Bondioli & Pavesi HPP2 User manual

rev. 00 1
HPP2
HPP2 PUMP
Service Manual

rev. 00
2
HPP2
HPP2 PUMP PARTS OVERVIEW
(direct hydraulic piloting)

rev. 00 3
HPP2
HPP2 PUMP PARTS OVERVIEW
(electro-hydraulic piloting)

rev. 00
4
HPP2
Important Remarks
The following information refers to the situation as of 1st of December, 2007.
Descriptions, adjustment procedures and drawings contained are subject to updating, according to the
modifications made to the HP Hydraulic range.
HP Hydraulic reserves the right to modify products, setting and testing procedures without prior notification.
HP Hydraulic declines all liability for faults, accidents and tampering due to failure to observe the specifications
given in this manual or current safety standards, even if the latter are not explicitly mentioned herein.
HP Hydraulic declines all liability for errors contained in the present manual.
In the event of doubt, please refer to the HP Hydraulic central office for information.
Copyright: HP Hydraulic S.p.A. - December 2007 - printed in Italy.
Data reported in this document are not binding.
HP Hydraulic reserves the right to change specifications without notice.
Informations reserved to HP Hydraulic sales organization.
HPP2 pump with direct hydraulic piloting and swashplate
supporting bushings – cross sectional view

rev. 00 5
HPP2
Pump Startup
Take care of cleaning all machine parts that will contact hydraulic circuit fluid (tank, lines, heat exchangers,
filters, etc.). Be sure that nothing will obstruct normal pump suction (close faucets on suction duct, slack
connections that could cause air inlet into lines, etc.).
Assemble controlling gauges on the high pressure lines and on the pump low pressure circuit.
When filling, use filtered fluid at 10 microns, so as to prevent any dross getting into the system. Also new
hydraulic fluid may have some impurities. Fill tank and the other big capacity components (filters, heat
exchangers) with the fluid. Fill the pump and the hydraulic motor with oil through a drain port, and be sure that
casing is at least 50% full with it.
Machine start up must be done so as to allow the complete air elimination from the hydraulic circuit before
subjecting it to stress. For this purpose it is needed that machine shaft components can rotate freely and
without any load. If you are not able to disconnect mechanical shaft to moving parts it is possible, for example,
to lift the machine from the ground so that the shaft can rotate freely.
HPP2 pump with electro-hydraulic piloting and swashplate
supporting rollers cages – cross sectional view

rev. 00
6
HPP2
!!! IMPORTANT !!!
Do not run the pump and the hydraulic motor before filling them as specified in the previous
paragraph. Components can be seriously damaged!
Check that the pump is set to zero displacement.
Run the pump at minimum rpm (e.g. run diesel engine using only starter) until the boost pump begins to work
regularly. Regular charge pump working is shown by the manometer placed on the pump feeding circuit, that
will indicate a few bar minimum pressure. Now it is possible to start up diesel at minimum speed.
Operate with pump control lever in both directions, and check that controlled parts direction of rotation is
correct.
Run transmission until you are sure that all the air has been ejected and there is no mixture of oil and air.
Usually few minutes are sufficient.
Increase rotating speed and check that charge circuit pressure reaches a 18-20 bar value, and that
manometer vacuum on suction line does not exceed a 0.5 bar value with cold oil and 0.2 bar with warm oil.
Increase loading gradually, checking maximum working pressure by means of high pressure manometers.
Check continuously hydraulic fluid level in the tank during machine starting up and, if necessary, fill to proper
level.
Filtration
The selection of a filter depends on many factors, including contamination input rate and scheduled service
periods. Filters must be selected to meet the above requirements using rating parameters of efficency and
capacity.
Filter efficency may be measured using the .Beta. ßx-ratio, that is defined by ISO standard as the ratio of the
number of particles greater than a given size (x) measured in microns upstream of the filter to number of
particles greater than the same size downstream of the filter.
A filter with a ß-ratio within the range of ß15-20=75 (ß10 = 10) or better is typically required.
Since each system is unique, the filtration requirement for that system will be unique and must be determined
by test in each case. It is essential that monitoring of prototypes and evaluation of components and
performance throughout the test program be the final criteria for judging the adequacy of the filtration system.
!!! IMPORTANT !!!
Do all settings with warm oil, at a temperature of about 50°C. Avoid oil leaks and any environmental pollution,
even accidental.
!!! WARNING !!!
!!!!!!!!!!!!!!!!!!!!!!
Pay great attention to all moving machine parts, and observe all safety rules in force. Contact with moving
parts could result in serious injury or death.
Machine flushing
With “machine flushing” we mean the best possible elimination from the hydraulic circuit of all pollution in
hydraulic fluid and machine components.

rev. 00 7
HPP2
It is needed to flush machine when it is new and at time of complete overhauls, when replacing important parts
or destructive particles that can put into circulation some metallic dross.
Do flushing before you put the components under stress.
Use additional 3-10 microns filters and put them temporarily on tank return lines and on suction lines; their size
will be in accordance with requested capacities and pressures.
Operate drive so that repeated moves cause polluting dross removal from lines and hydraulic machine parts.
Flushing has to go on enough to make the whole hydraulic fluid pass through the filters for at least 15-20
times. When flushing ends, replace hydraulic fluid and remove additional filters.
TROUBLESHOOTING
Information contained in this section provides a guide to trouble shooting or malfunctioning hydraulic
components. So they are an useful instrument to eliminate some eventual easy solvable problems.
We know by experience thet we can summarize the problems we met till now in some main cases.
These cases have been charted in the following pages in form of flow charts.
Following the logical way illustrated by the diagram, there are showed step by step the checkovers to do and
adjustments or replacements of necessary components.

rev. 00
8
HPP2

rev. 00 9
HPP2

rev. 00
10
HPP2

rev. 00 11
HPP2