(15)
(15)
Pressu re Overide Adju stment Range
Minimu m Sy stem Pressu re Requ ired at Po rt A, B, o r G Fo r
Co rrect Co ntro l Fu nctio n
Doc. 2920025-47-5 Rev. 2
B-77
Automatic Control High Pressure Related
With the automatic, high pressure related control, setting of the displacement is effected automatically as a
function of the operating pressure.
Start of control at Vg min (min. torque, max. speed)
End of control at Vg max (max. torque, min. speed)
This control device measures the operating pressure at A or B internally (no pilot line required) and swivels
from Vg min to Vg max once the pressure setting of the control is reached.
HA1
Version with virtually no pressure increase from start of control to end of control.
Pressure increase (Vg min to Vg max) £ Dp 145 psi (10 bar)
Start of control adjustable between 1160-5100 psi (80-350 bar) (State required setting in clear text when
ordering)
HA2
Version with pressure increase from start to end of control.
Pressure increase (Vg min to Vg max) £ Dp 1450 psi (100 bar)
Start of control adjustable between 1160-5100 psi (80 .350 bar)
(State required setting in clear text when ordering)
Doc. 2920025-47-5 Rev. 2
B-78
Variation:
Hydraulic Override of Pressure Setting (HA1T, HA2T)
On versions HA1, HA2 the pressure setting (start of control) can be influenced by applying a pilot pressure
at port X.
The pressure setting is reduced by 250 psi per 14.5 psi pilot pressure (i.e. -Pilot pressure to high pressure
ratio. 1:17)
Example:
Pilot pressure at port X 0 psi (0 bar)
Pressure setting 4350 psi (300 bar)
Start of control 4350 psi (300 bar)
150 psi (10 bar)
4350 psi (300 bar)
1885 psi (130 bar)
If the override is only required to set the max. displacement (motor swivel to Vg max), a pilot pressure of up to
1450 psi (100 bar) max. is permissible.
Pressure Override
Control Description
Motors fitted with this option allow remote control of the motor displacement until system pressure reaches
the pressure setting of the pressure override (POR) valve. When this occurs, displacement adjusts automatically towards maximum angle, until the product of displacement and set (system) pressure satisfies the
output torque demand on the motor.
System pressure greater than the set pressure of the POR valve will keep the motor at maximum displacement, even if the HD, EP control signal is set to send the motor to minimum displacement
Adjustment Procedure
Turn adjustment screw A in so that the POR does not function then set HD begin point as describe in the
Adjustment Procedure for the HD Control Section of this manual. Then with the HD control commanding
the motor towards minimum displacement raise the pressure at the G port to the desired POR setting. Then
turn adjustment screw A until the pressure at M, is less than 1/2 of G port. Turning adjustment screw A
CW raises pressure at M1, turning adjustment screw A CCW lowers pressure at M1.
There are two types of self-cleaning swivel-time orifices available, a unidirectional and a bi-directional. This
means that one type of shuttle orifice will control flow in one direction and will free flow in the other The
second type of shuttle orifice will control flow in both directions. Both types of shuttle orifices are shown
above.
A swivel-time orifice kit is made up of two orifice plugs and one shuttle orifice. This kit is inserted into the
M1 port of the motor cap (see section on Port Information for M1 port location). There is only one way to
properly insert the swivel-time kit. First, thread orifice plug A into the M1 port until it bottoms. Caution: Do not over tighten this orifice plug. Next, insert the shuttle orifice in its proper orientation for desired
flow control. Finally, thread orifice plug B into the M1 port until it is tightly against orifice plug A.
Plug port M1.
Doc. 2920025-47-5 Rev. 2
B-79
The bi-directional shuttle orifice can be inserted with either tapered end in first. Its orientation does not affect
flow control. The orientation of the unidirectional shuttle is important With the unidirectional shuttle assembled into the motor cap as shown above, controlled flow will be from passage 2 to passage 1 (into the stroking piston). Free flow will occur from passage 1 to passage 2 (out of the stroking piston). To reverse flow
control, rotate the unidirectional shuttle orifice 180º. The orifice plug B requires a 5mm Allen Wrench and
orifice plug A requires a 6mm Allen Wrench.
Note:
When using a unidirectional shuttle orifice, it will typically be assembled to control motor swivel time from
minimum to maximum displacement. Contact Rexroth for more details.
Installation
The AA6VM motor may be mounted in any position. When mounting in a shaft up position, special considerations regarding the case drain line may be required to ensure the motor bearings are always immersed in
oil.
The AA6VM is usually face mounted to a final drive gear box with the shaft engaging a mating female
splined gear hub or spline adapter. The large drive shaft bearings permit vee or toothed belt pulleys, or gear
pinions to be mounted directly to the drive shaft. (Consult Rexroth for radial and axial force limitations.) The
motor may also be used to transmit power via a universal drive shaft. The case drain line should be connected to the highest case drain part so that the motor always remains full of oil.
Doc. 2920025-47-5 Rev. 2
B-80
For mobile applications, the oil reservoir capacity required (in U.S. gallons) is generally .75 to 1 times the
charge pump flow (in U.S gallons per minute) for a one pump, one motor transmission. The heat exchanger
should be located between the pump case drain and the reservoir, and sized to accept the full flow of the
charge pump at the maximum anticipated drive speed.
To accommodate slight shaft misalignment and to dampen vibration, use of a flexible coupling is recommended. The motor user should work closely with the coupling manufacturer in selecting and applying a
suitable coupling. When flexible couplings, Veebelts or toothed timing belts are to be used, the coupling
halve, gear or pulley, should be secured to the drive shaft using a spacer between the coupling and the shoulder on the drive shaft, and locking the coupling to the shaft by using a set screw into the threaded hole in the
end of the shaft. If this is not possible, as when mounting the motor to a drive gearbox, Optimoly Paste
White T multipurpose lubricating paste or equivalent must be applied to the shaft to avoid fretting corrosion
of the spline
Motor Flushing
A flushing valve is usually required when a motor will be operated for extended periods of time at high
speed and/or high-pressure conditions.
A flushing valve is available for manifold mounting on the rear cover of an AA6VM motor. This valve
provides a regulated flow of oil from the low-pressure side of the loop into the motor case. This oil is used to
cool and flush the motor bearings.
Note:
Consult Rexroth application engineer to determine if a motor flushing valve is required for your application
Filtration
The fluid should be filtered prior to system start-up, and continuously during operation to achieve and maintain a cleanliness level of ISO 18/15 (This corresponds approximately to NAS 1638 class 9, or SAE [1963]
Class 6.) This recommendation should be considered a minimum, as better cleanliness levels will significantly increase component life.
Each application should be analyzed to determine the proper method at filtration needed to maintain the
required cleanliness levels, as contaminant generation and ingression can vary greatly, depending on the
configuration and complexity of the system. For particular system requirement, or for application outside
these parameters, a Rexroth Applications Engineer should be consulted.
Doc. 2920025-47-5 Rev. 2
B-81
Pre-Start Procedure
This should be performed prior to start-up a new installation, or for a system in which new or overhauled
components have been fitted.
1
Ensure that hydraulic reservoir piping and pressure hoses are cleaned and flushed.
2
Fill the reservoir through fill pump and filter.
3
If there is any doubt regarding the absolute cleanliness of the system, fit high-pressure bi-direction
filters in high-pressure lines as shown in following diagram. The filters are in addition to the installed
suction and return filters
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Check that all filters have elements of the correct rating and the filter housing are filled with the hydraulic fluid to be used in the system
Where possible, fill the high-pressure lines.
Open suction line valves.
Fill pump and motor case to the highest drain or vent port.
Check that all pressure connections are secure.
Ensure all mechanical gear boxes have the correct oil type and are filled to the prescribed level.
Fully back off all high-pressure relief valves and then reset one half turn against the spring.
Fit 10,000 psi pressure gauges to each high pressure line.
Fit 500 psi pressure gauges to charge and pilot circuits.
Fit 100 psi pressure gauge to pump case drain port.
Fit vacuum gauge to the charge pump suction line, as close as possible to suction port.
Release brakes and jack up the driving wheels. Winches should be started without the cable fitted.
Ensure that the fluid temp. in the reservoir is 45ºF or higher.
Ensure that the motor minimum displacement (maximum speed) is set correctly as shown in the
Swivel Angle Adjustment section.
Star t-Up Procedure
The following procedure has been developed based on experience with most types of applications, however
certain applications may require a departure from or variation to this procedure.
For the start-up of new or overhauled installations.
1
If the prime mover is:
Internal combustion engine: (Diesel, gasoline or LP) Remove the coil wire, close the injector rack or
leave the gas turned off and turn the engine over until the charge pressure reaches 50 psi or more.
Electric Motor: Jog the starting circuit until the charge pressure reaches 50 psi or more.
Doc. 2920025-47-5 Rev. 2
B-82
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Start the prime mover, and if possible, maintain a pump speed of approximately 750 rpm for 5 minutes
This will allow the system to be filled.
Listen for any abnormal noises.
Check for oil leaks
Run prime mover to 1800 rpm. (Adjust to the design speed if less than 1800 rpm.)
Set charge and pilot pressure as required for the application. (Refer to circuit schematic).
10. Bleed the pilot lines by loosening the connections on the motor X port(s) and then actuate the
remote control unit in both directions until oil seeps from the connections. Also bleed the pilot lines to
the pump (if any).
Retighten all connections
Operate the control to work the hydrostatic transmission at approximately 20% of maximum speed.
Deaerate system by venting a bleed valve or by cracking the highest connection until fluid seeps out
without bubbles.
Check fluids level and add fluid if necessary.
Continue operating transmission and gradually increase to full speed, still with no load.
With controls neutralized, check for creep in neutral. If evident, centre the control in accordance with
the instructions in the pump service manual.
Check that the controls are connected so that the transmission operates in the correct direction related
to the control input.
Continue to monitor all pressure gauges and correct any irregularities.
Apply brakes and set high-pressure relief valves (and pressure override if installed) to levels required
for the application by stroking the pump to approximately 20% of maximum displacement.
Check security of high-pressure connections.
Check oil level and temperature
Remove and inspect high-pressure filter elements, if so equipped. Replace with new elements.
Operate transmission under no load conditions for about 15 minutes to stabilize the temperature and
remove any residual air from the fluid.
Again remove and inspect high-pressure filter elements, if so equipped. If clean, the high-pressure,
bi-direction filters may be removed from the circuit. If contamination is still evident, fit new elements
and continue flushing until the system is clean.
Replace the elements in the charge pump suction or pressure filter, whichever is installed.
Operate the transmission under full and normal load conditions.
Erratic operation may indicate that there is still air trapped in the system. By working the pump control
to one or both sides the remaining air can be eliminated. The system is free of air when all functions
can be operated smoothly and when the oil in the reservoir is no longer aerated. (Usually less than 1
hour of operation)
Note:
If, after following the Pre-Start and Start-up procedures, the transmission does not perform correctly, refer to
the relevant sections of the troubleshooting procedures.
Doc. 2920025-47-5 Rev. 2
B-83
Doc. 2920025-47-5 Rev. 2
B-84
Doc. 2920025-47-5 Rev. 2
B-85
Doc. 2920025-47-5 Rev. 2
B-86
Begin of Stroke Adjustment, Gauge Method
Preparation for Adjustment
For the HD control tee the pilot supply line and a 750-psi gauge into the X port. Remove the plugs in G and
M1 ports and connect a 10,000-psi gauge to each port.
For the HA control remove the plugs from G and M1 ports Then tee a 10,000 psi gauge with the supply line
into G port and connect a 10,000 psi gauge to M1 port
For the EP control remove the plugs from G and M1 ports. Tee a 10,000-psi gauge with the supply line into
G port and connect a 10,000-psi gauge to M1 port. An ammeter is also required to adjust the control. It must
be placed in the line that is feeding the motor solenoid. The control range for the 24 VDC solenoid is 200mA
to 600 mA. The control range for the 12 VDC solenoid is 400mA to 1200 mA.
Doc. 2920025-47-5 Rev. 2
B-87
The begin of stroke adjustment screw, which is located on the rear housing as shown, will be used to set the
begin of stroke. To allow for adjustment, break off the tamper resistant cap and back off the locknut while
holding the adjustment screw with a 3mm hex wrench. The locknut requires a 10mm wrench.
1)
2)
3)
4)
5)
6)
7)
1)
2)
3)
4)
5)
Adjustment Procedure for the HD Control
Lock or load motors and then bring pump on stroke until at least 600-psi loop pressure is developed.
Or supply pressure to the G port with an external pressure source. Caution: Do not allow oil to flow
over the high pressure relief valves for long periods of time, as excessive heat can be generated in the
pump.
Apply a variable low-pressure pilot signal at the gauged X port, either with the charge pump or an
external source, eg. Remote pilot controller or pressure reducing valve.
Gradually increase the pilot pressure at the X port while watching the stroking pressure on the M1
gauge. When the M1 pressure is approximately 1/2 of G note the pilot pressure on the X gauge. This is
the begin of stroke set point. The begin of control adjustment setting ranges from 29-290 psi on HD1
control and 72.5-725 psi on the HD2 control.
To change the begin of stroke set point turn the adjustment screw in (clockwise) to lower the setting
and out (counter clockwise) to increase the begin point setting.
Repeat steps 1 through 4 until the required begin of control set point is achieved and stable.
When the correct setting is reached, lock adjustment screw in place and adjust the pilot pressure above
and below the begin point to check motor operation.
After obtaining the desired setting shut down the system, remove gauges, reinstall plugs and reconnect
pilot line as it was originally.
Adjustment Procedure for the HA Control
Lock or load motors to accept pressure from either side of the loop. Gradually increase the loop pressure while watching stroking pressure on the M pressure gauge. This can be done with the main hydrostatic pump. Or by supplying pressure to the G port with an external pressure source. Caution: Do not
allow oil to flow over the high pressure relief valves for long periods of time, as excessive heat can be
generated to the pump.
When the M1 pressure is approximately 1/2 of G note the loop pressure on the G gauge. This is the
begin of stroke set point.
To change the setting turn the adjustment screw in (clockwise) to lower the begin point setting and out
(counter clockwise) to increase the begin point setting.
Repeat steps 1 through 5 until the required begin of control set point is achieved and stable. The G port
may require bleeding each time due to trapped pressure.
Note: The begin of control can be selected between 1160 and 5075 psi for HA1 control and HA2
control.
Doc. 2920025-47-5 Rev. 2
B-88
6)
7)
1)
2)
3)
4)
5)
After obtaining the desired setting lock begin of stroke adjustment screw into place. Shutdown system,
remove gauges, reinstall plugs in ports M1 and G. Caution: Port G may contain trapped pressure.
Note: If motor has control override option (T code) port X must be vented to tank during adjustment
procedure ie. X port must be free of any trapped pressure.
Adjustment Procedure for the EP Control
Lock or load motors to accept pressure from either side of the loop and then bring pump on stroke until
at least 600 psi loop pressure is developed. Or supply pressure to the G port with an external pressure source. Caution: Do not allow oil to flow over high pressure relief valves for long periods of time
as excessive heat can be generated in the pump.
Gradually increase the amperage to the solenoid while watching the stroking pressure on the M1
gauge. When the M1 pressure is approximately 1/2 of G read the ammeter This is the begin of stroke
set point.
If the setting is different from the amperage rating shown in the table in the Electrical Control with
Proportional Solenoid section, readjust the setting by turning the adjustment screw in (clockwise) to
lower the setting and out (counter clockwise) to increase the begin point setting.
Repeat steps 1 through 3 until the required begin of control set point is achieved and stable.
When the correct setting is achieved, lock the adjustment screw in place, shut down the system Remove gauges and ammeter reinstall plugs and solenoid connector.
Swivel Angle (Speed) Adjustment
Determine X dimension from corresponding charts below for desired displacement. Remove displacement
screw from motor and compare overall length of screw to recommended screw length on chart for desired
displacement. If the displacement screw in motor is not the recommended length, modify X dimension in
relation to the difference in actual and recommended screw length (Example: If the actual screw length is 10
mm longer than recommended, add 10 mm to the X dimension from chart.). Install screw into motor and
tighten seal nut while maintaining X dimension.
Note: See Technical Data section for motor speed/displacement limitations. When designing a hydrostatic
transmission for a vehicle or winch drive using these motors, we recommend a design speed of approximately 85% of the maximum speed at the reduced displacement. This allows for operating speeds up to the
maximum under overrunning load conditions.
MOTOR S IZE
ALLEN WRENCH
WRENCH
55
5mm
17mm
80, 107, 160, 200
6mm
19mm
Doc. 2920025-47-5 Rev. 2
B-89
Doc. 2920025-47-5 Rev. 2
B-90
Doc. 2920025-47-5 Rev. 2
B-91
Shaft Seal Replacement
To replace the shaft seal first remove the snap ring and support ring.
Thread two sheet metal screws into the seal.
Press new shaft seal, support ring, and retaining ring into the housing. Take care to press to proper depth.
Doc. 2920025-47-5 Rev. 2
B-92
Routine Maintenance
The AA6V variable motors are relatively maintenance free. Maintenance work is confined to the system, by
way of oil changes and renewal of filter elements. Both of these measures promote system cleanliness.
Monitoring and periodic maintenance of the system can prevent premature breakdowns and repairs. Under
normal application conditions, the following maintenance intervals are suggested.
1)
2)
3)
4)
5)
Renewal of Filter Elements
After commissioning.
After 500 operating hours.
Thereafter during a fluid change.
With suction filtration, the filter element should be renewed as soon as a charge pump inlet pressure of
less than - 3.2 psig (0.8 bar absolute) becomes evident with the transmission in warm running condition.
With charge flow filtration, watch for high-pressure differential across the filter element. (Refer to
filter manufacturers specifications)
Caution: Use only 10 micron, or finer, filter elements.
Note: Paper inserts cannot be cleaned, use throwaway cartridges (maintain a stock).
1)
2)
3)
Hydraulic Fluid Change
After 500 operating hours (1 fluid change).
After 2000 operating hours (2nd fluid change)
Thereafter every 2000 operating hours or annually irrespective of operating hours achieved.
st
The fluid should be drained with the system warm from previous running. Before re-filling, the reservoir
should be cleaned to remove any sludge.
Caution: Rags or other threading material must not be used.
The recommended interval between fluid changes is based on various factors and should be carried out
according to the type of fluid, the degree of aging and contamination of the fluid. The water content is also a
contributory factor.
Under application conditions with a heavy occurrence of dust or severe temperature fluctuations the intervals
between fluid changes should be shortened accordingly
Caution: Practical experience shows that most maintenance errors occur during an oil change due to:
1)
2)
3)
4)
Use of an unsuitable hydraulic fluid.
Use of fluid contaminated due to faulty storage.
Failure to clean reservoir.
Inadequate cleanliness when filling (dirty drums or containers).
Doc. 2920025-47-5 Rev. 2
B-93
Leakage Inspection
After commissioning
The complete transmission (pump, motor and all pipelines, filters, valves, etc.) should be checked for leakage
at regular intervals.
Caution: Leaking joints and connections must only be tightened in pressureless conditions.
Cleanliness Inspection
The oil tank breather should be regularly cleaned of dirt and dust to prevent clogging. The cooling surfaces
should be cleaned at the same time.
Caution: If hose couplings are used in the high pressure lines, it is imperative that the utmost care be taken
that no foreign bodies infiltrate the oil circuit when coupling and uncoupling (danger of damage to rotary
group, and even possibility of total breakdown).
Fluid Level Inspection
Inspect fluid level in reservoir after commissioning, thereafter daily.
Caution: Top up only with specified fluid type. Do not mix fluids.
Hydraulic Fluids
Most good quality, mineral oil based, hydraulic fluids exhibiting the following characteristics are suitable for
use in a Rexroth hydrostatic transmission.
Ø
Good antiwear performance
Ø
Resistant to oxidation degradation
Ø
Protection against rust and corrosion
Ø
Resistance to foaming
Ø
Ability to separate water rapidly
Ø
Suitable for widely varying temperature conditions
Ø
Good low temperature flow properties
Ø
Retains viscosity-temperature characteristics in service
Ø
Universally available
The prime consideration in the selection of hydraulic fluid is the expected oil temperatures extremes that will
be experienced in service. These extremes should be considered when selecting a fluid, so that the most
suitable temperature - viscosity characteristics are obtained.
The fluid chosen should permit the system to operate within the following viscosity ranges.
Ø
Maximum viscosity at start 7400 SUS (1600 cSt)
Ø
Normal operating viscosity range 66464 SUS (12100 cSt)
Ø
Optimum viscosity range 80170 SUS (1636 cSt)
Ø
Absolute minimum viscosity 42 SUS (5 cSt)
When the fluid viscosity is greater than 1000 SUS (216 cSt) the transmission should be operated at reduced
speed until the oil has been warmed to a temperature of 40ºF (4.5ºC).
For applications that will operate near the extremes of viscosity and/or temperature, the fluid manufacturer
should be consulted for assistance in selection of the most suitable type and grade of fluid for your application
Rexroth strongly recommends the selection and use of fluids from reputable and established suppliers.
Doc. 2920025-47-5 Rev. 2
B-94
Port Information
PORT
DES CRIPTION
CO N T R O L
55
80
107
160
200
A,B
High Pressu re Flange Po rts
AL L
3 / 4 " S AE
6000 PSI
1 " S AE
6000 PSI
1 " S AE
6000 PSI
1 1 / 4 " S AE
6000 PSI
1 1 / 4 " S AE
6000 PSI
X
Pilo t Pressu re Po rt
HD, HA
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
G
High Pressu re Po rt
AL L
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
M1
Stro ke Pressu re Po rt
AL L
9/16" -18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
9/16" - 18
UN F - 2 B
T
Case Drain p o rt
AL L
1 1/16" - 12
UNF -2B
1 1/16" - 12
UNF -2B
1 1/16" - 12
UNF -2B
1 1/16" - 12
UNF -2B
1 1/16" - 12
UNF -2B
U
Case Drain Po rt
AL L
7/8" -14
UN F - 2 B
7/8" -14
UN F - 2 B
7/8" -14
UN F - 2 B
7/8" -14
UN F - 2 B
7/8" -14
UN F - 2 B
Doc. 2920025-47-5 Rev. 2
B-95
Doc. 2920025-47-5 Rev. 2
B-96
Chuck Assembly Drawing
Doc. 2920025-47-5 Rev. 2
B-97
Rod Clamp Assembly Drawing
(Reference: Plate 1288b)
Doc. 2920025-47-5 Rev. 2
B-98
Electrical Schematic
Doc. 2920025-47-5 Rev. 2
B-99
Doc. 2920025-47-5 Rev. 2
B-100
Doc. 2920025-47-5 Rev. 2
B-101
Hydraulic Schematic
Block Schematic

B20 Maintenance

Transcription

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