Hydrokraft Axial Piston Pumps

Service Manual for the Basic Pump: Open Loop

PFX/PVX

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 1
Contents

1 Spare parts ................................................... 3 Appendix A

A1 Tightening torques for bolts
2 General points .............................................. 3
and screw plugs ......................................... 22
3 Disassembly of the axial piston pumps ...... 4
Appendix B
3.1 General points .............................................. 4
B1 Commissioning .......................................... 23
4 Assembly of fixed pumps B1.1 Setup ........................................................... 23
4.1 Model sizes 60/90/130/180/250 ..................... 4 B1.2 Pipe ports .................................................... 23
4.1.1 Subassembly - fixed angle swashplate ...... 4 B1.1.2 Leakage oil line .......................................... 23
4.1.2 Port plate ...................................................... 4 B1.3 Filtering ....................................................... 23
4.1.3 Valve plate .................................................... 4 B1.4 Fluid ............................................................ 23
4.1.4 Assembly holding down device .................. 5 B1.5 Initial commissioning ................................ 23
4.1.5 Subassembly cylinder block ........................ 7 B1.6 Pressure settings ........................................ 23
4.1.6 Shaft .............................................................. 7
4.1.7 Housing assembly ........................................ 8 Appendix C
C1 Adjustment specification settings ............. 24
5 Assembly of variable basic pumps C1.1 DF pressure compensator ......................... 24
5.1 Model sizes 60/90/130/180/250 ................... 10 C1.2 Pressure compensator with
5.1.1 Port plate .................................................... 10 load-sensing valve ..................................... 24
5.1.2 Valve plate .................................................. 10
5.1.3 Subassembly swash plate ......................... 11 Appendix D
5.1.4 Assembly holding down device ................ 11
5.1.5 Control piston ............................................. 13 D1 Retrofitting/later removal of limiting rings25
5.1.6 Control piston sleeve ................................. 14
5.1.7 Subassembly cylinder block ...................... 14
5.1.8 Shaft ............................................................ 14
5.1.9 Assembly of the subassembly
swashplate/port plate ................................. 15
5.1.10 Housing assembly ...................................... 16

6 Assembly position indicator ...................... 19

6.1 Without position indicator ......................... 19
6.2 Optical position indicator .......................... 19
6.3 Electrical position indicator ....................... 20
6.4 Electrical and optical position indicator ... 21
6.5 Pre-adjustment of potentiometer ............... 21
6.6 Electrical connection of potentiometer ..... 21

2 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
1. Spare parts Vickers - Hydrokraft
Repairs during the warranty period must be made Piston Pump
by EATON or authorized service stations only, Auftrag-Nr.
otherwise warranty claims will not be accepted. V
The CD-ROM „Hydrokraft Information“ V-PUPI-
TM005-E includes information on spare parts with
the number of the part and shows the availability of
the parts as a single part or as a subassembly. Sub-
assemblies are not available as single parts. Only
original spare parts should be used. All seals must
be replaced whenever an assembly is disassem-
bled. 350

20 .. 70 420
To ensure a fast response to inquiries and that the
correct spare parts are supplied, always provide the
model code, the part no. and the order no. as
shown on the name plate.
„Model code“ shows an abbreviated type code, in
which the last seven characters indicate a special
design. If it is not 0000-000, then this number must
always be provided to indicate the special design.
Example: P*XS-130-M-R-DF-0999-099
0999-099
For an explanation of the complete type code, see
the product brochure.
Name plate
Telephone contact:
+49 6081 103 0 (switchboard)

2. General points
General
The assembly manual assumes use of appropriate- Tighten all screws and screw plugs to the specified
ly trained technicians with specialized knowledge of torque (see Appendix A). Exceptions are specified
assembly and disassembly. in the text.

Assembly must be conducted in a clean environ- Grease O-rings and shaft sealing rings lightly with
ment. acid-free grease for easier installation and to hold
Dispose of leakage oil and oily cloths in an environ- the O-ring in place in its groove or cavity.
mentally responsible manner.
In addition to standard tools, the following tools are
Before assembly, carefully clean all parts and required:
blow out holes with compressed air. – Torque wrench 6-50 Nm, 40-200 Nm and
150-750 Nm.
Lock all bolts and straight pins in the housing with
Loctite, except for tension pins. Use Loctite The tapered sleeves required for ease of assembly
Type 222 or Type 274 for screws, and Loctite Type must be manufactured in house.
648 for straight pins and bolts. Follow the manufac-
turers directions at all times. Read the assembly manual for the axial piston
pumps and the associated controllers and actuators
thoroughly before starting work on the pumps. De-
pending on pump size some illustrations serve only
as examples.
EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 3
3. Disassembly of the axial piston pumps
piston

3.1 General
Disassembly of axial piston pumps takes place in
reverse order to the assembly operations described
below. For variable pumps the link between control
piston and swashplate must be released first. See
Appendix D.

4. Assembly of a fixed pump

4.1 Model sizes 66/90/130/180/250

4.1.1 Subassembly - fixed angle swashplate
Hammer four roll pins into the fixed angle swash-
plate.
The protrusion (see table) is dependent on
the model size of the pump.
PROTRUSION ROLL PINS Sliding disk
Size 66/90 130/180 250
Protrusion 13 mm 16 mm 23 mm

Treat the rear (chamfer on outer diameter) Fixed angle

of the guide disk with some drops of Loctite 274 swashplate
in a cross pattern at four point to fix it in place
and insert in the fixed angle swashplate.

4.1.2 Port plate

Mounting for the housing
Grind the inside of the port plate with a grinding
stone. Press in cylinder roller bearing to the stop.

Press in two roll pins to fix the valve plate in place. Roll pin for
The roll pins must fit exactly with the valve plate or valve plate
be slightly below and never project above it.

Mounting for
the housing

4.1.3 Valve plate

If the valve plate is guided over the roll pins, it
must not be under tension. It has a slight play rela-
tive to the roll pins.

Valve plate

4 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
4.1.4 Assembly/set
4.1.4 ting up the holding do
Assembly/setting wn device
down
Lubricate valve plate well. Set cylinder block on the
port plate with valve plate and lay the retaining
collar on the cylinder block.

Cylinder block

Valve plate

Retaining collar

Insert piston in the hole plate and place all pistons in

the holes of the cylinder block. Also lubricate the holes
of the cylinder block well beforehand.
Depending on the design, the hole plate has a tapered Holeplate
internal hole. The side with the greatest diameter must
be mounted pointing towards the cylinder block.

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 5
Lubricate the guide disk in the fixed angle swashplate
well and firmly mount the fixed angle swashplate on the
piston shoe. The roll pins in the fixed angle swashplate
align with the holes in the retaining collar. Introduce
thefour bolts from below and furnish them with springs,
washers and nuts.Insert four bolts from below and fit
with springs, washers and nuts. Tighten nuts until the
washers touch the swashplate.

RELEASE ANGLE BOLTED CONNECTION SWASHPLATE/RETAINING COLLAR

Size 66/90 130/180 250
Release angle 90° 110° 90°

This setting determines the contact pressure of the

piston shoe against the guide disk. Due to the use of
Locknut
Loctite, breakaway torque testing (see instructions on
page 7) must be carried out immediately.

The locknut is also to be secured with Loctite 274

and may only be used once. A new locknut must
be used if the bolted connection is unscrewed
completely during disassembly.

Only locknuts are used up to model size 180.

Model size 250 also has a counternut.

Locknut Counternut

6 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
Introduce the shaft in the cylinder block and port
plate to check the contact pressure of the piston
shoe against the guide disc. Screw bolt into the
rear of the shaft and determine the required torque
with a torque wrench to turn the cylinder block.
Apply the counter-torque using a screwed lever on
the fixed angle swashplate. The torque must be
read off for an evenly rotating shaft. If the values
according to the table are not reached then the set-
tings of the holding down device must be correc-
ted.
BREAKAWAY TORQUE
Size 66 90/130 180 250
Breakaway Torque 15-20 Nm 20-25 Nm 25-30 Nm 30-35 Nm

4.1.5 Subassembly - cylinder bloc

4.1.5 k
block
First lay the washer with the small outside diameter
in the cylinder block. Pretension by pressing the
spring and secure with the washer (large outside
diameter) and retaining ring.
Beware of the tensioned spring when disassem-
bling.
When ordering spare parts, the cylinder block is
supplied with the spring installed as a subassem-
bly.

4.1.6 Shaf
4.1.6 Shaftt
Pull the cylinder roller bearing for the shaft with the
loose cam belonging to the bearing to the coupling Adjusting washer
side of the shaft against the collar of the shaft. For
pump size 250 an additional adjusting washer is
required. Lock the opposite side with a retaining
ring.

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 7
4.1.7 Housing assembly
Lay a flat gasket on the port plate. The cylinder
block with fixed angle swashplate stands in its
right position on the valve plate. Standing in the
right position means that the housing with the Hole for
unsymmetrically located straight pins for fixing indexing pin
purposes is congruent to the port plate. The hole
in the housing to receive the indexing pin now
determines the position oft he swashplate. The
slot in the fixed angle swashplate to receive the
indexing pin points towards the corresponding
hole in the housing.
Slot for
indexing pin

Two grub screws about 400 mm long simplify po-

sitioning of the fixed angle swashplate in the hou-
sing when lowering the housing. Align the fixed
angle swashplate horizontally for this purpose. A
tilted position makes
it more difficult to screw in the grub screw. Lower
the housing until the tapped holes in the fixed
angle swashplate are still visible. Lead grub
screws from above through the respective holes in
the housing and screw them into the fixed angle
swashplate. Lower the housing further until it sits
on the port plate. Tighten the fixed angle swash-
plate slightly with bolts over the two free holes.
The grub screws can now be taken away and re-
placed by bolts. Tightening diagonally to the spe-
cified torque takes place later after retracting the
shaft and knocking in the indexing bolts.
Screw in the four bolts for connection of the port
plate with the housing finger-tight.

8 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
Lead the shaft with the splined shaft through the
housing into the cylinder block until this sits
against the spring pretension of the cylinder block.
Place the spacer ring in the outer race of the roller
bearing. If the shaft is seated properly then the
spring pretension is perceptible. The O-ring will lie
in the housing or in the corresponding groove in Spacer ring
the cover depending in the design of the cover.

Press shaft sealing ring into the cover all the way.
The spring-tensioned dust lip points to the hou-
sing. Lead cover with shaft seal over the shaft and
tighten diagonally. See appendix A for the tighte-
ning torque. Provide mounting screws with a
sealing ring.
A tapered sleeve pushed over the shaft simplifies
assembly and prevents possible damage of the lip
due to the shoulder on the shaft.
The O-ring for sealing will lie in the housing or the
cover has an appropriate groove for receiving the
O-ring depending in the design of the cover.

Screwing in of the screw plugs provided and

tightening of the previously finger-tight tightened
bolts to the required torque completes the assem-
bly operation.

Indexing pin Swashplate

Locknut Spring Valve plate

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 9
5. Assembly of variable basic pumps
5.1 Model sizes 66/90/130/180/250 Control piston

5.1.1 P
5.1.1 or
ortt plat
Por e
plate Control piston
Grind the inside of the port plate with a grinding sleeve
stone. Press in the control piston sleeve from outsi-
de all the way. Insert the control piston from the
inner side of the port plate into the control piston
sleeve.
Press in cylinder roller bearing to the stop.
Press in two roll pins to fix the valve plate in place.
The roll pins must fit exactly with the valve plate or
be slightly below, but never project above it. Port plate
Press in two straight pins to fix the housing in pla-
ce.

Press in the two longer straight pins for supporting

Swashplate Swashplate
the swashplate to the respective dimension
support support
(see table). Secure straight pins with Loctite 648.
PROTRUSION SWASHPLATE SUPPORT
Size 66/90 130/180 250
Protrusion 53 +0,2 mm 67,5 +0,3 mm 83,7 +0,3 mm

Roll pin
valve plate

Mounting for the housing

5.1.2 Valv
5.1.2 e plat
alve e
plate
If the valve plate is guided over the roll pins, it
must not be under tension. It has a slight clearan-
ce against the roll pins.

Valve plate

10 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
5.1.3 Subassembly - sw
5.1.3 ashplate
swashplate
Hammer four roll pins into the swashplate.
The protrusion (see table) is dependent on
the model size of the pump.
PROTRUSION ROLL PINS
Size 66/90 130/180 250
Protrusion 13 mm 16 mm 23 mm Sliding disk

Treat the rear (chamfer on outer diameter) of the

guide disk with some drops of Loctite 274
in a cross pattern at four point to fix it in place
and insert in the swashplate.
Roll pin

5.1.4 Assembly/set
5.1.4 ting up the holding do
Assembly/setting wn device
down
Lubricate valve plate well. Set cylinder block on the
port plate with valve plate and lay the retaining
collar on the cylinder block.

Cylinder block

Valve plate

Lay the retaining collar on the cylinder block.

Retaining collar

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 11
Insert piston in the hole plate and place all pistons
in the holes of the cylinder block. Also lubricate the
holes of the cylinder block well beforehand.
Depending on the design the hole plate has a tape-
red internal hole. The side with the greatest diame-
ter must be mounted pointing towards the cylinder
block.

Hole plate

Lubricate guide disc in swashplate well and place

on the piston shoe. The roll pins in the swashplate
align with the holes in the retaining collar. Turn the
swashplate is such a way that the lugs on the cradle
bearing do not sit on the straight pins.
Introduce four bolts from below and furnish them
with springs, washers and nuts. Tighten the nuts
tension-free then loosen the connections with the
rotation angle according to the table.
The picture opposite shows a swashplate with
the model size 250.
RELEASE ANGLE BOLTED CONNECTION SWASHPLATE/RETAINING COLLAR
Size 66/90 130/180 250
Release angle 90° 110° 90°

This setting determines the contact pressure of the

piston shoe against the guide disc. Due to the
use of Loctite, breakaway torque testing (see in-
structions on page 13) must be carried out immedia- Locknut
tely.
The locknut is also to be secured with Loctite 274
and may only be used once. A new locknut must
be used if the bolted connection is unscrewed
completely during disassembly.

Only locknuts are used up to model size 180.

Model size 250 also has a counternut.

Locknut Counternut

12 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
In order to check the contact pressure, introduce
the shaft in the cylinder block and port plate. Screw
bolt into the rear of the shaft and determine the
required torque with a torque wrench to turn the
cylinder block. The torque must be read off for an
evenly rotating shaft. If the values according to the
table are not reached then the settings of the hol-
ding down device must be corrected.
BREAKAWAY TORQUE
Size 66 90/130 180 250
Breakaway Torque 15-20 Nm 20-25 Nm 25-30 Nm 30-35 Nm

5.1.5 Control piston

First bring the O-ring then the sliding sealing ring
over a tapered sleeve into the groove. Restore str-
etching of the sliding sealing ring, caused by the
pulling on, using the tapered sleeve (inner cone).
The sliding sealing ring is upset and sits with a
good fit in the groove. Grease the area of the seal
well to mount in the control piston sleeve.

O-ring Slide seal ring

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 13
5.1.6 Contr
5.1.6 ol pist
Control on sleev
piston e
sleeve
Bring two O-rings and two backup rings into the
grooves. The backu rings site on the outer side Backup
of the control piston sleeve. Grease the area of ring
the seal well to mount in the port plate.

The O-ring sealing to the flange face of the inter-

mediate plate requires a metal backup ring. Depen-
ding on the type of adjustment the backup ring may
O-ring Metal backup ring
also be part of the control piston sleeve.

Control piston Control piston

sleeve

5.1.7 Subassembly - cylinder bloc

5.1.7 k
block
First lay the washer with the small outside diameter
in the cylinder block. Pretension by pressing the
spring and secure with the washer (large outside
diameter) and retaining ring.

Beware of the tensioned spring when disassem-

bling.

When ordering spare parts the cylinder block is

supplied with the spring installed as a subassem-
bly.

5.1.8 Shaf
5.1.8 Shaftt
Pull the cylinder roller bearing for the shaft with
Adjusting washer
the loose cam belonging to the bearing to the
coupling side of the shaft against the collar of the
shaft. For pump size 250 an additional adjusting
washer is required. Lock the opposite side with a
retaining ring.

14 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
5.1.9 Assembly of the subassembly sw
5.1.9 ashplat
swashplat e/
ashplate/
portt plat
por e
plate
Lubricate the contact surface of the valve plate and
cylinder block as well the holes in the cylinder
block. After placing the cylinder block on the valve
plate, introduce the piston of the preassembled
device from the swashplate/piston into the holes in
the cylinder block. The swashplate is supported on
two straight pins. Lay in the flat gasket.

Flat gasket

Mount the connecting link for the control piston/swash-

plate. For model sizes 66 to 180, the connecting link
has a radius which must be mounted up to the swash-
plate. The bolts on the control piston side are fixed
with two retaining rings.
Control piston

Control piston sleve

The bolts on the swashplate side are fixed with a collar

by a cotter pin. Bend over the end of the cotter pin.
See figure in Appendix D. Swash plate

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 15
5.1.1
5.1.10 Housing assembly
.10
Fasten the two cradle bearings of the swashplate.
The screw head must be below the surface of the
cradle bearing and must never be the same height
or higher. See table in Appendix A for tightening
torques for the bolts; secure with Loctite 222.
Cradle bea-
Lubricate sliding surfaces on the cradle bearing ring
and place housing on the port plate with cylinder
block and in the right position for the swashplate.
Pull forward the pump standing vertically on the
port plate sufficiently to the edge of the assembly
table that two bolts for connecting the port plate
and housing can be tightened finger-tight. The
remaining two bolts are screwed in later finger-
tight when the pump is lying horizontally. Tighte-
ning to the specified torque (see Appendix A) takes
place after inserting
the shaft.
Spacer ring
O-ring
Lead the shaft with the splined shaft through the
housing into the cylinder block until this sits
against the spring pretension of the cylinder block.
Place the spacer ring in the outer race of the roller
bearing. If the shaft is seated properly then the
spring pretension is perceptible. Insert O-ring for
sealing the cover into the housing.

Press shaft sealing ring into the cover all the way.
The spring-tensioned dust lip points to the hou-
sing. Lead cover with shaft seal over the shaft and
tighten diagonally. See appendix A for the tighte-
ning torque. Provide mounting screws with a
sealing rings. A tapered sleeve pushed over the
shaft simplifies assembly and prevents possible
damage of the lip due to the shoulder on the shaft.

16 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
If a position indicator is not required, a cover is used to
seal the opening in the housing. Place a flat gasket on
top of the cover and secure cover with screws. The
number of fixing bolts is dependent on the size of the
pump. Tapped holes outside the swashplate bearing are
through holes. In this area bolts are fitted with a sealing
ring.

Cradle bearing

Cylinder pin

Size 250, vertical position

Sealing ring

Size < 250, vertical position

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 17
Place spring cup on the swashplate return spring
and position in the spherical cutout on the swash-
plate. Lead screw plug/spring guide over the some-
what protruding spring and tighten.

Screw plug Spring cup

For model size 250, the spring cup has two cylindri-
cal bearings that are led into the corresponding
cutouts on
the swashplate.

The final step is to screw in the screw plugs for

the various connections and tighten all bolts to
the prescribed torque (see Appendix A).

This completes the assembly of the basic pump. Screw plug

Additional assembly steps for variable pumps are
listed in the descriptions for the various actuators
or controllers.

18 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
6. Assembly position indicator

6.1 Without position indicator

If a position indicator is not required a cover is
used to close off the opening in the housing. See
picture on page 17.

6.2 Optical position indicator Dial Sleeve

In order to operate the position indicator the cylind-
rical pin must be inserted into the swashplate. See
picture on page 17.
Insert O-rings into the corresponding grooves of the
Levered
sleeve and of the levered shaft. Grease O-rings and
shaft
shaft before fitting into the cover. Press sleeve fully
into the inside of the cover. Insert the levered shaft
from the inside of the cover into the sleeve. Fit
shim and graduated dial from the outside and secu-
re using washer and bolt.
Place the flat gasket on top. When fitting the cover
the cylindrical pin of the swashplate must engage
with the lever. Rotate cover and/or lever in the cor-
responding direction and attach cover with bolts.
The number of fixing bolts is dependent on the size
of the pump. Tapped holes outside the swashplate
bearing are through holes. In this area bolts are
fitted with a sealing ring. See picture on page 17.

The dial must be rotated to the corresponding posi-

tion in relation to the fixed marker on the cover (far
left, far right, middle). The position is dependent on
drive direction and/or type of adjuster.

Sealing
ring

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 19
6.3 Electrical position indicator
In order to operate the position indicator the cylind- Dog flange
rical pin must be inserted into the swashplate. See
picture on page 12. Spacing
Insert O-rings into the corresponding grooves of the washer
sleeve and of the levered shaft. Grease O-rings and
shaft before fitting into the cover. Press sleeve fully
into the inside of the cover. Insert the levered shaft
Fork
from the inside of the cover into the sleeve. Slide
coupling
thrust washer and shim onto the shaft from the
outside and secure with retaining ring.
The potentiometer is connected via a fork coupling. Potentio-
Fit the drive end fork coupling to the shaft (with meter
recess for pin of fork coupling potentiometer) .
Attach dog flange with hole for connector to the Levered
cover using two bolts so that the connector points shaft
downwards when pump is in horizontal position. Cover
See picture.
Using three fixing clamps attach potentiometer to Connector
the spacing washer. The soldering tags of the poten-
tiometer must not interfere with the fixing bolts. Fit
the second half of the coupling to the potentiometer
shaft. Fit potentiometer and spacing washer to the
dog flange so that the outlet is aligned with the con-
nector cables. Both halves of the fork coupling
must mesh. This can be checked via a hole in the
dog flange, which will later be closed off with a
screw plug. Fit O-ring onto locating disk. Following Dog flange
electrical connection and final adjustment of the
potentiometer, the cover can be mounted using two Lever
bolts. position
Fit the subassembly to the pump by fitting a flat
gasket and securing the cover with four (or six)
bolts. The lever must engage with the cylindrical Sealing ring
pin in the swashplate.

20 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
6.4 Electrical and optical position indicator
Fit as per instruction in section 6.3.
The potentiometer has a second shaft end for fitting
the dial.
Dial
Fit the dial to the second shaft end. Fit O-ring
around spacing washer. Following electrical con-
nection and final adjustment of the potentiometer
and/or dial/glass the cover can be mounted using
two bolts.
The middle marker of the dial will be vertical when
the pump is horizontal and in center position. Dial
glass and marker should be rotated to the middle
marker before tightening the cover. The dial glass is
sealed with an O-ring to the cover.

Dial glass

6.5 Pre-adjustment of potentiometer

The potentiometer is adjusted so it registers both
directions of movement of the pump. The center
position of the pump corresponds to the center
position of the potentiometer.

Determine center position of the potentiometer by

measuring the resistance values. Measure the total
resistance between terminals 1 and 3 with an Ohm
meter. Divide this value by two and while measu-
ring between terminals 2 and 1 or 2 and 3 rotate the
potentiometer in the housing until it shows the
halved value in each case. The pump must be in
center position.
The final adjustment of the potentiometer (center
position of pump = center position of potentiome-
ter) is made during the test run on the test stand or
according to the type of application.

View soldering side

6.6 Electrical connection of potentiometer

The potentiometer is connected according to the
adjacent wiring diagram.
2

1 3

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 21
Appendix A
Tightening torques

A1 Tightening torques for bolts and screw plugs

TIGHTENING TORQUES
Bolts DIN 912/DIN 7991 12.9 M5 M6 M8 M 10 M 12 M14 M 16 M 18 M 20
Thightening torque 8 Nm 17 Nm 41 Nm 79 Nm 136 Nm 216 Nm 336 Nm 461 Nm 656 Nm
Bolts DIN 912/DIN 7991 8.8
Thightening torque 5,5 Nm 10 Nm 25 Nm 46 Nm
Screw plugs VSTI G 1/8 G 1/4 G 3/8 G1/2 G 3/4 G1 G 1 1/4 G 1 1/2
Thightening torque 11 Nm 30 Nm 50 Nm 80 Nm 130 Nm 200 Nm 400 Nm 450 Nm

22 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
Appendix B
Commissioning

B1 Commissioning B1.3 Filt

B1.3 er
Filtering
ering
Caution Clean fluid is required for fault-free operation and
The following directions for commissioning and long service life. This requires effective filtering.
operation must be observed at all times to ensure The fluid should be added through a filter system.
long service life and to prevent damage to or de-
struction of the unit when starting it for the B1.4 Fluid
B1.4
first time.
A high-quality mineral hydraulic oil of Group H-LP
is recommended. The viscosity should be 20 – 70
B1.1 Set
B1.1 up
Setup
mm2/s at an operating temperature of about 50°C.
Before assembly, check whether the direction of Special conditions are required for other fluids.
rotation of the drive assembly is the same as that Consultation
of the device–direction arrow on the housing. is required.
Mount device with leak connection pointing up-
wards. Align shaft for device and drive assembly B1 .5 Initial commissioning
B1.5
exactly. The unit is filled with fluid through the leakage oil
The shafts must be offset no more than 0.2 mm. port before starting the device for the first time. It is
A flexible coupling must be used to connect the also essential to connect the outlet line with the
shafts. The hole in the hub for the unit shaft must unpressurized return or to open the system so
be manufactured as per H7. that the air pushed out if the device can come out
Rigid connections and connections that generate unhindered.
axial tension or compression must not be used. The pressure is increased slowly with pauses. Un-
Consultation is required in the case of greater usual noises indicate that the conditions have not
radial loads. been fulfilled. Checking, particularly the suction
Never pull on coupling with a hammer. tube, is required.

B1.2 Pipe ports Observance of the above conditions are the prere-
quisite for validity of the warranty and for operati-
All pipes and hoses must be thoroughly cleaned
on without faults and a long service life
before assembly. The openings for the input, return
of the unit.
and leakage oil lines are to be adequately laid un-
der the level of the fluid.
B1.6 Pressure settings
B1.2.1 Pump suction ttube
B1.2.1 ube Adjust pressure settings in accordance with the
system requirements. Turning the adjustment screw
The input pressure in the intake line of the pump
to the right increases the pressure and turning it to
must not go below 1 bar (absolute). This is also
the left reduces the pressure. Lock setting using a
achieved for setup of the pump above the level of
locknut.
the fluid if an intake manifold with the largest pos-
If a pump is disassembled, the settings (position
sible cross-section (low pressure range) is used
of the adjustment screws according to a fixed
according to the size of the connection. The suction
point) must be noted. Only minor corrections will
tube is to be laid as short a possible without a bend
be required when the pump is put into operation
with the intake opening separate or sufficiently re-
again.
moved from the return and leakage oil lines. The
suction tube must be air-sealed.

B1.2.2 Leak
B1.2.2 ag
Leakage oil line
age
The pressure in the housing must not exceed
0.5 bar. This is ensured if the leakage oil line is con-
nected to the tank by the shortest path and has the
greatest possible cross-section (low-pressure se-
ries). The leakage oil line must be not bunched to-
gether with other lines, ore with the return line.

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 23
Appendix C
Adjustment settings

C1 Adjustment specification settings

C1.1 DF pressure compensator

Set the pressure compensator to the lowest possi-
ble pressure for the initial start-up.
If the system has a main pressure-restriction valve,
it must be set about 20 bar higher than the pressu-
re compensator at the pump. If the settings are too
similar then a part of the flow of the pump can be
dissipated to the oil tank. This not only causes po-
wer loss at the hydraulic drive but also increased
warming of the pressurizing medium.
In order to avoid cut off of the pump, the pressure
compensator must first be set significantly higher
than the pressure at the pressure relieve valve. Af-
ter setting the main pressure relieve valve then set
the required pressure on the pump pressure com-
pensator.

C1.2 DF Pressure compensator with load-sensing

valve
The pressure compensator is set up as described
above.
The setting of the load-sensing valve is >15 bar,
which means that the pump pressure with this set-
ting above the load pressure. The setting should be
increased if the required volume flow is not rea-
ched.

24 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006
Appendix D
Assembly limiting rings

Appendix D

D1 Retrofitting / later removal of limiting rings

Drain oil out if the housing.
Remove cover with pressure compensator by loo-
sening the four bolts.
Release swashplate return spring by loosening the
screw plug /spring guide.
Open the two connections L1 on the side by remo-
ving the screw plugs.
Push control piston inwards sufficiently until the
connection linkage - swashplate is visible incon-
nections L1.
Press together the ends of the cotter pin using
pliers and pull the cotter pin with washer out of the
bolt. Using a grub screw — M4 for model size 66/
90, M5 for model size 130/180, M6 for model size
250 — pull the bolt out of the connection linka-
ge - swashplate. Pin Swash- Splint Washer
Important: One must not allow individual parts plate pin
to fall into the pump housing! Threaded
Install limiting rings: Ring with collar for limiting pin
the max. swept volume on the piston side, ring
without collar for limiting the min. swept volume Needle
on the piston rod side. nose
Assembly occurs in reverse order. pliers

Removal of the limiting rings takes place in an ana-

logous fashion.

Pressure
compensator

Screw plug Return spring Min. limitation

Cover

Max. limitation

Swashplate Bolt with splint pin Linkage Control piston

EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006 25
 Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road Dr.-Reckeweg-Str. 1
Eden Prairie, MN 55344 Footscray D-76532 Baden-Baden
USA Victoria 3011 German
Tel: 952 937-9800 Australia Tel: (49) 7221 682-0
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (49) 7221 682-788
www.hydraulics.eaton.com Fax: (61) 3 9318 5714

© 2005 Eaton Corporation

All rights reserved
Printed in Germany
Document No. V-PUPI-TS003-E
January 2006

26 EATON CORPORATION Hydrokraft Axial Piston Pumps Service Manual V-PUPI-TS003-E January 2006