Hydraulic Power Unit Product Manual

Maha Hydraulics
 Product Manual-HPU

Function:- Flow rate or until the control is adjusted.

The pump and the hydraulic motor are
A complete hydraulic drive system from
connected together by flexible hoses and
MAHA HYDRAULICS Drives comprises the
piping if necessary.
Power unit with electric motor, pump and
At the motor the oil is distributed through
tank, the control system, the hydraulic
the valve plate to the pistons in the cylinder
motor and the piping system. The power
block 50% of them with high pressure and
unit type HPU is described in this
50% with charge pressure. The oil pressure
publication and uses a closed loop
forces the piston assemblies radially
hydraulic system to provide a highly
outwards against the cam-ring. This
dynamic drive system. We have expertise
produces a balanced and smooth rotation
ourselves in custom built hydraulic power
with extremely high torque which drives the
units.
machine. The speed of the motor is
controlled by the flow of oil from the pump.
In most offerings, all items except the
Drive motor speed is therefore proportional
piping and hydraulic motor are housed in a
to the swash plate angle of the pump. If the
sound insulated cabinet. The swash plate
swash plate is controlled over-centre, the
pump is driven by an electric motor running
flow is reversed and the motor direction is
efficiently at fixed speed.
therefore reversed.
The oil flow from the pump is determined
Both the hydraulic motor and the pump
by the swash-plate angle, which is
have a very low moment of inertia, which
controlled by a signal from the control
makes it possible to change speed and stop
system. Starting in an unloaded, neutral
or reverse direction quickly.
condition, the system ramps the flow up to
the required direction and rate and
A proportion of the return flow is used to
pressure is determined by the load up to
provide oil conditioning by cooling and
the limit set at the compensator. If pressure
filtering. The oil in the motor and pump
reaches compensator setting the pump will
case which provides lubrication and local
destroke, stopping the drive, so eliminating
cooling is fed back to tank via an adequately
heat buildup but maintaining the set
sized drain line.
pressure and therefore torque at the drive.
The pump will stay in this condition until
the system is unloaded where upon the
pump will immediately ramp up to the set

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MAIN COMPONENTS:
4 5
1.1 Power Unit with one pump
1. CABINET: The free standing cabinet is
built of a robust steel framework with
sound insulated doors, panels and cover. It
is surface treated to prevent corrosion and
ageing in tough process industry
environments. The solution is an open one,
which simplifies accessibility during
Maintenance and service.
2. ELECTRIC MOTOR: An electric motor is an
electromechanical device that converts
electrical energy into mechanical energy.
The electric motors that we use have high
efficiency and are also extremely reliable.
They are started with no load and run
optimally at fixed speed.
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Product Manual-HPU
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3. SERVO FILTER: The oil filters are
dimensioned for oils with high viscosity and
a high degree of contamination separation.
Servo filter can be supplied as an option,
allowing you to replace filters during
operation.
4. PUMP: The hydraulic pumps are of the
variable displacement axial piston type with
very fast acting pressure compensator
override. This virtually eliminates overloads
and is a major factor in system reliability. All
control valves are built in to keep pipe work
to an absolute minimum. The electro-
hydraulic stroke provides variable flow by
smoothly controlling the swash plate and
thereby pumps displacement.
 Product Manual-HPU

DIMENSIONS:

Power Unit with One Pump:

X Y

Power Unit with Two Pumps:

Y
X

*(X), (Y), Z) depends upon the Customer Technical Requirements.

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 Product Manual-HPU

X
Y

X Y

*(X), (Y), (Z) depends upon the Customer Technical Requirements.

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 Product Manual-HPU

Features of the HPU Power Unit

INCLUDED AS STANDARDS

The Motor power range starting
Charge Pressure Filter

from 1.5Kw to 315kw Squirrel cage
Return Line Filter
rotor, 4-pole electrical motor.
Ball Valve

Axial piston pump with electro
Suction valve
hydraulic control.
Hand Pump

Fast pressure compensator, charge
Check Valve
pump and flushing valve.
Shuttle valve

Motor/pump set mounted on anti
Limit switch
vibration pads.
Isolator Valve

All internal pipe work and
Pressure Gauge

Wiring included.
Coupling

oil tank
Pressure relief Valve

Air-oil cooler and water Solenoid
Accumulator(Bladder Type)
valve.
Oil level Indicator

Temperatures switch with two
Anodized Circuit Plate
switches and temperature indicator.

Suction line valve with switch.

Charge pressure switch.

Oil filling point with quick release
Connector.

Electric junction box.

Pressure gauges

Thermostat And Thermo well

Bi-Metal Thermo meter

Float Switch

Pressure Switch

Air Breather

Manifold Block

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 Product Manual-HPU

TECHNICAL DATA FOR DENISON GOLD CUP

The Gold Cup pump is designed specifically

to MAHA HYDRAULICS Specifications to
provide a neatly packaged pump with
integral Boost pump, electro-hydraulic
displacement stroked and extremely Fast
compensator to reduce pressure spikes on
tough drives.

Maximum Volume adjustment screws and a displacement indicator are included. A double shaft
seal arrangement is provided to eliminate leakage and is designed to give long trouble free life
in line with MAHA HYDRAULICS drives systems generally. The Gold Cup has been employed
successfully for many years by MAHA HYDRAULICS providing a more limited range of
Displacements than other pumps but provides some useful steps between the sauer
Displacements.

It is a most compact pump with low inertia, excellent servo Control and extremely fast acting
compensator which is very useful in some applications. It is also user friendly with light weight
common controls and valve blocks. Because an external boost pump is always mounted it is
relatively easy to add auxiliary circuits to the Gold Cup.

The pump is designed to operate in any position. For verticals mounting it is recommended that
the shaft bearing be drained via the drain port provided. The mounting hub and mounting
flange are in full conformance with SAE standards. The Shaft must be concentric with the pump
shaft with in 0.006in., 0.152mm to prevent bearing failure. This concentricity is particularly
important if the shaft –coupling inter face must be lubricated with lithium molydisulfide or
similar grease.

Maximum at cold start 7500 SUS, 1600 CST

At low pressure, low flow and if possible, low speed

Maximum at full power 750 SUS, 160 CST

Optimum for maximum life 140SUS, 30 CST
Minimum at full power 60 SUS, 10 CST

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 Product Manual-HPU

Series Terms Units P6 P7 P8 P11 P14 P24 P30

Displacement Max in3/rev 6 6 8 11 14 24.6 30.6
cm3/rev 98.3 98.3 131.1 180.3 229.5 403.2 501
Pressure Continuous psi 5000 5000 3600 5000 5000 5000 5000
bar 350 350 250 350 350 350 350
Intermittent psi 6000 6000 4500 6000 6000 5500 5500
bar 420 420 310 420 420 370 370
Speed Pump-Max stroke rpm 3000 3000 2100 2400 2400 2100 1800
motor- Max stroke rpm 3000 3000 NA 2400 2400 2100 1800
motor- Max@50% stroke rpm 3600 3600 NA 2800 2800 2100 1800
Mounting Flange -2 Bolt SAE 127-2(C) 127-2(C) 127-2(C) - - - -
165-
Flange -4 bolt SAE 152-4(D) 152-4(D) 152-4(D) 4(E) 165-4(E) 177-4(E) 177-4(E)
shaft-keyed SAE 32-1(C) 32-1(C) 32-1© 44-1(E) 44-1(E) 50-1(F) 50-1(F)
Keyed SAE 44-1(D) 44-1(D) 44-1(D) - - - -
Shaft-splined SAE 32-4(C) 32-4(C) 32-4(C) 44-(4) 44-(E) 50-4(F) 50-4(F)
Splined SAE 44-4(D) 44-4(D) 44-4(D) - - - -
325-
Weight pump-less control lbs 175-300 175-300 175-300 530 325-531 750-835 750-836
145-
mass kg 80-135 80-135 80-135 240 145-241 340-375 340-376
Weight motor-Fixed lbs 110 110 N/A 250 250 510 600
mass kg 50 50 N/A 110 110 230 270
Weight Motor Variable lbs 110 110 N/A 300 300 650 670
Mass kg 50 50 N/A 135 135 290 300
Inertia lbs-in2 92 92 92 290 290 821 977
kg-m2 0.027 0.027 0.027 0.085 0.085 0.24 0.286
Torque per 100 psi lbs-in2 95.5 115.4 N/A 175 222 392 487
per 100 bar Nm 157 189 N/A 287 362 623 797
at 5000 psi lbs-in2 4774 5769 N/A 8750 11100 19576 24351
at 300 bar Nm 539.5 651.9 N/A 990 1250 2158 2752
Power per 100 rpm hp 7.6 9.2 N/A 13.8 17.6 31.1 38.6
kw 5.7 6.8 N/A 10.3 13.1 23.1 28.8
at 2000 rpm hp 151.5 183.1 N/A 227.8 353.5 621.3 695
kw 113 136.6 N/A 207 263.7 463.5 518.2
Torque apporx .stalled %theo 81 81 N/A 81 81 81 81
running %theo 93 93 N/A 93 93 93 93
Case Pressure Max.allowable continuous psi 75 75 75 75 75 75
bar 5.2 5.2 5.2 5.2 5.2 5.2 5.2 5.2
intermittent psi 125 125 125 125 125 125 125
bar 8.6 8.6 8.6 8.6 8.6 8.6 8.6
Flow Max displ.@1500 rpm gpm 39 47 52 71 91 160 199
lpm 148 178 197 269 344 606 753
1800 gpm 47 57 62 86 109 192 238
lpm 178 216 235 326 413 727 901
Displacement Internal aux.pump P6,8P,S,V P11,14P,s P11,14V P24P P24S P30P P30S
in3/rev 1.07 (2) 1.07 1.07 2.81 2.81 2.81 2.81
cm3/rev 17.5 (2) 17.5 17.5 46.1 46.1 46.1 46.1
Flow 1500 rpm gpm 6.9 (2) 6.9 6.9 18.2 6.5 18.2 6.5
lpm 26.1 (2) 26.1 26.1 68.9 24.6 69.1 24.6
1800rpm gpm 8.3 (2) 8.3 8.3 21.9 7.8 21.9 7.8
lpm 31.4 (2) 31.4 31.4 82.9 29.5 82.9 29.5

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 Product Manual-HPU

TECHNICAL DATA FOR SAUER PUMP

The SAUER pump is designed specifically to

MAHA HYDRAULICS drives specifications to
provide a neatly packaged pump with
integral boost pump, electro hydraulic
displacement strokes and fast compensator
to reduce pressure spikes on tough drives.
Flow direction is reversed by tilting the
swash plate to the opposite side of the
neutral (zero displacement) position.

The Rated Speed is the highest speed

recommended at full power condition at
which normal life can be expected. All other
operating conditions (e.g. fluid viscosity and
Temperature, charge pressure) must be within recommended ranges. Series 90 pumps are
designed with a bypass function. The bypass is operated by mechanically rotating the bypass
hex on both multi-function valves three turns counter clockwise (CCW).

Charge flow is required on all Series 90 pumps applied in closed circuit installations to make up
internal leakage, maintain a positive pressure in the main circuit, provide flow for cooling,
filtration, replace any leakage losses from external valving or auxiliary systems and provide flow
and pressure for the control system. Many factors influence the charge flow requirements and
the resulting charge pump size selection.

These factors include system pressure, pump speed, pump swash plate angle, type of fluid,
temperature, and size of heat exchanger, length and size of hydraulic lines, control response
characteristics, auxiliary flow requirements, hydrostatic motor type, etc. When initially sizing
and selecting hydrostatic units for an application, it is frequently not possible to have all the
information necessary to accurately evaluate all aspects of charge pump size selection.

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 Product Manual-HPU

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 Product Manual-HPU

TECHNICAL DATA FOR LINDE PUMPS

The LINDE pump is designed specifically to

MAHA HYDRAULICS Specifications to
provide a neatly packaged pump with
integral Boost pump, Electro-hydraulic
displacement stroked and extremely Fast
compensator to reduce pressure spikes on
tough drives.

Axial piston pump in swash plate design for

high pressure closed loop system. Clock
wise or counter clock wise rotation.

Integrated high pressure relief valves with make-up function. Integrated low pressure relief
valves for boost, control and cooler circuits. It has a replaceable filter. Boost pressure pumps for
internal and external suction, integrated cold start relief valve optional. It can be use an optional
tandem pump and multiple pumps.

Product advantages:-

 Compact design
 High power density
 Dynamic response
 High reliability
 Long service life
 Noise-optimized
 Precise and load-independent servo control

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 Product Manual-HPU

Model Name 55 75 105 135 165 210 280

Rated size Maximum displacement cm3/rev 54.8 75.9 105 135.6 165 210 280

Maximum continuous speed

speed (at 100% duty cycle) min-1 3300 3100 2900 2700 2500 2300 2000
Maximum speed
(intermittent) higher speed
on request min-1 3200 2900 2700 2500 2200
Minimum continuous speed min-1 500 500 500
Maximum operating
Pressure pressure bar 420 420 420
Maximum pressure
(intermittent) bar 500 500 500
Continuous pressure(P) bar 250 250 250
Permissible housing
pressure bar 2.5 2.5 2.5
Continuous input torque
Torque at continuous pressure Nm 220 305 420 540 1100 840 1115
Maximum input torque
at max. operating pressure
and
19 bar boost pressure Nm 350 485 670 870 170 1340 1785

Continuous power
at max. continuous speed,
Power continuous pressure KW 75 98 127 153 275 201 234
Maximum power at max.
Continuous speed, max.
operating pressure and
19barboost pressure KW 121 157 204 245 275 322 373
Permissible shaft
loads Axial N 2000 2000 2000
on on
Radial N request request
Perm. housing Perm. housing temperature
temperature with
Minimum perm. viscosity >
10 cSt °C 90 90 90
inclusive IGP (Size
55-135) without oil HPV with H1-control
(approx.) without oil (approx
or EGP (Size 210-
280) Kg 46 49 66 72 95 132 164
Filling volume HPV
housing with filter dm3 2.1 2.8 3.4 3.8 4.2 4.8 5.5

Maximum moment of inertia kgm²x102 0.54 0.84 1.49 2.2 3.11 4.77 9.38

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 Product Manual-HPU

Choose the best method of your application

 A system of few components, but

many combinations and
configurations, to provide any
solution for the MAHA HYDRAULICS
drives performance range. The
perfect load sharing characteristics
enables multi-pump and/or multi
motor combinations to suit the
application.
 User friendly - pressure and flow and
therefore torque, speed and hence
power can be adjusted. It is easy to
upgrade to suit changing production
demands. This versatility can
transform a machine into an
intelligent high production unit.
Features such as extremely fast pump
compensators to give fast response
and reduce stresses and strains on
the machine, load sensing and power
limiting enable functionality
unavailable from other systems.
 The ability to split the drive from the
power unit enables freedom of
application. The power unit can be
positioned away from the machine
without foundation requirements.
 The unit is easy to install, it is fully
function tested before delivery and
takes a short time to commission.
Installation can be undertaken
usually during a normal shutdown
period so no production losses are
experienced.

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 Product Manual-HPU

IMPROVEING THE WORK ENVIRONMENT: HYDRAULIC SYSTEM NOISES:-

Six routines must be followed in order to

minimize the chances of your hydraulic
equipment suffering costly, premature
component failures and unscheduled
downtime:

 Maintain fluid cleanliness.

 Maintain fluid temperature and
viscosity within optimum limits
 Maintain hydraulic system settings
to manufacturers' specifications
 Schedule component change-outs
before they fail.
 Follow correct commissioning
procedures.
 Conduct failure analysis.

In a good work environment the sound

levels are important. Environments where
the sound levels are kept down make a
difference for operator health and well
being. MAHA HYDRAULICS drives low speed
hydraulic motors generate very low sound
levels due to the low speed. The dominating
sound sources in a hydraulic drive system
are the power unit and the piping systems.
Noise reduction at Component level:
Which focuses on
the reduction of noise from individual
component like hose, control valve, pump
mounts and fixtures .This can be accomplished
by a suitable design modification of the
component so that it radiates least amount of
noise.

The sound can be divided into three basic

kinds:-
 Structured Borne Sound-(From the
instance of a pump)
 Air Borne Sounds-(From a Cooling
Fan or Air oil cooler.)
 Fluid Borne Sounds-(From Pump or
Motor as pulsation in the oil flow).

Each of these has to be treated separately

to manage the overall sound level and to
specify the level, the combined effect must be
considered.

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 Product Manual-HPU

Applications:

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 Product Manual-HPU

Maha Hydraulics Private Limited

Plot No. F-62, Sipcot Industrial Complex,
Irungattukottai, Sriperumbudur Taluk,
Kanchipuram Dist – 602 105, Tamilnadu, India,
Tel: +91-44-4719 3081/82/83,
Fax: +91-44-4719 3080
E-Mail: sales@mahahydraulics.com

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 Product Manual-HPU
www.mahahydraulics.com

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