Eaton DuraForce™ HPV Conversion Procedurespub/@eaton/@hyd/docu… · EATON Duraforce HPV...

Eaton® DuraForce™ HPV Conversion Procedures

2 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Content Page #

Table of Contents

Introduction 3

Model Code 4

Tools Required 6

Exchanging Response Orifices in HPV Pump Controls

Set Up and Procedure 7

Exchanging Cold-Start Relief Valves


Exchanging Charge Relief Valves


Exchanging Combineation Relief/Make-Up Valves


Exchanging POR Spool

Set Up and Disassembly Procedure 11

Disassembly Procedure (continued) 12

Assembly Procedure 13

Installing a Filter Elimination Block


Exchanging Controls

Set Up 15

Procedure 16

Converting to Manual Control

Set Up 17

Procedure to Convert to a Standard HPV Manual Control 18

Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pumps Attached

Set Up 21

Procedure "A" 22

Procedure "B" 23

Installing a PTO Kit onto HPV Pumps Directly (without Auxiliary Pump)

Set Up 28

Procedure 29

Changing Rotation on Eaton Charge Pumps


Procedure (continued) 33

Assembling Tandem Eaton Charge Pumps


Procedure (continued) 36

Exchanging Regulation Begin Springs

Set Up and Procedure to Install Filter Elimination Book 40

Procedure to Exchange the Valve III for POR function 41

Exchanging Solenoids on HPV Pumps Controls


HPV Maximum Displacement Adjustment for M1 (Mechanical-Hydraulic Control


Maximum Flow Adjustment Procedure with "H" or "E" Controls

Set Up 44

Adjustment Procedure 45

Operational Parameters 46

3EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

This manual will provide you with information and procedures for general conversions of Eaton® DuraForce™ HPV Variable Pump for Closed Loop Operations. Procedures outlined in this manual will allow you to be more flexible with your inventory and better service your customers. To ensure accuracy of conversion and prevent part loss or damage, certain components or subassemblies are disassembled, inspected, and reassembled when removed from the pump.

Training

You have been provided information on the conversion of DuraForce products. Proper application of the information requires specific training and may require use of specialized tooling and equipment. All requests for training must be coordinated through your Eaton Account Manager. He can also provide you price and availability of any specialized tooling. If you choose to proceed with the conversion of the DuraForce products absent the necessary training and/or these specialized tools, you do so at your risk.

Eaton will accept no claim for warranty resulting from deficiencies in the conversion. Please refer to the Eaton literature web site for warranty information at www.eaton.com/hydraulics/warranty.

Labeling Converted Units

All units that have been converted must retain the original Eaton label and have a second Eaton label placed on the unit. This second label at a minimum must state

Converted Eaton Model Code # (Final Eaton model code of the converted unit)

Conversion done by (Name of your company)

Conversion Parts

All requests for specific conversion part information should be addressed to your Eaton account representative. Additional information can be found through your Eaton customer connect portal. All requests or inquiries must be accompanied by the complete model and serial number of the base unit you want to convert.

Cleanliness

Cleanliness is extremely important when repairing a hydrostatic pump or motor. Before disconnecting the lines, clean foreign material from exterior of unit. Work in a clean area. Clean all metal parts in clean solvent. Blow parts dry with air. Don’t wipe parts with cloth or paper towel, because lint or other matter could cause damage. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Don’t use coarse grit paper, files or grinders on parts.

Environmental Concerns

Protection of the natural fundamentals of life is one of our predominant tasks. We are continuously improving the protection of the environment as far as applications are concerned. We encourage you to contribute your share to comply with this demand. In connection with work to be performed, the environmental regulations of the machine manufacturer must be respected.

In general:

• Greases and oils which cannot be used any more have to be collected. They are normally a threat to water reserves and must be kept away from the environment.

• Adhere to national and local regulations for waste disposal.

Seals

A good conversion policy is to replace all old seals with new seals whenever units are disassembled. This avoids potential damage during seal removal. Lubricate seals with petroleum jelly. Use only clean and recommended oil when assembling unit. Information on recommended filters and fluids can be found in the Operational Parameters section.

Torque

All torque specifications are for lubricated threads. Bolts for gasketed surfaces should be checked for proper torque.

Introduction


Model CodeHPV – Variable Pump for Closed Loop Operation

1 2 3 ProductHPV – Closed Loop Variable

Displacement Pumpl l l l l l l

4 5 6 Displacement055 – 055 cc/r l075 – 075 cc/r l105 – 105 cc/r l135 – 135 cc/r l165 – 165 cc/r l210 – 210 cc/r l280 – 280 cc/r l

7 RotationR – CW l l l l l l lL – CCW l l l l l l l

8 Mounting Flange0 – SAE J744 standard (size 135:

(*d))l l l l l l

1 – SAE J744 standard / additional threads (sizes 105; 135: (*u))

• • •

2 – SAE J744 standard / additional holes (sizes 135; 165: (*u) / size 135: (*d))

• l

9 10 Input Driveshaft S1 – splined ANSI B92.1 12/24- 14

teeth (SAE J744 C) (size 105: (*w))

l l •

S2 – splined ANSI B92.1 12/24- 17 teeth (SAE J744 C-C)

l •

S3 – splined ANSI B92.1 8/16- 13 teeth (SAE J744 D&E)

l

S4 – splined ANSI B92.1 8/16- 15 teeth (SAE J744 F) (sizes 210, 280: (*t))

l l

T1 – splined ANSI B92.1 16/32- 21 teeth (*t)

l l


l


l l l


l

11 PortingM – ISO 6149 metric l l l l l l lD – DIN 3852 • • • •12 Pump ControlA – M1: mechanical hydraulic • • • • • • •B – H1: hydraulic proportional l l l l l l lC – H1P: hydraulic proportional /

pressure cut-offl l l l l l l

D – E1: electro-proportional (*y) l l l l l l lE – E1P: electro-proportional /

pressure cut-off (*y)l l l l l l l

F – E2: electro-proportional / shutt-off (*z)

• • • • • • •

G E5: electric three position (*y) • • • • • • •

H CA: speed related hydraulic mechanical (*c)(*d)(*r)(*z)

t t t t

K – E1T: electro-proportional / torque cut-off (*c)(*y)

t

13 Control Pressure Range Hydraulic and Electric Controls

0 – not applicable (M1;CA) • • • • • • •1 – 4-10 bar l l l l l l l2 – 4-16 bar (not for E5) • • • • • • •14 Control Solenoids0 – not applicable (M1; H1; H1P) l l l l l l lA – AMP / 12V l l l l l l lB – AMP / 24 V l l l l l l lC – DIN / 12 V • • • • • • •D – DIN / 24 V • • • • • • •E – Deutsch / 12V (E1; E1P; E2;

CA)(*z)• • • • • • •

F – Deutsch / 24V (E1; E1P; E2; CA)(*z)

• • • • • • •

15 Response Orifices0 – without response orifices l l l l l l lC – 0,8 mm (standard for M1, H1,

H1P controls)• • • • • • •

E – 1,0 mm (standard for E1, E1P, E2 controls)

l l l l l l l

G – 1,2 mm • • • • • • •J – 1,5 mm • • • • • • •16 System Relief ValvesA – 150 bar • • • • • • •B – 200 bar • • • • • • •C – 250 bar l l l l l l lD – 285 bar • •E – 300 bar • • • • •F – 305 bar • •G – 350 bar l l l l l l lH – 360 bar • •J – 380 bar • • • • • • •K – 400 bar • •L – 420 bar l l l l l l l

17 Charge Relief Valves0 – purge orifice • • • • • • •1 – 19 bar l l l2 – 20 bar l l l l3 – 22,5 bar l l l4 – 23 bar l l l l5 – 24 bar l l l6 – 29 bar l l l l7 – 17.5 bar (CA control only,

CA default)t t t t

18 Filter Configuration0 – No Filter–straight flange port

(*d)• • •

1 – Filter flange with filter cartridge l l l l l l l2 – 90° charge port flange without

filterl l l l l l l

55 75 105 135 165 210 280 55 75 105 135 165 210 280

HPV 055 R 0 S1 M E 1 E E L 1 1 0 0G BA A E 000 000 00 A A A

32 331 2 3 26 27 28 29 30 314 5 6 11 14 17 24 3413 16 198 12 15 18 25 35 367 20 21 22 239 10

• Available Option l Preferred Option t Separate Specification Required


HPV 055 R 0 S1 M E 1 E E L 1 1 0 0G BA A E 000 000 00 A A A

32 331 2 3 26 27 28 29 30 314 5 6 11 14 17 24 3413 16 198 12 15 18 25 35 367 20 21 22 239 10

Model CodeHPV – Variable Pump for Closed Loop Operation

19 Swash Angle Sensor0 – Without swash angle sensor l l l l l l lS – With swash angle sensor (*m) • • • • •

20 21 Auxiliary Pad and Shaft Definition

0G – to add gear pump see positions 22,23

• • • • • • •

AA – SAE J744 A Pad without shaft coupling (default)

• • • • • • •

AB – SAE J744 A / ANSI B92.1 16/32 - 9 teeth (A)

• • • •

AC – SAE J744 A / ANSI B92.1 16/32 - 11 teeth

• •

AD – - SAE J744 A / ANSI B92.1 16/32 - 13 teeth

•

AE – SAE J744 B without shaft coupling

• • • • • • •

AF – SAE J744 B / ANSI B92.1 16/32 - 13 teeth (B)

• • • • • • •

AG – SAE J744 B / ANSI B92.1 16/32 - 15 teeth (B-B)

• • • • •

AH – SAE J744 C without shaft coupling

• • • • • • •

AJ – SAE J744 C / ANSI B92.1 12/24 - 14 teeth (C)

• • • • • • •

AK – SAE J744 C / ANSI B92.1 16/32 - 21 teeth

• • • •

AL – SAE J744 C / ANSI B92.1 16/32 - 23 teeth

• • •

AM – SAE J744 D without shaft coupling

• • •

AN – SAE J744 D / ANSI B92.1 8/16 - 13 teeth (D)

•

AP – SAE J744 D / ANSI B92.1 12/24 - 17 teeth

•

AQ – SAE J744 D / ANSI B92.1 16/32 - 27 teeth

• • •

AR – SAE J744 E without shaft coupling

•

AS – SAE J744 E / ANSI B92.1 16/32 - 27 teeth

• •

AT – SAE J744 E / ANSI B92.1 16/32 - 33 teeth

•

22 23 Charge Pump (Internal Gear) or Tandem Adapter

00 – without l l l l l l l

BA – Internal gear pump 16 cc l l l l

BB – Internal gear pump 22,5 cc l l l l

BC – Internal gear pump tandem 16+16 cc

• • • •

BD – Internal gear pump tandem 16+22,5 cc

• • • •

BE – Internal gear pump tandem 22,5+16 cc

• • • •

BF – Internal gear pump tandem 22,5+22,5 cc

• • • • • •

BG – external gear pump 31 cc (*r) • • •BH – external gear pump 38 cc • • • • •BJ – external gear pump 44 cc (*r) • •BK – HPV/R 55 mounting

preparation (*s)• • • • • • •

BL – HPV/R 75 mounting preparation (*s)

• • • • • •

BM – HPV/R 105 mounting preparation (*s)

• • • • •

BN – HPV/R 135 mounting preparation (*s)

• • •

BP – HPV/R 165 mounting preparation (*s)

• •

BQ – HPV/R 210 mounting preparation (*s)

• •

BR – HPV/R 280 mounting preparation (*s)

•

24 Auxiliary Drive on Gear Pump0 – Without internal gear pump • • • • l • •A – SAE J744 A / ANSI B92.1

16/32 - 9 teeth (A) (default)l l l l l l

B – SAE J744 B without shaft coupling

• • • •

C – SAE J744 B / ANSI B92.1 16/32 - 13 teeth (B)

• • • •

D – SAE J744 B / ANSI B92.1 16/32 - 15 teeth (B-B)

• • • •

E – SAE J744 C without shaft coupling

• • • •

F – SAE J744 C / ANSI B92.1 12/24 - 14 teeth (C)

• • • •

25 Gear Pump Supply0 – without gear pump l l l l l l lE – external supply port l l l l l l l

26 27 28 Displacement Setting – P Port000 – Catalog Pump Rating l l l l l l l

29 30 31 Displacement Setting – S Port000 – Catalog Pump Rating l l l l l l l

32 33 Special Requirements00 – without special requirements

(default)l l l l l l l

34 Surface Coating0 – anti rust conservation oil

(default)l l l l l l l

A – primer blue l l l l l l l

35 Unit IdentificationA – Eaton l l l l l l l

36 Type Code ReleaseA – Revision Level l l l l l l l

55 75 105 135 165 210 280 55 75 105 135 165 210 280

(*c) Always set option C in position 24(*d) DIN porting only (see position 11)(*e) Availability depends on controller type

(see position 12)

(*m) ISO metric porting only (see position 11)(*r) CW rotation only (see position 7)(*s) Second HPV/R unit has to be specified

separately

(*t) Recommended if HPV/R unit is attached to PTO (see position 22,23)

(*u) Required for PTO flange size C (see position 22,23)

(*w) Not for tandem units (see position 22,23)(*y) Solenoids with square cross section(*z) Solenoids with circular cross section


Tools Required

Exchanging Response Orifices in Controls

• 4mm Allen wrench


• Two M8 teflon-coated set screws (Eaton Part Number 0009033195), if required

• Two M6 orifices (Eaton Part Numbers presented in table below)

• Torque wrench capable of setting between 5.9 N-m (4.4 ft-lb) and 15 N-m (11 ft-lb)

Exchanging Cold-Start Relief Valves

• 14mm wrench

• Torque wrench capable of setting 30 Nm (22ft-lb)

Exchanging Charge Relief Valves

• 14mm wrench (HPV55,75,105)

• 24mm wrench (HPV135, 165, 210, 280)

• Torque wrench capable of setting between 30N-m (22ft-lb) and 40 N-m (30 ft-lb)

Exchanging Combination Relief/Make-Up Valves

• 12mm Allen wrench (HPV55)

• 24mm wrench (HPV75, HPV105)

• 30mm wrench (HPV135, HPV165, HPV210, HPV280 )

• Torque wrench capable of setting 140 N-m (103 ft-lb) [HPV55, 75, and 105 ONLY]

• Torque wrench capable of setting 250 N-m (184 ft-lb) [HPV135, 165, 210 and 280 ONLY]

Exchanging POR Spool

• 18mm socket wrench

• Small Magnet

• Torque wrench capable of 100 ft-lb (136 N-m).

Installing a Filter Elimination Block


• Torque wrench capable of setting 25 N-m (18 ft-lb)

Exchanging Controls


• Torque wrench capable of setting 25 N-m (18 ft-lb)... [For "Type-A" controls ONLY]

• Torque wrench capable of setting 34 N-m (25 ft-lb)... [For "Type-B" controls ONLY]

Converting to Manual Control

• Measurement Tool (refer to Tool List in LINDOS)


• Torque wrench capable of setting 34 N-m (25 ft-lb)

• Blue Loctite No. 243 (for correct part number please refer to Eaton Spare Parts Catalog)

• Two M8 S.H.C.S. G10.9 (for correct part number please refer to Eaton Spare Parts Catalog)

• Acetylene torch

• Digital depth calipers

• Finger for Manual control (for correct part number please refer to Eaton Spare Parts Catalog)

• 0.1mm finger shims (for correct part number please refer to Eaton Spare Parts Catalog)

0.5mm finger shims (for correct part number please refer to Eaton Spare Parts Catalog)

• Snap ring (for correct part number please refer to Eaton Spare Parts Catalog)

• Snap ring wrench (to squeeze a snap ring open)

• Manual control (with all o-rings, metal split pins, and mounting S.H.C.S. already included)

Installing Power Take-Off (PTO) Kits onto Pumps with Eaton Charge Pumps Attached

Procedure "A"

• Metric wrenches

• Torque wrench (setting as specified)

• Clean grease for o-rings

Procedure "B"

• Metric wrenches

• Metric Allen wrenches

• PTO Kit for HPV (please refer to Eaton Price and Policy Guide for part numbers)

• Snap ring wrench (to open or expand a snap ring)

• Torque wrench capable of setting between 13 N-m (10 ft-lb) and 85 N-m (63 ft-lb)

• Clean grease for o-rings

Installing a PTO Kit onto HPV Pumps Directly (W/O Auxiliary Pump)

• Metric Wrench (various sizes depending on the unit size)

• Allen wrench (various sizes depending on the unit size)

• Grease or petroleum jelly (optional)

• PTO Kit

Changing Rotation on Eaton Charge Pumps

• Metric Wrenches and Allen Keys.

• Torque wrench capable of 60 N-m (44 ft-lb)

• New intake plate (only if using internal or combination internal / external feed charge pump).

• O-rings (refer to LINDOS).

• Plugs (refer to LINDOS).

• Green Loctite No. 270.

• Petroleum Jelly (clean grease) for o-rings.

Assembling Tandem Eaton Charge Pumps

• 5 mm Allen Wrench.

• 10 mm socket wrench.

• Snap Ring Pliers (to widen a snap ring).

• Torque wrench capable of 110 N-m (81 ft-lb).

• Petroleum Jelly or clean grease.

Exchanging Regulation Begin Springs

• Spanner Wrench.

• New Regulation Begin Spring.

• Regulation Begin Cup O-Ring (it may be required).

• Pliers.

• Torque Wrench capable of 11 ft-lb (15 N-m), if applicable.

• 13mm Wrench, if applicable.

Exchanging Rectangular Solenoids on HPV Pump Controls


• Torque wrench capable of setting 2.7 N-m (2.0 ft-lb)

HPV Maximum Displacement Adjustment for M1 (Mechanical-Hydraulic Control)

• 13mm open or close end wrench


Maximum Flow Adjustment Procedure with "H" or "E" Controls

• 0-600 psi pressure gauge or transducer (optional)

• 13mm offset closed-end wrench



Exchanging Response Orifices in ControlsSet Up and Procedure

Note

The Reponse Orifices are used to control the rate of displacement change on the HPV pump. They restrict the oil flowing into and out of the actuator piston chambers. Decreasing the diameter of the orifice results in greater restriction, thus the pump will be slower when changing displacement. Likewise, increasing the diameter of the orifice results in less restriction, thus the pump will change displacement more rapidly.

Eaton does NOT recommend using Response Orifices smaller than 0.7mm. There are no restrictions on the maximum size of the Response Orifices, but be warned that increasing the orifice size too much will lead to abrupt displacement changes in the HPV.

Procedure to Exchange Response Orifices

Using the illustration above, locate the HPV control type and the location of the Response Orifices.

Remove the two outer M8 set screws with the 4mm Allen wrench. Discard them once removed. If the outer plugs are P/N 009524046, remove them with T25 Torque type wrench and keep them for reuse.

Remove the two existing Response Orifices with the 3mm Allen wrench and replace them with the two new Response Orifices. Torque each one to 5.9 N-m (4.4 ft-lb).

Either install two new teflon-coated M8 set screws (P/N 0009033195) and torque each one to 10 N-m (7.4 ft-lb) or reinstall o-ring plugs (P/N 0009524046) and torque each one to 15 N-m (11 ft-lb).

1

2

3

4

Part Orifice Number Diameter

0009037005* 0.6mm*0009037052 0.7mm0009037047 0.8mm0009037059 0.9mm0009037045 1.0mm0009037050 1.2mm0009037515 1.3mm0009037074 1.4mm0009037046 1.5mm0009037073 1.6mm0009037511 1.8mm0009037099 1.9mm0009037510 2.1mm*Not Recommended

List of M6 Orifices Available from Eaton


Exchanging Cold-Start Relief Valves Set Up and Procedure

Procedure to Exchange Cold-Start Relief Valves

Based on the rotation of the pump, refer to the illustration above to verify the position of the Cold-Start Relief Valve.

Remove the existing Cold-Start Relief Valve from the pump with the 14mm wrench.

Inspect the O-Ring on the new Cold-Start Relief Valve to insure it is in good condition (i.e. undamaged).

Install the new Cold-Start Relief Valve and tighten it with the 14mm wrench. Torque it to 30 N-m (22 ft-lb).

1

2

3

4


Exchanging Charge Relief Valves Set Up and Procedure

Important

This procedure must be performed in a clean environment using clean Parts, Tools and Lubricants.

Procedure to Exchange Charge Relief Valves

Remove the existing Charge Relief Valve with the appropriate wrench.

Inspect the O-Ring on the new Charge Relief Valve to insure it is in good condition (i.e. undamaged).

Install the new Charge Relief Valve and tighten it. Torque it to 30 N-m (22 ft-lb) for HPV55, HPV75, HPV105. For HPV135, HPV165, HPV210 and HPV280 torque it to 40 N-m (30 ft-lb).

1

2

3


Exchanging Combination Relief / Make-Up ValvesSet Up and Procedure

Procedure to Exchange Combination Relief/Make-Up Valves

Remove the two existing Relief/Make-Up Valves with the appropriate wrench.

After removal, inspect O-Ring #1 to verify it is in good condition (i.e. undamaged). Please note that O-Ring #1 is NOT part of the Relief/Make-Up Valve. It is an o-ring fitted into the pump housing as illustrated above.

Prior to installing the two new Relief/Make-Up Valves, inspect O-Ring #2 on each of them to confirm they are in good condition (i.e. undamaged).

Install the two new Relief/Make-Up Valves and tighten them with the appropriate wrench.

Torque each Relief/Make-Up Valve to: - 140 N-m (103 ft-lb) for HPV55, HPV75, and HPV105

pumps. - 250 N-m (184 ft-lb) for HPV135, HPV165, HPV210

and HPV280 pumps.

1

2

3

4

5


Exchanging POR Spool Set Up and Disassembly Procedure

Important

This document is valid for HPV pumps with H1P and E1P controls. This document uses an E1P control type to demonstrate all necessary steps for the procedure but it is also valid for H1P control type.

The POR spool on the H1P and E1P controls change with the rotation of the unit as seen to the right; in order to have a functioning POR, the POR spool must match the pump’s rotation.

This is an E1P control. The POR function on this control depends on the POR spool which is shown in the next image.

In order to remove the POR spool from the control body, you must first remove one of the POR cartridge assemblies located on either side of the POR spool.

Disassembly Procedure


Exchanging POR Spool Disassembly Procedure (continued)

Use an 18mm socket wrench to loosen the POR cartridge assembly as shown.

1

Remove the POR cartridge assembly as shown.2

Use a small clean magnet to pull out the remaining piece of the POR cartridge from the housing.

3

Using a small clean magnet remove the POR spool from the housing as shown.

4

A better look at all the parts that are included in the POR cartridge assembly.


Exchanging POR Spool Assembly Procedure

A better look at the POR cartridge cavity after the POR cartridge and POR spool have been removed.

For pump controls with the POR feature remove the original “L” or “R” stamping from the pump control if they do not agree with the pump’s new rotation (Location shown as “stamping1”here). Re-stamp the control around the same location with the correct rotation:

• Clockwise (CW): R

• Counterclockwise (CCW): L

7

Install the POR cartridge back into the control housing as shown here and torque it to 96 ft-lb (130 N-m).

6

Insert the new POR spool into position as shown here.5

Important

The POR spool must slide into its position without any efforts; in case of any resistance, stop and inspect parts for any type of damage.

Important

• Inspect the unit name tag and correct the rotation indicator if necessary to reflect the new rotation.

• At the end of this procedure, the unit must be tested for functionality and settings.


Installing a Filter Elimination BlockSet Up and Procedure

Important


Procedure to Install a Filter Elimination Block

Remove All S.H.C.S from the Filter Mounting Flange with the 6mm Allen wrench.

Remove the Filter Element, Filter Mounting Flange, and the two existing S.H.C.S. from the pump and keep together as an assembly. Make sure that the o-ring beneath the Filter Mounting Flange is also removed and kept with the other parts as an assembly.

Prior to installing the Filter Elimination Block, inspect the O-Ring to insure it is in good condition (i.e. undamaged) and is properly placed in the o-ring groove.

Install the Filter Elimination Block onto the pump (For the 90˚ FEB on HPV55…135, the port can be oriented towards the front or rear of the pump). Use the new S.H.C.S. that came with the Filter Elimination Block to fasten it to the pump.

Tighten all new S.H.C.S. with the 6mm Allen wrench and torque each one to 25 N-m (18 ft-lb).

1

2

3

4

5


Exchanging ControlsSet Up

Important

Not all HPV controls are directly or indirectly interchangeable with each other. Those HPV controls which contain the integrated pressure override (POR) feature, can ONLY be interchanged with pumps controls which also contain the POR feature. You CANNOT interchange HPV pump controls without the POR feature, with the controls that have the POR feature.

The pump controls (Henceforth called Type-A Controls) illustrated directly below are completely interchangeable with each other and no special considerations must be made:

Important

This Conversion Bulletin can be used if exchanging "Type-A" controls with each other or if exchanging "Type-B" controls with each other.

E2 CONTROLE1 CONTROL

ZY

H1 CONTROL

E1P CONTROL H1P CONTROL M2FP CONTROL


ZY

H1 CONTROL

E1P CONTROL H1P CONTROL M2FP CONTROL

The pump controls (Henceforth called Type-B Controls) illustrated directly below are completely interchangeable with each other and no special considerations must be made:

Note

The standard HPV Manual control is indirectly interchange-able with those HPV controls without the POR feature ("Type-A" Controls). However, special instructions are required to do this conversion. Please refer to the section titled Converting to Manual Control found within this bulletin on how to make this conversion. The standard HPV Manual control is completely non-interchangeable with those HPV controls with the POR feature ("Type-B" Controls).


Exchanging ControlsProcedure

Remove the four Socket Head Cap Screws (S.H.C.S.) with the 6mm Allen wrench, then set them aside.

Pull the existing control straight off of the pump.

1

There will be one large o-ring and several small o-rings on the bottom of the existing control. Some or all of the o-rings may stick to the pump when the existing control is removed. Make sure to remove all o-rings from the pump and keep them all with the existing control.

Set aside the existing control, the o-rings, and the four S.H.C.S. as an assembly - Do not reuse any of these parts for this conversion.

Once the existing control is removed, the Finger will protrude from the pump as illustrated below.

3

6 The Alignment Stud must mate with the female linkage inside of the new control. Take this opportunity to locate the female linkage inside of the new control.

Prior to installing the new control, check it to insure that the following things are present:

a Two metal split pins pressed into two passages on the bottom of the control

b One large o-ring in good condition (i.e. undamaged) and properly placed in the o-ring groove

c Several small o-rings in good condition (i.e. undamaged) and properly placed in the o-ring grooves .

2

Note

There will be two metal split pins used to hold the control in place after the four S.H.C.S. are remove. There will be a slight resistance to remove the existing control - This is due to the split pins. You can over come this resistance by pulling the control straight off of the pump.

4

5

Note

You can use a little petroleum jelly to help hold all o-rings in place.

Install the new control onto the pump making sure that:

a The Alignment Stud on the Finger is properly positioned into the female linkage inside the new control.

b The metal split pins are aligned with the corresponding passages in the pump.

Fasten the new control with four new S.H.C.S. Tighten the S.H.C.S. with the 6mm Allen wrench and torque each one to:

• 25 N-m (18 ft-lb)…..[For "Type-A" controls ONLY]

• 34 N-m (25 ft-lb)…..[For "Type-B" controls ONLY]

Test the pump for functionality using Eaton Test Procedures and adjust the control if necessary to achieve desired settings.

8

7

9

10


Converting to Manual ControlSet Up

Important

This Conversion Bulletin is ONLY valid if exchanging "Type-A" controls with the standard HPV Manual Control.

The pump controls (Henceforth called Type-A Controls) illustrated directly above are completely interchangeable with each other and no special considerations must be made. Please refer to the section titled Exchanging Controls found within this document for detailed instructions on how to exchange "Type-A" controls with other "Type-A" controls.

The standard HPV Manual Control is interchangeable with the HPV controls ("Type-A" Controls) illustrated above, but special instructions are required to do this conversion. The standard HPV Manual Control is NOT interchangeable with those HPV controls with the integrated pressure override (POR) feature.


ZY

H1 CONTROL


Converting to Manual ControlProcedure to Convert to a Standard HPV Manual Control

Important


From the existing control, remove the four S.H.C.S. with the 6mm Allen wrench, then set them aside.

Pull the existing control straight off of the pump.

1

There will be one large o-ring and several small o-rings on the bottom of the existing control. Some or all of the o-rings may stick to the pump when the existing control is removed. Make sure to remove all o-rings from the pump and keep them all with the existing control.

Set aside the existing control, the o-rings, and the four S.H.C.S. as an assembly - Do not reuse any of these parts for this conversion.

Once the existing control is removed, the Finger will protrude from the pump as illustrated below.

3

2

Note

There will be two metal split pins used to hold the control in place after the four S.H.C.S. are remove. There will be a slight resistance to remove the existing control - This is due to the split pins. You can over come this resistance by pulling the control straight off of the pump.

4

5

Note

Please note the dimension "25.4mm" illustrated below. This dimension can be acquired via the digital depth calipers by using the measurement tool demonstrated during training. This dimension signifies that the Finger is shimmed for a "Type-A" Control. The Finger itself is specially configured and sized for the "Type-A" Controls only. A new Finger and shimming is required for the Manual Control, as explained below.



Important


The existing Finger must be removed from the pump. To do this, use the following steps (Use the illustration above as a reference):

a With the Acetylene torch, slowly heat the two S.H.C.S. Do not heat them too hot - You only need to heat them enough to break the Loctite loose.

b With the 6mm Allen wrench, remove the two S.H.C.S. Once removed, discard them.

c Pull the Finger from the pump. Be careful, the Finger may still be hot.

d Leave the two metal split pins in the pump for reuse. (Or reinstall them if they come out of the pump with the Finger)

The new Finger for the Manual Control must be installed:

a Install the new Finger into the pump by pressing it onto the two metal split pins. Refer to the illustration above to insure the new Finger is oriented correctly.

b Following the manufacturer’s recommendations, apply Blue Loctite No. 243 into the threaded holes on the swash plate.

c Install the two new M8 S.H.C.S. into the pump and tighten them with the 6mm Allen wrench. Torque each one to 34 N-m (25 ft-lb).

6

7

MeasurementTool

"B"

d Calculate Shim thickness:

Total Shim and Snap Ring Thickness =

e Install the required Shims onto the new Finger.

f Install the new Snap Ring.

A - B + 19.4 +0.1mm- 0.0mm

Important

The amount of shim calculated in the previous step includes the snap ring thickness; when measuring actual shims for selection, the snap ring must be included also.

Shim the new Finger as follows (Use the illustration below as a reference):

a Measure the length of measurement tool as Dimension “A”:

b Install the measurement tool on the finger.

c Using the digital depth calipers, measure from the top of the measurement tool to the pump housing as Dimension “B” (see illustration below):

8

Note

There will be two metal split pins used to hold the Finger in place after the two S.H.C.S. are remove. There will be a slight resistance to remove the Finger - This is due to the split pins. You can over come this resistance by pulling the Finger straight off of the pump.



Important


Install the new control onto the pump making sure that:

a The Alignment Stud on the Finger is properly positioned into the female linkage inside the new control.

b The metal split pins are aligned with the corresponding passages in the pump.

11

Note

As illustrated below, removing the metal plug or plastic shipping plug from this port will make it easier to install the Alignment Stud into the female linkage. You can use this port as a window during the installation of the Manual Control.

Leave ThisPort Open

ManualControl

Fasten the Manual Control with four new S.H.C.S. Tighten the S.H.C.S. with the 6mm Allen wrench and torque each one to 25 N-m (18 ft-lb).

Test the pump for functionality using Eaton Test Procedures and adjust the control if necessary to achieve desired settings.

12

13

Repeat the measurement steps with the shims and snap ring installed to confirm your selection.

Prior to installing the Manual Control, verify that the following things are present:

a Two metal split pins pressed into two passages on the bottom of the control

b One large o-ring in good condition (i.e. undamaged) and properly placed in the o-ring groove

c Several small o-rings in good condition (i.e. undamaged) and properly placed in the o-ring grooves

9

Important

The Alignment Stud must mate with the female linkage inside of the Manual Control. Take this opportunity to locate the female linkage inside of the new control.

10

Note

You can use a little petroleum jelly to help hold the o-rings in place.


Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pump AttachedSet Up

Important


Important

The instructions contained in the following document is valid for all size HPV pumps. Appearances and dimensions of the illustrations in this document will vary according to the size HPV pump the user is working with.

There are two (2) procedures included in this section:

Procedure "A": How to install an SAE "A" PTO Kit on an HPV pump while using the Eaton charge pump.

Procedure "B": How to install an SAE "B" or larger PTO Kit on an HPV pump while using the Eaton charge pump.


Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pump AttachedProcedure "A"

The illustration below highlights some key items that will be referenced throughout Procedure "A".

Note

All HPV pumps supplied from Eaton with an Eaton charge pump is already equipped with an SAE "A" PTO Kit. As explained below, there is no additional hardware required to have an SAE "A" PTO. Steps #2-#5 explain how to install an additional pump.

1Inspect the O-Ring to ensure that it is in good condition (i.e. undamaged) - Replace if damaged. Make sure that the O-Ring is properly positioned in the o-ring groove. You can use a little grease to help hold it in position.

As illustrated below, install the pump with an SAE "A" pilot and SAE "A" spline drive shaft into the back of the HPV charge pump. You may have to rotate the new pump drive shaft to allow its splines to align with the splines in the charge pump coupling.

4

Fasten the new pump to the HPV charge pump with threaded bolts (not supplied by Eaton) and torque accordingly.

Remove and discard the two (2) Hex Head Bolts from the Charge Pump Cover Plate.

Remove and discard the Cover Plate from the back of the charge pump.

2

3

5


Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pump AttachedProcedure "B"

The illustration below highlights some key items that will be referenced throughout Procedure "B".1

Remove the two(2) Hex Head Bolts from the Charge Pump Cover Plate.

Remove the Cover Plate.

Remove O-Ring #1 and inspect it for damage. Replace it if damaged, otherwise keep it for reuse.

Remove O-Ring #2 and inspect it for damage. Replace it if damaged, otherwise keep it for reuse. Remove the seven (7) Fastening Bolts and Washers and keep them for reuse.

3Remove and discard the two(2) Charge Pump Mounting Bolts. Remove the Charge Pump and Charge Pump O-Ring from the back of the HPV. Keep the Charge Pump O-Ring for reuse.

2

4

5

6


Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pump AttachedProcedure "B" (continued)

Position the Charge Pump as illustrated below. Pull the Intake Plate out of the Charge Pump (it should just slide off of the drive shaft). When doing this, please note the Inner Needle Bearing will slide off still inserted in the Intake Plate.

Remove O-Ring #3 from the Charge Pump and inspect it for damage. Replace it if damaged; otherwise keep both the Intake Plate and O-Ring #3 for reuse.

7

Pull the drive shaft straight out of the Charge Pump as illustrated below. Please note that the Inner Gear and two Snap Rings will be removed along with the drive shaft.

8

Flip the drive shaft over so that it is oriented as shown below. Using a snap ring wrench, remove the Outer Snap Ring from the drive shaft and keep it for reuse.

9

Slide the Inner Gear off of the drive shaft as illustrated below. Once the Inner Gear is removed, the Shaft Key will slide out of the drive shaft. Keep both the Inner Gear and Shaft Key for reuse.

10

Using a snap ring wrench, remove the Inner Snap Ring from the drive shaft and keep it for reuse.

The drive shaft is no longer needed for this conversion - Set it aside.

11



Use the illustration below for the following steps:

a Acquire the new charge pump drive shaft. You will notice that it has two spline ends. The spline ends are different from each other. One end is identical to the drive shaft from step #11. As shown below, the end that is identical to the drive shaft in step #11 is pointing downward.

b Reinstall the Outer Snap Ring from step #9.

c Reinstall the Shaft Key from step #10.

d Reinstall the Inner Gear from step #10 making sure to capture the Shaft Key.

12Use the illustration below for the following steps:

a Position the Charge Pump as shown.

b Flip the new drive shaft 180° from its orientation in step #13.

c Apply a thin layer of grease to the designated surface of the drive shaft.

d Install the drive shaft into the Charge Pump. Please note that the drive shaft must be installed into the Outer Needle Bearing.

14

As illustrated below, reinstall the Inner Snap Ring from step #11.13



Use the illustration below for the steps below:

a Reinstall O-Ring #3 from step #7. Make sure that it is properly positioned in the o-ring groove. Use a small amount of grease to help hold it in position.

b Apply a thin layer of grease to the designated surface of the drive shaft.

c Align the seven (7) threaded holes in the Intake Plate with the holes in the charge pump housing. Then install the Intake Plate into the charge pump.

The seven (7) holes in the Intake Plate and charge pump housing are NOT evenly spaced. The Intake Plate can only be mounted with all seven Fastening Bolts when oriented in one particular position - The correct position.

15Use the illustration below for the following steps:

a Reinstall the seven (7) Fastening Bolts and Washers from Step #6 to fasten the Intake Plate to the Charge Pump. Torque each Fastening Bolt to 13 N-m (10 ft-lb).

b Reinstall O-Ring #2 from step #6 into the Charge Pump. Make sure that the o-ring is properly positioned in the o-ring groove. Use a small amount of grease to help hold the o-ring in position.

16

As illustrated below, reinstall the O-Ring into the HPV o-ring groove. Use a small amount of grease to help hold the o-ring in position.

Reinstall the Charge Pump back into the HPV. You may have to rotate the charge pump drive shaft to allow the mating splines to align. Once aligned, the Charge Pump should easily slide into the HPV.

17

18



As illustrated below, reinstall O-Ring #1 into the charge pump o-ring groove. Use a small amount of grease to help hold the o-ring in position.

Install the PTO Coupling onto the charge pump drive shaft.

19As illustrated below, install the PTO O-Ring into the PTO Adapter Flange o-ring groove. Use a small amount of grease to help hold the o-ring in position.

At this point, there are two options to finish:

• As illustrated below, install the new pump onto the PTO Adapter Flange. The new pump must have a mount and spline drive shaft to match the PTO flange and coupling just installed. Mount the pump with bolts (not supplied by Eaton) and torque accordingly.

OR

• You can install a cardboard or platic cover (not supplied by Eaton) over the opening in the PTO flange.

23

20

As illustrated to the right, install the PTO Adapter Flange onto the Charge Pump. The PTO Adapter Flange will have two mounting holes (unthreaded and countersunk) and two attachment holes (threaded) [Refer to the illustration on the top right of this page for hole identification]. Align the PTO Adapter Flange so that the two mounting holes align with the two mounting holes in the Charge Pump.

Fasten the PTO Adapter Flange to the Charge Pump and HPV by using two long S.H.C.S. Torque each S.H.C.S. to 85 N-m (63 ft-lb).

21

22


Installing a PTO Kit onto HPV Pumps Directly (Without Auxiliary Pump)Set Up

Important

This procedure must be performed in a clean environment using clean Parts, Tools and Lubricants

Important

This procedure is valid for all sizes of HPV pumps (without auxiliary pumps) and various sizes of PTO kits. The steps in this document are performed using an HPV135 with E1P control type and an SAE C PTO kit.


Installing a PTO Kit onto HPV Pumps Directly (Without Auxiliary Pump)Procedure

Remove the two bolts that secure the PTO cover on the back of the HPV pump.

1

Remove the PTO cover as shown here. 2

Remove the o-ring and inspect it to make sure that it is not damaged.

Install the o-ring back on the pump using petroleum jelly.

3

Position the PTO plate as shown here.

Identify the bolts on the HPV pump’s rear head that match with the bolt holes on the PTO plate.

5

4

Important

PTO plates used with HPV pumps differ in look and size. Since the bolt pattern on the HPV pump's rear head is asymmetric, there is only one way to align the PTO plate and the HPV pump's rear head.

6


Installing a PTO Kit Directly (Without Auxiliary Pump)Procedure

In order to install the PTO plate, the identified bolts must be removed.

7

Important

Do not remove all the bolts from the rear head; this will result in separating the rear head from the housing which will require further disassembly of the pump to correct.

Important

The location and number of removed bolts may vary depending on the HPV pump’s size and the PTO kit selected.

Install the PTO plate on the HPV pump’s rear head as shown here.

Align bolt holes on the PTO plate with the holes on the rear head.

8

Important

Pay attention to the o-ring on the rear head to prevent damages.

9

Install the new bolts on the PTO plate as shown below.

Torque the bolts. (See torque chart at the end of this document).

10

Note

These new bolts are longer than the original bolts removed from the rear head. For the correct bolt length and part number refer to Lindos.

11


Installing a PTO Kit Directly (Without Auxiliary Pump)Procedure

Install the new o-ring on the back of the PTO Plate using petroleum jelly.

Install the new PTO Cover as shown here.

12 Tighten the bolts on the PTO cover.14

13

Torque (ft-lb) Dimensions 4.6 4.8 5.8/22H/45H 6.8 8.8 10.9 12.9

Standard Thread M4 0.7 1.0 1.3 1.5 2.0 2.8 3.4 M5 1.5 2.0 2.5 3.0 4.1 5.9 7.0 M6 2.7 3.5 4.4 5.2 7.0 9.6 11.8 M8 6 8 10 13 17 24 29 M10 13 17 21 25 34 47 57 M12 22 30 37 44 59 81 100 M14 35 46 58 69 92 133 159 M16 54 7 4 90 108 144 203 243 M20 107 140 177 213 284 398 479 M24 184 243 302 365 487 686 811 M30 376 498 620 738 996 1364 1659 M36 649 863 1084 1298 1733 2434 2876Fine Pitch Thread M8 X 1 7 9 12 14 18 26 31 M10 X 1 15 19 24 29 38 53 70 M10 X 1.25 13 18 22 27 36 50 60 M12 X 1.25 24 32 41 49 65 92 111 M12 X 1.5 23 30 38 46 61 85 103 M14 X 1.5 38 52 64 77 103 144 173 M16 X 1.5 58 77 96 116 155 218 258 M18 X 1.5 85 111 140 170 225 313 376 M20 X 1.5 118 155 195 236 313 443 531 M22 X 1.5 159 210 262 313 420 590 708 M24 X 2 199 266 332 398 531 738 885 M27 X 2 291 387 483 579 774 1106 1328 M30 X 2 398 535 667 800 1069 1512 1844 M36 X 3 686 922 1151 1379 1844 2581 3024


Changing Rotation on Charge PumpsSet Up and Procedure

Important


Important

To change rotation on an Eaton charge pump, the plug and cold start relief valve must be exchanged with each other.

Some clockwise (right-hand) charge pumps may not have the plug on the opposite side of the cold start relief valve; in this case, you must replace the charge pump with a left handed version.

Remove the existing plug from the charge pump and discard it.

Remove the existing cold start relief valve from the charge pump. Inspect the o-ring on the cold start relief valve to ensure that it is in good condition (i.e. undamaged). Replace it if damaged.

Reinstall the cold start relief valve into the charge pump where the plug from step #1 was. Torque the cold start relief valve to 30 N-m (22 ft-lb).

Apply Blue Loctite No. 243 to the threads of a new Plug. Install the Plug into the charge pump where the cold start relief was. Torque the Plug to 60 N-m (44 ft-lb).

1

Note

There may be a plug with an o-ring on it. If the charge pump you are working on has this type of plug, then you can reuse it.

Note

For those plugs with the o-ring, do not apply Loctite and torque it to 35 N-m (26ft-lb).

2

3

4


Changing Rotation on Charge PumpsProcedure

Remove the two(2) hex head bolts from the cover plate and keep them for reuse.

Remove the cover plate and O-Ring #1 and keep them for reuse.

Remove O-Ring #2 and keep it for reuse.

Remove the seven(7) fastening bolts and washers. Keep them for reuse.

Pull the intake plate out of the charge pump (it should just slide out). When doing this, please note that the needle bearing will slide off of the shaft along with the intake plate.

Do not press the needle bearing out of the intake plate. It is installed with Green Loctite No. 270 on its outer race. The needle bearing will be destroyed if removed from the Intake Plate, so just leave it in place.

Make sure that O-Ring #3 is properly positioned in the charge pump o-ring groove. Use a small amount of petroleum jelly to help hold O-Ring #3 in place.

Refer to LINDOS for the new intake plate part number to match the new pump rotation. You must also use a new needle bearing.

Apply a thin, uniform layer of Green Loctite No. 270 to the outer race of the new needle bearing.

5

6

Important

If you have an internal feed or a combination internal / external feed charge pump follow steps #5 through #19. If you are working with an external feed charge pump, the procedure is complete.

With the internal feed or combination internal/external feed charge pump, there is an intake plate that must be exchanged to accommodate the rotation change. Use these illustrations for the following charge pump disassembly/assembly instructions.

7

8

9

10

11

12

13


Changing Rotation on Charge PumpsProcedure

The orientation of the needle bearing is important. On one face of the needle bearing, there will be some stamping (bearing manufacturer's name, etc.) and the other side will be blank. The side of the needle bearing with the stamping must be facing away from the charge pump when installed into the intake plate (as illustrated above). Install the new needle bearing into the new intake plate and wipe away any excess Loctite.

Align the seven(7) threaded holes in the new intake plate with the holes in the charge pump housing. Then install the new intake plate into the charge pump.

Reuse the seven(7) fastening bolts and washers to fasten the intake plate to the charge pump then torque the fastening bolts to 13 N-m (9.5 ft-lb).

Reinstall O-Ring #1 into the charge pump o-ring groove. Use a small amount of petroleum jelly to help hold O-Ring #1 in place.

Reinstall the cover plate and fasten it to the charge pump with the two(2) hex head bolts.

Reinstall O-Ring #2 into the charge pump and make sure that it is properly positioned in the o-ring groove. Use a small amount of petroleum jelly to help hold O-Ring #2 in place.

At this point the Rotation Change is complete.

14

Note

The seven(7) threaded holes in the charge pump housing and intake plate are not evenly spaced. The intake plate can only be mounted with all seven fastening bolts when oriented in one particular position - The correct position.

15

16

17

18

19


Assembling Tandem Charge PumpsSet Up and Procedure

Important


Note

The front charge pump does not need modified. The following instructions are for modifying the rear charge pump.

Remove the cover plate and the o-ring behind it as shown here.

Remove the mounting o-ring from the opposite side.

1 Remove the seven (7) bolts shown here.3

2

Also, remove the seven (7) washers as shown here.4


Assembling Tandem Charge PumpsProcedure

Gently, tap on the shaft’s end to push out the shaft and port plate cover from the charge pump housing.

5

Separate the port plate cover from the shaft.6

Remove the first snap ring using snap ring pliers as demonstrated during the training.

7

Remove the gear as shown here.8

Remove the key and the second snap ring from the shaft.

9

Replace the existing shaft with the one required for tandem assembly as shown here.

10



Install one of the snap rings then install the key on the shaft.

11

Install the gear on the shaft.

Install the second snap ring.

12

Insert the new shaft / gear assembly into the charge pump housing as shown here.

Important

Make sure the side with a chamfer on the gear (as shown) is facing the charge pump housing.

14

Inspect the o-ring around the outer gear and make sure that it is positioned properly.

Align the bolt holes on the port plate cover with the holes on the charge pump housing.

15

13

16

Note

This bolt pattern is not symmetric; there is only one way to align them.

Install the port plate cover as shown here.17



Insert the short shaft designed for tandem assembly into the front face of the charge pump as shown here.

21

Install all seven (7) washers.

Install all seven (7) bolts and torque them to 13 N-m (9.5 ft-lb).

18 Install the o-ring on the charge pump mounting face as shown here.

22

Inspect the o-ring on the back of the front charge pump to insure it is positioned correctly.

23

19

Align the shaft on the rear charge pump with the spline on the front charge pump and insert it.

Important

Pay attention to the o-rings during this step to prevent damages.

24

Install the snap ring on the short shaft designed for tandem assembly. The snap ring is positioned on the slot that is cut into the shaft spline.

20


Assembling Eaton Charge PumpsProcedure

Torque the two mounting bolts to 110 N-m (81 ft-lb).

Inspect the o-ring on the back of rear charge pump to insure it is positioned properly.

Install the PTO cover on the back of the rear charge pump.

30Insert the mounting bolts into the tandem charge pump assembly as shown.

25

Inspect the o-ring on the back of the HPV pump to insure there are no damages.

Make sure that the coupling is positioned correctly.

Align the splines on the charge pump shaft with the coupling

Install the tandem charge pump assembly on the HPV pump.

26

At this point, the assembly of tandem Eaton charge pumps is complete.

27

28

29

31

32


Exchanging Regulation Begin Springs Set Up and Procedure

Important


Important

Although the drawing to the right represents an H1control type, this procedure can be used for all control types on HPV pumps, except for Manual Controls.

Procedure to Exchange Regulation Begin Springs

Important

After this procedure has been completed, both Regulation Begin and Maximum Displacement adjustments must be reset.

Use the spanner wrench to loosen the spanner nut. It is important not to move the spanner nut more than a quarter of a turn.

Important

Do not to move the spanner nut more than a quarter of a turn since it will be used as your initial positioning guide during assembly.

Rotate and remove the Regulation begin sub-assembly. This sub-assembly includes the spring hat, spanner nut, regulation begin cup, maximum displacement adjustment and locking nut.

Note

The spring hat and the spring may or may not come out with the regulation begin cup. You may have to remove the spring using pliers.

The o-ring on the regulation begin cup may be damaged during removal.

Replace the regulation begin spring with a new one.

Inspect the spring hat for damages then install it on the spring.

Place the spring and spring hat inside the regulation begin cup then install the sub-assembly in the pump control. Turn the regulation begin cup IN until the spanner nut touches the pump control housing.

Tighten the spanner nut.

As mentioned above, reset the regulation begin and maximum displacement adjustments.

Repeat steps #1 through #7 for the regulation begin spring on the opposite side of the pump control, as required.

Important

If you are working on a control with POR function and converting from 2-8 bar springs to 4-10, 4-16 bar or vice versa, you must also change valve III as follows:

2-8 bar: Valve P/N 600 340 5512

4-10 bar: Valve P/N 600 340 5510

4-16 bar: Valve P/N 600 340 5510

1

2

3

5

6

7

8

4


Exchanging Regulation Begin Springs Procedure to Exchange the Valve III for POR function

As shown here use a 13mm wrench to loosen the valve III body.

Note

Valve III is made of two different bodies. All together there are 3 places where a wrench can be applied: The main body, the second part of the body and the locking nut. Separating the two body pieces can result in damage or loss of internal parts. Please insure that the wrench is applied to the main body as shown here.

1 The Pump control is stamped to reflect the correct regulation begin spring range, shown as “Stamping2” here. This stamping must change to reflect the correct spring range:

Control Pressure Range: 2-8 bar: A 4-10 bar: B 4-16 bar: C

Control Pressure Range and 2-8 bar: D limited spool stroke, by 4-10 bar: E mechanical end stop: 4-16 bar: F

5

Important

At the end of this procedure, the unit must be tested for functionality and settings.

Remove the valve III in one piece as shown here.

Inspect the o-ring on the replacement valve for damage and replace as required. Install valve III into the cavity.

2

3

Torque the valve III body to 11 ft-lb (15 N-m).

Note

The POR must be reset on the pump control after valve III is exchanged.

4


Exchanging Rectangular Solenoids on ControlsSet Up and Procedure

Procedure to Exchange Rectangular Solenoids:;

Remove the four S.H.C.S. from the Proportional Solenoid with the 3mm Allen wrench. Keep the four S.H.C.S. with the existing solenoid as an assembly.

Remove the existing Solenoid O-Ring and keep it with the existing solenoid as an assembly.

Make sure that the new Solenoid O-Ring is in good condition (i.e. undamaged) and is properly placed in the o-ring groove on the new solenoid.

Install the new Proportional Solenoid onto the pump control and fasten it with the four new S.H.C.S. that came with the new solenoid.

Tighten the S.H.C.S. with the 3mm Allen wrench and torque each one to 2.7 N-m (2.0 ft-lb).

1

2

3

4

5


Maximum Displacement Adjustment for M1 (Mechanical-Hydraulic) ControlSet Up and Procedure

Adjustment Procedure:

Loosen the flow-stop lock nut with 13mm wrench.

Turn the cam lever in the appropriate direction.

Turn the adjustment stud IN to decrease the flow or OUT to increase the flow using the 4mm Allen wrench.

When desired flow is acquired, hold the adjustment stud stationary with the 4mm Allen wrench and tighten the lock nut with the 13mm wrench (the proper torque for the lock nut is 14 N-m [10 ft-lb]).

1

2

3

Turn Lever Pressure In Direction From Port

For CW (Right Hand) Rotation X P Y SFor CCW (Left Hand) Rotation X S Y P

Flow Orientation:


Maximum Flow Adjustment Procedure with “H” or “E” ControlsSet Up

Note

This Service Bulletin is valid for HPV pumps with either "H" (Hydraulic Remote) or "E" (Electro-Hydraulic Remote) Controls

The drawing below illustrates an "H1" Control, but the information is also valid for “H1P”, “E1”. “E1P, and “E2” Controls.

E2 Control

MsSolenoid


WARNING

If performing this procedure on a vehicle, care must be taken. The pump will be put on stroke during this procedure; hence the vehicle must be safely elevated to allow the motor to free-wheel. If this is NOT possible, then the pump work-ports "P" and "S" must be short circuited to each other. Install a properly sized flow-meter in the short circuit line between "P" and "S" to avoid movement of the motor.

(Optional) Install the 0-600 psi gauge into gauge port "Y".

Set the input speed to high idle.

For E2 Controls, make sure that Ms Solenoid is energized.

Supply full control pressure to port "Y" or full current to solenoid "My". (Optional) Confirmthat the pressure at port "Y" is adequate to put the pump at full displacement.

Measure the rotational speed of the motor, the wheel, the gearbox, etc. and calculate if the pump is supplying enough flow. If using a short circuit line, measure the flow from the flow-meter.

To Adjust the Maximum Flow:

a. Use the 13mm wrench to loosen "Locking Nut #2".

b. Use the 4mm Allen wrench to turn "Max. Flow Adjustment Stud #2". Turn it IN to decrease the maximum flow or turn it OUT to increase it..

c. Once the desired maximum flow has been acquired, hold the flow adjustment stud stationary with the 4mm Allen wrench and tighten the locking nut with the 13mm wrench (the proper torque for the locking nut is 10 ft-lb [14 N-m]).

1

Maximum Flow Adjustment Procedure with “H” or “E” ControlsAdjustment Procedure

2

3

4

5

6

WARNING

The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump. Care should be taken when turning the flow adjustment stud OUT. DO NOT turn the adjustment stud OUT more than 26mm as illustrated on previous page.

(Optional) Install the 0-600 psi gauge into gauge port "Z".

Set the input speed to high idle.

For E2 Controls, Make sure that Ms Solenoid is energized.

Supply full control pressure to port "Z" or full current to solenoid "Mz". (Optional) Confirm that the pressure at port "Z" is adequate to put the pump at full displacement.

Measure the rotational speed of the motor, the wheel, the gearbox, etc. and calculate if the pump is supplying enough flow. If using the short circuit line, measure the flow from the flow-meter.

To Adjust the Maximum Flow:

a. Use the 13mm wrench to loosen "Locking Nut #1".

b. Use the 4mm Allen wrench to turn "Max. Flow Adjustment Stud #1". Turn it IN to decrease the maximum flow or turn it OUT to increase it.

Once the desired maximum flow has been acquired, hold the flow adjustment stud stationary with the 4mm Allen wrench and tighten the locking nut with the 13mm wrench (the proper torque for the locking nut is 10 ft-lb [14 N-m]).

7

8

9

10

11

12

WARNING

The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump. Care should be taken when turning the flow adjustment stud OUT. DO NOT turn the adjustment stud OUT more than 26mm as illustrated on previous page.

13


Operational ParametersLife Time Recommendations

Operational parameters. Filtration

In order to guarantee long-term proper function and high efficiency of the hydraulic pumps the

cleanliness level of the lubricant must comply with the following criteria according to

Eaton Hydraulic Fluid Recommendation 03-401-2010. Maintaining the recommended cleanliness

level can extend the service life of the hydraulic system significantly.

Beneficial Conditions For Long Service Life

Speed Lower continuous maximum speedOperating Pressure Less than 300 bar on averageMax. Pressure Only at reduced displacementViscosity 15 ... 30 cStPower Continuous power or lowerPurity of Fluid 18/16/13 in ac. with ISO 4406 or better

Eaton high pressure units are designed for excellent reliability and long service life. The actual service life of a hydraulic unit is determined by numerous factors. It can be extended significantly through proper maintenance of the hydraulic system and by using high-quality hydraulic fluid.

Available filter sizes

Filter size 55 75 105 135 165 210 280

No. 2 x No. 3 x x x x x x x

For reliable proper function and long service life

18/16/13 in accordance with ISO 4406 or better

Commissioning

The minimum cleanliness level requirement for the hydraulic oil is based on the most sensitive component. For commissioning we recommend a filtration in order to achieve the required cleanliness level.

Filling and operation of hydraulic systems

The required cleanliness level of the hydraulic oil must be ensured during filling or topping up. When drums, canisters, or large-capacity tanks are used the oil generally has to be filtered. We recommend the implementation of suitable filters to ensure that the required cleanliness level of the oil is achieved and maintained during operation.

International standard Code number according to ISO 440618/16/13

Adverse Factors Affecting Service Life

Speed Between continuous maximum speed and intermittent maximum speedOperating Pressure More than 300 bar on averageViscosity Less than 10 cStPower Continuous operation close to max. powerPurity of Fluid Lower than 18/16/13 in acc. with ISO 4406


Operational ParametersPressure Fluids

In order to be able to select the right hydraulic fluid it is necessary to know the working temperature in the hydraulic circuit. The hydraulic fluid should be selected such that is

optimum viscosity is within the working temperature range (see tables).

The temperature should not exceed 90 °C in any part of the system. Due to pressure and speed influences the leakage

fluid temperature is always higher than the circuit temperature. Please contact Eaton if the stated conditions cannot be met in special circumstances.

In order to ensure the functional performance and high efficiency of the hydraulic pumps the viscosity and purity of the operating fluid should meet the different operational requirements. Eaton recommends using only hydraulic fluids which are confirmed by the manufacturer as suitable for use in high pressure hydraulic installations or approved by the original equipment manufacturer.

• Mineral oil HLP to DIN 524-2

• Biodegradable fluids in accordance with ISO 15 380 on request

• Other pressure fluids on request

Recommend viscosity ranges

Permitted pressure fluids

Eaton offers an oil testing service in accordance with VDMA 24 570 and the test apparatus required for in-house testing. Prices available on request.

Viscosity recommendations

Pressure fluid temperature range [°C] -20 to +90

Working viscosity range [mm²/s] = [cSt] 10 to 80Optimum working viscosity [mm²/s] = [cSt] 15 to 30Max. viscosity (short time start up) [mm²/s] = [cSt] 1000

Working temperature [°C] Viscosity class [mm²/s] = [cSt] at 40 °C

Approx. 30 to 40 22Approx. 40 to 60 32Approx. 60 to 80 46 or 68

Further information regarding installation can be found in the operating instructions.

EatonHydraulics Group USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722www.eaton.com/hydraulics

EatonHydraulics Group EuropeRoute de la Longeraie 71110 MorgesSwitzerlandTel: +41 (0) 21 811 4600Fax: +41 (0) 21 811 4601

Eaton Hydraulics Group Asia PacificEaton BuildingNo.7 Lane 280 Linhong Road Changning District, Shanghai200335 ChinaTel: (+86 21) 5200 0099Fax: (+86 21) 2230 7240

© 2012 Eaton CorporationAll Rights Reserved Printed in USADocument No. E-PUPI-TM020-EJuly 2012

Eaton DuraForce™ HPV Conversion Procedurespub/@eaton/@hyd/docu… · EATON Duraforce HPV...

Documents

Transcript of Eaton DuraForce™ HPV Conversion Procedurespub/@eaton/@hyd/docu… · EATON Duraforce HPV...