Reference number | Pub.ME-0164C Date 2001.01.20 Products Publicity Section INSTRUCTIONS MANUAL FOR PERIODICAL INSPECTION, TROUBLESHOOTING AND ADJUSTMENT OF A-SERIES VARIABLE-DISPLACEMENT PISTON PUMPS 04EH CONTROL PUMPS Ifyou, when using a O4EH pump, suspect it out of order or fee its operation out of the ordinary, inspect it referring to this manual If you inspect the pump following the steps described in the manual and make readjustments to remove faults if any, you can eliminate almost all faults YUKEN KOGYO CO., LTD.ME- 0164C Contents ‘Components of 04EH Pump... Details of Amplifier Internals... Chapter 1 Inspection Flow Chart, Steps and Method: Flow Chart A1 Flow Chart A2 Flow Chart A3.. Flow Chart Ad. Flow Chart AS. Flow Chart A6. Flow Chart A7. Inspection Steps and Methods... Chapter 2. Adjustment of Electric Controls... E585-10D amplifier: users’ adjusting trimmers. 585-20D amplifier: users’ adjusting trimmers.. Outline of Adjusting Trimmers.. 2.4. DITHER Adjustments . 2.2. P GAIN Adjustments .. 2.3. MGAIN Adjustments....... 24 Low-Pressure Small-Flow Correction Adjustments (E585-20D only) 244 2.5 Adjusting the Pressure Span........ 212 2.6 Adjusting the Pressure Sensor... . 215 2.7 Adjustment for Volume Efficiency Correctior 247 2.8 Adjusting the Q Gain 2.9 Adjusting the Flow Rate Span 2.10 Adjusting the Potentiometer .. 219 224 +. 2-23 Chapter 3. Replacement of Pilot Valve Assembly. Removal of Pilot Valve Assembly... Mounting of New Pilot Valve Assembly .. 244 Chapter 4 Replacement of Assembly in Pump (A16 to A56).. Chapter 5 Replacement of Assembly in Pump Trunnion type (A80 to A125) Cradle type (A70 to A145). 5.1. Trunnion type .. 5.2. Cradle typvro4e me Chapter 6 Potentiometer Replacement Procedure... Chapter 7 Pressure Sensor Replacement Procedure...... Chapter 8 Cleaning of Pilot Valve... Chapter 9 Replacement of Oil Seals. Chapter 10 Control of Hydraulic Fluid Contamination seve 10-1 1. Effect of Hydraulic Fluid Contamination on Hydraulic Machines. 10-2 2. Tolerances of Hydraulic Fluid Contamination 10-2 3. Sampling of Hydraulic Fluid. 103 4. Analysis of Hydraulic Fluid 10-3 Chapter 11 Service Infomation.. 14-4meE—0164¢ Components of 04EH Pump ‘The 04EH pump consists of a number of components as shown below. Amplifier i Solenoig Pilot valve assembly Housing L Gasket feu Control body Bearing Piston assembly Oil seat ' | Push pin /) pivot [Port plate, (=X Bearing | & Sleeve ‘Swash plate | Cylinder’ block lie Slipper ret Shaft Cover Bins Niston Cvlin kit ‘Swash plate tilt angle sensor Tranion shaft Plate Seal piston Operating piston Coupling Oil seat, Shim pve x ‘Swash plate i Shaft (yoke) ‘Spring pusher Spring shoe S@lety valve spool SECTION AA Pin SECTION eeME—0164C Chapter 1| Inspection Flow Chart, Steps and Methods ‘Typical faults on the 04EH pump can be classified as shown below. From the fault concerned, find the flow chart No. and proceed to inspection. No. Fault Flow chat | Page 1 | No discharge from pump. No pressure rise. At P13 2 | Pump discharge flow is below/over the flow setting. ne P14 3. _ | During flow control, pump discharge fluctuates. a3. P45 4 _ | Pump discharge pressure is lowerigher than the setting. AG P16 5 | During pressure control, pump discharge pressure fluctuates. S P17 6 | Pump discharge pressure'does not confor fo command vtage for press. 16 P18 7 | Pump discharge flow does not conform to command voltage for flow. a P19 wtie on\ “eaeegas cones tes ‘N61 001 sm sg sso on FR NERD a ey en 2Ayd0n Goode syria nh fot spo Roe sg ETA we] TiO Site aed oyna sak Tptetioma Sap een Le Gl. {com spent mat opr} oA “svuseu0n Se a Be) ‘und Xe women Ginny pow ou 909!) we uosonp ous ant nan sara — ‘on \2eeoee eT) ‘989 amnssa1d on “dud wos 2B. ON “T Ty eH mo 2 ¥910~30,[Fwossy one ora fo NBunoeroy ¢ MOH 995 -Arjuesse ONen oy a 22014) __] — (ven0152) ean SF mom) TPs pusunua up en a6 UEUD Foypodsse or none Sunsng me dude enbeey ee veonne natant at Senay mane saa i Bue stig noe ern) posse eos Ed orn ost Bs pasaOD UD RATAN fumesmog ennova —_| ‘Bumi9s moy 211 s910,/molaq st oy a8zeN Dp ung “z v WEUID MOLE ‘6-2 a odes Bunsnipy 295 es D910-aw12 a sdng wourenpy 005, ‘eda Kissec0u sew m OoRDow 8 vo Seve fumas 1 99 ‘loses Ruowodon nen ond win pea) 22d snounsnpy 005 9010982 aoeg96a 01 8199R9¢ a01-5053, on "vn ome Rus pusunsoa ed out 1 “puodtaro1 mor ‘Gupemeny “Bane ‘misun amos ‘Soremiony Moy aseypsip ‘jovo> mop Bound “f ) ¥910-3w(era 1g sda Wourenpy 95 Wd Pm vat int pu Na TSE OW \\ shane nernpe eas ak Pie Sa VaRRA TET ‘ein 3 pi ug aaning seen ona ON \ addin us punico ig om 5 [98 mowader aida 994 = ro arena a euvneimumeyes |, _—_ / CORTES me Ew aT men suet SH te nparon tongs rose ‘zone om bony tpn) ; * 2989 (rite isaac ag au mn omar oro = Sugor sneer or oy tie umwano woe poy $5 ——— — ‘umes arp vey s24M4/ 9K 8 2aNSs044 aRseYDSP dung “F Py WENO mold 3y9L0—swSadundanune | | == ~~~ RO 7 “hqweesy BNA 10RY JO WaLPORIGDY E 2IdeyD 90g —— nn Bue SNS vance 9) inn rt en mera a 8 Kg Sooner 12 ons Sane. O17 2s) 9a uo npeoy ‘FADO pu edSiS vaRPAS eg) el pareibe Sowa Dy PR OFA BAT spremjong aunssaud 982eypsip Joxueo amnssoud BULNAS Sy HeYD MOL 2veL0-aw,Teed aa De BS WONDER URN O Pe aS WOM ord pornos any a pue was aan || ON L ‘36ne6 anton poe pumas 1 wang 220019 2 2K Hf 30] 9Be0n puEUIIOD WON s.opNP amNssaud aBIEYDSIP dung “9 ‘av HeND MOL 399t0~awta Hl “neqwossy omeny = igre LStuose eens ow acer | = Amu prmsonin meet 168 ond yes on LER One ond on nomi | on N80 MOY EWE YEnpeay ical ae (Gener i oS mo me pom eunno> veowieg 6 v 2 uy “may 201 22e0a puetmoo wos SsapH mop aBeY>sIp dung *L ‘iy BND mo Jv9L0~3wME-—0164C Inspection Steps and Methods When checking the amplifier in accordance with the inspection flow chart, the terminal and check pin voltages must be measured, In the following paragraghs, voltages must be measured with a digital voltmeter. Pre pare one. Voltages in EH pump amplifiers are DC voltages. Set the digital voltmeter to the DC voltage range before use. To check the fuse for the breakage, turn the digital voltmeter to the resistance range ‘Take out the fuse from the amplifier and measure the voltage with a probe touched to each end, Ifthe fuse is broken, the voltmeter reads a infinite or very large value of resistance. Ifthe fuse is proper, the value is 0.5 Q or less. ‘To measure the voltage while the pump is operating, take care to touch the probe prop- erly to the check pin or terminal. If the probe is touched to two terminals or a check pin and an adjacent electronic part at a time, internal parts of the amplifier may be damaged or the pump may be driven into trouble. Take care to handle the probe properly in touching. 1-9ME~0164 = Is the red amplifier lamp lit? If the power supply, 24 V DC, is ON, the red lamp at the left side of the amplifier cover is Tit. If the lamp is off, check if the operation power on the machine is ON. If the operation power supply is ON but the lamp is off, check up as follows: To check if the 24 V DC power is supplied to the EH amplifier, remove the amplifier cover (by removing 6 screws) and check the power terminals of the amplifier using a digital voltmeter as shown below. Ifthe amplifier power voltage isn the range: 21 to 28 V DC, the power feed is proper and the red lamp must be lit. Ifthe red lamp is not lit despite the proper feed of a 24 V DC voltage to the amplifier, the fuse may be blown. Check up referring to P.1-11 Digital (E58 5—10) voltmeter oo00e00 Za = (E585—20730) vatmeterME—0164 C m= CThe amplifier fuse is not blown? Remove the amplifier cover and you can find a fuse and a spare. Remove the fuse and check it for breakage. If it is broken, replace it with the spare. Fuse Spare fuse Fuse Spare fuse (E58 5—10) (E585—20/30) Notes: 1) The fuse is small and hard to pick out. To prevent it from slipping away, itis inserted tightly. Ifitis hard to remove, use small tweezers etc., while taking care not to crush the fuse. 2) If the spare fuse is used, prepare another spare. The fuse models are as follows: ‘Amplifier mode! Fuse model 585-100 CP-2500 Made by Nagasawa Denki 585-207 3 0 D| (CP-5000 Made by Nagasawa DenkiME—0164¢ a Are Qin and Pin input signals input! Using a digital voltmeter as shown below, measure the input command signal. Be sure to use a digital voltmeter. Flow command: Measure the voltage between Qin and C Pressure command: Measure the voltage between Pin and C If the measured values are equal to the output voltages from the machine, they are proper. Also check maximum voltages. The standard maximum is 5 V. Note that the maximum command voltage is specified as above 5 V for some pump mod- dls, Digital (E585—10) voltmeter 2000609) Digital voltmeter (E585—20730)ME—0164 © When Gothe When the pump, given a command signal, is under proper control, a current flows from the amplifier to the solenoid, causing the swash plate of the pump to tilt, which causes oil to gush out of the pump. This can be checked manually by operating the pilot valve by forcing the solenoid in. If oil is driven out, the oil discharging function of the pump is proper. As shown below, drive in the manual adjusting screw of the solenoid by turning it clock- wise. To try this test, first modify the hydraulic circuit so that the oil discharge from the pump can be checked. The most preferable load is a hydraulic motor, which permits the flow of the hydraulic pump to be checked by its own rotation. If there is no such motor available, operate the hydraulic cylinder and from its travel speed, estimate the flow rate. When the hydraulic cylinder reaches its stroke end, the discharged oil from the pump comes to a dead end, causing the pump discharge pressure to rise up to the pressure setting of the safety valve built in the pump. Note: In this test, the hydraulic motor and the hydraulic cylinder run suddenly or at high speed. For safety, take best precautions beforehand. Insert a hexagon wrench (8 mm) in the hexagonal slot at the solenoid end face and tum it clockwise. In this way, you can shift the pilot valve manually CF) 3 mm hexagon wrench After the check work, do not forget to return the changed parts to the original state; turn the 3 mm hexagon wrench counterclockwise and loosen the manual adjusting scew. If the adjusting screw is left screwed in, no electrical control will be permitted. 1-13ME-0164C mis the amplifier operating properl; To prove that the amplifier operates properly, measure the solenoid current. For this, using the digital voltmeter, measure the voltage between CH and C terminals as shown below. Ifthe CH-C voltage is in the range: 100 to 150 mV, it is proper. Digital (E585—10) voltmeter F\ooo0eco =a sa0008] ae 3 eos 6} CH Digital voltmeter ca ‘The CH-C volage being outside the proper range does not directly mean that the ampli- fier is out of order. ‘This is because of feedback control. If there is a faulty sensor output or if connections are loosened or in improper contact, the voltage may also be beyond the proper range. Before suspecting the amplifier, check the sensor output voltage (see P.1-15 and P.1-19) The current to the solenoid can be calculated from the CH-C voltage. Solenoid current (mA) = [CH-C voltage (mV)] x 5ME—0164C m_ Cisthe swash plate angle sensor voltage proper’ Checking the swash plate angle sensor voltage is meaningless unless the pump flow rate is under proper control. Modify the hydraulic circuit so that the oil discharge from the pump can be detected. Ifan oil motor is available as a load, from its speed the dischage flow from the pump can be calculated. Shit the circuit to it As shown below, measure the voltage between SMQ and C using a digital voltmeter, and change Qin to 1 V, then to 2 V. If the following relations hold, the SMQ-C voltage is proper. Regional frequency Voltage relation Tin voliage © SMO votage, thats, 50 Hz pin ifthe Qin voage (ow rate command signal is nearly equal othe SMQ voltage, the voltage is proper. Qin voltage = (SMO voltage) x 78), thats, 60 Hz pin ifthe Qin vokage (low rate command signal is nealy equal o the SMO voltage x5/6, the voltage is proper. For this check, to bring the pump operation into the flow rate control zone, set the Pin voltage (pressure command voltage) to more than double the pump discharge pressure. Digital (E585—10) voltmeter (E585—20/30) Digital voltmeter OES EOS: = feroucsME—0164C mm Cisthe cycle selector plug set for your regional frequency? ‘The flow rate control on the EH pump is achieved by controlling the swash plate angle. If the speed of the motor, which driving the pump changes, the flow rate also changes. If the motor for 50 Hz is used in 60 Hz, the flow rate increases corresponding to the increase in the speed of the driving motor. Ifa motor conditioned for 50 Hz regions is brought to a 60 Hz region, its speed increases, which causes the flow rate to increase. Ifthe machine in a 60 Hz region is brought to a0 Hz region, the pump discharge rate will decrease. ‘The machine can be set either for 60 Hz or 50 Hz by shifting the cycle selector plug appropriately. Ifit is set properly for the regional cycle of the region in which itis used, the predetermined flow rate command voltage functions properly without involving changes due to a cycle change. Check if the cycle selector plug is set for your regional frequency. If the cycle selector plug is shifted from 50 Hz to 60 Hz, the amplifier performs correc- tions, reducing command signal values by 20 percent. If the cycle selector plug is set improperly, the flow rate command values and pump discharge rates will deviate by about 20 percent. 50/60 selector plug (E585—10) 50/60 selector plug (E585—20/730)ME—0164C Is the pump discharge rate adjusting screw set at the specified a Position ‘The pump discharge rate adjusting screw is located as shown in the figure at left bottom. ‘The location slightly differs in accordance with pump models. Refer to the model. 60 so g & = E 5 = : Bx & & 5 8 [ B ad e a é 1 occa Omega 20 ea?s Specified position (1) of discharge Specified position (1) of discharge adjusting screw adjusting screw 220 180 ; [ates 100 & & = & < ie pre] o£ § a— 5 é s Boo & 5 é é | I ° To 36 Adjusting screw stick-out length () h hy 4 ‘Specified position (1) of discharge adjusting screw . = Discharge rate Discharge rate adjusting screw agjusting screw ATO~ ALS 4220ME—0164C Ts the pump safety valve (pressure) adjusting screw set at the - specified position 12? ‘The pump pressure adjusting screw is located as shown below. ‘The location slightly differs in accordance with pump models. Refer to the model. T Pump model Pressure rise per rotation of safety valve adjusting screw AI to AS6 6.27 MPa (64 kgt/cm*) ATO 10 A145 4.02 MPa (41 kgt/em*) MPa A70, 490, A145 {ket /on*) - ALE~ ASB £ iss S (200) a é Safety valve 2 : ‘adjusting screw {100} a ° 10 15 20 28 30 Specified position 12 of safety valve adjusting screw Saley vale pressive gusting seven mm acess tats (eameloral machines) Satey valve pressure ousting ABO, A125 ALG~ ASE Saley waive pressure acsting sere ‘Simm across tats =r Selva pressure ating veel OR Safety valve pressure aousing screw ATO type A90 type A145 typeME—0164C isthe pressure sensor voltage (SMP) proper? ‘The pressure sensor voltage is the voltage between SMP and C. Referring to the figure below, measure it with a digital voltmeter. Pressure under control | Normal if Pin voltage « SMP voltage Flow under control} Normal if Pin voltage > SMP voltage Digital (E58 5—10) voltmeter =| eco0ce 4 Digital (E585—20/730) voltmeterME—0164¢ m — (Geale of amplifier trimmer Remove the amplifier panel cover and you will find an array of adjusting trimmers. ‘The scale value in adjusting trimmers mentioned in this manual is discribed in the value of scale graduated clockwise as shown below. Example Check on the relative position between the siit on the center and the externally-graduated scale. ‘The externally-graduated scale is assigned clock- wise from 0 to 10. Ascale value indicates § in the diagram on the left. = Measurement of potentiometer (swash plate angle sensor) Note: This check cannot be carried out on amplifier E585-10 because this model has no TP] terminal. ‘The potentiometer output voltage can be checked by measuring the voltage between ‘TP1 and C with a digital voltmeter as shown below. For measurement, set the pump in an unloading state because measured values are hard to read with a command signal input. Itis normal if TP1 = 4.9 + 0.2 V with the pump in unloading. Digital (E585—20/30) voltmeter feseel) 4-20ME—0164C. m Cisthe pump drain increas ‘The pump drain pipe is connected from the drain port in the main body of the pump to the tank. Set the pump under pressure-control and set the pressure setting to 13.7 MPa {140 kgf/cm*). Then, remove the drain pipe, pour the drain into a measuring cylinder and measure the drain quantity collected in one min. (this is called draining rate) Draining rates vary with pump capacity. Proper draining rates are shown below. Ifthe drain increases over double the standard value shown below, the main body of the pump is considered out of order. In such cases, return the pump together with the Trouble Check Request sheet in chap- ter 11 tous. Pump model Standard pump draining rate Ate 3.5 H/min. or less A22 | 4.0 I/min. or less 437 45 l/min. or less ASG 9.0 I/min. oF ess ATO 2.0 L/min. oF less 80 8.0 L/min. oF less 90 9.0 l/min. or less A125 41.0 L/min, or less A145 11.0 I/min. or less ‘The values above are under pressure control at 13.7 MPa {140 kgf/cm*).ME-0164C m sthe solenoid cleared of air? Bring the actuator to its stroke end or block the solenoid valve on the pump discharge line and set the pump into full cut-off position, While slowly loosening the air bleeding plug on the solenoid as shown below, check if white bubbly oil flows out of the loosened part. This white bubbly oil is produced by included air. Until it no longer comes out, continue the work, Bleeding plug For bleeding, be sure to bring the bleeding plug upside by turning the holder beforehand, Note: When loosening the bleeding plug, do it slowly. Ifthe plug is taken off, oil will spout out. Take care not to let the plug slip off. After bleeding, tighten the bleeding plug completely.ME—0164 C - Are P SPAN and P MIN adjusted properly? Modify the hydraulic circuit so as to permit pressure control by using the load circuit of the hydraulic pump as the stroke end of the hydraulic cylinder or blocking the discharge side of the pump. Impressing a pressure command signal on the Pin terminal, record the pump discharge pressure read on the pressure gauge and check it with the following proper values: Pressure command signal 0.5 V: Maximum working pressure x 0.1 (kgf/cm?) Pressure command signal 5V: Maximum working pressure (kgf/cm?) - Are Q SPAN and Q MIN adjusted properly? If the load circuit of the EH pump has a hydraulic motor circuit, shift the line to it or prepare to operate the hydraulic cylinder. If the hydraulic motor is used, the pump discharge rate can be calculated from its speed. Bring the pump into a flow rate control state by setting the Pin command voltage to a level more than double the operating pressure of the pump. Then, setting the Qin com- mand voltage to 2.5 V, then to 0.5 V, check the pump discharge rates. Itis normal if the obtained values are nearly equal to the following: Qin command Factory set tlow rate l/min. o5v Rated flow rate of pump model x 0.1 25V Rated flow rate of pump model x 0.5 ‘yr Flow rate calculation with hydraulic motor Pump discharge rate Q (I/min.) = [Hydraulic motor capacity q (cm*/rev) x speed N (r/min)] / 1000 ‘x Flow rate calculation with hyddraulic cylinder Ifthe hydraulic cylinder is used for calculation, estimate the pump discharge rate by measuring the time needed for the cylinder to reach its stroke end. Pump dischange rate Q (I/min.) = (Hydraulic cylinder cross section area A (cm*) x speed V (cm/min.)} / 1000 Speed V (cm/min.) = Cylinder stroke ! (em) x Time to reach stroke end ¢ (min.) 1-28ME-0164C ‘There are two types of amplifiers and they are related to pump model Nos. as shown below. From your pump model No., you can know the proper amplifier model. Pump model No. Amplifier model A16/A22/A37/A56—*-¥-D4EH—##-K-4—4-JOHH A16/A22/A3T/ABE-#-*-O4EH HOH KAA 328 585-10 ABO/A125~4~4-O4EH=#-S-K-4—4-308 A16/A22/A37/A56-#404EH#A—4—4014 A16/A22/A3T/A56-**04E HA A= 4 264 £585-20/30 ATO/A90/A145~#404E Hite S 4-604 Note: The descriptions of inspection, adjustment etc. in the following chapters are divided under E585-10 and E585-2073 0.ME—0164C ‘Chapter 2 | Adjustment of Electronic Controls Ifyou find it necessary to adjust electronic controls when following an inspection flow chart in chapter 1, How Should You Proceed with It? This chapter explains it. For EH pumps, there are two types of amplifiers E585-10D and B585-20D and the amplifier to be mounted depends on the EH pump model. The descriptions in this chapter are divided into two groups under two types of amplifiers. Do not confuse them when making adjust- ments. EH amplifier adjustments can be divided into two steps: level 1 and level 2. For an initial adjustment, see pages 2-2 and 2:3, adjusting trimmers P.2. 200/30D amplifier: use adjusting trimmers} P. 2 Level 1 Perhaps some users want to change the factory settings a little when the pump is mounted on a machine or some want to make micro-adjustments required by changes made in machine loads etc. For adjustments at level 1, to help such users make adjust- ments easily, users’ adjusting trimmers will be explained. 2.1 Dither adjustments P26 2.2 _PGAIN adjustments P27 2.3 MGAIN adjustments P.2-9 2.4 Low-pressure smali-flow correction adjustments Pott Level 2 Remove the trimmer cover and you will find adjusting trimmers at level 2. Some of the adjustments here may be hard to understand. Read the adjusting steps carefully before setting to work. 2.8 _ Pressure SPAN adjustments P22 2.6 _ Pressure sensor adjustments P2415 2.7 _ Volume efficiency correction adjustments: P.247 2.8 QGAIN adjustments P2419 2.9 Flow rate SPAN adjustments, P.2-21 2.10 Potentiometer adjustments P2238) 24ME—0164C, E585-10D amplifier: users’ adjusting trimmers Remove the 6 screws from the amplifier cover and you will find several adjusting trimmers as shown below. ‘These adjusting trimmers are factory adjusted. However, they are to be readjusted by the user if some modification of the factory setting is considered preferable when the hydraulic pump is mounted on the user's machines. If the pressure oscillates when changed suddenly, tum the P GAIN trimmer a little counterclockwise by using a small screw driver. Mi For details, see 2. 2. If under pressure control, there is a per- ‘sistent vibrating sound or small pressure oscillation, turn the DITHER trimmer counterclockwise. WW For details, see 2. 1. ifthe discharge pressure oscillates violently, having @ flow when itis close to the command value (for example, when the hydraulic eyclinder is running under load), adjust the M GAIN, Tum the trimmer by a few points on the scale until vibration becomes smallest. MI For details, see 2. 3. 22»ME—0164C [ES85—200/730D amplifier :user’s adjusting trimmers) Remove the 6 screws from the amplifier cover and you will find several adjusting trimmers as shown below. ‘These adjusting trimmers are factory adjusted. However, they are to be readjusted by the user if some modification of the factory setting is considered preferable when the hydraulic pump is mounted on the user's machines. If the pressure oscillates when changed suddenly, turn the P GAIN trimmer a little counterclockwise by using a small sorew driver. I For details, see 2. 2. GAIN screw driver. If under low-pressure small-fiow control, the actual discharge rate is above the command value, turn the LOC trimmer a little counterclockwise by using a small Withe is below the command value, turn the trimmer clockwise, Mi For details, see 2. 4. If under pressure control, there is a per~ sistent vibrating sound or small pressure oscillation, turn the DITHER trimmer counterclockwise. M For details, see 2. 1 DITHER actual discharge rate Loc I3- a i Es AMG If the swash plate vibrates or the pressure gauge pointer vibrates violently, having a flow when the discharge pressure is close to the command value (for example, when the hydrau- lic eyetinder is running under toad), adjust the CMG. Turn the trimmer by @ few points on the scale until vibration becomes smallest. For details, see 2.3. 23 Ii the swash plate vibrates or the pressure gauge pointer vibrates violently when the discharge pressure is at the command value (for example, when the hydraulic cylinder is at its stroke end or when the discharge side is blocked), adjust the FMG. Tum it 2 few points on the scale until vi- bration becomes smallest. For details, see 2.3,ME—0164C Outline of Adjusting Trimmers With most of the adjusting trimmers in the EH amplifier, input and output are combined as shown to the right For pressure span ad- justments, for example, the P MIN and P SPAN adjusting trimmers are used. They are designed as follow: Zero point adiustments P MIN increased P MIN decreased Pressure ‘command value sv ‘Tiltadiustments P SPAN increased sv Output XN P SPAN decreased Pressure ‘command value sv sv © Output Input sy Turning the P MIN adjusting trimmer with the input: 0'V makes a shift upward or down- ward as shown to the left. ‘The P SPAN adjusting trimmer means to change the tilt with the input: 5 V. ‘The figure to the left shows changes made when the P SPAN is adjusted with the P MIN adjusted properly. 24ME-—0164C. ‘The explanation above is pressure span adjustments taken up as an example. From this asa key, understand what adjusting trimmers are like. You have probably understood that repeated adjustments are necessary for a span match- ing. For the following adjusting trimmers, the same adjusting steps are necessary. Zero point adjustments Tilt adjustments, Pressure span adjustments P MIN adjusting trimmer P SPAN adjusting trimmer Pressure sensor adjustments PS. ZERO adjusting trimmer PS, GAIN adjusting trimmer Flow span adjustments, Q MIN adjusting trimmer Q SPAN adjusting trimmer Potentiometer adjustments QS. ZERO adjusting trimmer QS. GAIN adjusting trimmer 25ME—0164C, 2.1 DITHER adjustments Dither is to jar the control valve spool of the EH pump a little constantly. It reduces the friction of the spool to help it move easily and raises the EH pump performance ulti- mately. If the dither is too small, it is ineffective and if it is too large, it may cause the pump pressure to vibrate or cause an unusual sound. Dither is factory adjusted as follows: Amplilier model Factory adjustment —585—10D The dither adjustment is the adjustment ofthe dither current amplitude ‘The dither current amplitude is maximum when the adjusting trimmer is set at 10 on the scale. ‘The trimmer is set at 6 to 10, which differs in accordance with the EH pump model. —585—20D 7300 On this amplifier model, what to adjust is not the dither current amplitude but the frequency. The frequency is maximum when the adjusting volume is set at 10 on the scale. The volume is set at 0 10 6, which differs in accordance with the EH pump model, + Adjusting Steps and Methods If the pump is not in good condition as described below, make dither adjustments refer- ring to the adjusting methods shown below. ‘Amplifier model Pump condition Adjusting method E585—10D Under flow control, vibration is caused when the pump discharge Pressure is low. Turn the DITHER trimmer clockwise (raise the DITHER level). [Under pressure control, the pressure loscillates or the pressure gauge pointer trembles persistently. Tum the DITHER trimmer counterclock- wise (to lower the DITHER level). E585—20 7300 Under pressure control, the pressure oscillates or the pressure gauge pointer trembles. Tum the DITHER trimmer clockwise or counterclockwise to reduce vibration (to| change the DITHER frequency}. Under pressure control, despite 2 constant flow rate signal setting, the swash plate flutters (SMQ voltage fluctuates) Tum the DITHER trimimer counterclock- wise (to lower the DITHER level). 26ME—0164 C 2.2 P GAIIN Adjustments If the discharge pressure oscillates shortly or persistently when the (command) pres- sure setting is shifted stepwise under pressure control, the oscillation can be eliminated or reduced by the P GAIN. At our works, standard load capacity measures (such as the gauges and lengths of the pipes coupled to the pump) are determined and adjustments are made during shipping inspection. Such troubles as described above can eliminated by fine P GAIN adjust- ments. See the adjusting steps described below. + Preparations Prepare a loaded condition to provide pressure control by bringing the hydraulic cylin- der or a similar load to its stroke end or blocking the discharge port. Ml Where a synchroscope is available: >* Adjustments laput conditions | Measurement Response waveform and adjustment |Flow rate command | Couple a synchro- Turn the P GAIN trimmer clock- wise. impress 5 Von Qin | scope between SMP and C to check re- |Pressure command | sponse waveform. impress 1 Vo 3V Istepwise on Pin | Time axis 50 mS/div oe Voltage axis 1 V/div PM Pressure command P GAIN is adjusted optimally. wl — W even Time Time P GAIN is too high ‘Tum its adjusting trimmer counter- clockwise. evsu =Time 27ME—0164C Ml Where a synchroscope is not available: Ifa measuring instrument for checking waveforms such as synchroscopes and oscillo- ‘scopes is not available when adjusting P GAIN, the only possible means of checking is to observe the action of the pressure gauge pointer or to listen to the sound but such meth- ods are no doubt inaccurate. Make adjustments referring to the following: ‘The pressure gauge pointer starts slowly. P GAINis low. due to vibration. The pressure gauge pointer waves. Noise is large P GAIN is too high. Note: If the pressure gauge is provided with a gauge cock, fully open it. Note: Ifthe P GAIN is adjusted, the adjusted pressure span may be changed. ‘Thus, also adjust the pressure span. * Points of adit nt P.GAIN Oscilloscope « B585-10D ) 28ME-0164C 2.3 MGAIN Adjustments As the discharge pressure of the EH pump approaches the pressure command value, with the discharge rate entering a low zone (@ in the figure below), a pressure change causes a larger change in the discharge rate. In this situation, the pump is readier to vibrate. If with the flow rate entering this zone while the pump is in service on the machine, an unusual sound and machine vibration are generated and the pressure gauge to mon Flow rate tor the discharge pressure of the pump vibrates violently with the pointer in quiver, the M GAIN must be adjusted. M GAIN adjustments can eliminate or reduce such pres- sure vibrations. Pressure Note: If M GAIN adjustments do not help reduce vibration, it is necessary to review the phase compensation etc. Please consult us. Flowrate Q — Cut-off \ T c Full cut-off GAIN Cd va }ae ° TP Land pressure top. 20D (unctionally nearly the same as M GAIN of 100) £858-20/30D Model ‘Adjusting trimmer Adjustment M. GAIN Tum the M GAIN trimmer point by point counterclockwise, allowing the M GAIN to 585-100 move from the flow rate control zone to the flow rate-pressure control zone (b to ¢ in the figure above) until vibration decreases. oma ‘Turn the M GAIN trimmer point by point counterclockwise, allowing the M GAIN to move from the flow rate control zone to the flow rate-pressure control zone (b to c in the figure above) until vibration decreases. FMG. (for pressure control only) If vibration arises when the pump shift into pressure control, turn the FMG trimmer one ‘way or the other until vibration decreases.*ME-0164¢ > Point of adiustment ( Bp85-10D) CMG EMG.ME-0164C 2.4 Low-Pressure Small-Flow Correction Adjustments (E58 5—20D730D only) Since the hydraulic control of the EH pump utilizes the discharge pressure of the pump, the control declines as the pump pressure falls ‘Thus, in such zones with a low pressure and a low flow rate, the sensitivity of the control system is so low that the pump discharge flow rate increases as the pump pressure de creases. To eliminate such flow rate increases, the electronic control performs correc- tions. At our works, actual flow rates are measured and in pressure ranges below about 2.5 MPa {about 25 kef/em’}, the LQC adjusting trimmer is adjusted so that the pump dis- charge rate remains flat. Flow rate Flow rate With no LOC @ adjustments Q With Lac. adjustments {Controlled flow rates ¥ \ lias. adjustments Pressure +P about 25 kgt/om* { Pressure =P about 25 ker? On an injection molding machine, for example, small-flow corrections (LQC adjust- ments) must occasionally be readjusted to run the ejector cylinder under low pressure. Tapa conations | Check Adjustment Flow rate command | * Check the cylinder operating Impress 0.05 V on | — speed (visually or otherwise). Qin, * Check if the cylinder working pressure (SMP) is below 25 kat/om*, If the cylinder speed is higher than the Qin commend, turn the LOC adjusting trimmer clock- wise. If the oylinder speed is lower, tum the LOG trimmer counter- clockwise. Note: Where the EH pump is mounted on the machine, it is difficult to check the cylinder speed. When adjusting low-pressure small-flow corrections, take good care.ME—0164C 2.5 Adjusting the Pressure Span ‘The pressure span indicates how the voltage (SMP voltage) of the pressure sensor detecting the pump discharge pressure is associated with the pressure command value (0~S V) for the EH pump. ‘Simply put, the pressure span indicates the value {kgf/em?) of pump pressure to be generated at ‘each value (V) of pressure command voltage Pin. Although the pressure span is factory-adjusted as listed below, it must be readjusted when the adjustment of the P gain has changed the relationship between pressure command voltage and pump discharge pressure. Pressure command | SMP voltage: Pump pressure: voltage Pin: 0.5 V Within 0.5 # 0.05 V 1/10 of maximum rated pressure Example: _1.57 MPa {16 keffem} Pressure command | SMP voltage: ‘Pump pressure: voltage Pin: 5.0V Within 5.00.05 V Maximum rated pressure * Example: 15.7 MPa {160 kgficm?) ‘+ The maximum rated pressure is a reference value depending on each model. SMP voltage sv Pressure P ‘Maximum rated pressure Example: 15.7 MPa {160 kgflem?} ‘When the P gain is adjusted, the voltage-pressure relationship in the above chart may be shifted from factory adjustment line "a" to "b" or "c”. In this case, adjust the pressure span so that the relationship matches line "a". * Preparation Either set the pump load circuit to the stroke end of the hydraulic cylinder or block the pump discharge side to make the circuit pressure-controllable. 212ME—0164C. > Adjustment procedure and methods Pressure ‘Adjustment ‘command Measurement Actual pressure ‘Actual pressure voltage can be measured cannot be measured ‘Apply pressure | a) Measure the actual | When the actual pressure | When the SMP voltage is ‘command pressure is higher than 10% of the | higher than 0.5 V, slowly voltage Pin of | 4) ifthe actual pressure | Tted pressure slowly | turn the P.MIN trimmer osv. cannot be measured | tumthe PMIN trimmer | counterclockwise to while the SMP voltage | counterclockwise to set | lower the voltage to a Jsfound to be normal, | He actual pressure to | value approximating to perform the following: | 10% of the rated osv. oO Pressure. ‘When the SMP voltage i Measure the SMP-COM age Is voltage using a digital | When the actual pressure | lower than 0.5 V, slowly comer is lower than 10% of the | turn the P.MIN trimmer rated pressure, slowly | clockwise to raise the Cet eed tum the P.MIN trimmer | voltage to a value : measured voltage (SMP | clockwise to set the approximating to 0.5 V. voltage) is within 0.5 | actual pressure to 10% of os. the rated pressure. “Apply pressure | a) Measure the actual | When the actual pressure | When the SMP voltage is command pressure. is higher than the rated | higher than 5.0 V, slowly voltage Pin of | i¢the actual pressure | Pressure, slowly tum the | tum the P.SPAN trimmer 50V ‘cannot be measured but | P-SPAN trimmer ‘counterclockwise to while the SMP voltage. | COUnterclockwise to set__| lower the voltage to 5.0 jsfound to be normal, | the actual pressure to the | V. perform the following: | Ted pressure. ‘When the SMP voltage is @ Measure the SMP-COM | When the actual pressure | lower than 5.0 V, slowly Voltage using a digial | iSlowerthan the rated | tum the P.SPA trimmer ce pressure, slowly tum the | clockwise to raise the PSPAN trimmer voltage to 5.0 V. Cesk whether ie clockwise to set the measured voltage (SMP | sctual pressure to the votage) is witin 50 | ted pressure Perform the adjustment steps = @ in the above table, then repeat them to check whether the SMP pressure falls within the specified value range using a digital voltmeter. If the SMP voltage is outside the range, repeat steps © > @ = © > @ for further adjustment. Note: For better adjustment of the pressure span, the point is to set the SMP voltage gradually closer to the specified value without trying to set it right to that value. When the SMP voltage is higher than the specified value, for example, adjust the P.MIN trimmer to set it to @ value approximate to the specified value ©, adjust the P.GAIN trimmer to set the voltage to @ value approximate to the specified value ©, then perform the next set of steps @ = @ for checking, This approach reduces the number of repetitions of adjustment steps. 213ME—0164 C > Adjustment points PSPAN P.MIN ‘ \ [ Digital voltmeter Digital voltmeter 214ME-0164C 2.6 Adjusting the Pressure Sensor Before shipment from the factory, the discharge pressure and SMP SMP voltage voltage (pressure sensor output) of the EH pump are adjusted to have the relationship shown as line (a) in the graph on the right. Sv} Ifthe rel set values. > Preparation ship changes due to the aging of the pressure sensor or a electronic circuitry, adjust the pressure sensor to recover the factory- Pressure => P To load the EH pump, either set the hydraulic cylinder to the stroke end or block the discharge side of the pump. > Adiustment method EH pump input . nee Check items ‘Adjustment Stopthe EH | Measure the SMP- | Turn the P.S.ZERO control trimmer so that the SMP pump driving | COM voltage using @ | voltage becomes 0 0.05 V. motor. digital voltmeter. | Leave however | No adjustment is the EH pump | required ifthe amplifier measured SMP powered at 24 | voliage is 0+ 0.05 V. Voc. ‘Star the EH” | Measure the SMP- | Obtain the desired pressure from the following equation pump motor | COM voltage using a_| using the measured SMP voltage. cal cD digital voltmeter. Desired pressure (P) = Rated pressure x SMP voltage/5 | command If the actual pressure is lower than the desired pressure voltage Pin to (®), tum the P.S.GAIN trimmer counterclockwise sv (clockwise when higher) to satisfy the following condition: Desired pressure (P) = Actual pressure Sctthe EH | Measure the SMP- | Obtain the desired pressure from the following equation pump pressure | COM voltage using #_ | using the measured SMP voltage Sommand digital voltmeter. Desired pressure (P) = Rated pressure x SMP voltage/S voltage Pin to 5 : oly. If the actual pressure is lower than the desired pressure (P), tum the P.S.GAIN trimmer counterclockwise (Clockwise when higher) to satisfy the following condition: Desired pressure (P) = Actual pressure Note 1: The P.S.ZERO and P.S.GAIN trimmers need to be adjusted finer than a single scale division in many cases. Be careful not to turn them excessively during adjustment. 215ME—0164 C Perform the adjustment steps © =? @ => @ in the table on the previous page, then repeat steps ® = @ tocheck whether the pump pressure and SMP voltage have the relationship shown as line (2) in the graph on the previous page. Ifadjustment is not enough, repeat steps @ > @ > @ > @. (Uf the actual pressure cannot be obtained while Pin = 5 V when checked in step @, the pressure span must be adjusted. See Section 2.5 on page 2-12 to adjust the pressure span.) Note 2: The pump discharge pressure should be measured with a precision class of pressure gauge. As the pressure gauge built in the machine has an error of several percent, therefore, the pressure sensor must be adjusted with that deviation accepted. Tip: After adjusting the pressure sensor, be sure to adjust the pressure span. By adjusting the two items, you can check the "pressure command voltage =) SMP Voltage => pump pressure” relationships. Adjustment points PS.GAIN PS.ZERO Digital voltmeter PSGAIN PS.ZERO Digital voltmeter a 216ME-01645 27 Adjustment for Volume Efficiency Correction The discharge rate of the EH pump decreases slowly as the pump pressure increases even with the swash plate kept at a constant slant angle. Itis called the volume efficiency of the pump. The adjustment for volume efficiency correction increases the swash plate angle depending on the pump pressure to keep the pump discharge rate constant. It is difficult to perform this correction accurately with the EH pump installed on the machine. Do not touch the Q.COMP trimmer unless you are obliged to adjust it. Flow rate Pressure =>P + Preparation Set a load such as a high-capacity, high-pressure hydraulic cylinder to the stroke end. % Adjustment method input command | Measurement ‘Adjustment Pin=5V Pump discharge | Ifthe pressure rises slowly to value between 2.5 MPa Qin=0.05 V pressure {25 kgflem’} and the maximum pressure and stops there, slightly tum the Q.COMP trimmer clockwise so that the pressure reaches the maximum, If the pressure rises slower in the lower-pressure area and faster in the higher-pressure area between 2.5 MPa {25 kgf/cm’) and the maximum pressure, slightly turn the Q.COMP trimmer counterclockwise, Finish adjusting the trimmer when the pressure rises slowly at a constant speed from 2.5 MPa {25 kgficm?} to the maximum operating pressure. 247ME~—0164¢ * Adjustment points Q.coMP - ecccsc sooccel aME—0164 © 2.8 Adjusting the Q G ‘The EH pump is a variable discharge pump which can control the discharge rate by input of electrical signals. The discharge rate is changed by controlling the swash plate angle. The swash plate swinging axis contains a potentiometer for detecting the slant angle, making up the feedback control system. ‘The swash plate control system gain (Q gain) must therefore be adjusted appropriately to maintain. the response and repeatability ofthe swash plate swinging axis. The Q gain is optimized before shipment from the factory. Note: Be careful when adjusting the Q gain because it affects the pressure control system as well. * Preparation ‘+ When the pump has been installed on the machine, switch the load to a hydraulic motor circuit if available. If no hydraulic motor is available, the hydraulic cylinder is used instead but i must not be set to the stroke end. (Setting the hydraulic cylinder to the stroke end automatically switches the pump not to flow control but to pressure control, preventing the Q gain from being adjusted.) When a synchroscope is available ®* Adjustment method Input condition ‘Measurement Response waveform and adjustment Setthe pressure | Connect the Tum the Q.GAIN command Pinto 5 | synchroscope between ‘immer clockwise. v. SMQandC to measure | S Setthe flow rate | @response waveform. | M command Qin to 2 V | Time base: 50 mS/div Q in step mode. Voltage base: 1 V/div 8 = Time Flow rate command (Q.GAIN optimized s M w a 0 => Time = Time ‘The QGAIN is 100 high. Tum the s ~~" Q.GAIN trimmer M counterclockwise. Q 0 = TimeME-0164C ‘If no synchroscope is available 1f'@ measuring instrument for monitoring a waveform, such as a synchroscope or oscilloscope, is not available during adjustment of the Q gain, you have to visually check the movement of the actuator (hydraulic motor or hydraulic cylinder). ‘The manual check lacks accuracy inevitably. In such a case, adjust the Q gain as follows. ‘The actuator (hydraulic motor or cylinder) | The Q gain is low. starts or runs slowly. ‘The actuator or pump has vibration ‘The Q gain is too high. ZXcauTION ‘@ After adjusting the Q gain, you should adjust the flow rate span because it may shift during Q gain adjustment. * Adjustment points ; QGAN Oscilloscope (00006 > Q.GAIN / 2 9 Oscilloscope 2-20ME—0164C. 2.9 Adjusting the Flow Rate Span ‘The flow rate span indicates the correspondence between the flow rate command and the EH pump swash plate angle. Precisely, it represents the relationship between the flow rate command value Qin and the SMQ voltage which is the swash plate angle sensor output voltage. Assuming that the relationship between the SMQ voltage and the actual swash plate angle 0 is adjusted in Section 2.10 "Adjusting the Potentiometer”, this section describes how to adjust the relationship between the SMQ voltage and the flow rate command voltage. Discharge rate (¢/min) max. Q 50/60 xmax. Q 30 Re ove 0 0 Qin (vy) 5 The flow rate span is factory-adjusted as follows. Flow rate command Qin: 0.05 V | The Q.MIN trimmer is adjusted so that the flow rate is set to 1% of the maximum rated flow rate. Flow rate command Qin: 5 V ‘The QSPAN trimmer is adjusted so that the flow rate is set to the rated value. Since the above adjustments cannot be performed with the EH pump installed on the machine, adjust the flow rate span while estimating the flow rate from the speed of the hydraulic motor as a load, Preparation Ifa hydraulic motor circuit is available as a load circuit of the EH pump, switch to the motor circuit. For the hydraulic cylinder, the adjustment must be performed during movement to the stroke end, 2.21ME—0164C » Adjustment ‘Since the flow rate cannot be measured accurately with the EH pump installed on the machine, adjust the flow rate span while estimating the flow rate from the minimum and maximum motor speeds on the machine. Input conditions ‘Adjustment © | Input the low rate command Qin | Tum the QMIN trimmer to set the hydraulic motor to the for 0.05 V. ‘minimum operating speed. @ | Input the fow rate command Qin | Turn the QSPAN trimmer to set the hydraulic motor to for SV. the maximum operating speed, For also flow rate span adjustment, perform steps © =? @ and repeat them to set the hydraulic. motor to the minimum and maximum operating speeds. Like pressure span adjustment, this adjustment requires that the procedure be repeated as @ => ® = © until the final desired speed is set. (The point is the same as for pressure span adjustment. See Section 2.5 "Adjusting the Pressure Span” as well.) > Adjustment points QSPAN QMIN i Digital °. voltmeter Digital voltmeter co 2-22ME-0164C, 2.10 Adjusting the Potentiometer The potentiometer is a sensor for detecting the swash plate angle of the EH pump. You do not, have to touch the potentiometer during routine maintenance. ‘You have to perform potentiometer adjustment, for example, after replacing the potentiometer. Note that the new potentiometer must be connected to the swash plate axis correctly before this adjustment can be performed. Since itis difficult to replace the potentiometer and adjusting the new one with the pump installed on the machine, perform sufficient prior examination before starting this adjustment. ‘The potentiometer axis and the swash plate swinging axis are assumed to be connected in an electrically adjustable angle range. (See Chapter 6.) SMQ terminal voltage (V) sv ‘Swash plate angle (0) Maximum swash plate angle Potentiometer adjustment aims to have the above relationship between the swash plate angle and the 'SMQ voltage (potentiometer output voltage). * Preparation Ifa hydraulic motor circuit is available as a load circuit of the EH pump, switch to the motor circuit. For the hydraulic cylinder, the adjustment must be performed during movement to the stroke end, * Adjustment ‘Condition setting Measurement ‘Adjustment ‘Tum the pilot valve solenoid adjusting | Measure the SMQ-C | Tum the QS GAIN serew clockwise (tighten it by about three | voltage (SMQ voltage) | trimmer to set the SMQ tums) using 3 mm Allen wrench to set the | using a digital voltmeter. | voltage to 5 + 0.05 V. pump's swash plate to the maximum slant angle. Tum the pilot valve solenoid adjusting | Measure the SMQ-C__| Turn the QS ZERO screw counterclockwise (loosen it by three | voltage (SMQ voltage) ‘trimmer so that the SMQ. tums to retum it to the initial position) using a digital voltmeter. | voltage falls within the 0 using a3 mm Allen wrench to unload the £0.05 V voltage range. pump. (Check the lowest pressure with the hydraulic pressure gauge.) (Get Pin and Qin to 0 V.) ‘After performing the adjustment steps (D) => @, repeat them continue adjustment until the SMQ voltage falls within the specified range. 2:23ME—0164 C QXcaution ‘It is not possible to precisely adjust the potentiometer with the EH pump installed on the actual machine. End the adjustment after the potentiometer has been adjusted to work practically ith no problem. > Adjustment points QS.GAIN QS.ZERO voltmeter 0009 ¢g ‘SMQ ce 2.24ME—0164C Details of Amplifier Internals ‘The amplifier is composed as shown below. In the following chapter, the sketches of amplifier internals are rather small. For their de tails, see the sketches shown on this page. Swash plate angle sensor connector Power pilot lamp Trimmers = | © Q||=p feR=3 ean x oo BOG D aa SSS a Belelslelelé ; ‘el 50/60 Hz selector switch Terminal block ee Power lo tmp 50/60 Hz selector switch ‘Trimmers: Fuse ‘Swash plate angle \ mansr Conneoice Terminal blook Phase compensator cartridgeChapter 3| Replacement of Pilot Valve Assembly ‘The pilot valve assembly is composed of an amplifier, a pilot valve and a proportional sole- noid, Its models are grouped by the amplifier models and by the pump mounting position. Pilot valve model Amplifier model $B1099-50D E585-10D_ 8110-500 ‘$B1099-60D £585-20D $81100-600 $B1099-62D 585-300 $B1100-62D $B1166-10 585-200 $B1166-10 a Replacing a pilot valve assembly include removing the electric cables. Before setting to work, familiarize yourself with the replacing work steps. After the new pilot valve assembly is mounted, it may be necessary to adjust electronic con- trol parts. For this work, see chapter 2. a4ME -OI6FA Removal of Pilot Valve Assembly |- 1 Turn the machine operation power supply off. Check that the motor for driving the pump is stopped and that the red lamp on the amplifier is out. Ss = 2 Detach the cable connector of a the swash plate position sensor. Connector With 40 design, remove first the amplifier cover, then the connector. 3 Using a4mm hexagon wrench, loosen the 4 fastening bolts (M5) of the pilot valve assem- bly and remove the pilot valve assembly from the pump. 4 Using a screwdriver, loosen the 6 cross-recessed head round screws (M3)and remove the amplifier cover. Amplifier cover 32ME—0164C. 5 Disconnect the cables (7) from the terminal block. Loosen the connectors and pull out the cables from the amplifier. M3 screws are so small that take care not to lose them when dis- connecting the cables from the terminal block. E585-20D/30D (pump 40D and 42D) eat 33ME—0164¢ Mounting of New Pilot Valve Assembly 1 Prepare a new pilot valve as- sembly. Loosening the 6 crossrecessed head round screws (M3), remove the am- plifier cover. 2 Check if the cycle selector plug is set for the regional frequency of your district. Ifitis not, shift the selector plug. (S0Hz, 60Hz)ME-0164C 3 Connect the cables to the amplifier. Couple each cable No. to the proper terminal. After proper connection, fas- ten the cables by tight ening the connectors.ME—0164¢ 4 a Mount the pilot valve as- sembly on the pump, while checking if the O rings (3) are attached to the valve gasket sur- faces. Couple the cable connec- tors for the swash plate po- sition sensors to the ampli- fier 30D and 32D pumps use metal connectors, which might be loosened by vi- bration. Screw them in tightly. 3-6™ME—U164 C 6 Turn the machine op- eration power supply on and check if the power pilot lamp of the ampli- fier is lit. If the lamp is not lit, the amplifier is out of order. Check it referring to chapter 1 7 Start the pump and check that it operates properly. Ifthe pressure gauge pointer pulsates or fluctuates, adjust the P GAIN as follows (with an jection molding machine as an example). Adjustments are so delicate that turn the trimmers very slowly. [ithe pointer pulsates Set the injection pattern to velocity V: 90% and pressure P: 99% and turn the P GAIN trimmer slowly counterclockwise (0.5 to 1 point). tho Ifthe pointer fluctuates (when hold pressure is shifted). Set the injection pattern to initial velocity V: 90%, final velocity: 20%, injection pressure P: 75% and hold pressure P: 20% and turn the P GAIN trimmer clockwise (0.5 to 1 point) a7ME-0164C Chapter 4] Replacement of Assembly in Pump (A16 to AS6) To replace the assembly in the pump, prepare beforehand necessary tools including an oil pan to receive oil flowing out of the pump and clean rags. If the connectors and the terminal blocks are stained with oil, it will later result in contact failures. During work, take care to keep electronic control parts away from oil. Ifthe connectors and the terminal block are stained with oil, it will later result in contact failures. If such parts are stained with oil, clean them with alcohol wet cloths. Place the new assembly to be built in the pump on a clean cloth and take care to keep it away from dust. Ifthe pistons of the assembly, in particular, are dirtied with metallic or other dust, they may damage the pump body. Take care about this.ME—-0164C 1 Turn the machine operation power supply off. Check that the motor for driving the pump is stopped and that the amplifier lamp is out. 2 Discount the cable connectors of the swash plate detector sen- sors. With the 40D pump, remove the amplifier cover first, then pull out the connections. e Prepare an oil pan and receiving oil, remove the suction and dis- charge flanges from the cover. 4 Prepare an oil pan and receiving oil flowing out, remove the cover fastenig bolts. A16, A22: hexagon wrench 8 mm across flats (M10) A37: hexagon wrench 10 mm across flats (M12) ASG: hexagon wrench & mm across flats (M10) 5 Now, the connections between the cover and the housing have been removed. Remove the cover. Take care not to let the gasket slip off but retain it on the cover. 4 pyc NS Fastening bot iL 42ME—0164 © 6 Now, the assembly can be taken out of the housing. Holding the cylinder block in both hands, pull the assembly out. It comes out as shown to the right. 7 Holding the new assembly with both hands, insert it in the hous- ing. Engage the shaft serration with the cylinder block and pivot serrations properly and push the assembly in completely. 8 Attach the port plate to the cover removed in step 5, Set the whisker-grooved side of the port plate frontward and put pins in the pin holes on the back. Piston assembly Pin (3) G Slipper retainer Cylinder block Washer Spiro-locks or snap ringME—O164” 9. Press the cover fitted with the port against the housing and tighten the fastening bolts evenly. Check if the gasket, the pins, the bias piston and the op- erating piston are attached prop- erly. ‘Tightening toques for cover fastening bolts A16, A22: (M10) 618 to 756 kgf-cm A37: (M12) 800 to 1050 kef-cm_ ‘ANG, A22: (M10) 618 to 756 kgf-cm 10 Mount the suction and dis- charge flanges. Also, couple the cable connec- tors of the swash plate angle de- tector sensors. 11 Finally, fill the oil pump casing with clean hydraulic fluid to the required level. This is the end of replacing work. Volumes of hydraulic fluid A16, A22: 600 cm? A37: 1200 cm? A56: 1200 cm? Operating piston Pin 12 Set the pump into an unloading state and break it in in an un- loading state for 10 to 15 min. Do not neglect this before normal operation 44 é =) ort plate Whisker-grooved side Bias pistonME—0164C Chapter 5] Replacement of Assembly in Pump Trunnion type (A80 to A125) Cradle type _(A70 to A145) To replace the assembly in the pump, prepare beforehand necessary tools including an oil pan to receive oil flowing out of the pump and clean rags. If the connectors and the terminal blocks are stained with oil, it will later result in contact failures. During work, take care to keep electronic control parts away from oil. Ifthe connectors and the terminal block are stained with oil, it will later result in contact failures. If such parts are stained with oil, clean them with alcohol wet cloths. Place the new assembly to be built in the pump on a clean cloth and take care to keep it away from dust. Ifthe pistons of the assembly, in particular, are dirtied with metallic or other dust, they may damage the pump body. Take care about this. Some of the pumps A70 or up differ in structure. For work procedure, see appropriate para- graphs for your pump model, referring to the table below. Bearing type Pump capacity model Chapter 5.1 Trunnion ‘ABO, A125, Chapter 5. 2 Cradle ATO, ASO, A145 54ME—0164U 5.1 Trunnion Type Pump = A80 - 1 Turn the machine operation power supply off. Check that the motor of the pump is stopped and that the red lamp on the amplifier is out. 2 Using an oil pan and a trough, dis- charge oil from the pump case via the drain port (with the oil inlet opened to let air in). Hexagon wrench 8 mm across flats (M10) 3 While receiving oil with an oil pan, remove the suction and the dis- charge flanges. Hexagon wrench 10 mm across flats (M12) 4 Disconnect the cable connectors of the swash plate angle detector sen- sors. ‘With pumps 40D and 42D, remove the amplifier cover first, then pull out the connectors. 5 Remove the pilot valve assembly from the pump. Do not remove the cable. Place the removed pilot valve on the motor. Hexagon wrench 4 mm across flats (M5) 6 Remove the 2 cover fastening bolts (M12) shown to the right from the cover. Hexagon wrench 10 mm across flats (M12) 7 In these bolt holes, screw cover re- moving tie rod jigs (2). 8 Also, remove the remaining cover fastening bolts: 2 (M12) and 3 ™Mi10). Hexagon wrench 8 mm across flats (M10) pe = Use a trough, Oil pan Remove the amplifier cover. Drain port rierave | “Sty 3 M10 bolts M2, 180 long, tle rod jig 5-2ME—0164 ( - A125 - ‘Tum the machine operation power supply off. Check that the motor of the pump is stopped and that the red lamp on the amplifier is out. Using an oil pan and a trough, dis- charge oil from the pump case via the drain port (with the oil inlet opened to let air in). Hexagon wrench 8 mm across flats (10) While receiving oil with an oil pan, remove the suction and the dis- charge flanges. Hexagon wrench 10 mm across flats (M12), Remove the amplifier cover. Disconnect the cable connectors of the swash plate angle detector sen- sors. ‘With pumps 40D and 42D, remove the amplifier cover first, then pull out the connectors. Remove the pilot valve assembly from the pump. Do not remove the cable. Place the removed pilot valve on the motor. Hexagon wrench 4 mm across flats (M5) Pilot valve| assembly Remove the 2 cover fastening bolts (M16) shown to the right from the cover. Hexagon wrench 14 mm across flats (M16) In these bolt holes, screw cover re- moving tie rod jigs @). aK Also, remove the remaining cover fastening bolts: 2 (M16) and 3 ae M10). Hexagon wrench 8 mm across flats ——— (M10) M16, 180 long, tie rod jig 53ME—U104U - Matters common to A80 and A125 - 9 Now, the connections between the cover and the housing have been re- moved. Letting the cover slide which support- ing it with the tie rods screwed in in step 7, remove it out of the machine base. Take care not to let the gasket slip off but retain it on the cover. 10 Ii the port plate remains on the cylin- der block side when the cover is re- moved, remove it from the cylinder block. ‘The port plate and the cylinder block are stuck together by an oil film. Separate the port plate by sliding it. ‘The port plate will not be reused. Dis- pose of it. To pull out the internals, using a jig, pull the bearing out of the shaft. ‘There is no gap between the bearing and the cylinder block. A gap can be made by pushing down the yoke and pressing the cylinder block hand. ‘The bearing is tightly driven in the shaft. Using the bearing pullout jig, screw in a bolt as shown to the right and pull out the bearing by sliding it ‘The bearing will be reused. Take care not to damage it. : 12 Now, the internal parts can be taken out of the housing. Holding the ¢ylin- der block in both hands, pull it out. ‘The internal assembly can be taken out as shown to the right © Cylinder block @ Piston, 9 units @ Slipper retainer @ Pivot © Pin, 3 units Piston G assembly : Cylinder block 5-4 Tie rod jig Port plate” cof i Cylinder block Bearing pull-out jig = \ Hexagon handle 10mm across flats. Bearing Slipper retainer Pin @)ME—0164 U 13 The internal parts taken out will not be reused. Dispose of them. 14 Before mounting a new internal as- sembly, check that the swash plate is attached properly to the yoke. If the pump is seized, clean the inside of the housing. 15 Holding the new internal assembly in both hands, insert it in the housing. Engaging the shaft serration with the cylinder block serration, push the as- sembly in completely. (i the cylinder block is 2 to 5 mm in from the edge of the housing, assem- bling is proper.) _ 16 Using the jig shown to the right, drive in the bearing removed in step 11. In this insertion, set the bearing in proper position and check if the bear- ing is driven in completely to the shaft shoulder. If it is not driven in com- pletely, it will later be excessively loaded, resulting in breakage. Piston ‘assembly Cylinder block 5-5 Slipper retainer Pin (3 Sliding surface ‘Swash plate Yoke l Serration I a Driven-in fig \ ‘Shoulder Bearing HammerMeE—O0164( ~ A80 - 17 Attach the port plate Giron based), a part for replacement, to the cover. Set the whisker-grooved side of the port plate frontward and insert a stop pin completely in the pin hole on the back. Check that the bias piston is also attached completely to the spring. 18 Insert the cover fitted with a new port plate in the tie rod jigs set in step 7 and slide and press it onto the housing. Here, check if the gasket is stuck properly. 19 First, temporarily fix the cover by tightening the 3 M10 fastening bolts evenly and pull out the tie rod jigs. Then, tighten the 7 fastening bolts evenly. ‘Tightening torques as a guide M12 @): 1180 kgf-em M10 (3): 685 kef-cm 20 Now, return from step 5 to step 2. 21 Finally, fill the pump case with clean hydraulic fluid via the oil in- let. The replacement work is com- plete. ‘Volume of hydraulic fluid: 2800 cm? 22 Before starting normal operation, break in the pump in neutral (un- loading) position for 10 to 15 mi Port plate Stop pin Oi iniet TrME—U104.U - A125 - 17 Attach the port plate (iron based), a part for replacement, to the cover. Set the whisker-grooved side of the port plate frontward and insert a stop pin completely in the pin hole on the back. Check that the bias piston is also attached completely to the spring, 18 Insert the cover fitted with a new port plate in the tie rod jigs set in step 7 and slide and press it onto the housing. Here, check if the gasket is stuck properly. 19 First, temporarily fix the cover by tightening the 3 M10 fastening bolts evenly and pull out the tie rod jigs. Then, tighten the 7 fastening bolts evenly. Tightening torques as a guide M16 (4): 2800 kgf-em M10 @): 685 kgf-cm 20 Now, return from step 5 to step 2. 21 Finally, fill the pump case with clean hydraulic fluid via the oil in- let. The replacement work is com- plete. ‘Volume of hydraulic fluid: 6200 cm? 22 Before starting normal operation, break in the pump in neutral (un- loading) position for 10 to 15 min. 57 Stop pin Oil intet TyME—U164L 1 Turn the machine operation power 2 Using an oil pan and a trough, dis- 5 Remove the pilot valve assembly 6 Remove the 2 cover fastening bolts \ 7 In these bolt holes, screw cover re- moving tie rod jigs (2). 8 Also, remove the remaining cover 4 GP fastening bolts: 2 (M12) and 4 5.2 Cradle Type Pump ~AT0- supply off. Check that the motor of the pump is stopped and that the red lamp on & i + E+ the amplifier is out. charge oil from the pump case via 2 the drain port (with the oil inlet 7 opened to let air in). brainpor’\\) Use a rough. Hexagon wrench § mm across flats SS ot pan (tio) 3. While receiving oil with an oil pan, remove the suction and the dis- charge flanges. Hexagon wrench 10 mm across flats (M12) on suction side ‘8mmacross flats (M10) on discharge side Remove ‘the amplifier cover. sors. With pumps 40D and 42D, remove the amplifier cover first, then pull out the connectors. from the pump. Do not remove the cable. Place the removed pilot valve on the motor. Hexagon wrench 4 mm across flats (Ms) Safty valve pressure ajustng screw, Sm across 2fals of hexagon eiowane: | a (M12) shown to the right from the cover. Max. flow rate adjusting serew, Hexagon wrench 10 mm across — Smmecross2 flats of hexagon flats (M12) (M10) Hexagon wrench 8 mm across flats (M10) 5-8 M12, 180 long, tie rod jig