10 Common hydraulics – 10.4.

2 Axial piston pump with variable displacement 23

Hydraulic oil pump, checking

page
–

NOTE
Read the safety instructions for oil before work, see Workshop
manual section B Safety.

1 Operate and warm up the machine so that the hydraulic oil reach-
es operating temperature, approx. 50 °C.
2 Turn off the engine.
3 Connect pressure gauge to test outlet on hydraulic oil pump 1.
4 Start the engine and let it idle.
5 Check the stand-by pressure for one pump at a time in the follow-
ing order:
Hydraulic oil pump 1: 2.9 MPa
Hydraulic oil pump 2: 3.0 MPa
The settings apply to standard machine, certain machines can
have higher stand-by pressure. For correct stand-by pressure,
1. Hydraulic oil pump 1 see pressure plate. However, the difference in pressure between
2. Hydraulic oil pump 2 the different pumps must always be maintained.
6 Increase engine speed to approx. 1100 r/min and run extension
function against end-position (overflow).
Run out the boom to max. and continue to request max. exten-
sion with the control lever. This results in overflowing of the ex-
tension function.
7 Check max. pressure on hydraulic oil pump 1, the pressure
should match the value on the pressure plate.
MPa All pumps shall give the same pressure. The order between the
pumps is of no importance.
MPa
8 Turn off the engine.
9 Transfer the pressure gauge to the next pump and repeat steps
3–8 on all four pumps.

MPa

MPa

MPa MPa MPa MPa MPa MPa MPa

A49195.0400

Supplement for Workshop manual DRF 400–450 DDRF05.01GB

24 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement,

page
–

change

NOTE
Read the safety instructions for oil before work, see Workshop
manual section B Safety.
1 Park the machine with the cab in its rearmost position and the
boom fully raised and extended halfway.

C AUTION
Make sure that the oil level in the hydraulic oil tank is
below the mouth of the axial piston pump's suction
hose.

If the premises do not permit the boom to be raised, the hydraulic

oil tank will have to be drained, seetab 10 Common hydraulics,
group 10.6.8 Hydraulic oil.
2 Disconnect the main power supply.
3 Depressurize the brake and hydraulic systems, see Workshop
manual section B Safety.
4 Disconnect the brake oil pump or cooling pump from the hydraulic
oil pump, depending on which pump is to be changed.
5 Suspend the gear pump.
6 Use a plastic bag or similar to protect the connection on the gear
pump.

DDRF05.01GB Supplement for Workshop manual DRF 400–450

 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 25

Axial piston pump 2 (left)

Axial piston pump 1 (right) 7 Mark the hydraulic hoses and disconnect them from the axial pis-
ton pump.

NOTE
Plug all connections immediately to protect the hydraulic
system from impurities.
8 Attach hoisting equipment to the axial piston pump.
9 Remove the axial piston pump.
Remove the retaining bolts and lift the pump away.
10 Clean the flange on the gearbox, removing all silicone remnants.

C AUTION
Be careful and make sure that no gasket remains fall
down into the transmission.

Gasket remains may fall into the transmission and

cause product damage.

11 Transfer the connection adapters to the new axial piston pump.

NOTE
Check that the O-rings are intact and fitted correctly.
12 Brush sealing silicone on the axial piston pump flange that faces
the transmission, see Workshop manual section F Technical da-
ta.
13 Fit the axial piston pump in place.
Place the axial piston pump so that the pump shaft engages the
transmission's gears. Install the attaching bolts.
14 Connect the suction hose to the axial piston pump.

Supplement for Workshop manual DRF 400–450 DDRF05.01GB

26 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump 2 (left)

15 Fill the pump with oil through the connections at the top.
Axial piston pump 1 (right)

Axial piston pump 2 (left)

Axial piston pump 1 (right) 16 Connect the hydraulic hoses to the axial piston pump in accord-
ance with the marking.

NOTE
Check that the O-rings are intact and fitted correctly.
17 Brush sealing silicone on the gear pump's sealing face against
the spacer ring, see Workshop manual section F Technical data.

The illustration shows a separate pump.

DDRF05.01GB Supplement for Workshop manual DRF 400–450

 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement 27

18 Fit the gear pump in place.

Place the gear pump on the axial piston pump and install the at-
taching bolts. Be careful so that the O-ring on the spacer ring is
located correctly and that the gear pump's shaft engages the ax-
ial piston pump's output shaft.
19 Vent the axial piston pump, see Workshop manual section 10
Common hydraulics, group 10.4.2 Axial piston pump with varia-
ble displacement.

C AUTION
The illustration shows gear pump preassembled on
Vent the axial piston pump before starting the engine.
hydraulic oil pump 1
The oil in the axial piston pump may cavitate and
cause product damage.

20 Close the drain valve and tighten the lock ring on the accumulator
charging valve.
21 Turn on the main electric power and start the engine.
22 Check that the hose connections and seal between gear pump
and axial piston pump are airtight.
23 Check the pump pressures, see Workshop manual section 10
Common hydraulics, group 10.4.2 Axial piston pump with varia-
ble displacement.

24 Check the oil level in the hydraulic oil tank. The oil level shall be
at the top of the level glass. Top up as needed.

NOTE
If the pump is replaced due to malfunction, change the oil
and filter in the hydraulic system as well.

C AUTION
Overfilling the oil.

Leakage and environmental damage.

The hydraulic oil level is checked with the boom com-

pletely lowered and retracted.

Supplement for Workshop manual DRF 400–450 DDRF05.01GB

28 10 Common hydraulics – 10.4.2 Axial piston pump with variable displacement

Axial piston pump with variable displacement,

page
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venting

NOTE
Read the safety instructions for oil before work, see Workshop
manual section B Safety.

1 Remove the hydraulic oil tank breather filter.

2 Connect compressed air at max. 10 kPa to the hydraulic oil tank's
connection for breather filter.

Axial piston pump 2 (left)

Axial piston pump 1 (right) 3 Loosen the hoses to the hydraulic system's feed from the axial
piston pump one at a time and let oil flow out. Tighten the connec-
tions when oil free of air flows out.
4 Remove the compressed air from the tank and fit the breather fil-
ter.
5 Turn on the main electric power and start the engine.
6 Let the engine idle for at least one minute. Check that all connec-
tions seal tight.
7 Lower the boom and raise it again very slowly so that the pump
operates under minimum load while air pockets are eliminated.
8 Turn off the engine.
9 Wash the engine bay.

DDRF05.01GB Supplement for Workshop manual DRF 400–450

 –
page
mm mm mm mm mm mm
1 2 3 4 5 6
C+ C-
C+ C- C+ C- 8

11
9 10
VA VA D VB
VA D T VB D T
17 ACC B 16 H
15 14
45 12
B1 A1 B2 A2 M
44 A
P H 46 PP 13
47
T H 10
11
E Schematics

LS

25
28
P M T
T T 29
P P
E Schematics – E Schematics

D 26
48 24
48 PSS PS 18
27
34 30

Supplement for Workshop manual DRF 400–450

1
40 36
2
3 23
E Schematics

33 392 1 20
43 3
33 X1 X1
19
33 T P
38 LS CF EF
42 LS
B1 B1
T PP 21
P
37 32 31
35 22
41
S L2 L1 S L2 L1

011306 [A40470.0400 ver 01]

Hydraulic diagram basic machine
29

DDRF05.01GB
30 E Schematics – E Schematics

1. Lift cylinder 25. Oil return from attachment

2. Valve block lift cylinder 26. Brake oil filter
3. Extension cylinder 27. Hydraulic oil filter
4. Valve block extension cylinder 28. Cooler hydraulic oil
5. Lift cylinder 29. By-pass valve hydraulic oil cooler
6. Valve block lift cylinder 30. Fine filter hydraulic oil
7. Accumulator brake pressure 31. Priority valve
8. Brake valve 32. Pump cooling and filtering of hydraulic oil
9. Parking brake caliper 33. Non-return valve
10. Brake cylinder 34. Pressure feed to attachment
11. Wheel brake 35. Hydraulic oil pump 3 and 4
12. Drive axle block 36. Shuttle valve
13. Make-contact declutch 37. Pump brake system
14. Make-contact brake light 38. Valve block top lift hydraulics
15. Make-contact parking brake 39. Shuttle valve
16. Accumulator charging valve 40. Unloading valve attachment
17. Breaking contact brake pressure 41. Hydraulic oil pump 1 and 2
18. Cooler brake oil 42. Pressure limiting valve
19. Thermal by-pass valve 43. Valve block pump unloading
20. Breather filter brake oil tank 44. Pressure reducer
21. Brake oil tank 45. Accumulator servo pressure
22. Breather filter hydraulic oil tank 46. Servo filter
23. Steering valve 47. Control valve lift and lower as well as extension
24. Steering cylinder 48. High pressure filter

DDRF05.01GB Supplement for Workshop manual DRF 400–450