A4VG125 main pump

August 2003 / sk-gw Page 1 of 12

 The basic principles of
maintenance

Pressure gauge
Measuring point m1
Measuring point m8
Flow meter
Diagnostics case
Diagnostics socket

August 2003 / sk-gw Page 2 of 12

 The basic principles of
maintenance

Central gauge port - sensor

system
Pressure gauge - high pressure
range
m1 = high pressure
m6 = boom
m4 = agitator
m3 = accumulator

Pressure gauge - low pressure

range
m2 = low pressure/ON
m5 = feed pressure/OFF
m7 = actuating pressure
m8 = control pressure

August 2003 / sk-gw Page 3 of 12

 Messblatt - Maschinen-Nr. Fiche de mesures - N° de machine
Test Reading - Machine no. Hoja de medición - Máquina N°
22 01 00172
Maschinen-Typ Type de machine
Machine model
1 = Meßstelle; 2 = Meßwert
1=Test point; 2= Measured value
Modelo de máquina
1 = Point de mesure; 2 = Valeur mesurée
1 = Punto de medición; 2= V alor de medición
1
BRF 36.09 H
2
Test reading
Pumpe Pompe
BP

BP1
Pump
Hauptpumpe Hochdruck
Bomba
Pompe principale-haute pression
m1 360 bar
All the pressures, fluid
Main pump-High pressure Alta presión bomba principal
BP2
Hauptpumpe-Schockventileinstellung
Main pump-High pressure limiting valve
Niederdruck max.
Pompe principale-réglage du clapet limitateur de
pression
Válvula antichoque
Basse pression, bomba principal
max.
m1 420 bar volumes and engine
BP4 m2 27 bar

BP6
Low pressure, max.
Speisedrucksicherheitsventil
Feed pressure safety valve
Máx. Baja presión
Clapet de sécurité pression d'alimentation
Válvula de seguridad presión alimentación
m5 32 bar
speeds set in the works
BP9
Öldurchflußmenge
Rate of oilflow
Steuerdruck-Ausstellbeginn
Débit d'huile
Caudal de aceite
Pression pilotage-début de coupure
3a 55 l/min.
are noted here
BP10
Control pressure-Swivel start Presión de mando inicio
m8 8 bar
Steuerdruck-Ausstellende Pression pilotage-fin de coupure
BP11
Control pressure-Swivel end Presión de mando final
m8 18 bar
Steuerdruck max. Pression pilotage, max.
BP12
Contr.pressure to contr.unit max. Presión de mando máxima
m8 23 bar
Stelldruckregler Schaltpunkt Régulateur de la pression nominale
BP13
Pump-control pressure regulator Regulador de presión inicio bombeo
950 rpm
Push Over (POH) - Verzögerung
BP15
Push Over (POH) - delay Push Over (POH)-retraso
30 ms
Push Over (POH) - Dauer
BP16
Push Over (POH) -pulse time Push Over (POH)-tiempo de impulso
80 ms
Push Over (POH)-Dauer
BP17
Push Over (POH) -pulse time Push Over (POH)-tiempo de impulso
0,287 V

Speicherdruck max. - Abschaltpunkt Pression max. accumulateur-coupure de pression

BP18
Accumulator pressure max.cut off pressure Presión acumulador máxi+C88ma
m3 170 bar
Speichervorladedruck Pression d'admission accumulateur
BP19
Accumulator precharged pressure Precarga acumulador
m3 95 bar
Rohrweiche Anfahrdämpfung (Umdr.)
BP20
Amortiguación cambio tubo oscilante inicio (vueltas) 2,0
Rohrweiche Endlagendämpfung (Umdr.)
BP21
Amortiguación cambio tubo oscilante final (vueltas) 1,5
Mischerdruck Pression malaxeur
BP22
Mixer pressure Presión agitador
m4 160 bar

BP23
Wasserpumpe -Öldruck
Water pump-Oil pressure
Wasserpumpe -Wasserdruck
Pompe à eau-pression d'huile
Presión de aceite bomba de agua
Pompe à eau-pression d'eau
m4 190 bar
Important:
BP24 22 bar

BP33
Water pump-Water pressure
Hubzeit lastfrei (Bodenseitig)
Stroke time,w ithout load (Bottom side)
Presión de presión bomba de agua
Temps de course, sans pression (côté semelle)
Tiempo de embolada en vacío (pistón) 2,2 s Always check all values
Pumpeneingangsdrehzahl lastfrei max. Régime alimentation pompe max.,sans
BP34

BP35
Pump input speed,w ithout load,max.
Motordrehzahl lastfrei max.
pression
Régime moteur max.,sans pression
2665
1800
rpm

rpm
before setting
Engine motor speed, w ithout load,max. Máx revoluciones motor en vacío
Förderdruck max. theo. (Bodenseitig) P ression de refoulement max. théor. (côté semelle)
BP37
Delivery pressure,max.theo.(Bottom side) Máx presión de trabajo teórico (pistón) 78 bar
Abschalt-Ölmeßtemperatur Température de coupure d'huile
BP38
Sw itch-off oil temperature reading Desconexión temperatura máxima de aceite
95 °C

August 2003 / sk-gw Page 4 of 12

 A4VG125 main pump

Setting: - Hydraulic zero position

- Feed pressure (m5)
- Low pressure (m2)
August 2003 / sk-gw Page 5 of 12
 HDC A4VG125
From the control
block
Function
Deflect the swashplate via the lever
C1
connection to the servo piston

C2
Hydraulic zero position
From the control
There must be no oil flow on -A- or -
block B- so that the drive cylinders do not
move
ð Equal pressure at the two m7
test points
ð Delivery cylinders must
remain stationary
August 2003 / sk-gw Page 6 of 12
 Hydraulic zero position
Prerequisite
- Hydraulic fluid at operating temperature
(approximately 40 - 50°C)
- Connect two 40 bar pressure gauges to m7
- Maximum engine speed
- Pump “OFF”
Setting procedure
- Equal pressure at the two pressure gauges
- If not:
Turn adjusting screw on the HDC controller
until the same pressure is displayed on the
pressure gauges
August 2003 / sk-gw Page 7 of 12
 Feed pressure
Prerequisite
- Hydraulic fluid at operating temperature
(approximately 40 - 50°C)
- Connect one 60 bar pressure gauges to m2/5
- Maximum engine speed
- Pump “OFF”
Setting procedure
- Set feed pressure on the pressure limiting valve
in accordance with the test reading

August 2003 / sk-gw Page 8 of 12

 A4VG125 alternating flush
valve

Function
Flushing and replacement of with a defined volume of fluid from the
closed hydraulic circuit via the radiator into the tank
August 2003 / sk-gw Page 9 of 12
 Low pressure
Prerequisite
- Hydraulic fluid at operating temperature
(approximately 40 - 50°C)
- Connect one 60 bar pressure gauges to m2/5
- Connect a flow meter at “3a”
- Maximum engine speed
- Pump “OFF”

Setting procedure
- Set low pressure on the pressure limiting
valve in accordance with the test reading
- Check pressure and flushout volume
August 2003 / sk-gw Page 10 of 12
 Possible sources of faults

• Fluid flowing out through 3a when pump is OFF

ð Spring fracture

• Constant change of low pressure level and flushing fluid

volume
ð Wear on the low pressure valve

• Stroke time, low pressure and high pressure are

assymetrical
ð Wear on the alternating valve piston

August 2003 / sk-gw Page 11 of 12

 SI 840322

August 2003 / sk-gw Page 12 of 12