®
No. 7-404July, 1995
Heavy Duty Hydrostatic Transmissions
Variable Displacement PumpVariable Displacement MotorFixed Displacement MotorFixed Displacement Motor(With Integral Shuttle)Troubleshooting Guide for
Eaton Hydrostatic Transmissions
Contents
Introduction..............................................................................2Typical Hydrostatic System......................................................3Gauge Requirements, Gauge Port Size and Locations...........4-5Typical Pressure Readings.......................................................6Fault-Logic Troubleshooting................................................7-11Action Step Comments......................................................12-13Hydraulic Fluid Recommendations....................................14-15
2
Introduction
This manual provides troubleshooting information for a typicalhydrostatic system. It will help you to diagnose minor problemsthat may occur with Eaton Heavy Duty HydrostaticTransmissions.
The following publications are also available for Eaton HeavyDuty Hydrostatic Transmissions:
Technical Data for Hydrostatic Closed-Circuit Schematics...............................................................................No. 3-403Eaton Heavy Duty Hydrostatic Start-Up Procedure
...............................................................................No. 2-402Eaton Hydrostatic Variable Pump Repair Manual (Series 0)...............................................................................No. 7-603Eaton Hydrostatic Variable Pump Repair Manual (Series 1)...............................................................................No. 7-606Eaton Hydrostatic Fixed Pump Repair Manual (Series 0)
...............................................................................No. 7-122Eaton Hydrostatic Fixed Pump Repair Manual (Series 1)
...............................................................................No. 7-127Eaton Hydrostatic Variable Motor Repair Manual (Series 0)...............................................................................No. 7-121Eaton Hydrostatic Variable Motor Repair Manual (Series 1)...............................................................................No. 7-140
Typical Hydrostatic SystemVariable Pump-Fixed Motor111239104567182123456Variable Displacement PumpFixed or Variable Displacement MotorReservoir
Shut-off Valve (Optional)Filter
Charge Pump Inlet Line789101112Pump and Motor Case Drain LinesHigh Pressure LinesHeat Exchanger
Heat Exchanger By-pass ValveReservoir Return Line
Reservoir fill Cap and Breather
3
Gauge Requirements, Gauge Port Size and LocationsVariable Displacement Pumps Charge Pressure Gauge0 - 600 PSI [ 0 - 37 bar ]30020040010 Inlet Vacuum Gauge- 30 to + 30 inHg (Mercury)[ -1 to + 2 bar ]( Compound Gauge )051015 Charge Pressure Gauge 0 - 600 PSI [ 0 - 37 bar ]30020040010050020201005000PSICompound60030Vac30Press25Charge PressureRelief ValveOptionalIPOR Valve0PSI600 7/16 - 20 UNF 2B - 4 SAE O-Ring Port 1-5/16 - 12 UN 2B -16 SAE O-RIng Port OptionalPower Limiter ValvesCustomer must supply fittingFixed Displacement MotorsCase Pressure Gauge0 - 300 PSI [ 0 - 20 bar ]150100200System Pressure Gauges ( 2 )0 - 10,000 PSI [ 0 - 610 bar ]50004000300020001000600070008000400030002000100005000600070008000502500PSI300PSI0AB900010000 7/8 - 14 UNF 2B -10 SAE 0-Ring PortPSI900010000Customer mustsupply Fitting1 - 1/16 - 12 UN 2B- 12 SAE O-Ring PortChargePressureReliefValveAB7/16 - 20 UNF 2B- 4 SAE O-Ring PortsOptionalCase PressureGauge LocationOptionalSpeedSensorShuttleValveHigh PressureRelief Valve(A Port)High PressureRelief Valve(B Port)4
Gauge Requirements, Gauge Port Size and Locations
Fixed Displacement Motors
(with Integral Shuttle)
Case Pressure Gauge0 - 20 bar [0 - 300 PSI]
150100200System Pressure Gauges ( 2 )0 - 610 bar[0 - 10,000 PSI]
50004000300020001000600070008000400030002000100005000600070008000502500PSIPSI09000PSI90003001000010000Customer mustsupply Fitting1 - 1/16 - 12 UN 2B- 12 SAE O-Ring Port9/16 - 18 UNF 2B- 6 SAE O-Ring Ports System PressureGauge Port (B)Shuttle ValveBA System PressureGauge Port (A)OptionalCase PressureGauge Location OptionalSpeed SensorCharge PressureRelief ValveVariable Displacement Motors
Case Pressure Gauge0 - 20 bar [0 - 300 PSI]
15010020040003000System Pressure Gauges ( 2 )0 - 610 bar[0 - 10,000 PSI]
500060007000800050004000300020001000060007000800050250200010000PSI300PSI09000PSI9000Control Pressure Port7/16 - 20 UNF 2B- 4 SAE O-Ring PortsChargePressureReliefValve10000100007/16 - 20 UNF 2B- 4 SAE O-Ring Ports1 - 1/16 - 12 UN 2B- 12 SAE O-Ring PortNote: Gauge Shown Installed into Optional Case Port
ShuttleValve
High PressureRelief Valve(A Port)
ANote: To protect your instrumentation, all gauges should be dampened (or snubbed) and mounted with flexible lines.
BHigh PressureRelief Valve(B Port)
5
Pressure Readings
The pressures given in this manual are gauge pressures or deltapressures. A pressure gauge reads zero when connected toatmospheric pressure. Any reading above or below this zeropoint is referred to as gauge pressure (bar [PSI]). Delta
pressure is the difference of two gauge pressures in a hydrauliccircuit.
Example:Charge pressure reading of 16,5 bar [240 PSI]-Case pressure reading of 1,5 bar [20 PSI]Differential pressure of 15,0 D bar [220 D PSI]
Typical hydrostatic circuits usually include a inlet pressure, casepressure, low or charge pressure and system or high pressure.These pressures will vary per each individual application andoperating conditions.
6
Nominal Operating Pressures
(At Normal Operating Temperature)Inlet Vacuum:
Should not exceed 254 mm [10 in.]mercury (Hg.) for an extended period oftime
Case pressure:
Should not exceed 2,8 bar [40 PSI]for an extended period of time
Charge Pressure:*Neutral15,2 bar [220 PSI]
Forward or Reverse11,0 bar [160 PSI]*Charge Pressure Relief valves are factory preset to their
nominal setting with a 7,6 l/min [2 GPM] flow rate. The originalvalve pressure will increase approximately ,45 bar per 3,8 l/min[6.5 PSI per 1 GPM] additional flow over the valve. The chargepressures given above are typical. Higher charge pressures maybe set at the factory for your particular application.
Fault-Logic Troubleshooting
This guide is designed as a diagnostic aid for the user to locatepossible transmission problems. Match the transmissionsymptoms with the problem statements and follow the actionsteps shown in the box diagrams. This will help in correctingminor problems, eliminating unnecessary mixer down time.Following the fault-logic diagrams are diagram action
comments to further help explain the action steps shown in thediagrams. Where applicable, the action comment number ofthe statement appears in the action block of the diagram.
Symptom:ActionStepCommentNumberDecision1Inspect?DefectiveRepairorReplaceOkSolutionNeutral Difficult or Impossible to FindInspect ExternalPump Control1Linkage (if Used)DefectiveRepairorReplaceOkInspectPump ControlValve2DefectiveRepairorReplaceOkReplace Pump7
8
kyOlnsOerovl faneVti clereeeoRetvrpiiitcs caaitnmmepriIeLfeolpct reReseyeDRSwroiPD3 enKOO nloritt cneseoevrepCvilites cacnpaVepratImfeolpaueReRrPD2epOkO noil)sadnloersertstnUixo efvremE Ci(iic tt cpecaasepmgeprlafeopnsukeRenPnDR iaILr1T4evtreceiieltetacptvcleprasuafeolpnhVeDReRISkO5seetvrecevliitegacacraprV epolpsakfenhceReICeDRhCkOecpalpmeuRPkO3s enderirs rovlwae3 faowrorve1eVti clreeLoegeFRrav)reeeevrekerhlaovretiicpRitcguaics mcaraepoplersCiVtt ocprahastfeoplnmiIeLfeeReChdceMefCerri Ret PaeltepeARsrRyeDSw2nwresR(Do1isn orIPwFreo,lovLaerktROukeNO5s1sae2)tg1)aPdre)Rde-aveeHyeehlpavtOsereCVmicPre BsvretaiceIUvi taict Ui uracr ftaictfcpprficpraeeicpracePefeoplso(eeoplpg( efeoplei lteen fsneeRepeARRIReeRenavlDRsDOvRlDIhanR(PacVIVxE8kkOOkO9reovtloa)e10ertdceeMVdvritc etetrc cgdeeetsscaitacsepraopletnenpgllleaUfei paagasngFpepPfeisehgenIolInHcoCRs-(DReRnyIxlIBECCl7 kkOOkOlnr)lireOnieooiovvreeiot tiklveorrLtelce14tcsceegpcaicasM eve lpevprepraplmiheswlioeeoFrsamfeoplCLRleesePLnhuICPDReRRnp &amr6BTu(PkO9
System Operating HothsiggulS esnopseR metsyS10
kO)ncteooregpevreepiccsiotsarmiuctaasM nhPepralICplmiefeopes &4ReRnp1DRamTruP(kOkOctdeepeterecgasnlltgnIFiopleIme0ClR1evstaleyVd)vreS eisstic scakctaU epralOePfeopp(ifeResy-DRnIB9daregreneav)lpehavre iorwskFCVmica uctiOowl,orervtfpraLaecePefeolprRei utpltReReseAeNnR(DI21olctntreeoevepCvirtics alcaranpVepolImfepeueegPDRRreav)lre2ndeshaovre iarCVtiic octatfpraoworervceMeLorweFRei eolpltefpReRkseA(DOnRI31keeecguregreharssav)leChlCehapvrePrwarVmicontC uctiaratf3LIuecePepolp1Nei pltefeeseAnR(DRRI21System Will Not Operate in Either DirectionOkOkOkInspect ExternalPump Control1Linkage (if Used)Inspect MotorBy-Pass Valve(if Used)9CheckCharge11PressureDefectiveRepairorReplaceLow inNeutral,ForwardorReverseLow inForward orReverseDefectiveRepairorReplaceCheck OilLevel in6ReservoirBelow LevelFill toProperLevelOkInspect ChargeRelief Valve(At Motor)13DefectiveInspectChargePump14OkOkInspect ChargeRelief Valve(At Pump)12DefectiveCloggedInspectInletFilter10DefectiveOkReplaceRepairorReplaceRepairorReplaceRepairorReplaceReplaceTransmission(Pump & Motor)Ok DefectiveInspectPump ControlValve2OkInspectPOR or IPORValve (if Used)15DefectiveOkInspectSystem Relief orPower Limiter Valves3Defective11
RepairorReplaceRepairorReplaceRepairorReplaceDiagram Action Step Comments
1.Inspect External Pump Control Linkage for:
(Manual Operated Controls)A.Misadjusted or disconnectedB.Binding, bent or broken
(Hydraulic Remote Controls)A.Improper pilot pressureB.Defective proportional valve
(See proportional valve manual for repairs.)(Electrical Operated Controls)
A.Disconnected electrical signal connection
2.Inspect Pump Control Valve for:
(Manual Operated Controls)A.Plugged control orificeB.Damaged mounting gasket
C.Misadjusted, damaged or broken neutral return springD.Broken control connector pin
E.Broken or missing control linkage pin(s)F.Galled, stuck or bent control spool
(Hydraulic Remote Controls)A.Plugged control orificeB.Damaged mounting gasket
C.Misadjusted, damaged or broken neutral returnspring (2)
D.Broken control connector pin
E.Broken or missing control linkage pin(s)F.
Galled, stuck or bent control spool
(Electrical Operated Controls)A.Plugged control orificeB.Damaged mounting gasket
C.Galled, stuck or bent control spoolD.Stuck solenoid valve(s)E.Defective solenoid coil(s)
F.Misadjusted speed sensor (when used)G.Defective speed sensor (when used)H.Defective electronics module
NOTE: When the electronic transit mixer control is used,follow the control box fault dector instructions.
12
3.Inspect System Relief or Power Limiter Valves for:
(System Relief Valves)
A.Improper pressure relief setting
(Consult owners/operator manual for system relief valvesettings)
B.Damaged or missing O-ring and/or back-up ring(s)C.Plugged orifice
D.Piston galled or stuckE.Valve poppet held off seat
(Power Limiter Valves)
A.Improper pressure relief setting
(Consult owners/operator manual for power limitervalve setting.)B.Broken springC.Valve held off seat
4.Inspect Shuttle Valve for:
A.Bent or broken return centering springB.Galled or stuck shuttle spoolC.Bent or broken shuttle spool
5.Inspect Charge Check Valves for:
A.Damaged or missing O-ring and/or back-up ring(s)B.Damaged check ball seatC.Stuck check ball6.Check Oil Level in Reservoir:
A.Consult owner/operators manual for the proper type
fluid and level.7.Inspect Heat Exchanger for:
A.Obstructed air flow (air cooled)
B.Obstructed water flow (water cooled)C.Improper Plumbing (inlet to outlet)D.Obstructed or insufficient fluid flowE.Cooling fan failure (if used)8.Inspect Heat Exchanger By-Pass Valve for:
A.Improper pressure settingB.Stuck or broken valve9.Inspect Motor By-Pass Valve for:
A.Valve held in partial and/or open position
10.Inspect Inlet Filter for:
A.Plugged or clogged filterB.Obstructed inlet or outlet
C.Collapsed inlet line to charge pump C.Open inlet to charge pump
11.*Check Charge Pressure:
A.Consult page 4 in this manual for charge pressure
gauge installation location.
B.Consult owner/operators manual for charge relief valve
settings.12.*Inspect Charge Relief Valve for:
(at Pump)
A.Improper charge relief pressure settingB.Plugged Orifice
C.Piston galled or stuck open and/or closedD.Damaged or missing O-ringE.Valve poppet held off seat13.*Inspect Charge Relief Valve for:
(at Motor)
A.Improper charge relief pressure settingB.Plugged Orifice
C.Piston galled or stuck open and/or closedD.Damaged or missing O-ringE.Valve poppet held off seat14.Inspect Charge Pump for:
(Standard and A-Pad Pumps)A.Broken drive tang
B.Damaged or missing o-ring(s)C.Broken drive key
D.Galled or broken gerotor set
(B-Pad Pumps)
A.Stripped or broken drive couplingB.Stripped or broken drive splineC.Damaged or missing o-ring(s)D.Broken drive key
E.Galled or broken gerotor set
15.Inspect POR or IPOR for:
(POR, Pressure Override)A.Plugged orifice
B.Misadjustment of maximum pressure settingC.Stuck or missing check ballD.Stuck or broken sensing pinE.Stuck or broken control spoolF.Obstructed or broken sensing line
(IPOR, Internal Pressure Override)A.Plugged orifice
B.Misadjustment of maximum pressure settingC.Load sensing pins reversedD.Stuck or broken sensing pinE.Stuck or broken control spool
Diagram Action Step Comments
*System / Charge Relief Valve Pressure Setting Identification
The system and charge pressure relief valves are all factorypreset. For identification, a pressure code is stamped on the hexplug located on the end of the system and charge pressurevalve cartridges.
This same code is also used on the power limiter valves. Thecode number is stamped on the end of the valve cartridge.(Power limiter valves must be removed to view pressure code.)To determine the pressure setting of each valve, add a zero tothe right of the stamped coded number.Charge Pressure Valve Examples
016 = 11,0 bar [160 PSI] Setting022 = 15,2 bar [220 PSI] Setting
System and Power Limiter Valve Pressure Examples
400 = 275 bar [4000 PSI] Setting500 = 345 bar [5000 PSI] Setting
13
Hydraulic Fluid Recommendations
Introduction
The ability of Eaton hydraulic components to provide desiredperformance and life expectancy depends largely on the fluidused. The purpose of this document is to provide readers withthe knowledge required to select the appropriate fluids for usein systems that employ Eaton hydraulic components.One of the most important characteristic to consider whenchoosing a fluid to be used in a hydraulic system is viscosity.Viscosity choice is always a compromise; the fluid must bethin enough to flow easily but thick enough to seal andmaintain a lubricating film between bearing and sealing
surfaces. Viscosity requirements for each of Eaton’s productlines are given on the back of this document.
Viscosity and Temperature
Fluid temperature affects viscosity. In general, as the fluidwarms it gets thinner and its viscosity decreases. The oppositeis true when fluid cools. When choosing a fluid, it is importantto consider the start-up and operating temperatures of thehydraulic system . Generally, the fluid is thick when the
hydraulic system is started. With movement, the fluid warms toa point where a cooling system begins to operate. From thenon, the fluid is maintained at the temperature for which thehydraulic system was designed. In actual applications thissequence varies; hydraulic systems are used in many environ-ments from very cold to very hot. Cooling systems also varyfrom very elaborate to very simple, so ambient temperaturemay affect operating temperature. Equipment manufacturerswho use Eaton hydraulic components in their products shouldanticipate temperature in their designs and make the appro-priate fluid recommendations to their customers.
Cleanliness
Cleanliness of the fluid in a hydraulic system is extremelyimportant. Eaton recommends that the fluid used in its
hydraulic components be maintained at ISO Cleanliness Code18/13 per SAE J1165. This code allows a maximum of 2500particles per milliliter greater than 5 µm and a maximum of 80particles per milliliter greater than 15 µm. When componentswith different cleanliness requirements are used in the samesystem, the cleanest standard should be applied. OEM’s anddistributors who use Eaton hydraulic components in their
products should provide for these requirements in their designs.A reputable filter supplier can supply filter information.
14
Fluid Maintenance
Maintaining correct fluid viscosity and cleanliness level isessential for all hydraulic systems. Since Eaton hydrauliccomponents are used in a wide variety of applications it isimpossible for Eaton to publish a fluid maintenance schedulethat would cover every situation. Field testing and monitoringare the only ways to get accurate measurements of systemcleanliness. OEM’s and distributors who use Eaton hydrauliccomponents should test and establish fluid maintenanceschedules for their products. These maintenance schedulesshould be designed to meet the viscosity and cleanlinessrequirements laid out in this document.
Fluid Selection
Premium grade petroleum based hydraulic fluids will providethe best performance in Eaton hydraulic components. Thesefluids typically contain additives that are beneficial to hydraulicsystems. Eaton recommends fluids that contain anti-wearagents, rust inhibitors, anti-foaming agents, and oxidationinhibitors. Premium grade petroleum based hydraulic fluidscarry an ISO VG rating.
SAE grade crankcase oils may be used in systems that employEaton hydraulic components, but it should be noted that theseoils may not contain all of the recommended additives. Thismeans using crankcase oils may increase fluid maintenancerequirements.
Hydraulic fluids that contain V.I. (viscosity index) improvers,sometimes called multi-viscosity oils, may be used in systemsthat employ Eaton hydraulic components. These V.I. improvedfluids are known to “shear-down” with use. This means thattheir actual viscosity drops below the rated value. Fluidmaintenance must be increased if V.I. improved fluids areused. Automotive automatic transmission fluids contain V.I.improvers.
Synthetic fluids may be used in Eaton hydraulic components. Areputable fluid supplier can provide information on syntheticfluids. Review applications that require the use of syntheticfluids with your Eaton representative.
Viscosity Requirements
OptimumProduct Line
MinimumRangeHeavy Duty Piston60 SUS80 - 180 SUSPumps and Motors
[10 cSt]
[16 - 39 cSt]
Additional Notes:
•Fluids too thick to flow in cold weather start-ups will causepump cavitation and possible damage. Motor cavitation isnot a problem during cold start-ups, except for two speedmotors. Thick oil can cause high case pressures which inturn can blow motor shaft seals.
•When choosing a hydraulic fluid, all the components in thesystem must be considered and the optimum viscosityrange adjusted accordingly. For example, when a mediumduty piston pump is combined with a Geroler motor theoptimum viscosity range becomes 100 - 150 SUS [20 - 32cSt] and viscosity should never fall below 70 SUS [13cSt].
ISOCleanlinessMaximumRequirements
Comments
10,000 SUS18/13
[2158 cSt]
•If the natural color of the fluid has become black it ispossible that an overheating problem exists.
•If the fluid becomes milky, water contamination may be aproblem.
•Take fluid level reading when the system is cold.•Contact your Eaton representative if you have specificquestions about the fluid requirements of Eaton hydrauliccomponents.
15
Eaton CorporationHydraulics Division15151 Hwy. 5Eden Prairie, MN 55344Telephone 612/937-9800Fax 612/937-7130Form No. 7-404
Eaton Ltd.Hydraulics DivisionGlenrothes, FileScotland, KY7 4NWTelephone 44/1-592-771-771Fax 44/1-592-773-184ACCREDITED BYTHE DUTCH COUNCILFOR CERTIFICATIONReg. No. 24ISO-9001 CERTIFICATED FIRMDET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS Quality System CertifiedProducts in this catalog are manufacturedin an ISO-9001-certified site.Copyright Eaton Corporation, 1995All Rights ReservedPrinted in USA
因篇幅问题不能全部显示，请点此查看更多更全内容