START-UP PROCEDURE PROPEL PUMP

© Blue Graphics Concept Sauer-Danfoss


START-UP PROCEDURE PROPEL PUMP

InstructionSauer-Danfoss Belgium – T. Van Mossevelde

Know-How in Motion™ / Sauer-Danfoss 2

Example of propel setup

EXAMPLE:H1-pump + H1-variable motor• Reservoir screen 10 µm• Charge pressure filter


Start-up procedure

WARNINGUnintended movement of machine or mechanism may cause injury to

technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.

Prior to installing the units, check for shipping damage

Ensure that the hydraulic fluid and system components (reservoir,

hoses, valves and valve blocks, fittings, heat exchanger,... ) are

clean and free of contamination.

Install the different components

Add a measuring point (minimess) or 50-60 bar gauge on the

charge pressure port. (monitor charge pressure)

Check if line fittings are tightened properly

Do not connect input signal to servo control of pump

A) Preparation and installation


Start-up procedure

Mount connection for external filling pump on:• Integral charge pressure filtration: on point before filter (see schematic)• No charge pressure filtration: on measuring point M3 (pressure charge pump)

Hydraulic filling group (flow 1 to 20 l/min) must have a relief

valve that is set to 35-40 bar. This group must have a fine

pressure filtration !The charge pressure relief valve in the pump is set between 20 and 30 bar.

Filling of pumpcase will be ensured because oil will be directed to case when the pressure of filling pump exceeds

the charge pressure setting.

Start filling hydraulic circuit with clean and filtered oil untill oil is

visible through level glass in hydraulic tank.When high pressure system is filled, pressure from external pump will rise to level set at charge pressure relief

valve in propel pump. The pump case will be filled, followed by the drain line to cooler to tank...

If present, repeat this step for other propel circuits untill oil level

in tank is starting to rise.

B) Filling of hydraulic system with external pump (preferred method !!)


Start-up procedureB) Filling with external pump – charge pressure filter mounted

Charge pressure relief valve – filling oil to case and to tank when high pressure system is filled


Start-up procedure

Fill housings of pumps and motors by adding filtered oil in the

upper case drain ports.

Open the case plug on top of pump (or plug on highest position

of pump) to assist with air bleed.

continue filling untill oil is present Fill hydraulic reservoir completely with clean oil of

recommended type and viscosity. After some time, the oil level will lower due to gravity

Loosen suction line of charge pump to check if oil present.

if not, fill suction line completely or make sure that oil is

coming to avoid cavitation at inlet port of charge pump !

C) Filling of hydraulic system via hydraulic tank


Start-up procedure

Use a common method to disable the engine to prevent the engine from starting. Preferably: disconnect electrical connector (if present) from controller of

diesel engine. In some cases, it is possible to actuate the diesel engine start motor without starting the diesel engine. The pumps are rotated by start motor movement.

Crank the starter for several seconds

(do not exceed recommendation of engine manufacturer)

Wait for a minute (cool down start motor) and crank the engine

a second time

this operation helps remove air from system lines

Keep an eye on reservoir level refill untill recommended level

D) Starting diesel engine with start motor


Start-up procedure

Continue previous steps untill charge pressure on pump (or all propel pumps if present) reaches 3,5 bar.

Start diesel engine and let it run at idle speed for at least 30

seconds

work air out of system

When required charge pressure is reached at all pumps (20-30

bar), increase engine speed to normal operation rpm.

residual air out of system

Shut off the engine and connect control signal

E) Starting diesel engine


Start-up procedure

Start engine and check to be sure that the pumps remain in

neutral position

Increase engine speed to normal rpm and carefully check

forward and reverse control

Continue to cycle between forward and reverse for at least 5

minutes

purge air from system

Check if reservoir level is at required level

The system is now ready for operation

F) Initial movement of machine


Start-up procedure

Air entrapment in fluid under high pressure may damage

hydraulic components cavitation

Do not run at maximum pressure until system is completely free

of air and fluid has been filtered thorougly

Always ensure recommended fluid supply, as this may damage

hydraulic components when insufficient.

In case of contamination, immediatly stop working and build off

all affected components to check internal damage.

Flushing of complete system is necessary, oil samples need to

be checked when same oil is used after flushing the system.

Warnings



START-UP PROCEDURE OPEN CIRCUIT PUMP

Instruction LS/PC pumps Series 45Sauer-Danfoss Belgium – T. Van Mossevelde


Start-up procedure Series 45-pump

WARNINGUnintended movement of machine or mechanism may cause injury to

technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.

Prior to installing the units, check for shipping damage

Ensure that the hydraulic fluid and system components (reservoir,

hoses, valves and valve blocks, fittings, heat exchanger,... ) are

clean and free of contamination.

Install the components

Add a measuring point (minimess) in suction line (as close as

possible to pump inlet) and on case of pump (see schematic)

Check if line fittings are tightened properly

A) Preparation and installation


Start-up procedure Series 45-pumpB) Schematic example

S45 LS pump + PVG32 valve• Reservoir screen 125 µm• Return line filter + cooler• Reservoir: Minimum oil level should

be higher than the suction inlet port of the open circuit pump

• Drain line of pump case directly to tank, mounted on top of reservoir submerged under oil level



Pump installation position recommended under minimum oil level maintain low inlet pressure at all times

Suction line: short distance without corners if possible. Check fluid line speed for dimensioning diameter of suction line

Filtration

Suction filtration: 125 µm (150 mesh) screen

Do not use a suction filter element ! high pump inlet pressure

Return line of open circuit must be filtered: β10 = 10

See manual with id 520L0467 for more info about filtration

Oil fluid cleanliness: ISO 4406-1999 class 22/18/13 or better

Case drain line of pump case must be connected directly to tank, whitout a

filter, under the minimum oil level. Position must be as far away as

possible from pump suction line !

Use highest case drain connection (L1 or L2) of pump

Oil capacity of reservoir for open circuit: 1x to 3x pump volume

C) Installation guidelines



Inlet pressure Minimum continuous working: 0,8 bar absolute / - 0,2 bar Minimum at cold start: 0,5 bar absolute / - 0,5 bar

Case pressure Maximum continuous working: 0,5 bar above inlet Intermittent (cold start): 2 bar above inlet

D) Operation parameters

Difference between case pressure and suction pressure must be within specification at all times

Damage of pump when this condition is not fulfilled !

See catalogue: TI Series 45



Fill pump housing with clean oil at highest case drain port

Fill suction line completely with oil

Fill oil tank to suffient level

Check if suction line is bleeding to make sure that the oil is

present at the inlet port when loosening the inlet connection.

Loosen plug at highest point to purge air from system Use a common method to disable the engine to prevent the

engine from starting.

Keep an eye on reservoir level refill untill recommended level

The oil level will lower due to the filling of the open circuit functions (valve

blocks,...)

E) Start-up guidelines



Start diesel engine and let the diesel engine run at idle speed for a couple of minutes whitout actuating open circuit functions purge air from system

Check difference between pump case pressure and suction pressure (See section D)

In case of LS-system: purge air from LS-signal line by actuating one work function that is not building up pressure untill LS-signal line is filled completely with oil.

If pressures are correct at cold start, increase engine speed to normal rpm and carefully check all open circuit functions: Check for abnormal noise when high flow is delivered (avoid cavitation,...) Check case pressure and suction pressure

Suction pressure will drop when higher flow is requested ! specification

When these tests are ok, the pump is ready for operation

E) Start-up guidelines

START-UP PROCEDURE PROPEL PUMP

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