SECTION 4 - BASIC HYDRAULIC INFORMATION & SCHEMATICS
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General Repair Instructions
REMOVAL
PRIOR TO PER FORMING REPAIRS, REMOVE THE UNIT FROM THE
MACHINE. CHOCK WHEELS ON THE MACHINE TO INHIBIT MOVEMENT.
BE AWARE THAT HYDRAULIC FLUID MAY BE UNDER HIGH PRESSURE
AND/OR HOT. INSPECT THE OUTSIDE OF THE PUMP AND FITTINGS FOR
DAMAGE. CAP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION.
KEEP IT CLEAN
Clean the outside of the pump thoroughly before disas-
sembly. Take care not to contaminate system ports.
Clean parts using a clean solvent wash and air dry.
AS WITH ANY PRECISION EQUIPMENT, YOU MUST KEEP ALL PARTS
FREE OF FOREIGN MATERIAL AND CHEMICALS. PROTECT ALL EXPOSED
SEALING SURFACES AND CAVITIES FROM DAMAGE AND FOREIGN
MATERIAL. IF LEFT UNATTENDED, COVER THE PUMP WITH A PROTEC-
TIVE LAYER OF PLASTIC.
REPLACE ALL O-RINGS & GASKETS
Replace all o-rings and seals during service. Lightly
lubricate o-rings with clean petroleum jelly prior to
assembly.
SECURE THE UNIT
Place the unit in a stable position with the shaft point-
ing downward. It will be necessary to secure the pump
while removing and torquing fasteners and compo-
nents.
PERFORMING MINOR REPAIRS ACCORDING TO THIS SECTION WILL
NOT AFFECT THE PUMP’S WARRANTY. MAJOR REPAIRS REQUIRING
THE REMOVAL OF THE UNIT’S CENTER SECTION, SERVO SLEEVES, OR
FRONT FLANGE VOIDS WARRANTY.
Start-Up Procedure
Follow this procedure when starting-up a new pump
installation or when restarting an installation in which
the pump has been removed and re-installed on the
machine. Ensure pump has been thoroughly tested on a
test stand before installing on a machine.
These pumps should never be dry started. The time it
takes for the charge pump to create a vacuum to draw
in the fluid, send it out through the charge pump filter
and then back in to the pump may take 30-40 seconds.
During this time the surface between the cylinder barrel
and valve plate are running dry. This can affect the volu-
metric efficiency of the pump and cause premature fail-
ure of the pump. Pre-filling the case also reduces the
time it takes fro the pump to create a vacuum to draw
fluid into the pump.
TO PROTEC T AGAINST UNINTENDED MOVEMENT, SEC URE THE
MACHINE OR DISABLE/DISCONNECT THE MECHANISM WHILE SERVIC-
ING.
NOTE:
Prior to installing the pump, inspect for damage that
may have occurred during shipping.
1. Ensure that the machine hydraulic oil and system
components (reservoir, hoses, valves, fittings, and
heat exchanger) are clean and free of any foreign
material.
2. Install new system filter element(s) if necessary.
Check that inlet line fittings are properly tightened
and there are no air leaks.
3. Install the pump. Install a 1000 psi (50 bar) gauge in
the charge pressure gauge port M3.
4. Fill the housing by adding filtered oil in the upper
case drain port. If the control is installed on top, open
the construction plug in the top of the control to
assist in air bleed.
5. Fill the reservoir with hydraulic fluid of the recom-
mended type and viscosity. Use a 10-micron filler fil-
ter. Fill inlet line from reservoir to pump. Ensure
construction plug in control is closed after filling.
6. Disconnect the pump from all control input signals.
7. Close construction plug removed in step 4.
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