Verstellpumpe Variable Pump: With Electro-Hydraulic Control E1

Variable Pump
Verstellpumpe
HPV 55 - 02
with electro-hydraulic control E1
DocumentNo.:
Document No.:HPV
HPV55
...--02
0222500
22500EE
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Hydraulic ServiceTraining
Contents
Training Documents: Variable Displacement Pump HPV 55 - 02 L E1
with electro- hydraulic control E1
Document No.: HPV 55 - 02 22500 E
Page Title Edition 09.99
1 Circuit diagram
2 Working and gage port diagram
3-9 Function
10 Basic design of rotating group
11 Basic design of port plate housing
12 Basic design of control system E1
13 Basic design of mechanical zero position
The technical data, functional descriptions and basic design diagrams contained in this document are intended
for reference purposes. The contents of this document shall not constitute the basis for any claims whatsoever.
This training document is made available for in house purposes only and remains the exclusive property of the
LINDE AG Industrial Trucks and Hydraulics Division. © ®

Variable Pump
Hydraulic
Description: Date: 09.99
HPV 55 - 02 L E1
Service Training with electro-hydraulic control Page: 1 / 13
Circuit diagram
F
2 bar
10 micron
9
S (P) B
X
Ms
11 8
L
1 14 4
A B
2 13
6 7
12
D1 D2
10
5
3
17
16 MY MZ
Mp
X
X
X
P (S) Y X Z X
T U A
solenoid My energized » HP pressure in port S

EXPLANATIONS solenoid Mz energized » HP pressure in port P
P, S High pressure port
B Pressure port boost pump Displacement Relative to Control Current
A Suction port boost pump
F Control and boost pressure supply 100
T Tank and vent port
X Boost pressure gage port 12 Volt
Y, Z Control pressure gage port
MY, MZ Proportional solenoid 12V
50
Ms, Mp High pressure gage port
U Drain, flushing return from hydr. motor
L Oil filling, tank and vent port
0
0 1 2 3 4 5 6 7 8 9
Control pressure (bar) I
Control current (mA)

350 ± 10 720 ± 20
LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 4 16 09

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Working and gage port diagram
MZ Y Z
MZ
MY
L (U)
F
X
F
A B
Mp Ms
P (S) S (P)
MS
U (L)
MY
solenoid connection Y
diagramme:
Flow Direction
1 2
The flow direction of the fluid is dependant upon:

- the pump direction of rotation
- the over centre direction of the swash plate
DRIVE SENSE OF ROTATION: counterclockwise viewed on S

Solenoid My energized > 350 mA: HP pressure in port S Z
MZ
Solenoid Mz energized > 350 mA: HP pressure in port P
F X
EXPLANATIONS
P, S High pressure port L (U)
B Pressure port boost pump Start up:
A Suction port boost pump fill pump housing with oil and vent prior to commissioning.
F Control and boost pressure supply For kind of oil please refer to the technical data sheet.
T Tank and vent port Permissible case pressure 1,5 bar (2,5 bar abs.),
X Boost pressure gage port please adhere to installation instructions!
At no point of the hydraulic installation the temperature
MY, MZ Proportional solenoid 12V should exceed 90° C.
For applications involving radial shaft loading
please contact LFH.
Oil filling, tank and vent port
Further performance data to be found in the technical
L
data sheets.
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Description
Type HPV - 02 variable pumps are axial piston pumps of swash plate design with variable
displacement for hydrostatic transmissions (HST) in closed loop application.
The HPV - 02 pump described in this paper is equipped with an E1 type electro-hydraulic
control.
All auxiliary features for closed loop are integrated in or attached to the pump:
- Servo control E1: this device can be mounted on or taken off without inter-
fering with the main pump.
- Ancillary pump: inner ring gear pump for one sense of rotation, internal
suction; without interfering with the main pump the ancillary
pump can be put on or off.
Its suction side is screen-protected.
· it provides control pressure for the swash plate.
· leakage from the closed loop is restituted with a defined
preload.
- Cold start valve: protects the cooler; responds only when back pressure in the
cooling or filtration circuit exceeds the set level. Its setting
is always higher than that of the boost pressure relief valve.
- Boost pressure relief valve: it limits the maximum control and boost pressure.
- Combined high pressure relief and boost check valves:

· the relief valves limit the maximum working pressure in the high
pressure line.
· the boost check valves are for make-up in the closed loop circuit
(to replace leakage losses) .
- Cartridge filter: 10 micron replacement cartridge filter. The entire flow of the
ancillary pump passes through this filter.
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Functional description
1. Mechanical zero position

2. Hydraulic zero position
3. Boost and high pressure circuit
4. Servo control E1
5. Pressure relief valve
6. Ancillary pump
1. Mechanical zero position
As long as the HPV pump is not driven by the prime mover it is held in neutral position
by mechanical means:
The swash plate (item 2 in the circuit diagramme) is positively held in its no- flow position
by two springs (1) at the displacement pistons, so that at the moment of starting the pump
runs without 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 altered from outside.
2. Hydraulic zero position
When the pump is driven it is held in neutral by hydraulic means:

Precondition: proportional solenoids My and Mz are not energized:
Boost pressure reaching the servo control device E1 via channel 13 acts as a control
pressure.
In its central position pilot valve (5) connects both displacement pistons (6) and (7) with the
control pressure, thus keeping the swashplate in its neutral position.
The hydraulic tuning of zero position is done at LINDE`s on the test rig. It may be changed
only in exceptional cases by trained experts. The corresponding Service Information must
be adhered to.
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
3. Boost and high pressure circuit
In the neutral position of the swash plate there is no axial stroking of the pistons and
therefore no pump delivery, neither
The pump shaft drives not only the rotating group of the main pump but also the ancillary
pump (4). This sucks hydraulic oil from inside the pump housing and sends it on a trip from
port B (see circuit diagram) to a cooler (if available) and back into the HPV pump at port F.
The cold start valve (8) responds only if backpressure in the cooling and filtration circuit ex-
ceeds the set value. The entire flow runs through the 10 micron cartridge filter (9). Back in
the pump the oil passes the two boosting valves (combined valves 11+12), flows on to the
two high pressure ports (P+S) and then to the servo control (14).
The excess oil not 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 return side of
the main circuit.
Depending on the direction of swash plate tilt either port P or S carry high pressure, at the
same time closing the respective boost valve (11 or 12). Boost oil can only be fed in on the
low pressure side.
In case high pressure exceeds the set max. value of the combined boost and high pressure
relief valve the surplus spills over through the connecting channel to the opposite boost
valve and into the low pressure line.
4. Servo control E1
The "electro hydraulic servo control" uses for its actuation a pilot valve (5) integrated in the
servo device (15).
The pilot valve (5) is moved by means of the actuation piston (3) which normally is accur-
ately held in its middle position by two springs. Pilot valve (5) and actuating piston (3) are
mechanically linked to each other by a lever (see functional schema E1). Control of the
actuating piston (3) is realized with a control pressure selected at the solenoid My or Mz,
which determines both amount and direction of pump flow.
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
How the control device works:
It is supposed that the proportional solenoids My and Mz are not actuated.

If the HPV is driven there is boost pressure in channel (13). The boost pressure (control pres-
sure) present in the servo E1 will get to channel (13) up to the un-powered proportional
valves (16) and (17).
The HPV is in its hydraulic zero position (see description item 2).
If a current induced by the electronics flows in the proportional solenoid (My) this generates
a proportional magnetic force Fm at the pin of the solenoid. In the subsequent proportional
valve (16) a pressure 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 proportional 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)
tilts in the corresponding direction.
If the signal Fm at the solenoid (My) is lessened, the proportional valve (16) reduces the
pressure towards actuation piston (3) and the swash angle becoms smaller.
Diagram
Displacement Relative to Control Current
100
12 Volt
50
0
0 1 2 3 4 5 6 7 8 9
Control current (mA) 350 ± 10 720 ± 20
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
5.Pressure relief valves
5.1 Boost pressure and cold start valve DBE 6 (8 and10)
The pressure relief valves DBE 6 fitted in the HPV 55 - 02 and its auxiliary pump are factory-
set spring-loaded conical seat ones. They consist of valve body, compression spring and
valve poppet which is forced down on its seat.
The spring force can be varied by means of appropriate springs and shims, in order to adjust
the response pressure to the required level of pressure limitation. The complete valve must
be fastened with the prescribed locking torque.
The bodies of the two valves are not identical, see fig.1. They must not be interchanged to
avoid malfunction. Sealing is realized by cutting edge on the bottom and by O - ring on the
top.
plug
Ma = 10 Nm
valve body (SW 14)

Ma = 30 +5 Nm
nominal pressure marked
spring
spacers
O - ring
Fig. 1
spool
OUT boost pressure relief valve (10) cold start relief valve (8)
IN
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
5.2 Combined pressure relief and make-up valves VD 9 (11) and (12)
The VD9 valve cartridges screwed into the HPV-55 valve plate housing are factory-set direct
acting pressure relief valves with make-up function. They consist of valve body, plug, spring 1,
spring 2, snap ring, spring plate and valve spool. The setting is not adjustable. For other
pressure settings the VD9 valve has to be exchanged as a whole.
5.2.1 Function as boost valve (make-up)

There is always pressure in the F line (boost pressure). Should pressure in channel
P/S be lower than in channel F, pressure in chamber F , due to the differential pressure,
acts on the effective area of the check valve poppet which is thereby shifted against the
force of spring 2 and thus connects channel F with P/S. Pressures are balanced off,
thus avoiding cavitation.
5.2.2 Function as pressure relief valve
When high pressure in channel P/S, acting on area D of the valve spool, reaches the
setting of spring 1, the spool moves against the force of the spring. Connection to
channel P/S is established, and pressure can be relieved.
Nominal pressure marked plug

Ma = 60 Nm S/P F
back-up ring
spring 2 O - ring
make-up
spring plate
snap ring
spring 1
high pressure
check poppet
valve body
P/S channel
D
valve spool
F
boost pressure line
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
6. Auxiliary pump
The inner ring gear pump is mounted onto the main pump as a complete unit. Its drive shaft is connected to
the shaft of the HPV by means of a coupling muff. Its sense of rotation is unidirectional, yet it can be converted,
as explained in the Service Information. A further ancillary pump can be attached, see Technical Data Sheet.
Auxiliary pump with internal suction (counterclockwise rotation)

cold start valve DBE 6
B A
pressure port suction port
1. O- ring 12. O- ring

2. coupling muff 13. plug
3. screen 14. O- ring
4. needle bearing 15. valve body
5. snap ring 16. spool
6. cover 17. spring
7. shaft 18. spacer
8. disc key 19. spacer
9. pump gear 20. plug
10. inner gear
11. housing
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Basic design of rotating group
14 MZ
18
29 4
28
21
26
22
2 23 24 27
39
25
2. swash plate 25. holding clamp

4. ancillary pump 26. retainer plate
14. electro hydraulic control E1 27. screen
18. link 28. feed back lever
21. shaft 29. dowel (centering of control E1)
22. working piston 39. tube
23. cylinder barrel
24. port plate
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Basic design of port plate housing
8
14
4
9
10
12 A B
11
4. ancillary pump
8. pressure relief valve DBE 6 (cold start valve)
9. cartridge filter
10. pressure relief valve DBE 6 (boost pressure)
11. pressure relief valve VD 9 (combined high pressure relief and boost check valve) "S"
12. pressure relief valve VD 9 (combined high pressure relief and boost check valve) "P"
14. electro hydraulic control E1
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Basic design of control system E1
30
31 31
15 18 28 15
3
32 32
34
35
34
33
35 36
37
33
16 D1
D2
Mz
My
3. actuating piston 32. plug
5. pilot valve 33. lock nut Ma = 25 Nm
15. spring 34. end stops for max. flow
16. proportional valve 35. seal nut Ma = 23 Nm
18. link 36. lock nut Ma = 25 Nm
28. feed back lever 37. hollow screw
30. housing
31. spring plate
This electro-hydraulic control E1 is realized as one complete assembly. It is mounted on top of the HPV and
consists of the housing (30) with solenoids My and Mz. It contains a slave piston (3), a pilot valve (5) and
two proportional valves (16) and (17). Response throttles (D1) and (D2) are integrated in the housing (30).
The device has a vent port T and two gauge connection ports Z and Y.
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Basic design of mechanical zero position
39
41 42
40 40
1 7
25
14
2
1. spring (mechanical zero position)

2. swash plate
6. displacement piston
7. displacement piston
14. electro hydraulic control E1
25. holding clamp
39. tube
40. seal ring
41. O - ring
42. spacer shim
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Service Training with electro-hydraulic control Page: F 1 / 2
Circuit diagram
F
2 bar
10 micron
9
S (P) B
X
Ms
11 8
L
1 14 4
A B
2 13
6 7
12
D1 D2
10
5
3
17
16 MY MZ
Mp
P (S) Y Z
T U A
solenoid My energized » HP pressure in port S

EXPLANATIONS solenoid Mz energized » HP pressure in port P
P, S High pressure port
B Pressure port boost pump Displacement Relative to Control Current
A Suction port boost pump
F Control and boost pressure supply 100
T Tank and vent port
X Boost pressure gage port 12 Volt
MY, MZ Proportional solenoid 12V
50
L Oil filling, tank and vent port
0
0 1 2 3 4 5 6 7 8 9
Control current (mA)

350 ± 10 720 ± 20
LINDE AG
M. Zivkovic

Variable Pump
Hydraulic
HPV 55 - 02 L E1
Service Training with electro-hydraulic control Page: F 2 / 2
Basic design of control system
LINDE AG
M. Zivkovic

Verstellpumpe Variable Pump: With Electro-Hydraulic Control E1

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Variable Pump

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Page Title Edition 09.99

2 Working and gage port diagram

10 Basic design of rotating group

11 Basic design of port plate housing

12 Basic design of control system E1

13 Basic design of mechanical zero position

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solenoid My energized » HP pressure in port S

Control current (mA)

Document No.: HPV 55 - 02 22500 E

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Working and gage port diagram

The flow direction of the fluid is dependant upon:

DRIVE SENSE OF ROTATION: counterclockwise viewed on S

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- Combined high pressure relief and boost check valves:

Document No.: HPV 55 - 02 22500 E

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1. Mechanical zero position

1. Mechanical zero position

2. Hydraulic zero position

When the pump is driven it is held in neutral by hydraulic means:

Document No.: HPV 55 - 02 22500 E

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3. Boost and high pressure circuit

Document No.: HPV 55 - 02 22500 E

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How the control device works:

It is supposed that the proportional solenoids My and Mz are not actuated.

Control current (mA) 350 ± 10 720 ± 20

Document No.: HPV 55 - 02 22500 E

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5.Pressure relief valves

5.1 Boost pressure and cold start valve DBE 6 (8 and10)

valve body (SW 14)

Document No.: HPV 55 - 02 22500 E

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5.2.1 Function as boost valve (make-up)

Nominal pressure marked plug

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Auxiliary pump with internal suction (counterclockwise rotation)

pressure port suction port

1. O- ring 12. O- ring

Document No.: HPV 55 - 02 22500 E

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Basic design of rotating group

2. swash plate 25. holding clamp

Document No.: HPV 55 - 02 22500 E

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Basic design of port plate housing

Document No.: HPV 55 - 02 22500 E

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Basic design of control system E1

Document No.: HPV 55 - 02 22500 E

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Basic design of mechanical zero position

1. spring (mechanical zero position)

Document No.: HPV 55 - 02 22500 E

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solenoid My energized » HP pressure in port S

Control current (mA)