HPA4

HPA4 PUMP
Service Manual

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HPA4 PUMP PARTS OVERVIEW HPA4

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Pump Startup

Make sure the reservoir and circuit are clean and free of dirt and debris prior to filling with hydraulic fluid. Fill
the reservoir with filtered oil to a level sufficient to prevent vortexing at suction connection to pump inlet.
It is good practice to clean the system by flushing and filtering using an external slave pump. Before starting
the pump, fill with fluid through one of the ports. This is particularly important if the pump is above the fluid
level of the reservoir. When initially starting the pump, remove all trapped air from the system. This can be
accomplished by loosening the pump outlet fittings or connections before starting the pump, or by using an air
bleed valve. All inlet connections must be tight to prevent air leaks. Once the pump is started, it should prime
within a few seconds. If the pump does not prime, check to make sure that there are no air leaks in the inlet
line and connections. Also check to make sure that trapped air can escape at the pump outlet. After the pump
is primed, tighten the loose outlet connections, then operate for five to ten minutes (unloaded) to remove all
trapped air from the circuit. If reservoir has a sight gage, make sure the fluid is clear–not milky. Add fluid to the
reservoir up to the proper fill level.

HPA4 pump – cross sectional view

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SETTING INFORMATIONS

Important Remarks

The following information refers to the situation as of 1st of December, 2007.

Descriptions, adjustment procedures and drawings contained are subject to updating, according to the
modifications made to the HP Hydraulic range.
HP Hydraulic reserves the right to modify products, setting and testing procedures without prior notification.
HP Hydraulic declines all liability for faults, accidents and tampering due to failure to observe the specifications
given in this manual or current safety standards, even if the latter are not explicitly mentioned herein.
HP Hydraulic declines all liability for errors contained in the present manual.
In the event of doubt, please refer to the HP Hydraulic central office for information.

Copyright: HP Hydraulic S.r.l. - December 2007 - printed in Italy.

Data reported in this document are not binding.

HP Hydraulic reserves the right to change specifications without notice.

Informations reserved to HP Hydraulic sales organization.

1 - Servocontrolled pumps for open circuits

1.1 - characteristics

In the open loop circuit field it is very important to set pump displacement automatically, in order to avoid to
waste power.
Load Sensing control type choice gives following advantages:

- controls automatically pump displacement depending on the pump speed and working pressure due to the
load.

Pump flow adjusts automatically according to working pressure, depending on the applied load, until it reaches
the maximum preset pressure.

- limits automatically the maximum pressure.

Pump displacement zeroes automatically at the preset pressure value.

When using only max. pressure presetting, load sensing becomes a Constant Pressure control type, with
following feature:

- limits automatically the maximum pressure.

Pump displacement zeroes automatically at the preset pressure value.

Actually it is not available an HP Hydraulic Constant Power control type.

Load sensing and Constant pressure control types are obtained from the same pump type, with two different
setting procedures described in the following paragraphs.

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1.2 - starting conditions

It is important to fix that when pump is not rotating because the engine is off, pump sets itself automatically at
the max. displacements.
This means at the engine starting, in addition to the internal frictions of the pump, the engine must win also the
counterpressure caused by the max. pump displacement and residual pressure in the plant.
For example, for a pump of 45cc starting at 1450 rpm, if we have a typical minimum pressure around 20 bar
we can calculate the needed starting power to be around:

1450 x 45 x 20 / (1000 x 612) = 2.1 kW

In the same way can be found the starting power for other displacements and speeds.
To this value must be added the internal friction of the pump, depending on oil type and cold starting
temperature, and cannot be fixed easily.
We can consider the engine must have a starting power at least double of the calculated value; it is important
to check this engine data when studying the hydraulic plant.

1.3 - filtration

It is imperative that only clean oil be allowed to enter the pump in order to prevent parts wear.
Filtration class:
It is needed to use a system filtration that is able to grant a fluid cleanliness to ISO class 16/14/11 or better.
Suction:
Suction line filters are not recommended, to prevent any cavitation problem.
A 125 microns (200 mesh) strainer located in the reservoir or in the pump inlet line is recommended to protect
the pump from coarse particles.
Return:
The selection of a return filter depends on many factors, including contamination input rate and scheduled
service periods. Filters must be selected to meet the above requirements using rating parameters of efficency
and capacity.

Filter efficency may be measured using the .Beta. ßx-ratio, that is defined by ISO standard as the ratio of the
number of particles greater than a given size (x) measured in microns upstream of the filter to number of
particles greater than the same size downstream of the filter.
A filter with a ß-ratio within the range of ß15-20=75 (ß10 = 10) or better is typically required.
Since each system is unique, the filtration requirement for that system will be unique and must be determined
by test in each case. It is essential that monitoring of prototypes and evaluation of components and
performance throughout the test program be the final criteria for judging the adequacy of the filtration system.

2 - Setting identification and explanation

Identification and explanation of the two setting points over Load Sensing control (see picture).

2.1 - flow regulator: screw no.1

When load sensing pump works with zeroed displacement, a minimum pressure value used for:

- to compensate pressure drops into load sensing regulation circuit.

- to generate a control pressure for the pump internal servomechanisms.

This minimum pressure is preset with the no.1 screw over the control block, that can be easily recognized
because it is farther to the pump housing than the other control screw. Setting range is comprised between 14
and 25 bar. For values lower than 14 bar pump control becomes slow and inaccurate.

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Values higher than 25 bar increase wasted power when pump rotate with zeroed displacement.
Setting range: 14 - 25 bar
Standard setting: 20 bar
Other values: on request, according to above
range no.2 screw
no.1 screw
2.2 - pressure regulator: screw no.2

This screw sets high pressure value who zeroes

automatically pump displacement. This value can
be set between around 180 and 350 bar.
Displacement starts to zero when working
pressure raises a value around 3-5 bar lower than
the setting value. For values lower than 180 bar
pump control becomes slow and inaccurate.
Relief valve: It is always needed to assembly a
relief valve over the pump high pressure output, to
protect itself from overloads. Relief valve setting
must be at least 20 bar higher than pressure
regulator setting, in order to allow a good
regulator working.

3 - setting procedure

3.1 - needed tools:

hexagonal wrench 4 mm
c-fork wrench 13mm
manometer f.s. 300 bar over high pressure line

3.2 - recommendations:

Be sure pump output is protected by a relief valve, preset at least 20 bar higher than desired pressure
regulator setting.
To set the pump it is needed to close pump output; this can be done by means of a variable flow restrictor, or a
tap, or by means of the load sensing control valve used in the hydraulic circuit of the machine.

!!! IMPORTANT !!!

Always install on the pressure an external relief valve.
Pump output must be plugged after the main relief valve insertion point, in order to protect pump against any
possible overload.
Do all settings with warm oil, at a temperature of about 50°C
Avoid oil leaks and any environmental pollution, even accidental.

!!! WARNING !!!

!!!!!!!!!!!!!!!!!!!!!!
Pay great attention to all moving machine parts, and observe all safety rules in force. Contact with moving
parts could result in serious injury or death.

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3.3 - Load Sensing control setting

1 - with no running pump, tighten completely the flow regulator no.1 setting screw.
2 - close the tap over pump output, in order to close the output and load sensing signal.
3 - run the pump at 1500 rpm and check the pressure over high pressure manometer.
4 - set screw no.2 of the pressure regulator to the choosen value; once find correct setting, fix the screw
tightening the nut.
5 - unscrew the no.1 setting screw; pressure read on the manometer falls down immediately.
6 - set the no.1 screw in order to fix the choosen minimum pressure value; once find correct setting, fix the
screw tightening the nut.

3.4 - Constant Pressure control setting

1 - with no running pump, tighten completely the flow regulator no.1 screw and fix the screw tightening the nut.
2 - close the tap over pump output, in order to close the output and load sensing signal.
3 - run the pump at 1500 rpm and check the pressure over high pressure manometer.
4 - set screw no.2 of the pressure regulator to the choosen value; once find correct setting, fix the screw
tightening the nut.

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