Service Training PV Series 42Service Training PV Series 42

PVPVplusplus

Typical Service TasksTypical Service Tasks

Service of PVService of PVplusplus

• change shaft sealchange shaft seal• change shaftchange shaft• access to servo piston and servo sleeveaccess to servo piston and servo sleeve• add displacement feedbackadd displacement feedback• convert to horse power compensationconvert to horse power compensation• change of contour sleevechange of contour sleeve• pump disassembly pump disassembly • replace internal componentsreplace internal components

Section through the PVSection through the PVplusplus, frame size 2, PV046 , frame size 2, PV046

Change shaft seal, change shaftChange shaft seal, change shaftstep 1: remove keystep 1: remove key

Remove the key from keyed shaft, to avoid damage of the shaft seal

Change shaft seal, change shaft Change shaft seal, change shaft step 2: loosen the pilot coverstep 2: loosen the pilot cover

When loosening the pilot cover, the barrel hold down spring is unloaded.

Change shaft seal, change shaft Change shaft seal, change shaft step 3: remove pilot coverstep 3: remove pilot cover

Remove the pilot cover carefully

Change shaft sealChange shaft sealstep 4: exchange of shaft sealstep 4: exchange of shaft seal

For first assembly (new shaft) press in shaft seal, assemble washer and snap ring.for repair (used shaft) assemble washer first and then press in shaft seal.

First assembly (new shaft)

Repair (used shaft)

Change shaft sealChange shaft sealsituation new / used pumpsituation new / used pump

New shaft:shaft seal first, then washer. shaft seal is located further out

Used shaft:washer first, then shaft seal.sealing lip and dust protection lip are running on a new, un-damaged area further in the pump.

Change shaftChange shaftstep 4: remove shaftstep 4: remove shaft

To remove the shaft set the pump on the end cover (shaft vertical). That avoids, internal parts moving and damaging sealing surfaces .(See next slide)

Change shaftChange shaftstep 4: remove shaftstep 4: remove shaft

In this position all internal parts stay in their position. If the ingression of contamination is avoided, the pump can be used again without re-testing after assembling the replacement shaft.

Change shaftChange shaftstep 4: assemble new shaftstep 4: assemble new shaft

Keyed shaft can be replaced by splined shaft or vice versa.by changing shaft and mounting flange,the pump can be converted from metric mounting interface to SAE interface.

Change shaftChange shaftstep 4: assemble new shaftstep 4: assemble new shaft

Assemble shaft carefully by carefully turning insert the shaft into the barrel spline.Insert shaft carefully into the rear bearing.Front bearing must be below the mounting face before assembling the pilot cover.

Change shaftChange shaftstep 7: tighten boltsstep 7: tighten bolts

Mount pilot cover carefully. Avoid any damage of the shaft seal at the key slot or at the spline edges. First tighten two bolts only alternating.That compresses the barrel hold down spring.

Assemble of front bearing to the shaftAssemble of front bearing to the shaft

Access to servo piston and servo sleeveAccess to servo piston and servo sleevestep 1: remove displacement adjustmentstep 1: remove displacement adjustment

Open servo piston cover with two-hole wrench.

Self made two hole wrenchSelf made two hole wrench

Proposal for a selfmade two holewrench.two bolts M4, M5 or M6 can be used as „pins“.

Access to servo piston and servo sleeveAccess to servo piston and servo sleevestep 1: remove displacement adjustmentstep 1: remove displacement adjustment

The section view shows the location of the internal parts.

Access to servo piston and servo sleeveAccess to servo piston and servo sleevestep 2: remove servopistonstep 2: remove servopiston

Washer and tapered sleeve can be removed by lifting the pump to vertical.

Section through PVSection through PVplusplus, washer at servo piston at , washer at servo piston at full stroke, swash angle = 18°full stroke, swash angle = 18°

Tolerance compensation:

Not enough flow at full stroke: remove washer.

Section through PVSection through PVplusplus, washer at servo piston at , washer at servo piston at dead head, swash angle = 0°dead head, swash angle = 0°

Tolerance compensation:

Minimum flow at dead head: add washer.

Assembly PVAssembly PVplus plus displacement limiterdisplacement limiter

Contains:• servo piston plug• stroke limiter• seal-lock nut• o ring

Assembly tapered-/contour sleeveAssembly tapered-/contour sleeveand servo pistonand servo piston

Assembly of servo piston, washer and feedback sleeve into the vertical standing pump makes it easier to „find“ the thread of the swash plate connnector.See also next slide.

Assembly tapered-/contour sleeveAssembly tapered-/contour sleeveand servo piston (section view)and servo piston (section view)

Assembly of servo piston, washer and feedback sleeve into the vertical standing pump makes it easier to „find“ the thread of the swash plate connnector.

Access to servo piston and servo sleeve Access to servo piston and servo sleeve

Displacement feedback is done via the tapered feedback sleeve.

Tapered sleeve for pumps with Tapered sleeve for pumps with electrical displacement feedbackelectrical displacement feedback

Access to servo piston and servo sleeve Access to servo piston and servo sleeve

Displacement feedback is done with the contoured sleeve.

Contour sleeve for pumps with Contour sleeve for pumps with mechanical displ. Feedback (hp mechanical displ. Feedback (hp control)control)

Access to servo piston and servo sleeve Access to servo piston and servo sleeve disassembly with displacement feedbackdisassembly with displacement feedback

Putting the pump on one side avoids parts of the displacement feedback falling into the pump, when the servo piston and the feedback sleeve are removed.Alternatively the feedback device (LVDT or pilot cartridge) could be removed before removing the servo piston. Note: Do not change settings!

Remark:With the pump vertical (shaft upwards) the feedback components also stay in place and the re-assembly of servo piston and feedback sleeve is easier.

Change of a PV with standard compensator to a Change of a PV with standard compensator to a horse power compensated versionhorse power compensated version

plug M6 x 6pilot cartridgecontour sleeve

Disassembly of the pumpDisassembly of the pumpstep 1: Loosen bolts, remove three boltsstep 1: Loosen bolts, remove three bolts

If all 4 bolts are removed the internal parts of the pump can move uncontrolled and sealing surfaces could be damaged.

Disassembly of the pump, step 2: open, when pump Disassembly of the pump, step 2: open, when pump is verticallyis vertically

Remove fourth bolt and lift housing. That keeps all internal parts in position. Shaft could still be in the housing or removed first. Servo piston should be removed before disassembly.

PVPVplusplus end cover end cover

Remove or assemble rotating group carefully, to avoid any damage of the metal to metal sealing surfaces.

Air bleed valve

Gasket(steel, coated and bossed)

PVPVplusplus swash plate swash plate

The screw lock on the swash plate connector is good for 4 - 6 assemblies/disassemblies.The screw lock for the retainer screws is good for 2 assemblies/disassemblies.Nominal clearance of the slippers to the retainer is 0,03 - 0,09 mm.wear limit is: 0,15 mm.

PVPVplusplus cylinder barrel cylinder barrel

The spring is not dynamically loaded and needs not to be replaced for wear reasons.Caution when disassembling! Spring has high pre-load!

PVPVplusplus end cover, complete end cover, complete

PVPVplusplus servo piston sleeve servo piston sleeve

PVPVplus plus spring, carrier and washerspring, carrier and washer

PVPVplusplus air bleed valve air bleed valve

PVPVplusplus end cover end cover

Bearing is pressed in.port plate to be mounted with brass side up.plug M6 x 6 to be removed for horse power compensated pumps.

PVPVplusplus, prepared for through drive, prepared for through drive

PVPVplusplus, with thru drive, with thru drive