Columbia AA4VG71 User manual

Knowledge Base
Article Type: Instructions
Hydrostatic Pump, 40/50 HP for
Models, 50/60
WARNING
Never work on, clean or service this unit, control panel or any machine or open
or remove any protective cover, guard, grate, door, or maintenance panel until
the power or energy sources has been turned off, locked out / tagged out, and all
moving parts have come to a complete stop and or blocked to prevent
movement. Machinery is dangerous –avoid personal injury and or death by
following manufacture, Local, and OHSA safety procedures. Contact Columbia
Machine for safety decals, guards, horns and beacons.
Description:
Instructions on “How to” properly adjust the Hydrostatic Pump 40/50 HP,
“AA4VG71”. Adjusting relief valves, fine and course adjustments,
checking oil temperature, and pump itemized breakdown.

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HYDROSTATIC PUMP
HYDROSTATIC
40/50HP PUMP
AA4VG71
Columbia Machine, Inc.
Vancouver, Washington
HYDROSTATIC PUMP SYSTEM INFORMATION
This manual provides information applicable to the Columbia Block Machine
16HF/1600 manufacturing s stems equipped with the H drostatic drive.
CONTENTS
Adjusting Relief Valves ............................................................................... 2
Fine Adjustment ......................................................................................... 4
Course Adjustment ..................................................................................... 5
Preparation for Adjustment ......................................................................... 6
Charge Pressure Setting ............................................................................ 7
Removal & Installation of Shaft Seal ........................................................... 8
Checking the Oil Temperature .................................................................... 9
Pump Itemized Breakdown....................................................................... 10

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HYDROSTATIC PUMP
NOTE
NOTE
PROCEDURES FOR ADJUSTING THE HYDROSTATIC
40/50- HP VT CARDS, COURSE AND FINE ADJUSTMENTS
AND ACCELERATION AND DECELERATION HIGH
PRESSURE CROSS PORT RELIEF VALVES
If the vibrator is rolling over in the neutral position, no signal to
run vibrator or is offline, remove the electrical pin connector
from the E-P controller if the vibrator stops the problem is
electrical. Adjustment to the VT-2 K or VTVSPA1 electrical
card can be done after all manual adjustment have been
completed. (Refer to electrical card adjustments). To proceed
with relief valve settings if vibrator continues to roll over with
electrical pin connector disconnected you must first adjust the
fine null adjustment. Refer to fine and course null
adjustments before continuing with this procedure.
Adjustment to the VT-2 K or VTVSPA1 electrical card can be
done after all manual adjustment have been completed.
(Refer to electrical card adjustments)
To adjust the model AA4VG71 pump, follow the steps below:
All high pressure relief valve adjustments on sizes 71 and 9
to be done with a 11 mm box wrench and a 19 mm box
wrench. On 125 and 18 to be done with a 5 mm allen wrench
and a 17 mm box wrench.
For new pump replacement, check to ensure that the orifice
plugs in Port X1 and Port X2 have been removed. If orifice
plugs have not been removed, remove orifice plugs and then
proceed to acceleration/deceleration relief cartridge set-up.
1. Make sure you have a charge pump pressure of 35 psi on the center gauge (see
picture for location.
2. Standing at the opposite end of the pump main shaft thereare two relief cartridges.
The one on the right is for acceleration and the one on the left is for deceleration. .
Note: In some applications acceleration and deceleration may be opposite. These
cartridges can be adjusted without removing cartridges. (See picture for location)
3. The pump must be set statically with both pressure lines plugged. Remove the two
high-pressure lines from the vibrator motor and cap the two hydraulic motor fittings
and plug the two hoses. There should not be any electrical voltage leak influencing
the E-P controller so remove the electrical pin connector from the E-P controller coil.
4. First test the acceleration pressure by manually pushing the detent pin located on the
bottom of the E-P controller in the center of the coil. Hold for just a few seconds to
see what the maximum gauge pressure is reading on the acceleration gauge (see
NOTE

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HYDROSTATIC PUMP
picture for location). If you have no acceleration or deceleration gauge pressure,
check to make sure tow option has been disengaged. To disengage tow option,
loosen lock nut and turn tow option screw all the way out until it stops and lock the
lock nut down. (See picture for location.) Acceleration pressure is to be set at 35
psi. Deceleration set at 25 psi. If gauge reading is above 35 or 25 psi to
decrease pressure turn adjustment screw out counterclockwise. This may only
require a small adjustment of possibly 1/32 turn. For increasing pressure turn screw
in clockwise. (See relief cartridge below for adjustment locations.) Acceleration and
deceleration pressures can be noted at gauges hooked to Ma and Mb ports.
5. Stroke the pump to approximately 2 percent of full flow in one direction and adjust
the high pressure relief for that flow direction. Acceleration pressure at 35 relief
should begin to open. Deceleration set at 25 psi. For the AA4VG71 and AA4VG9
one turn equals 22 psi (15 bar).
6. Remember one complete turn clockwise on AA4VG71 and 9 equals 22 psi (15
bar).
7. Make sure that the POR valve is not in use for our application. Turn POR valve in
clockwise until it stops do not over tighten. Back off counterclockwise ¼ to ½ turn
and lock down.
Tow Option Engagement for AA4VG71 and AA4VG 0 (Use a 4mm allen wrench)
To actuate tow option turn tow option engagement screw (Ref. #4) out three turns. To
Disengage tow option turn tow option engagement screw in until it stops.
Perform step 4 as quickly as possible to prevent overheating
of the pump. Flow should not be permitted to spill over the
high-pressure relief valves for longer than 1 seconds,
especially at higher temperatures.
High pressure relief valve adjustments on size 71 and 9 to be
done with a 11mm box wrench and a 19mm box wrench, 125
and 18 to be done with a 5mm allen wrench and a 17mm box
wrench.
1
234
Relief valve for AA4VG71 and AA4VG90
1 - Nut used to torque relief valve into port block.
- Lock nut for high pressure relief adjustment.
3 - Adjustment screw for high pressure adjustment.
4 - Tow option engagement screw.
NOTE
NOTE

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HYDROSTATIC PUMP
FINE ADJUSTMENT
The only time fine adjustment would be made is if electrical pin
has been disconnected and vibrator is still slightly rolling over.
Look at the acceleration and deceleration gauges. These will be the two outside gauges.
You will notice that at this time one of the gauges will have a higher reading then the
other.
With electrical pin connector disconnect from EP controller insert flat tip screwdriver into
adjustment screw slot and hold adjustment screw from turning while breaking jam nut
loose. While making your adjustment watch the gauges and with very slight adjustment
right or left of the adjustment screw you will notice one of the gauges increase in
pressure. Turn the adjustment screw the opposite direction and the other gauge will
start to increase in pressure. Turn the adjustment screw back until both gauges read
the same pressure. At this time hold the adjustment screw and lock the lock nut down.
Again check the gauges to make sure pressure are the same. Some times it may be
necessary when locking down the lock nut you may need to slightly turn the adjustment
screw back so when locking the lock nut down your pressures will be equal.
At this time your vibrator should not be rolling over.
If the vibrator is still rolling over and you cannot equal the pressures on both gauges you
will need to make adjustment to the course adjustment to center the pump and then
return to the fine adjustment procedures again once you have completed the course
adjustments.
NOTE
For fine adjustment
jam nut and slotted
screw is located here.

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HYDROSTATIC PUMP
COURSE ADJUSTMENT
For course adjustment the following parts will be needed:
1. Two each ¼ inch 37 degree straight thread O-ring fittings.
2. One each ¼ inch hydraulic hose with two ¼ inch 37 degree straight female swivel
fitting on both ends. Length to be 1 inches long with hydraulic fittings.
Make sure pump is turned off and locked out before removing or installing these parts.
With the pumping unit locked out locate x1 and x2 ports and remove the O-ring plugs.
Install the fittings and attach the hose to the fittings installed in x1 port and x2 port. Make
sure all fittings are tightened down.
You are now ready to turn the pumping unit back on.
Following instructions below you will notice gauges installed in Ma and Mb ports these
are the two outside gauges which we refer to as acceleration and deceleration which
you will be reading for the following procedures. You do not have to plug port A or B due
to the EP controller not in use at this time.
With allen wrench install break jam nut loose. Turn adjusting screw in either direction
until you have 1 psi on one of the gauges. At position of allen wrench handle make a
mark below handle with pencil or black felt pen. Turn adjusting screw the opposite
direction until you read 1 psi on the other gauge. Note position of allen wrench handle
and mark below. Split the difference between the two marks, which should center the
pump. Lock jam nut down.
Turn pump off and lock out. Remove hose and fittings and install plugs back in x1 and x2
ports.
It may be necessary now to adjust your fine adjustment again. Follow steps for fine
adjustments on previous page.

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HYDROSTATIC PUMP
PREPARATION FOR ADJUSTMENT
The control piston has strong centering springs to ensure that once the pump is
adjusted for the neutral position it will always return to neutral. If an adjustment is
necessary follow the steps listed below.
To ensure there is equal pressure on both sides of the control module during the
centering operation, it is necessary to connect the X1 and X2 ports together by means of
hose or tubing (No less than a ¼ inch ID). The port sizes are as follows:
Size 289 7/16-2 UNF
Size 125 & 25 9/16-18 UNF
Pump Size Allen Wrench Wrench
2856 6 mm 19 mm
719 6 mm 24 mm
12525 8 mm 24 mm
With pressure gages installed at Ma and Mb, and with A and B ports blocked (or motor
stalled), and with the pump running loosen the jam nut. Turn the mechanical centering
adjusting screw until 1 psi is read on Ma or Mb then turn screw opposite direction
until 1 psi is read on other pressure port. Turn the screw back, splitting the distance
between the previous two positions. This should be the neutral position. Pressure on Ma
and Mb should be equal.
Tighten jam nut, stop the pump drive, remove the hose connecting ports X1 and X2.

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HYDROSTATIC PUMP
CHARGE PRESSURE SETTING
If you notice that you have no charge pressure at gauge check
the following. Turn unit off. Lock out pump and remove
inspection cover over coupler assembly that connects the
pump and electrical motor. Make sure that coupler has not slid
back or insert is not destroyed. When setting up coupler do
not force coupler halves together. Allow approximately 1/32
gap between each half and insert. After repairs have been
completed install inspection plate and unlock pump and turn
unit on. Check pumps charge pressure. Charge pressure
should be set at 35 psi to max 4 psi.
NOTE
Change Pressure Relief Valve Adjustment
For AA4VG28AA4VG56
With pressure gauge installed at G port
run pump at normal operating speed and
temperature. If pressure is low, remove
relief valve and add shim(s). If pressure
is high, remove relief valve and take
shim(s) out.
Note: 1mm=56.5 psi (3.9 bar)
For AA4VG71AA4VG25
With pressure gage installed at G port
run pump at normal operating speed and
temperature. If pressure is low loosen
jam nut and turn set screw clockwise. If
pressure is high loosen jam nut and turn
set screw counterclockwise.
Note: 1 turn = 55 psi (3.8 bar) for sizes
71 thru 125
Note: 1 turn = 43.5 psi (3. bar) for sizes
18 thru 25 .
Pump Allen Box Wrench
Size Wrench Wrench To Remove
28-56 N/A N/A 27 mm
71-125 5 mm 17 mm 27 mm
18 -25 5 mm 17 mm 32 mm
1. Adjustable charge pressure relief valve for sizes 71180.
. Shim charge relief for sizes 8 and 56.

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HYDROSTATIC PUMP
REMOVAL & INSTALLATION OF SHAFT SEAL
Remove the retaining ring with snap pliers
Screw in sheet metal screw into the holes fitted
with rubber.
Pull out shaft seal with pliers.
Press in shaft seal with bushing to the stop.
Then replace snap ring.

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HYDROSTATIC PUMP
CHECKING THE OIL TEMPERATURE
1. Maximum oil temperature should be 14 ºF (6 ºC).
2. The oil heater should be set to activate at an oil temperature below 1 ºF (37.8ºC)
If adjustments on temperature are needed remove heater cap
and set dial to desired temperature.
3. The oil cooler has a fixed thermostat that is activated when temperature reaches
11 ºF.
4. For cold weather start-up, always engage the vibrator several times to get the warm
oil circulating through the motor.
5. There is a high temperature cut off if the oil temperature rises above 15 ºF. This will
shut down the pump.
6. Check the oil temperature at least once per shift. Record the value to understand the
normal oil temperature. If the oil temperature is above normal the system may have a
problem.
Items to check:
 Is the cooler on? If not, check the thermostat it may have failed. Also check the
fuses. If the thermostat is good, check the oil cooler three phase lockout and the
start overloads and fuses. If all are good then check the oil cooler motor.
 Is the heater set too high or not shutting off? Remove the heater cap and check to
see what the temperature is set at.
 Acceleration or deceleration relief valves stuck? Check acceleration and deceleration
relief gauges. The pressure should drop off once the vibrator has started or stopped.
 Pump starting to fail? Check case drain line from pump to return header. If it is hot to
the touch, too much oil flow is passing through the case drain. Charge pump
pressure will drop off. Check the vibrator motor case drain. Check the high-pressure
filters. If plugged the filter indicators will show red. Change filters and reset filter
indicators by pushing the reset on the filter indicator. Check the charge pump filter. If
plugged, filter indicator will show red. Change filter and reset filter indicator. Check oil
for contamination. If oil smells burnt, replace with AW46 oil and change all filters. If
problem continues call the Columbia Service Department for assistance.
NOTE

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HYDROSTATIC PUMP
12
3
4
5
6
7
8
9
10
11
12
13
40/50 HP Hydro tatic Pump Unit
1. Oil Fill AW46
2. Tank Filter
3. Deceleration pressure return rom hydraulic
motor
4. Acceleration pressure out to hydraulic
motor
5. Case drain return rom hydraulic motor
6. Gate valve shut-o
12
3
4
5
6
1. Deceleration pressure (MA)
2. Charge pump pressure (G)
3. Acceleration pressure (MB)
4. Return ilter high pressure
5. Heat exchanger
6. Charge pump ilter
7. Return rom hydraulic motor
8. Tank Heater element
9. Tank suction line
10.Return rom high pressure ilter deceleration
11. To ilter rom (FE port)
12.Return rom ilter to (FA port)
13.Pressure to vibrator motor (MA)

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HYDROSTATIC PUMP
40/50 HP Hydro tatic Pump Unit
1. Pump case drain
2. Filter out to FA port
3. Filter in rom FE port
4. X2 Port
5. X1 Port
6. POR Valve
7. Null ine adjustment
1
23
4
5
6
7
1
2
3
4
5
7
8
1. Fan motor
2. Fan switch
3. Low oil
4. Over temperature
5. Electric pump motor
6. EP controller coils
7. Null course adjustment

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HYDROSTATIC PUMP
40/50 HP Hydro tatic Pump Unit
1. G port charge pump pressure
2. MB gauge port acceleration
3. MA gauge port deceleration
4. Null course adjustment
5. Detent pin override on EP controller valve
6. Acceleration relie cartridge
7. Deceleration relie cartridge
12
3
4
5
6
7

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HYDROSTATIC PUMP
1. Fan switch 125 degrees - Part # 2327616
2
.Low oil switch shut down - Part # 237089
3
.Over temperature 150 degrees shut down - Part # 232618
(2) Low Oil
(3) Over Temperature
(1) Fan Switch
High pressure
pump filter.
Heat exchanger
motor lock-out
Main pump
electric motor
lock-out
40/50 HP Hydro tatic Pump Unit

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HYDROSTATIC PUMP
Return Filter and
filter indicator
gauge.
Oil level sight gauge and oil
Temperature.
Oil tank reservoir
40/50 HP Hydro tatic Pump Unit