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p10v45 service / repair

1. The control adjustments should point to the inlet side of the pump Install the four 1 4 bolts not all will have lockwashers Torque to 10 FT LBS 9150 g 2188 2298 THRU 0 062X45 0 312 2 PLACES CENTER PERMISSIBLE 388 3 80 0 38 188 pe 9287 0 162 031X45 0200 F1101 SAE BB 92 859 3 00 DEEP 1 147 9 992 TOOL MARKS MAX R 62 Por 2 18 lan E F 1993 3 9150 0188 THRU 62x45 8512 2 PLACES CENTER PERMISSIBLE 30 KNURL 388 3 80 238 188 0 287 B J 0 162 H M 20 877 0 002 0 031X45 01200 01 544 SAE B 90859 300 DEEP 2 38 0 002 1 170 0 000 4 875 F 1093 1 TIRE TA 91 005 40 002 C F 1093 2 P ee Application Notes Piston Pumps Filtration Inlet e Use 100 mesh screen e Inlet filters are not recommended except for super charged systems Outlet e Filters either pressure line or return should be capable of keeping fluid cleanliness as follows Operating Pressure ISO Cleanliness lt 2000 PSI 18 16 14 2000 to 3000 PSI 17 15 13 gt 3000 PSI 16 14 12 Inlet Conditions e Check pumps drive speed against required inlet pressure e Make adjustments for altitude if necessary e Install pump below reservoir to assure flooded inlet when possible e f necessary install charge pump on auxiliary pad SAE A or B e Conditions must be met at lowest operating temperatures Case Pressure IMPORTANT e Use one case
2. A DELTA Q A A DELTA Q A DELTA Q A A DELTA Q A A DELTA Q A DELTA Q SERVICE P10V45 SERIES AXIAL PISTON PUMPS Plant Location and Mailing Address 10827 Tower Oaks Blvd Houston TX 77070 Website www deltag com Email info deltag com Phone 281 807 1840 or 800 650 3110 Fax 281 807 4457 12 2008 INTRODUCTION This service manual contains procedures for trouble shooting and repairing the DELTA Q LTD P10V45 series piston pump It does not include the controls see Control Service Manual for that information It is DELTA Q LTD policy to continually upgrade their products This may from time to time make some of the discussion in the repair manual not agree exactly with the compo nents you are looking at if a major change had taken place that would be reflected in the Model Number WARNING Before breaking a circuit connection make certain that power 19 off and system pressure has been released Lower all cylinders discharge all accumulators and block any load that might move and generate pressure PUMP DESCRIPTION The P10V45 series piston pump is open loop and axial in design Split flange and SAE O Ring Ports are available on either side or rear An SAE A amp B Mounting pad is available on the rear to drive a small pump The P10V45 pump may be driven by any source of power Diesel Gasoline Electric Plumbing is of the utmost importance to prevent cav
3. Plate to the Cover being sure it sits flat on the Cover Install the Spring onto the C Balance Piston lubri cate the C Balance Piston and Control Piston with 10W oil or Petroleum Jelly and install in on their posts Note If there was a stroke spacer it should be installed under the Control Piston here Grasping the Cover assembly using your fingers to hold the C Balance and Control Pistons in place install it onto the Adapter assembly noting the posi tion of the C Balance Post The C Balance Piston with the Spring should reside on the same side of the cam that has the two external holes discussed earlier Install the four 7 16 bolts with lockwashers Torque the bolts evenly to 55LB FT Turn the assembly onto it s cover Lubricate the seal inside and out with petroleum jelly Using a seal thimble install the seal The seal can be installed without a thimble but the shaft would need to be buffed at the leading chamfer with 600 grit paper before the shaft was assembled if not the seal could be cut at assembly Install with open end of Seal towards pump Drive the seal in place with a seal driver do not drive too hard there is no stop and the seal will be driven in to far Install the seal retaining ring Prepare to install the control shown are two configura tions there are many Note the positions of any exter nal orifices and return them to their original locations Not all controls have orifices
4. both held 10 place with Loc Tite 242 on the threads apply considerable CCW torque to remove Note the position of each relative to the Port Cover and note there are no O Rings THE CYLINDER BLOCK SHOULD ALWAYS BE DISASSEMBLED AND CLEANED A tool like this can be made from a 1 2 x 3 inch bolt m two nuts and a washer OD 1 21 with a flat ground rn on the washer to clear the retaining ring ears to com gp press the spring Or you can make one as shown as TLO008 in the tool section of this book CYLINDER BLOCK DISASSEMBLY CAUTION spring is under compression use care when removing With a tool to compress the spring snap ring pliers with the nose bent 90 and an arbor press compress the spring just enough to remove the retaining ring do not over compress the spring Pump Assembly Keep it clean Gather all the parts be sure they are clean Coat all rubbing parts such as Pistons Cylinder Block Spools Cam and Valve Plate with 10W oil Set up the adapter on a suitable base Be sure to note the location of the case drain ports Install the two 1 4 roll pinslif they were removed in the top of the adapter They can be driven in with a hammer Press in the shaft bearing cup using a suitable tool that allows bearing cup to seat against adapter bore Press the shaft bearing cone onto the shaft with a suit able tool Pay attention to the roller cage so it is not crushed during assembly The diameter
5. drain per pump 2 inch dia Minimum e Do not use filters or coolers in case drain lines e Case pressure must not exceed 7 PSI above inlet pressure Example If inlet pressure is 10 PSI case pressure must not exceed 17 PSI e 25 PSI maximum case pressure e Use upper most case drain port e Connect case drain below fluid level in side of reservoir e Run case lines in such a manner to prevent draining siphoning or air locking of fluid Compensator setting e Compensator settings are factory set but may be field adjusted e lf adjustments are necessary CW rotation will increase setting CCW rotation will decrease setting Load Sense Lines e Use of 1 4 O D steel or steel braid load sense lines may be required for stability if distance from pump to control valve is excessive e On load sense controls sense line must be connected to pressure for high pressure cut off to occur For low pressure standby the sense line must be vented to tank unless dynamic load sense pin 15 used then line may be blocked Start Up e Install required gages prior to filling pump with fluid to observe case pressure system pressure and inlet pressure to make sure it is within DELTA Q ratings e Check all fittings to be sure they are tight e Fill reservoir with filtered approved oil e Fill pump case with filtered system oil Make sure case is at least half full before start up Internal leak age will not provide enough lubrication if cas
6. ARINGS FOR SCORING AND WEAR REPLACE IF PRESENT ADAPTER BEARING BORE COVER BEARING BORE ASSEMBLY TORQUE ASSEMBLY BOLTS 4 EARLY DESIGN WITH GASKET ASSEMBLY BOLTS 4 CURRENT DESIGN WITH SEAL CONTROL AND COUNTERBALANCE POST CASE LEAKAGE AT 2500PSI AND 110 F CONTROL SET gt 3000PSI 0 190 MIN 0 147 0 010 MIN 0 005 MAX 0 020 MIN 0 6705 MAX 0 002 TIGHT 2 4404 MAX 1 7805 MAX 75 LB FT 55 LB FT 40 LB FT lt 0 75 GPM THESE SPECIFICATIONS ARE TO BE USED AS A GUIDE ONLY DISASSEMBLY AXIAL PISTON PUMP KEEP IT CLEAN The Axial Piston Pump is a precision machine with low tolerance for dirt and contaminants The real work in overhauling the pump begins before the pump is removed from its application Use commercial solvent or steam clean the pump and its fittings It is a common error to leave a hose open and drop it in the dirt Granuals of sand and dirt finding a way into the hose will destroy the pump no matter how clean your disassembly area may be PLUG THOSE HOSES Have hose plugs ready so that as each hose is disconnected it can be immediately sealed against dirt and dust Similarly each newly exposed opening and port In the pump should be sealed immediately with a plug If you have no plastic plugs use new clean rags but be careful that cloth fibers are not retained when the rag is removed Naturally the work area must be clean and well light ed Do not work on hydraulic pumps in a
7. IS 4000 BOTH CAN BE MODIFIED BY THE SHAFT RATING STAMP COMPLETE MODEL NUMBER HERE DEFINITION OF SERIAL NUMBER TAG JAN 2006 AND LATER IF CUSTOMER REQUEST SERIAL NUMBER STAMPED HERE Deere pr i DEFINITION OF SERIAL NUMBER ALL 7 DIGITS MUST BE STAMPED 40 N C 016 LOCATION OF ral Lage IS A SEQUENCE NUMBER AND 49 AUGUSTA STARTS OVER EACH MONTH 30 HOUSTON START AT 001 1 V4545B1B9CAYAR YEAR PUMP IS BUILT MONTH PUMP IS BUILT HODE AHER i MADE IN USA P 2006 A JANUARY 3000 300 po NOT USE I OR 0 DO NOT USE I OR 0 RESTART AT A AFTER USING Z IF CUSTOMER REQUEST A SETTING STAMP IT HERE TE 3000 FOR JUST A COMPENSATOR 3000 300 FOR COMPENSATOR AND STAND BY STAMP PRESSURE RATING OF THE PUMP HERE AP4 S ARE 3500 AND P1 V45 IS 4000 BOTH CAN BE MODIFIED BY THE SHAFT RATING STAMP COMPLETE MODEL NUMBER HERE TROUBLE SHOOTING This trouble shooting guide lists common problems encountered with piston pumps in hydraulic systems It indicates probable cause and remedies for each problem TROUBLE PROBABLE CAUSE REMEDY Excessive noise in Low oil level in reservoir Fill reservoir to proper level with recom pump mended fluid DO NOT OVERFILL Air in the system 1 Open reservoir cap and operate hydraulic system until purged 2 Bleed hydraulic lines at highest point downstream of pump while system is under pressure for obstructions and leaks pT Thick oil Empty and refill with correct oil Cold Weather Actuate h
8. e Loading Pins Place the spring on top of the washer just installed Using a tool that will allow you to compress the spring can be made from a bolt two nuts and a washer Compress the spring just far enough to install the retaining ring depressing it more will over stress the spring Assemble the rotating group as shown Lubricate the pieces with 10W oil before assembling Using a device such as an O Ring wrap it around the pistons this will hold the assembly together while it is installed into the adapter Turn the rotating group upside down and lower it into the adapter rotate it slightly to align the splines In the shaft with the splines in the cylinder block and pivot ring Now that the rotating group is assembled install the Molded O Ring to the top of the adapter lubricate the O Ring first to hold it in place Install the Bear ing Shim and Cone onto the Shaft oN lt FI WO Il M Install the C balance Post and Control Post Note the position of each the Control Post must be in the hole C BALANCE POST next to the Control Apply Loc Tite 242 Blue to the threads before installing torque to 40 LB FT Note these post do not require O Rings Press the bearing cup into the port cover Install the dowel pin next to the Control Post Lubricate the underside of the Valve Plate with petroleum jelly this will keep it in place while the cover is assembled Assemble the Valve
9. e is dry Pump must not run dry e Open any shut off valves between reservoir and pump e If the pump is used in a closed outlet system discon nect the outlet line until pump is primed and pumping fluid Pump must not be allowed to pump into a Closed system application until the pump has primed or damage to the pump will occur e Start prime mover and operate at minimum speed and minimum pressure until all air is purged from the pump Stop the prime mover and reconnect pump outlet hose then purge air from the system by starting the prime mover and operating control valve e Check fluid lines for leaks Inlet line must be air tight e Re check reservoir fluid level add if necessary e Cycle pump observe system pressure case pressure and inlet pressure to ensure that they fall within the pump rating Pump Rotation e Can be changed by installing opposite rotation cover and valve plate Application Assistance e Professional application and controls engineering assistance Is available e Complete the pump application form and contact DELTA Q WARNING e Failure to comply with any of these requirements and procedures will result in a voided warranty
10. eal Driver and Thimble to install the Seal Method to compress the Cylinder Block Spring Small fixture with three holes to assist installation of Loading Pins Needle Nose Pliers to install Loading Pins Arbor Press to install un install Shaft Bearings Round Tube to press bearings so not to damage the cage Using the wood block previously made secure the pump to it and then mount the wood block in a large bench vise Before starting to disassemble mark the relation between the cover and Adapter This will assure the pump will go back together correctly Remove the control and note the position of the gt fice s if present Note also that the adjustment points to the inlet side Loosen the four assembly bolts and remove the Cov er With the cover will come the Control Post and C Balance Post these post will not have to be removed further unless they are damaged Note the location of the Control and C Balance Post relation to the Adapter Now remove the loose pieces Valve Plate Bearing Cone Bearing Shim Dowel Pin Control Piston C Balance Piston with Spring and Molded O Ring Inspect the bearing for pitting the pistons for scor ing and the valve plate for cavitation and scoring Replace any of the components that show these signs of damage Remove the Cylinder Block Assembly If the Cylinder Block is going to be reused it should be disassembled to clean the spring chamber The spring chamber is a
11. itation at the inlet as well as compliance on the outlet In some applications super charging the inlet may be required The pump is rated for 4000 psi therefore the discharge piping must be capable of that pressure There are a variety of controls available such as pressure compensation load sense torque limiter and variations of these Controls are continually being developed so check with DELTA Q if a particular con trol 1s required RELATED PUBLICATIONS Installation dimensions for the P10V45 series piston pump and controls are not included in this manual Individual parts numbers are also not included Refer to the related publications that include this type of information Sales and Application includes installation drawings Theory of Pump operation Theory of Control operation Service Book pump this booklet Service Parts Book pump Approved Fluids DEFINITION OF SERIAL NUMBER TAG PRIOR TO JAN 2006 SERIAL NUMBER STAMPED HERE IF CUSTOMER REQUEST THEIR NUMBER STAMP IT HERE DEFINITION OF SERIAL NUMBER ALL 6 DIGITS MUST BE STAMPED 29 MC 16 DAY OF a t THIS IS A SEQUENCE NUMBER AND STARTS OVER EACH MONTH START AT 01 YEAR PUMP IS BUILT MONTH PUMP IS BUILT E 100 JANUARY DO NOT USE I OR 0 RESTART AT AFTER USING Z IF CUSTOMER REQUEST A SETTING STAMP IT HERE IE 3000 FOR JUST A COMPENSATOR STAMP PRESSURE RATING OF THE 3000 300 FOR COMPENSATOR AND STAND BY PUMP HERE AP40 S ARE 3500 AND P1 V45
12. low pressure area and collects contamination See the section at the end of the pump disassembly for Cylinder Block disassembly Remove the nine Pistons Return Plate and Pivot Ring as one unit Inspect the components for scratches scoring and wear replace if needed Inspect the bronze shoes for wear and rounding they can be reconditioned See the Work Specification page at the beginning of this book Remove the Cam and Shaft with bearing cone by grasping the end of the shaft and lift straight out Note the end of the Cam with two holes position relative to the Adapter mark the Adapter so it will go back in the same position Inspect the Cam face and journals for wear and scor ing The Cam face and journals have a thin hard sur face and cannot be reconditioned replace if worn or scored Inspect the bearing for pitting and replace if found Inspect the shaft for wear where the seal runs replace shaft if itis grooved Inspect the face of the pivot shoes and re face if needed Remove the two Cam Bearing Halves noting how the anti rotation tabs fit Inspect the surface of the bearings for scoring they can be refaced with 500 grit paper Turn the Adapter upside down with a suitable tool remove the seal Retaining Ring Using around bar 1 1 2 inch diameter and a Rub ber Hammer drive the Seal inward until it is free IF THE CONTROL OR C BALANCE POST IS DAMAGED IT MUST BE REPLACED They are
13. of the push ing tool needs to be smaller than the inside diameter of the cage See TLOO5 TLO06 and TLO04 in the tool section of this book If any of these components have been replaced the bearing pre load must be checked SHAFT PORT COVER ADAPTER SHAFT BEARINGS Required pre load is 0 002 0 003 Inch Using a base shim of 0 080 and a dial indicater load the shaft up and down while rotating read the maximum move ment Add that amount to the 0 080 shim plus required preload and grind a new shim to obtain Note required shim thickness for later use Install the Cam Bearings making sure the anti rotation tabs are positioned correctly in the recess Install the shaft with bearing cone Install the cam assembly paying attention to which end has the two holes this is the Counter Balance end The orientation of the cam should have been noted at disassembly Lubricate the two journals with petroleum grease before installing WITH CASE DRAIN HERE Make a tool to hold the three loading pins as shown here Slide this fixture into the spline from the neck end of the cylinder block not the inside This is not the only way to install the pins use what ever method works TL009 Install the three loading pins with a needle nose plier as shown rotate each pin so the lip on the pin 1s out ward Now install the washer there is only one onto the loading pins Be sure the Washer OD fits inside the three tabs on th
14. reas near welding operation The welding smog you can see in the air contains abrasives Do not disassemble a pump outdoors or in other areas open to wind or rapidly moving air which can carry dust or dirt It is not a good idea to smoke while overhauling the pump the ash in smoke is abrasive Some controls have a Load Sense Pin be careful not to lose the small piston when the hose is discon nected This piston has no retainer and 1s free to fall out on the ground DO NOT LOSE THIS PISTON It will be useful to have some small plastic bags handy so that small parts can be stored out of harms way Also a large plastic Garbage bag is ideal for covering the pump overnight if you cannot complete the overhaul in one day 45 0008 Because the pump is disassembled shaft down either bore al 1 2 inch hole in the work bench or prepare a wooden support block A support block can be a 2X4X8 inches long It should have a 1 1 2 inch hole for the shaft holes for the pump flange and some method of securing the block to the bench top such as a large vise TOOLS NEEDED TO OVERHAUL THE PUMP Torque Wrench capable of 55 LB FT Allen Wrench 1 2 for pump assembly bolts Allen Wrench 3 16 for control bolts Snap Ring Pliers Internal for Seal and Cylinder Block Soft Faced Hammer for driving the seal 500 Grit Paper to re face the Pistons and Cylinder Block and a lapping plate Tray of Mineral Spirits Solvent S
15. ydraulic system until pump is warm to the touch Pump overheating Internal leakage If determined that excessive case flow exists then return pump to maintenance shop for overhaul Heat exchanger Locate trouble and repair refer to not functioning machine manufacturers guide a Fluid level low Add oil to proper level determine cause System not Compensator malfunctioning Replace adjust or repair developing pressure MN High case flow Return to maintenance shop for repair mn Broken shaft Return to maintenance shop for repair valves not open Pump rotating in Correct by changing pump or drive wrong direction rotation CAUTION do not run in this configuration or damage will result Loss of fluid Failed hydraulic line Leaking pump seals or Check the O Ring between mating pump system seals surfaces shaft seal and system seals replace P10V45 SERIES WORK SPECIFICATIONS CAM NOTE THE CAM HAS A VERY THIN HARD COAT AND MAY NOT BE REFACED VALVE PLATE THICKNESS NOTE WATCH FOR CAVITATION CAUSED EROSION NEXT TO KIDNEYS AND HOLES THIS WILL NOT AFFECT PUMP PERFORMANCE BUT MAY INCREASE NOISE AND REDUCE LIFE CAVITATION SHOULD NOT BE PRESENT AND THE CAUSE SHOULD BE ELIMINATED PISTON ASSEMBLIES SHOE FLANGE THICKNESS SHOE FACE RECESS SHOE TO PISTON END PLAY CYLINDER BLOCK GROOVE DEPTH PISTON BORE DIAMETER SHAFT END PLAY BEARINGS INSPECT FOR GALLING AND OR PITTING IF PRESENT REPLACE INSPECT CAM BE

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