Hydraulic

Service Information
# E 105/01 E

TESTING AND SETTING INSTRUCTIONS

FOR THE E1P TYPE CONTROL OF THE HPV-02 PUMP

 )*
Hydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 1 / 6
# E 105 / 01 E

TESTING AND SETTING OF THE E1P CONTROL

Range of applicability
This test and setting instruction refers to the E1P type control, i. e.
-electro-hydraulic control E1 and maximum pressure regulation (POR) P.
Safety instructions by the machine manufacturer (OEM) must be strictly adhered
to throughout all works on the machine!

INSTRUCTION FOR TESTING AND SETTING

All settings have already been done on LINDE's production test rig. Should ex-
ceptional circumstances (e.g. exchange of control device) impose checking the control
device of the HPV 02 pump as well as correcting its setting, the points below have to
be adhered to!

1 - At the service test rig

All test and setting data to be taken from the Test insructions of LINDE AG
Aschaffenburg. For up-to-date test instruction and installation drawing consult bill
of material (Stückliste).
2 - On the machine
All test and setting data to be taken from the valid data sheet of the machine maker.

- Preconditions for testing

. during all test and setting activities the fluid temperature in the boost circuit or in
tank must have reached working level.
The working temperatur depends on the viscosity class of the hydraulic fluid.
. pump and control device E1P to be thoroughly vented!
. drive speed >1500 rpm.
. boost pressure level must be reached with load and without.
- Testing instruments
. temperature gauge
. pressure gauge: 2 pcs 0-40 bar and 2 pcs 0-600 bar, or electric gauges.
Note: all pressure gauges have to be calibrated.
. electrical universal measuring instrument.
. possibly a speed gauge for the engine.

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 )*
Hydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 2 / 6
# E 105 / 01 E

CIRCUIT DIAGRAMME OF THE HPV-02R E1P

CLOCKWISE ROTATION

S (P) A

Ms

20
11
L

1
A B
6 2 7

D1 D2 12
B
5

3 Z
Y
D3 D4 18/1 18/2
16 17 F
18
MY MZ
19 15
Mp

X
P (S) X X
T U

Electro-hydraulic control E1P CW Electro-hydraulic control E1P CCW

Valve spool Valve spool

3 3

18 18
2 1 2 1

3
x x x
3
Z
x Z
Y Y

Y Z Y Z

MY MZ MY MZ

16 17 16 17
x x
T T
5 5

T F A B T A B
F
13 13
(P) S (S) P S
(P) (S) P
(HP1) (HD2) (HD1) (HP2)

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 ABHydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 3 / 6
# E 105 / 01 E

Connecting, measuring and adjustment ports review

E1P control T
Y Z 33b
33a 32b
35b
32a
MZ DC solenoid Y Z 34b
MY DC solenoid 34a
Z control pressure gauge port 44b
Y control pressure gauge port 35a
43b
T tank connection and vent port 43a
15 pressurizing valve Ma =15+5Nm 37
32(a/b) plug M 40 x 1,5 44a 36
33(a/b) groove nut Ma =25 Nm 173 X
34(a/b) mechanical stroke limiter threaded stud M8x1,25
35(a/b) seal nut Ma = 23 Nm X=14,75 mm
36 groove nut Ma =25 Nm
37 hollow screw
43a setting screw DA HD2 My Mz
44(a/b) seal nut Ma = 14 Nm 47
43b setting screw DA HD1
45 setting screw 46
45
46 lock nut Ma = 5 Nm 15
47 nut Ma= 9 Nm

HPV-02R E1P
My Y T Z

Mz

Flow Direction
The flow direction of the fluid is dependant upon:
- the pump direction of rotation
- the over centre direction of the swash plate
X
DRIVE SENSE OF ROTATION: right hand viewed on shaft F
Solenoid My energized > 175 mA: HP pressure in port P B A
Solenoid Mz energized > 175 mA: HP pressure in port S
X

(S)
P EXPLANATIONS
P, S High pressure port F
B Suction port boost pump
A Pressure port boost pump
F Control and boost pressure supply
T Tank and vent port
X Boost pressure gage port
Y, Z Control pressure gage port
MY, MZ Proportional solenoid
Ms, Mp High pressure gage port
U Drain, flushing return from hydr. motor
Ms
L Oil filling, tank and vent port
P (S) S (P)
Mp

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 )*
Hydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 4 / 6
# E 105 / 01 E

2.2 Hydraulic zero position

Input speed >1500 rpm
Connect two gauges 0 - 600 bar to gauge ports Mp and Ms (HPV pump).
·Pressure balance
Both DC solenoids My and Mz to be de-energized, delta p Y-Z = tank pressure (case pressure).
Check gauge ports Mp and Ms for identical pressure in closed loop, to be +- 4bar. If the pressure
difference is > 4 bar the hydraulic neutral position can be corrected by turning the
pilot housing (hollow screw 37), refer to page 3. Fine tuning is, however, not feasible this way!
Loosen the groove nut, use only a ring spanner to slightly turn the hollow screw (37) until pres-
sures are the same.For rough tuning check pre- setting measure "X" to be 14,75 mm at the
hollow screw (37) and adjust if necessary while the groove nut (36) is loose. Afterwards secure
with 25 Nm.
· Symmetry
Symmetry is also necessary to be verified during balanced pressure operation. To do this, the
pump has to be tilted in one direction against a blocked function ( hydraulic motor) until high
pressure reaches some 150 bar. Switch power off, and pump must return to pressure balance
operation +-4 bar. Now tilt pump to the other side and switch current off. Pump must again come
back to the pressure balance state of +- 4 bar. If there is no symmetry, turn the hollow screw (37)
slightly- without loosening the grove nut- and check once more.

2.3 Control begin (start of delivery)

Input speed >1500 rpm.
Add two pressure gauges 0-40 bar to gauge ports Y and Z of the E1P control. Energize one of the
solenoids, e.g. My. Start slowly while steadily increasing the signal current. Swash control has
begun when some 10 + 20 bar increase is seen in the main circuit.
Correction can be made via the pack of springs in the control device.
Agitation of the right hand solenoid will correct the left hand pack of springs. Loosen cap nut (33)
and set by means of the plug (32).Finally secure cap nut (33)with a socket wrench, Ma = 25 Nm.
Note:if a correction is made at plug (32), the mechanical stroke limiter (34) must follow up.
Attention: parts (32) and (34) have different thread pitches,see page 3.

Displacement as per signal current below

regulation begin of MDR
Diagramme
100
Fördervolumen [%]

Example of standard execution!

Consult O.E.M.'s data sheet .
50

0
0 1 2 3 4 5 6 7 8 9
control pressure [bar]
24 Volt 175 ± 5 350 ± 20
signal current [mA]
12 Volt 350 ± 10 710 ± 40

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 )*
Hydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 5 / 6
# E 105 / 01 E

2.4 Maximum flow

The stroke of the input spool in the E1P control determines the swash angle of the HPV pump.
The maximum permissible stroke is adjusted by means of the mechanical stroke limitation(34).
For technical reasons this must not be realized with the pump mechanics.
If speed or synchronous run (in a tracked vehicle) are no longer in line, and if it has been found out
that the pump control needs re-adjusting, this has to be carried out in the following manner:
- to achieve synchronous running it is always the swash angle of the pump of the faster track that
has to be reduced with the help of the mechanical stroke limiter (34).
- to obtain the flow needed for the desired speed, re-adjustment can be made with the help of the
mechanical stroke limiter (34).
Procedure:
- stop engine.
- Remove seal nut (35).
- Turn grub screw of the corresponding side (34) in so that it touches the slave piston.
- Wind grub screw out again:
HPV 55-02 by 16,2 +/- 0,1 mm
HPV 75, 105, 135 - 02 by 15,8 +/- 0,1 mm
- Prior to fitting the seal nut (35) write down how much the grub screw protrudes out of the plug (32),
in order to check this once the seal nut is fitted.
- Fit seal nut and check the measure written down before.
In pumps which have a reduced swash angle for application reasons the setting can be realized
only by means of measuring device nr. PR 8551/1-3 and the corresponding table. Further information
to be obtained at dept. HK 1.

2.5 Maximum pressure regulation P (POR)

The control feature with maximum pressure regulation reduces pump delivery on reaching a
maximum pressure that can be selected at the set screws 43a and 43b.While system pressure is
maintained, only a weak residual flow (adjustable at valve 15) will pass the high pressure relief
valves (11 and 15), thus optimizing both energy consumption and thermal balance of the system.

Diagramme Displacement as function of signal current

and pressure cut-off relief valve
setting
control pressure ∆ p Y/Z [%]

POR
100 100
displacement [%]

Vorspannventil

Testing and setting 0 0

0 max
- drive speed >2000 rpm high pressure (bar)

- connect two gauges 0-40 bar to gauge ports Y and Z.

- connect two gauges 0-600 bar to gauge ports Mp and Ms.
For proper checking and setting it is necessary to block the hydraulic motor by brake. Should
this not be possible for reasons on the vehicle side, the high pressure connection ports of the
HPV pump have to be blanked off. Caution - risk of contamination ! Clean pump and pipework
carefully before commencing the job. Leak oil has to be collected and disposed of according to
prevailing local regulations.

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 )*
Hydraulic Description: Date: 11.01
E1P CONTROL OF HPV-02 PUMP
Service Information TESTING AND SETTING INSTRUCTIONS Page: 6 / 6
# E 105 / 01 E

a. High pressure valves (11 and 12) and preloading valve (15)
Gradually increase signal current to proportional solenoid , e.g. My (Mz) until set value E*
of high pressure valve is reached without further rising. This is measurable at port Mp (Ms),
example for HPV pump ,cw rotation, refer difference cw/ ccw on page 2.
The set value of the preloading valve (15) can now be read, it is measurable at port Y/Z (see
circuit diagramme). The control pressure differential delta p Y-Z/Z-Y has to be >-2,6 up to
<-3+0,2 bar . At this point of operation the system ought to be stable. Stabilization can be achiev-
ed by setting the preloading valve (15) within >- 2,6 to <-3+0,2 bar.
E* = setting value of high pressure valve according to OEM order specification (e.g.420 + 30 bar).
·High pressure valve cannot be adjusted. If the valve does not allow to reach the reference value
E* the valve cartridge (11 or 12) has to be changed as a whole. Yet before, the reference value of the
high pressure valves should also be checked without POR function.This requires blocking of the
preloading valve (15) by means of the setting screw (45)(attention: note number of revolutions).
Check reference value again. If not reached, exchange the valve cartridge. If still not reached, the
mistake is in the system, perhaps internal leakage in the closed loop.
Has the reference value already been reached after changing the valve cartridge, put the set screw
(45) of valve (15) in original postion. Check function and reference value of the valve (15). In rare
cases the high pressure valve itself may be instable. Also in this case, the whole cartridge (11 or
12) has to be exchanged.
· Preloading valve has to be set to the corresponding delta p Y - Z/Z-Y.
- Too low a set value may render the whole system unstable during the POR operation.
- If the set value has been tuned higher, a greater residual flow will bleed across the high pressure
valves. This may impair the energy consumption and thermal balance of the system.
If needed, adjustments can be made at the set screw (45). Afterwards lock the nut (47) with 9 Nm
and the locking nut (46 ) with 5 Nm.
- If the set value cannot be fixed at <3 bar , the regulation begin of the POR control is likely to be
late. Check regulation begin and correct if necessary (see description).

b. Regulation begin of POR control

When it is necessary to check and/or reset the POR, the entire preloading valve (15) has to be
loosened by ½ turn and the signal current of the proportional solenoid, e.g. My, has to be raised
gradually until control pressure at port Y stays constant or rises only slightly (+ 0.2 bar). The high
pressure that can now be measured represents the regulation begin point: reference value E* - 40 +
10 bar.
Attention. At this point of operation the system tends to become unstable (high pressure oscillations).
This is a normal reaction. - Repeat the procedure on the other side (Mz). At last fasten the entire
preloading valve (15) with 15 + 5 Nm.
In case certain required values are not reached, adjustment is possisble via the set screw 43a or 43b.
One revolution of the set screw corresponds to about 60 bar. Then fasten the corresponding seal nut.

The above-described procedures ought to be performed rapidly, in order to avoid excessive heating-
up of the system.

LINDE AG
M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephone: 0 60 21 / 99 15 66 Department HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephone: 0 61 88 / 41 36 09
 )*
Hydraulic Benennung: Date: 11.01

TROUBLE SHOOTING CHART

Service Training For E1P type control of HPV 02 pump
Seite: 1 / 1
Document # FDE1P 105/01 E

Hydraulic zero positioning

- start engine Pull off both magnetic plugs from the control
- electrical control of pump not to be activated okay not okay
- pressure balance: to be ± 4 bar
- symmetry at pressure balance
okay not okay Electrical control
Check, if necessary replace.

Correct hydraulic zero positioning.

. pressure balance to be ± 4 bar
. symmetry due to pressure balance operation
Control begin (start of delivery)
okay not okay
. energize solenoid My, check begin of control
. energize solenoid Mz, che ck begin of control
okay not okay
Take E1P control off as a whole, check, and,
exchange if required

begin of control to be corrected at the

corresponding spring assy.
max delivery okay
. actuate solenoid My with max signal current.
. actuate solenoed Mz with max signal current.
okay not okay
signal current check , compare data sheet
okay not okay

electrical control
check, if necessary replace
high pressure valves (11 and 12) check ref. value E*.
charge pump against load P/S.
okay not okay control solenoid/signal pressure check
okay not okay

control solenoid/pressure reducing valve

check, replace if necessary.

preloading valve (15) check ref value delta p Y-Z/Z-Y

. load pump against implement use mechanical stroke limitation (34a/b)
. at this point of operation the system should be stable. to correct max displacement. Caution: do not
okay not okay exceed max stroke!
okay

checking/setting finished ! preloading valve (15) check ref. value »p

okay not okay
Preloading valve adjust
okay not okay
preloading valve adjust

okay Preloading valve (15) to be blocked down by set

Adjustment of preloading valve (15) <3,5 bar is not screw (45). Important: note number of turns.
possible. Regulation begin of POR comes late. Check ref. value of high pressure valves
Check regulation begin for P/S and correct. not okay
Subsequently adjust preloading valve (15).

High pressure valve cannot be adjusted.

Preconditions - to be fulfilled before starting to work: Fit a new high pressure valve. Also with instability
· pump and control E 1P vented carefully. of high pressure valve fit a new valve
· fluid temperature in tank 55 ± 5°C (HLP 68). cartridge..Check ref. value.
· input speed to HPV pump approx. 2000 rpm. okay not okay
· check boost pressure level. Has to be attained under load
and without. Otherwise investigate the auxiliary pump,
HPV pump or hydraulic motor for damage. Mistake in the system!
· for setting data refer tothe relevent OEM data sheets. Possibly internal leakage in closer loop, check
components (pump, motor)
· study Service Information E 105/ 01 E.

For information only! Not subject to technical modification service

LINDE AG M. Zivkovic
Industrial Trucks and Hydraulics Division.
Schweinheimer Straße 34, 63743 Aschaffenburg, Telephon: 0 60 21 / 99 15 66 Abteilung HK 1
Hanauer Landstraße 100, 63796 Kahl / Main, Telephon: 0 61 88 / 4 136 09