a

saue
 Open and Closed circuit
a Differences
• Swashplate functions on one side of
neutral - Always bias to full stroke
• Controlled with system pressure, not
charge pressure
• No charge system - Large end cap
inlet core for natural aspiration
• Cylinder block and valve plate
optimized for filling
a Product Scope

Series 45 is...
• Axial piston variable displacement
pumps for medium power open circuit
applications in mobile market
• Customer-driven design
• Current Displacements: 57 & 74 cc
• Designed and Manufactured in Ames
a Product Schedule
• 57cc Introduced in Early 1995
• 74 cc frame size
– Market Released - First Quarter 1999

• Torque control for 74cc in

development
– Targeting Late ‘00

• Additional displacements
– Various stages of development (Smaller
Displacements Initially)
a Market Applications

• Loader-backhoes • Graders
• Ag. tractors • Cotton pickers
• Wheel loaders • Combines
• Scrapers • Pavers
• Crawlers • R.T. forklifts
• Excavators • Planers
• Cranes • Aerial Lifts
a Competitive Products
• Vickers Discovery • Parker PAVC
– 57, 74 cc/rev – 65 cc/rev

• Rexroth A10VO • Oilgear PVG PVW

– Series 31 – 46, 63, 76 cc/rev
• 45, 71 cc/rev • Eaton 70423/
– Series 52 70523
• 45, 60 cc/rev – 45, 69 cc/rev

• Cassapa Plata • VOAC

• Commercial • Bosch
• Denison
a Design Comparisons
Series 45 57 cc Rexroth A10VO Vickers PVH
140%

120%

100%

80%

60%

40%

20%

0%

Number Threaded Number of

of parts Fastener Leak paths
Comparison
a Operating Parameters
• Displacement:
• 57cc/rev (3.48 CIR)
• 74 cc/rev (4.52 CIR)

• System Pressure:
• Continuous: 280 bar (4060 psi)
• Maximum (Peak): 350 bar (5075 psi)
– Less than 2 % of duty cycle

• Case Pressure:
• 0.5 bar (7 psi) maximum above inlet
• 2.0 bar (29 psi) maximum absolute
a Operating Parameters
• Inlet Pressure:
• Continuous: 0.8 bar (11.8 psi) absolute {23.2 in
Hg}
• Minimum: 0.5 bar (7.4 psi) absolute {14.8 in Hg}

• Speed (Dependent on Inlet Conditions):

• Minimum at 1 bar absolute inlet: 500 rpm
• Maximum at 1 bar absolute inlet:
57 cc = 2600 rpm, 74 cc = 2300 rpm
• Maximum at 1.5 bar absolute (charged):
57 cc = 3200 rpm, 74 cc = 2800 rpm
 Case Pressure
a
Requirements
• Must use full size case drain line
– 5/8” (16mm) I.D.
– Case spikes from PC transients (57 cc)
– Nothing else tied to case drain line
such as other drain lines, cooler, filter
– *Note- Max continuous case pressure
must not be greater than 3 bar (44 psi)
above inlet! (Pulled Slippers!)
a Control Options
• Controls:
– Pressure compensating (PC)
– Load sensing/pressure compensating
(LS)
– Remote pressure compensating
• Using externally mounted valves

– Torque (LT) in development

a Control Options*
• Pressure Compensator settings
– 100 to 280 bar (1450 to 4060 psi)
• Load Sense settings
– 10 to 30 bar (145 to 435 psi)
• Control Orifices
– Pilot Orifice (57 cc only, LS/LB Options)
• 0.8mm size, as required for system stability
– Bleed orifice (Flat on spool, LB Option only)
• Required to vent LS line or pump may go to PC setting
– Gain Orifice (57 cc only, all control options)
• Standard is 0.7mm
* Tamper resistent hardware, SB-9845
a Port Options

• Axial or Radial, 57cc & 74 cc

– Code 61 per SAE J518
– Suction: 2” SAE flange
– Pressure: 1” SAE flange
– Code 62 available upon request (74 cc
only)
– Oring boss (ISO or SAE) in development
(57 cc only)
a Housing Options

• Standard Front Flange

– SAE C 4 - bolt standard
• 57 cc Housing options
– SAE B 2 - bolt (diagonal)
– SAE B 2 - bolt - Available
Dec ‘99
a Options
• Auxiliary Flanges
– Standard SAE: A (9T or 11T), B, BB, C
– Full through torque
– With radial ported end caps
• Displacement Limiters
– Externally adjustable % of max. angle
a Shaft Options
• Shaft Seal (viton)
• Input Shafts
– 14 tooth 12/24 pitch
– 15 tooth 16/32 pitch (with SAE B flange
only)
– 1.25 inch tapered
– 1.25 inch straight keyed
– 17 & 21 tooth (74 cc only upon market
request)
a Section View
Servo
Piston
Swashplate

Bias
Piston
Bias
Bias
Guide
Spring
 Exploded View of Internal
a Parts
a 57 cc Control Cross Section
LS Control
Option

Load Sense (LS)

Adjustment
Pressure
Comp (PC)

Cartridge LS Signal Port (‘X’ Port)

w/ Pilot Orifice
 a
57 cc Exploded View External Parts
Servo Piston Load Sense (LS)
Gain
Assembly Control Kit
Orifice

Pressure Comp
Pilot Orifice
(PC) Control Kit

Bias Piston

Assembly
a 57 cc Control Design Features

• Cost Effective PC cartridge valve

– Simple assembly, service, and presetting
• Orifices accessible without removing
control
• Integral LS control
– Fast, direct communication to servo
– Small size
a
74 cc Exploded View Control Parts

Load Sense (LS)

Control Kit

Pressure Comp

(PC) Control Kit

a 74 cc Control Design Features

• Non-integrated control for easy

interchange to other controls
• Traditional two spool load sense control
– Simple design gives fast, direct
communication to servo
• Maximum stop on pressure comp. setting
a Pump Design Features

• One endcap for both rotations

• Only 4 bolts -- easier servicing
• Fewer parts -- 20% less than A10V,
25% less than PVH
• Fewer leak paths -- all O-ring seals
• Proven rotating kit
a Housing Design Details
• Swashplate cradles machined without holes
in side of housing resulting in:
– Increased stiffness
– Fewer leak paths
– Fewer parts
• Large case drains
– Minimize case pressure
• Controls directly adjacent servo
– Direct communication between control and
servo
a End Cap Design Details

• Inlet optimized for filling speed and to

minimize losses
• Short bolt span for less deflection
• One end cap for both rotations (rotate
180°)
• Pilots to end cap for
better alignment &
Improved bearing life
• Oring seal - no gasket
a Cylinder Block Design
Details
• Large kidneys for minimum entrance
losses
• Similar design to highest volume
closed circuit pumps
• Optimized for filling
a Valve Plate Design Details

• Large inlet opening for minimum flow

losses
• Pilots on bearing cup for alignment
• Optimized for efficiency (lapped
surface) and noise (fish tails)

CCW CW
a
Shaft & Bearing Design Details

• Timken tapered roller bearings

• Reduced shaft deflection/narrow span
leads to improved life
• Slip fit in front and rear
• Easy assembly/service
a Press. Comp. Applications

• Closed Center System

• When valve is in neutral, pump is near
zero displacement at PC pressure
• Valve meters flow to actuators
• Load on actuators determines system
pressure
• At outlet pressures below PC setting
the pump is at full displacement
 Press. Comp. Controls
a
Testing
•Pump at full flow when control not active
•Control brings swashplate out of stroke when system
pressure reaches the PC setting
Pressure Compensator Characteristic
40

35
Full Flow
Control causes
swashplate to
30
System Flow, Q, GPM

25
modulate at an angle
20
which maintains
15
system pressure at
10 the PC setting
5

PC Setting
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
System Pressure, PSI
 57 cc Press. Comp. Control
a Cross Section

-Set at 220 psi (Low

Pressure Stand-By)
 57 cc Pressure Comp.
a Control Schematic

B Port X PORT

BIAS
Remote Port

Plug

M4 Port

L1,L2 Ports S port

Gain Orifice (Optional)
 57 cc Pressure Comp.
a Control Diagram
‘X’ Port To Case

PUMP
OUTLET
PRESSURE

TO SERVO

Playme.exe PUMP OUTLET PRESSURE CONTROL PRESSURE

CASE PRESSURE SERVO PRESSURE
 57 cc PC with Load at
a Setpoint
‘X’ Port To Case

PUMP
OUTLET
PRESSURE

TO SERVO

PUMP OUTLET PRESSURE CONTROL PRESSURE

CASE PRESSURE SERVO PRESSURE
 74 cc Press. Comp. Control
a Cross Section
 74 cc Pressure Comp.
a Control Schematic
CONTROL
VALVE

B port

M2 port

Bias Servo
M4 Port

Gain Orifice
L1,L2 Ports S port
 74 cc Pressure Comp.
a Control Diagram

To Case

PUMP
OUTLET
PRESSURE

TO SERVO

PUMP OUTLET PRESSURE SERVO PRESSURE

CASE PRESSURE
 74 cc PC with Load at
a Setpoint

To Case

PUMP
OUTLET
PRESSURE

TO SERVO

PUMP OUTLET PRESSURE SERVO PRESSURE

CASE PRESSURE
a Typical Load Sense Application

• Closed Center System

• When valve is at neutral, pump is at
low pressure standby
• Pump delivers only the amount of
flow commanded by the LS signal
• If actuator stalls, pump goes to high
pressure standby
a Load Sense Controls Testing
• Pump can operate at any pressure and flow within the PC
setting and the maximum flow limit
• Pump control provides an amount of flow dependent on
the LS signal
Load Sensing Characteristic
40
• Flow provided is
35
Full Flow
independent of
30
load pressure and
pump input speed
System Flow, Q, GPM

25

20

15 50% Flow

10

PC Setting
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

System Pressure, PSI

 Load Sense (LS) Application -
a 57cc Shown

Pilot Line

Application
 Load Sense Operation
a Theory

LOAD
PRESSURE
CONTROL
HANDLE
VALVE /
ORIFICE

FLOW TO
SERVO
SYSTEM PISTON
PRESSURE

PUMP
 57 cc Load Sense Control
a Cross Section
Load Sense
Pilot Port
(‘X’ Port)
Pilot Orifice

Press. Comp.
Adjustment
Load Sense
Adjustment

Case Pressure

System Pressure
Servo Pressure
 57 cc Load Sense Control
a Schematic
CONTROL
VALVE
X PORT
B Port

BIAS
Remote Port

Bleed Orifice (LB

Control)Plug (LS Control)

M4 Port

L1,L2 Ports S port

Gain Orifice (Optional)
 57 cc Load Sense Control
a
Diagram
‘X’ Port To Case

PUMP
OUTLET
PRESSURE

TO SERVO
PC 57 LS.exe

PUMP OUTLET PRESSURE CONTROL PRESSURE

CASE PRESSURE SERVO PRESSURE
LS PRESSURE
a 74 cc Load Sense Control Cross
Section
‘X’ Port (Both Sides)
 74 cc Load Sense Control
a
Schematic
CONTROL
VALVE
X PORT

B Port

2 port Optional Spool

with Bleed Orifice

Bias Servo
M4 Port

Gain Orifice
L1,L2 Ports S port
 Pressure Setting Definitions
a (TS 338)
• Pump Load Sensing (LS) Margin is defined as
the delta pressure between the pump outlet and
the pressure at the ‘X’ port when the pump is at
50 +/- 10% of Maximum flow and 500 +/- 50 psi
outlet pressure
• Pump Pressure Comp (PC) is defined as the
pump outlet pressure minus the pump case
pressure when the pump outlet is blocked
(dead-headed)
• Pump 2nd Stage Setting for PC only control
(57cc only) is defined as the delta pressure
between pump outlet port and pressure at ‘X’
port when ‘X’ port is connected to tank
a Service Bulletins
• SB-9707 Addition of Brass Sleeve in the
Servo Bore
• SB-9708 Adapter Pad and Radial Ported
End Cap Change
• SB-9728 Incorporating a New LB Spool
• SB-9744 Max Displ. Limit Adjustment
Screw
• SB-9845 PC & LS Tamper Resistant
Hardware
a Published Literature
• Technical Manual BLN-10128
• Sales Brochure BLN-10127
• Service Parts Manual (57cc) BLN-2-41689
• Service Parts Manual (74cc) BLN-2-41699
• Service Manual BLN-10129
• Repair Instructions BLN-10130

-All Manuals & Instructions are updated to include 74cc;

Service Manual just sent to printer
a Any Questions?