Service Training Training document Variable displacement pump HPV 135-02R Electro-hydraulic control E1WA Document no. HPV 135-02R E1WA 52594 E Date of Issue 05.2011ve Contents Training Document: Variable Displacement Pump HPV 135-02R with electro-hydraulic control E1WA. Document Nc. HPV 135-02R E1WA 52594 E Circuit diagram Connection and gage port diagram Connection nd gage port diagram General description Functional description of HPV 135-02 Functional description of HPV 135-02 Functional description of the pressure relief valve VO8, Functional description of the pressure relief valve VD18-01 Basic design of rotating group Basic design of port plate housing Basic design of control system E1WA Basic design of mechanical zero position Circuit diagram Basic design of control system E1WA General hints for fitting and installation The technical data, functional descriptions and basic design diagrams contained in this document are intended for reference purposes. The contents of this dacument shall not constitute the basis for any claims whatsoever. In this context we would like to draw your attention to the training courses organized and performed by Linde Hydraulics in Aschaffenburg. For detailed information do not hesitate to contact our training department. This training document is made available for inhouse purposes anly and remains the exclusive property of Linde Material Handling GmbH Linde Hydraulics 63741 Aschaffenburg, Germany Grossostheimer Strasse 198 Phone +49 (0) 602199 26 37 Fox +49 (0) 6021992949 info@linde-hydraulics.com www.linde-hydraulics.com © 2011. tis document was create by Michael Zvkovic 2 05.11 ‘ovale placement Pup HPY 135-02 wth electoral contol TWA Document No, HPV 135-028 EWA 2504 ECircuit diagram Explanation BS [ain ors, high pressure i Control nd boost pressure supplypar Cont pressure supplypot, 5 Coton portfor accurate ey 1 frenkand vent pat Dc proportional solenods Dav Ms, NO [csuge por high pressure Lu Jo iting tank and vet por uz [consol pressure gauge port 05.11 Solenoid My actuated » High pressure in port P Solenoid Mz actuated » High pressure in port S Document. HPV 135-028 E1WA 52504 E \ajiabl isplacement ump HPV 135-028 wth elec hydraulic contol TWA. 3Connection and gage port diagram Ley General hints The installaticn of the HPV 135-02 pump must be completed according to the information contained in the Circuit and piping diagram, the operating instruction, the technical data sheet and the installation drawing The pump housing remains campletely filled with fluid after initial filing, venting and in every state of operation. » Fill with oil and vent pump case before start-up. » Type of oil: see technical Linde Hydraulics data sheet: Mineral-oil-based hydraulic fluids » Max. oil-temprature in pump case: 90 °C » Permissible housing pressure: 1,5 bar (2,5 bar abs.) The pump flow and direction of the flow are controlled by an electrical signal input at the solenoids (MY or MZ) and control pressure supply at the port E. The flow direction of the fluid depends on: = the pump direction of rotation - the over certre direction of the swash plate. Clockwise Drive sense of rotation: Counterclackwise Solenoid My actuated: >700 mA: High pressure in port P Solenoid mz actuated: »700 mA: High pressure in port S ‘My and Mz are 24 V DC proportional solenoids Document No. HPV 135-02REIWA 52594 E 05.11 abl placement Pump HPY 135-028 wth elect syéral contol TWAConnection and gage port diagram Explanation 7S_[Wo pis igh pressure F [conte and boost pressure sup pat Teontalpessueswolvoat i [option tir accumulator 1 Fankand vent pt Ty [OC proportional solenaids 207 1s, Mo [Gave pot, high ores Lol filing tankand er por 1.7 [contelpressute pune port ; Document No. HPV 135-02R E1WA 52594 05.11 ‘ail Displacement Pup HPY 135-028 wth electoral como TWA.General description va “ Type HPV-02 variable pumps are axial piston pumps in swash plate design with variable displacement for hydrostatic transmissions (HST) in closed loop application, The HPV 135-02 pump described in this training document is equipped with proportional electro-hydraulic control E1WA. Servo control E1WA This device can be mounted on of taken off without interfering the main pump. Boost pressure relief valve VO8-802 It limits the maximum boost and servo pressure. Combined high pressure relief and boost check valves VO18-01 The relief va ves limit the maximum working pressure in the high pressure line. The boost check valves catty out the make-up function and replace the leakage losses in the closed loop circuit Document No, 5 135-02REWA 52594 E 05.11 ‘atl Osplacement np HPV 135-028 wth elecoshydrauli contol WA, 6. Functional description of the HPV 135-02 Ley 1. Mechanical zero position 2. Hydraulic zero position 3. Boost and high pressure circuit 4, Servo control E1WA. 5. Pressure relief valves 1 Mechanica’ zero position ‘As long as the HPV pump isnot driven by the prime mover its held in neutral position by mechanical ‘means: The swash plate, item 2 in the circuit diagram, is positively held in its no-flow position by two springs (1) atthe actuator pistons (6) and (7), so that at the moment of starting the pump runs in zero position with no displacement. Precondition: The proportional solenoids My and Mz are not energized. This mechanical setting of the zero position is done during assembly in the factory and cannot be adjusted from outside. 2 Hydraulic zer0 position ‘When the pump is driven its held in zero position by hydraulic means: Precondition: Proportional solenoids My and Mz are not energized: The boost pressure which reaches the servo control device E1WA (14) via channel (13) acts as a control pressure. In its central position pilot valve (5) connects both actuator pistons (6) and (7) with the control pressure, thus keeping the swashplate (2) in its neutral position The hydraulic tuning of zero position is done at LINDE test rig It may be changed only in exceptional cases by trained exserts. The corresponding Service Information must be adhered to. 3 Boost and high pressure circuit Inthe neutra position of the swash plate there is no axial stroking of the pistons and therefore no pump delivery, neither, the pump shaft drives not anly the rotating group of the main pump but also the an- cillary pump icustomer part). This sucks hydraulic ol from the hydraulic tank and sends it on a trip into the HPV pump through the port F. Back in the pump the oil passes the two boosting valves, combined valves (11) and (12), flows on to the two high pressure ports (P) and (5) and then to the servo control (14. The excess oll nat required to make up for leakage losses bleeds off at the boost pressure relief valve (10) This maintains the set boost pressure for the low pressure retum side of the main circuit, Depending on which direction the swash plate is tilted, either port (P) or (S) carries high pressure. At the same time it closes the respective make up valve (11) or (12). Boost oil an only be fed on the low pressure side, When high pressure exceeds the maximum set value of the combined high pressure relief and make up valve the surplus spills over through the connecting channel to the opposite make up valve and into the low pressure line ‘Document Ho. HPV 135-02R E1WAS2594 E 05.11 ‘arable placement Pun HPV 135-02 wt elec hydauli contol ETA.2 Functional description of the HPV 135-02 oe Lae 4 Servo control E1WA The "electro hydraulic servo control uses for its actuation a pilot valve (5) integrated in the servo device (14). The pilet valve (5) is moved by means of the actuation piston (3) which normally is accurately heldin its middle position by two springs. Pilot valve (5) and actuating piston (3) are mechanically linked to each other by a lever (18), see functional schematic E1WA. Control of the actuating piston (3) is realized witha control pressure selected at the solenoid My or Mz, which determines both amount and direction of puma flow. Precondition: Control pressure is supplied to the port E How the control device E1WA works Itis supposed that the proportional solenoids My and Mz are not actuated. If the HPV-02 is driven there is boost pressure in channel (13). f control pressure is supplied to the port E it will get to the un-powered proportional valves (16) and (17). The HPV-02 is in its hydraulic zero position, see description item 2. Ifa current induced by the electronics flows in the proportional solenoid My then a proportional magnetic force Fm at the pin of the solenoid is generated. In the subsequent proportional valve (16) a pressure (hydraulic force Fh) is sent to the actuation piston (3) which corresponds to the solenoid signal The actuation piston (3) shifts accordingly, fluid on the opposite side is discharged to tank via the propor tional valve (17), the pilot valve (5) is moved and supplies control pressure to the control piston (6), control piston (7) is relieved to tank and the pump swashplate (2) tlts in the corresponding direction, Ifthe signal (magnetic force Fm) at the solenoid My is decreased, the proportional valve (16) reduces the pressure towards actuation piston (3) and the swash angle becomes smaller. The supply pressure in the port E, at the control E1WA, serves as a signal for the contral pressure of the proportional valves (16) and (17). Switching off the pressure at the port E effects directly the position of the actuating piston (3). The swashplate (2) is centred to its zero position and the HPV-02 is in its hydraulic zero position. There is no axial stroking of the working pistons (22) and therefore no pump delivery. Pressure port E As an option the function state of the pressure port € can be used for a watchdog function Pressure port F3 ‘Asan option the port F3 can be used as a pressure supply port for an accumulator to stabilize the servo pressure if required in certain situations. Diagram Displacement [%] Control pressure [bar] ————+ 0 2 4 6 8 0 12 14 16 Control current (mA) = = 70010 1750 +20 Document No, HPV 135-02R E1WA 52594E 05.11 ‘aril Dspacement Pump HPV 135-028 wth elect hy raul convo EWA 8Presi elevale v8 02 5 Pressure relief valves 5.1 Boost pressure relief valve VO8-802 (10) The pressure relief valve VO8-B02, fitted in the port plate housing of the HPV 135-02 pump, limits the mati mum control and boost pressure. Function The valve spool is pushed against the seat by the tension of the spring and closes the passage (13) from the tank port (pump housing). The spring chamber of the valve is also drained via a bore in the valve hous- ing to the tark port. ‘When the pressure in the passage (13) exceeds the spring force (acting on the area of the valve spool) the valve spcol is lifted off its seat and oils relieved from passage (13) inta the pump housing, The increase of the pressure is limited Construction ‘VO8-B02 is afactory-set spring-loaded conical seat type. It consists ofthe valve body, the compression spring and the valve spool which is forced down on its seat, In order to adjust the response pressure to the required level of pressure limitation, the spring force can be varied by means of appropriate springs and shims. Permissible rated pressures for the ol filter has to be observed! The complete valve must be fastened with the prescribed locking torque. Sealing is realized by a cutting edge on the bottom and by an O-ring on the top. Plug Ma = 201m Nominal pressure marked Valve body Ma = 40 Nm Zo v “a Spacers ‘Spring my Uy ven o-ring —~ | i! ! = | + Valve spool OUT Prior to beginning the envisaged work the system pressure must be released and implements unloaded > Pressure and flow values of the HPV 135-02 pump are factory set according to the order specifications. > Readjustments in exceptional case and only by trained and qualified personnel permitted. > Any amencments, attachments and modifications of hydraulic components must not be applied without consulting us. Protection of the natural fundamentals of life is one of our predominant tasks. in connection with work to be performed, the environmental regulations of the machine manufacturer must be respected Document No. HPV 135-02REIWA 52594 05.11 ‘atl Osplacemen np HPV 135-028 wth elect hydra contol TWA, 7