Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual
Contents
1. 1 T P104 360 Bias spring and servo piston set swashplate position Cross section PC control P104 049 PC spool shifts to port system pressure to servo piston overcomes the force of the PC spring the spool shifts porting system pressure to the servo piston and the swashplate angle decreases When system pressure drops below the PC setting the PC spring shifts the spool in the opposite direction connecting the servo piston to pump case and the swashplate angle increases The swashplate is maintained at whatever angle is required to keep system pressure at the PC setting 520L0607 Rev AB March 2007 SAUER DANFOSS CONTROL OPTIONS continued Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Features LS control Typical load sensing control valve The LS control design matches pump O Load Return flow with system demand The LS control le presse senses the flow demand of the system Tank as a pressure drop across the External 5 Control Valve ECV As the ECV opens a d and closes the pressure delta across ta my the valve changes When opening the LA delta decreases When closing the delta increases The LS control then increases Load sense ones stem pressure pressure or decreases pump flow to the system until the pressure delta b2. Correct inlet pressure conditions 520L0607 Rev AB March 2007 17 S SAUER SYSTEM OPERATING HOT LOW PUMP OUTPUT FLOW PRESSURE OR FLOW INSTABILITY 18 Series 45 J Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Check fluid level in reservoir Description Insufficient volume of hydraulic fluid will not meet cooling demands of system Action Fill reservoir to proper level Verify proper size of reservoir Inspect heat exchanger Check air flow and input air temperature for the heat exchanger Insufficient air flow high input air temperature or undersized heat exchanges will not meet cooling demands of the system Clean repair or replace heat exchanger as required Verify proper size of heat exchanger Check external system relief valve setting Fluid passing through relief valve adds heat to system Adjust external system relief valve setting following manufacturer s recommendations External relief valve setting must be above PC setting for proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions Item Check fluid level in reservoir Description Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Action Fill the reservoir to proper level Hydraulic fluid viscosity above acce
3. ACTUATOR RESPONSE IS SLUGGISH Series 45 J Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Check fluid level in reservoir Description Insufficient hydraulic fluid causes cavitation Action Fill the reservoir to proper level Check for air in system Air in system causes noisy erratic control Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Improper inlet conditions cause erratic behavior and low output flow Correct pump inlet pressure vacuum conditions Refer to Hydraulic parameters page 10 Inspect shaft couplings A loose or incorrect shaft coupling causes excessive noise and or vibration Repair or replace coupling and ensure that correct coupling is used Check shaft alignment Misaligned shafts create excessive noise and or vibration Correct shaft misalignment Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Item Check external system relief valve setting Description Low external relief valve setting slows down sy
4. 3 9 16 28 34 68 Nem 25 50 Ibf ft Case drain port L1 0 300 bar 0 4351 psi ow 9 16 28 34 68 Nem 25 50 Ibfeft oi 2 P104 367E The LS setting is a differential pressure Subtract pilot pressure at port X from system pressure at port M1 to compute the actual setting PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 520L0607 Rev AB March 2007 21 SAUER DANFOSS SHAFT SEAL REPLACEMENT Caution Don t damage the pump housing or shaft Caution Premature bearing failure can result if the shaft seal contacts the shaft bearing Press the seal into the housing only far enough to clear the retaining ring groove 22 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Minor repair The Series 45 open circuit variable pumps use a lip type shaft seal You can replace this seal without major disassembly of the unit Replacing the shaft seal requires removing the pump from the machine Removal 1 Using the appropriate snap ring pliers remove the retaining ring K010 from the housing 2 Remove the shaft seal K020 from the bore in the pump housing and discard 3 Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal Sup RC ij ff y an V7 LE J l H S y Insta
5. Co OHG Postfach 2460 D 24531 Neum nster Krokamp 35 D 24539 Neum nster Germany Phone 49 4321 871 0 Fax 49 4321 871 122 Sauer Danfoss ApS DK 6430 Nordborg Denmark Phone 45 7488 4444 Fax 45 7488 4400 www sauer danfoss com
6. fittings gauges or components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 520L0607 Rev AB March 2007 5 SAUER DANFOSS SYMBOLS USED IN SAUER DANFOSS LITERATURE Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Introduction These symbols are in the illustrations and text of this manual They communicate helpful information at the point where it is most useful to the reader In most instances the appearance of the symbol itself denotes its meaning The legend below defines the symbol and explains its purpose A e ds e El g s UE WARNING may result in injury CAUTION may result in damage to product or property Reusable part Non reusable part use a new part Non removable item Option either part may exist Superseded parts are not interchangeable Measurement required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port 520L0607 Rev AB March 2007 LU B e Ee Deo a Ne RJ a Tip helpful suggestion Lubricate with hydraulic fluid Apply grease petroleum jelly Apply locking compound Inspect for wear or damage Clean
7. 126 0 137 7 156 0 162 6 180 Flow at rated speed theoretical US gal min 33 3 36 4 41 2 42 9 47 5 Input torque at maximum Nem bar 0 716 0 811 0 956 1 035 1 193 displacement theoretical Ibf in 1000 psi 436 9 495 1 583 6 631 4 728 1 Mass moment of inertia of kg m 0 00455 0 00455 0 00455 0 00433 0 00433 internal rotating components slug ft 0 00336 0 00336 0 00336 0 00319 0 00319 Axial ports kg lb 23 13 51 Weight e por g lb bu Radial ports 26 65 58 8 Rotation Clockwise Counterclockwise Mounting 2 bolt SAE B 4 bolt SAE C Auxiliary mounting SAE A SAE B SAE BB SAE C System ports type SAE R ring boss 4 bolt split flange System ports location Axial Radial Control types PC Remote PC LS LS with internal bleed Splined 13 tooth 14 tooth 15 tooth Shafts Tapered 0 31 75 mm 1 25 in 1 8 taper Straight 31 75 mm 1 25 in Displacement limiters N A Ratings Model Rating Units J45B J51B J60B J65C J75C minimum 500 Input speed continuous min rpm 2700 maximum 3240 310 continuous Working 4495 bar psi pressure 400 400 400 350 350 maximum 5800 5800 5800 5075 5075 g 226 226 226 226 226 External moment M Nem lbf in External shaft 2000 2000 2000 2000 2000 loads 2200 2200 2200 2200 2200 Thrust in T out Ta N Ibf 495 495 495 495 495 at 140 bar 2030 psi 29712 29712 29712 10755 10 755 at 210 bar 3045 psi 6834
8. 5 8 Ibf ft Using petroleum jelly to retain them install the 4 interface O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using the 4 screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Check and adjust the control setting See Adjustments page 20 520L0607 Rev AB March 2007 25 SAUER DANFOSS PLUG AND FITTING SIZES AND TORQUES 26 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Minor repair If any plugs or fittings are removed from the unit during service install and torque as indicated here This drawing is a composite Your configuration may differ but here is the appropriate wrench size and torque Plug locations sizes and torques J041 uu e 38inch 9 Yainch SS Z 55 135 Nm Z 27 47 Nem D 40 100 Ibf ft 20 35 Ibfeft P ii KO40A KO70A Sy K070 e 9 3 inch 55 135 Nm 40 100 Ibfeft E101 257 520L0607 Rev AB March 2007 SAUER Series 45 J Frame Open Circuit Axial Piston Pumps S DANFOSS Service Manual Notes 520L0607 Rev AB March 2007 27 SAUER DANFOSS OUR PRODUCTS Hydrostatic transmissions Hydraulic power steering Electric power st
9. 6834 6834 2474 2474 Bearing life B hours at 260 bar 3770 psi 3151 3151 3151 at 310 bar 4495 psi 1666 1666 1666 Mounting flange Vibratory continuous Nem Ibf in SAE C 1500 14 000 SAE B 735 6500 em Ibf in load moments Shock max SAE C 5600 50 000 SAE B 2600 23 000 1 Continuous input speeds are valid at 1 bar absolute 0 in HG vac inlet pressure Maximum input speeds require changing the inlet pressure or reducing pump displacement 520L0607 Rev AB March 2007 9 SAUER DANFOSS HYDRAULIC PARAMETERS 10 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications Inlet pressure Minimum pressure continuous 0 8 bar absolute 6 7 inches Hg vac at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 15 1 inches Hg vac Pressure compensator valve setting Minimum 100 bar 1450 psi Maximum 310 bar 3770 psi depending on displacement For more information refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information 520L0676 Case pressure Maximum continuous 0 5 bar 7 psi Above inlet Intermittent 2 bar 29 psi Cold start Hydraulic fluid Refer to Sauer Danfoss publication Fluids and Filtration BLN 9887 or 520L0463 For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465 See Fluid and filter maintenance page 16 for recommended fluid and filt
10. External relief valve must be set above PC setting to operate properly Inspect PC control spring Broken damaged or missing spring will cause erratic operation Replace the spring as required Inspect PC spool for wear Wear of PC spool causes internal leakage in the control Replace the spool as required Inspect PC spool for proper orientation Improper orientation results in poor operation Correct orientation of spool Check PC control for contamination Contamination may interfere with movement of the PC spool Clean PC control components take appropriate action to eliminate contamination Item Check fluid temperature Description Low temperature increases viscosity High fluid viscosity causes high inlet vacuum Action Allow system to warm up before operating Inspect inlet screen Blocked or restricted inlet screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Too many fittings bends or long piping causes high inlet vacuum Eliminate fittings to make path more direct Hydraulic fluid viscosity above acceptable limits High fluid viscosity causes high inlet vacuum Select fluid with appropriate viscosity for expected operating temperature See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 520L0607 Rev AB March 2007 19 SAUER DANFOSS
11. PC CONTROL A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 20 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Adjustments PC setting is indicated in the pump model code Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual 520L0676 for more information Before performing adjustments read page 14 Pressure measurement 1 Install a pressure gauge in port M1 to measure system pressure Install a pressure gauge in case drain port L1 or L2 to measure case pressure 2 Start the prime mover and allow fluid to reach normal operating temperature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 3 Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 Clock
12. shown Remove the shipping cover or auxiliary pump and its seal J120 2 Remove the drive coupling J140 if present 3 Remove the 4 screws J100 retaining the pad adapter J080 to the endcap Discard the pad adapter O ring J090 if present Also discard the J095 O ring Auxiliary mounting pads J095 TS 8mm 2 48 5 61 Nem 35 45 lbfft 6 O NS J110 W o Ss Jiao Secus 48 5 61 Nem 35 45 Ibf ft 3110 O sinch 2 38 50 Nem 27 37 Ibf ft E101 256 Installation 4 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 5 Install the 4 screws J100 and torque to 48 5 61 Nem 35 45 Ibfeft 6 Install the drive coupling J140 if present 7 Install shipping cover or auxiliary pump with seal J120 0 8 Install the screws J130 and torque to 94 115 Nem 67 82 lbfeft If you have an auxiliary A pad install the screws J130 and torque to 37 50 Nem 27 37 Ibf ft 520L0607 Rev AB March 2007 23 SAUER DANFOSS CONTROL 24 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly LE Remove the 4 screws C300 holding the control housing onto the end cap Remove the control and discard the 4 interface O rings C200 Remove the PC set screw C102 PC adjusting plug C138 O ring C138A springs C134 C135 and s
13. A i 14 Place the two PC springs C134 8 10 Ibf ft C132 8 C135 onto the spring guide C133 A and install into the PC bore Place ge page a new O ring C138A onto the glci 3 g Osinch PC adjusting screw and thread it A MUN into the PC bore until flush then B 10 Ibf ft make another full turn Install and ii C105A torque the PC set screw C102 to C102 7 5 10 8 Nem 5 5 8 Ibf ft IW 106A G mm C106 2 7 5 10 8Nem For PC only controls skip steps 15 3 6 inch 5 5 8 Ibfeft through 17 2 10 8 13 5 Nem cago S b amp 8 10 bff S 15 Install the LS spool C112 spherical eis gres C300 end first into the LS bore Using En c9 j4 mm a new O ring C105A or C106A Z 5 4 7 5 Nm install the plug C105 or C106 C 4 8 ca 4 5 5 Ibfft Torque the plug C105 or C106 to BlcnsB e z z 10 8 13 5 Nem 8 10 Ibf ft Sicns e 1384 i Wicuss o dii Ls 16 Using a new O ring C1044 install Ericus the plug C104 Torque the plug to P E101 226 17 18 19 20 SRI ORE LS control shown parts C104 through C106 and Place thetwols springs C114 C115 C112 through C118 are not used on PC control onto the spring guide C113 and install into the LS bore Place a new O ring C118A and back up rings C118B onto the LS adjusting screw and thread it into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5
14. ANFOSS ADJUSTMENTS MINOR REPAIR Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Contents Paroni o EE EEE RR RETE ET 20 US CONTON PR TRONER EEEREN 21 Shaft Seal replacement pinerang rans ti aiaia iana ea Ri iasi 22 Removal Installation Auxiliary pads R MOVA AAEE AATA TE A A EE A TOEA ei nes Installation CIMCON AAPEEE AAEN A AEEA T IE EA AE AEA AEE E M Disassembly Inspection REASSEMMDIY em Plug and fitting sizes and torques eterne tenent ttennnttnnnntttnnnittnnntttennnitenn 26 520L0607 Rev AB March 2007 SAUER DANFOSS OVERVIEW SAFETY PRECAUTIONS Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Introduction This manual includes information for the installation maintenance and minor repair of the Series 45 frame J open circuit axial piston pumps The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures Performing installation maintenance and minor repair of Series 45 J frame axial piston pumps according to the procedures in this manual will not affect your warranty Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanli
15. C118 are not used on PC control Remove the C104 plug C104A O ring and C112 LS spool from the control housing discard the O ring Note orientation of the spool for reassembly Inspect the adjusting plugs for wear at the tips and where they contact the springs Inspect the springs and spring guides for wear or damage replace as necessary 10 Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 11 Inspect the control housing for damage Check the spool bores for excessive wear 12 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0607 Rev AB March 2007 SAUER DANFOSS CONTROL continued Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Reassembly Control assembly 13 Install the PC spool C132 spherical ee end first into the PC bore Using a Gl 3neinch new O ring C103A install the plug x C103 Torque the plug C103 to C104 un po 10 8 13 5 Nem 8 10 Ibfeft 3s inch 2 10 8 13 5 Nem 9 CI03
16. DANFOSS RECOMMENDATIONS 16 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Fluid and filter maintenance To ensure optimum life of Series 45 products perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Water in the fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Change the fluid and filter per the Fluid and filter change interval vehicle machine manufacturer s Reservoir type Maximum change interval recommendations or at these intervals Sealed 2000 hours Breather 500 hours Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater that the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replace all fluid lost during filter change 520L0607 Rev AB March 2007 S SAUER EXCESSIVE NOISE AND OR VIBRATION
17. P104 362 520L0607 Rev AB March 2007 7 SAUER DANFOSS SYSTEM CIRCUIT Pictorial circuit diagram Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Introduction The pump receives fluid directly from the reservoir through the inlet line A screen placed in the inlet protects the pump from large contaminants The output of the pump is directed to a PVG 32 multi section load sensing directional control valve which directs fluid to the actuators in the system Fluid returning from the system is cooled by a heat exchanger and cleaned by a filter before returning to the reservoir The speed of the actuators in the system depends on the volume of fluid being provided by the pump The operating pressure varies depending on actuator load but is limited to an adjustable maximum setting by the PC section of the pump control and by a system relief valve integrated into the side module of the PVG valve The position of the PVG valve sets the demand for flow in the system and communicates this to the pump control by means of a hydraulic signal load sense signal The pump will provide as much flow to the system as it demands while limiting the maximum pressure Therefore flow and pressure in the system are compensated to meet requirements Naz gt Double acting cylinder J Frame Series 45 open circuit axial piston pump with load sensing control PVG 32 multi
18. SAUER Series 45 DANFOSS bas Open Circuit Axial Piston Pumps Service Manual SAUER Series 45 J Frame Open Circuit Axial Piston Pumps S DANFOSS Service Manual Revisions HISTORY OF REVISIONS Table of Revisions Date Page Changed Rev March 2007 21 typo in illustration set screw torque is 7 5 10 8Nm AB 5 5 8 Ibfeft May 2005 First edition A 2007 Sauer Danfoss All rights reserved Printed in U S A Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations aren t in conflict with agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group Front cover illustrations F101 478 F101 480 F101 479 P101 854 2 520L0607 Rev AB March 2007 SAUER DANFOSS INTRODUCTION TECHNICAL SPECIFICATIONS FEATURES PRESSURE MEASUREMENT INITIAL START UP PROCEDURES FLUID AND FILTER MAINTENANCE TROUBLESHOOTING Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Contents OWEN CW E EE AE E E ouesespdaasueds ia sanussesseucssaransasceastoeters Safety precautions ss Unintended machine movement Flammable cl
19. area or part Be careful not to scratch or damage Note correct orientation Mark orientation for reinstallation Torque specification Press in press fit Pull out with tool press fit Cover splines with installation sleeve Pressure measurement gauge location or specification SAUER DANFOSS GENERAL DESCRIPTION Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Introduction Sauer Danfoss Series 45 J frame open circuit piston pumps convert input torque into hydraulic power Rotational force is transmitted through the input shaft to the cylinder block The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block A lip seal at the front end of the pump prevents leakage where the shaft exits the pump housing The spinning cylinder block contains nine reciprocating pistons Each piston has a brass slipper connected at one end by a ball joint The slippers are held to the swashplate by the spring retainer and block spring The block spring also holds the cylinder block to the valve plate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation Via the valve plate one half of the cylinder block is connected to pump inlet and the other half to pump outlet As each piston cycles in and out of its bore fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the sys
20. arning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Adjustments The LS setting is indicated in the pump model code Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual 520L0676 for more information Before performing adjustments read page 14 Pressure measurement 1 Install a pressure gauge in port M1 to measure system pressure Install a pressure gauge in drain port L1 or L2 to measure case pressure Tee in a gauge to the LS remote PC signal line port X 2 Startthe prime mover and allow fluid to reach normal operating temperature Slowly operate a hydr
21. aulic function that will demand approximately half flow from the pump but keep system pressure below the PC set point 3 Loosen the LS set screw While watching the pressure gauges turn the LS adjusting plug until the desired pressure differential between port M1 and port X is achieved Clockwise rotation increases the setting counterclockwise rotation will decrease it approximate gain 17 bar 250 psi per turn 4 While holding the position of the LS adjusting plug torque the LS set screw to 7 5 10 8 Nem 5 5 8 lbfeft 5 Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 6 Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M12 Clockwise rotation increases pressure counterclockwise rotation decreases it approximate gain 42 bar 610 psi per turn 7 While holding the position of the PC adjusting plug torque the PC set screw to 7 5 10 8 Nem 5 5 8 lbfeft 8 Stopthe prime mover remove the pressure gauges and return the system to its normal operating configuration LS control adjustment Gauge port M1 0 300 bar 0 4351 psi 9 16 28 34 68 Nem 25 50 Ibf ft LS remote PC signal port X LS set screw 0 300 bar 0 4351 psi 9 16 28 Z 7 5 10 8 Nem 5 5 8 Ibf ft Bole LS adjusting plug D 0 300 bar 0 4351 psi
22. eaning solvents Fluid under pressure rene ETE Symbols used in Sauer Danfoss literature G n ral description S y melo AA AA E O EEA General specication S ssanie Hydraulic parameters sn Inlet POSSUM samedis Pressure compensator valve setting Case pressure Hydraulic fluid Temperature TANGO hisser Fluid viscosi t Slice Auxiliary mounting PAS urnes 11 deeem M Control options ciue EE C EE E EEE EOE A OE A OERE dera LS CONTO pete ERN R quired toOlS ss c 14 Port locations and gauge installation 14 irl 15 Start up procedure mener 15 RECOMIME MG rs Milo eR RR 16 Excessive noise and or vibration nn 17 Actuator response is sluggish nn 17 System operating hot sienne rettet ttti ieri noire rii rehenes reet etude L w PUM POUT DUET OW er Eataa Pressure or flow instability js System pressure NOt reaching PC setting nn 19 Hig inlet Vag iumssssssssssmnrnnmnnnnmmanennRanannnennnennne 19 520L0607 Rev AB March 2007 3 SAUER D
23. eat C133 Discard the O ring Remove the plug C103 O ring C103A and PC spool C132 from the control housing Discard the O ring Note orientation of the spool for reassembly For PC only controls skip steps 5 through 7 5 C105A or C106A 6 Remove the LS set screw C102 LS adjusting plug C118 O ring C118A back up rings C118B springs C114 C115 and seat C113 Discard the C118A O ring Js Inspection 8 replace as necessary 9 Remove the plug C105 and O ring C105A or the plug C106 and O ring C106A Discard the O ring Control assembly C103 3h6 inch C104 10 8 13 5 Nem 8 10 Ibfeft 36inch oo 2 10 8 13 5 Nem C103A 1 8 10 Ibf ft c2 8 m C104A 9 ioe m d Bici 36 inch A 7 10 8 13 5 Nem Mi C105A 8 10 Ibf ft 3 C106A c C106 y Z 7 5 10 8 Nem hs inch 5 5 8 Ibfeft 2 10 8 13 5Nem lt 260 FE AN 8 10 Ibfft SS C300 C113 amm C115 e E B 2 5 4 7 5Nem C14 4 5 5 Ibfeft il C118B e SIci18A e it C118B e fac TE E101 226 LS control shown parts C104 through C106 and C112 through
24. ecomes equal to the LS setting as defined by the LS Pressure drop across external control valve defines system demand adjusting plug 7 and spring 8 The LS control consists of two spool valves that connect the servo piston Cross section LS control either to pump case or system pressure The PC spool 6 controls the pressure LS spring compensating function of the control LS adjusting as previously described The LS spool 9 plug controls the load sensing function The ih adjusting PC spool has priority over the LS spool p ug Spool Spring Through internal porting system Spring PC heavy guide pressure upstream of ECV is applied to the non spring end of the LS spool and through hydraulic line connected at port X LS pressure downstream of ECV is applied to the spring end This arrangement allows the LS spool to act on the delta between system pressure and LS pressure The LS spring sets the threshold of operation LS setting P104 051 LS spool shifts to port system pressure to servo piston Because the swashplate is biased to maximum angle the pump attempts to deliver full flow to the hydraulic system When the flow being delivered exceeds demand the pressure delta across the ECV is great enough to overcome spring force and shift the LS spool porting system pressure to the servo piston The pump de strokes reducing flow until the delta across the ECV becomes equal to the LS settin
25. eering Electrohydraulic power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Orbital motors Transit mixer drives Planetary compact gears Proportional valves Directional spool valves Cartridge valves Hydraulic integrated circuits Hydrostatic transaxles Integrated systems Fan drive systems Electrohydraulics Microcontrollers and software Electric motors and inverters Joysticks and control handles Displays Sensors 520L0607 Rev AB March 2007 Sauer Danfoss Mobile Power and Control Systems Market Leaders Worldwide Sauer Danfoss is a comprehensive supplier providing complete systems to the global mobile market Sauer Danfoss serves markets such as agriculture construction road building material handling municipal forestry turf care and many others We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them Sauer Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design Sauer Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world Sauer Danfoss US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Fax 1 515 239 6618 Sauer Danfoss GmbH amp
26. er change intervals Temperature range Intermittent cold start 40 C 40 F Continuous 82 C 180 F Maximum 104 C 220 F Fluid viscosity Viscosity limits Rating mm s cSt SUS minimum 9 58 v continuous maximum 110 500 minimum 6 4 47 vintermittent maximum 1000 4700 cold start Filtration Required cleanliness level ISO 4406 Class 18 13 or better Refer to Sauer Danfoss publications Fluids and Filtration BLN 9887 or 520L0463 and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465 See Fluid and filter maintenance page 16 for recommended fluid and filter change intervals 1 Hydraulic fluid viscosity must be maintained within the prescribed limits As measured at the hottest point in the system e g drain line 520L0607 Rev AB March 2007 SAUER DANFOSS AUXILIARY MOUNTING PADS INPUT SHAFTS Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Features Auxiliary mounting pads are available for Auxiliary pad options all radial ported Series 45 pumps These pads are typically used for mounting auxiliary hydraulic pumps Since the auxiliary pad operates under case pressure an O ring must be used to seal the auxiliary pump mounting flange to the pad The drive coupling is lubricated by oil from the main pump case For details refer to Series 45 J Frame Axial Piston Open Circuit Pumps Tech
27. g When flow being delivered is less than demand the delta across the ECV drops below the LS setting and the LS spring shifts the spool connecting the servo piston to pump case The pump strokes increasing flow until the delta across the ECV becomes equal to the LS setting When the external control valve is placed in neutral it connects the LS signal line to drain With no LS pressure acting on the non spring end of the LS spool the pump adjusts stroke to whatever position necessary to maintain system pressure at the LS setting The pump is now in standby mode Because of the series arrangement of the LS and PC spools the PC spool will override the LS spool If at any time system pressure reaches the PC setting the PC spool will shift blocking the passage that connects the LS spool with the servo piston and porting system pressure to the servo piston causing the pump to destroke 520L0607 Rev AB March 2007 13 SAUER DANFOSS REQUIRED TOOLS PORT LOCATIONS AND GAUGE INSTALLATION 14 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Pressure measurement The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown Calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges The illustration below shows gauge port locations Recommended pressure gauges and fittings are in the table Gauge and port inf
28. llation 4 Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Shaft seal and retaining ring _ K010 E101 187 5 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation 6 Keeping the seal perpendicular to the shaft press the new seal into the housing just far enough to clear the retaining ring groove O Install seal with the cupped side toward the shaft bearing Do not damage the seal during installation 7 Using the appropriate snap ring pliers install the seal retaining ring 8 Remove the installation sleeve 520L0607 Rev AB March 2007 SAUER DANFOSS AUXILIARY PADS Caution Shipping cover is intended only to retain coupling during shipment and storage Do not operate pump with coupling and shipping cover installed C34 inch Q sP 2 91 111 Nem J120 67 82 Ibf ft Q Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Minor repair You may install auxiliary mounting pads on pumps equipped with through drive radial ported endcaps Follow these steps to either remove replace or exchange auxiliary mounting pads Removal 1 Remove the screws J130 retaining the cover plate J110 or auxiliary pump not
29. ness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Sauer Danfoss Authorized Service Centers ASCs is available for major repairs Major repairs require the removal of the unit s endcap which voids the warranty unless done by an ASC Sauer Danfoss ASCs are trained by the factory and certified on a regular basis You can locate your nearest ASC using the distributor locator at www sauer danfoss com Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take these general precautions whenever servicing a hydraulic system Unintended machine movement A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses
30. nical Information 520L0676 P104 361 Series 45 J frame pumps are available with a variety of splined straight keyed and tapered end shafts For information on shafts refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information 520L0676 520L0607 Rev AB March 2007 11 SAUER DANFOSS CONTROL OPTIONS 12 Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Features The Series 45 Frames J have two possible control options a Load Sensing LS control with Pressure Compensator PC or a PC only control Operation General The bias spring 1 pushes against the servo piston 2 which pulls the swashplate 3 to max angle causing the pump to stroke Internal pressure on the servo piston acts against the bias spring to reduce the swashplate angle causing the pump to destroke Swashplate angle determines pump outlet flow The pump control depending on conditions in the system circuit sets swashplate angle by metering system pressure to the servo piston PC control The PC control design maintains a constant pressure in the hydraulic circuit as flow varies The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as the PC adjusting plug 4 and spring 5 defines When system pressure acting on the non spring end of the PC spool 6 Cross section pump 2 3 rer
31. ormation Port Purpose Range of gauge Fitting M1 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting L1 L2 Case drain port 0 10 bar 0 100 psi 7 8 14 O ring fitting 7 16 20 O ring fitting X LS signal 0 300 bar 0 5000 psi tee into LS signal line P104 364 520L0607 Rev AB March 2007 SAUER DANFOSS GENERAL START UP PROCEDURE Caution Incorrect shaft alignment may result in damage to drive shaft bearings or seal which can cause external oil leakage Series 45 J Frame Open Circuit Axial Piston Pumps Service Manual Initial start up procedures Follow this procedure when starting up a new Series 45 installation or when restarting an installation in which the pump has been removed A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Prior to installing the pump inspect for damage incurred during shipping Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 1 Connect the pump to the prime mover Ensure that pump shaft is properly aligned with the shaft of the prime mover 2 Fill the reservoir with recommended hydraulic fluid Always filter fluid through a 10 micron filter pouring into the reservoi
32. ptable limits Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Check external system relief valve setting Eternal relief valve set below PC setting causes low output flow Adjust external relief valve following manufacturer s recommendation External relief valve setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Adjust PC and LS setting Refer to Adjustment page 20 Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions Check input speed Low input speeds decrease flow Adjust input speed Check pump rotation Incorrect rotational configuration causes low flow Use pump with appropriate rotational configuration Item Check for air in system Description Air in system causes erratic operation Action Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression Check control spools Sticking control spools cause erratic operation Inspect spools for f
33. r Never reuse hydraulic fluid 3 Fill the main pump housing with clean hydraulic fluid Pour filtered oil directly into the upper most case drain port 4 Fill the inlet line leading from the pump to the reservoir Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks 5 Toensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at port M1 to monitor system pressure during start up Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While watching the pressure gauge installed at M1 jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels minimum 11 bar 160 psi Once system pressure is established increase to full operating speed If system pressure is not maintained shut down the prime mover determine cause and take corrective action Refer to Troubleshooting page 17 8 Operate the hydraulic system for at least fifteen minutes under light load conditions 9 Checkand adjust control settings as necessary after installation Refer to Adjustments page 20 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M1 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 520L0607 Rev AB March 2007 15 SAUER
34. ree movement in bore Clean or replace 520L0607 Rev AB March 2007 S SAUER PRESSURE OR FLOW INSTABILITY continued SYSTEM PRESSURE NOT REACHING PC SETTING HIGH INLET VACUUM Caution High inlet vacuum causes cavitation which can damage internal pump components Series 45 J Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Description Action Low LS setti ay cause Adjust LS setting to proper level Check LS setting AIEN a d des instability See Adjustments page 20 Check LS signal line Blocked LS signal line interferes with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differential between PC setting and external relief valve Adjust external relief valve or PC control settings to appropriate level Relief valve setting must be above PC setting to operate properly Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace relief valve Item Check PC control setting Description System pressure will not rise above PC setting Action Adjust PC to appropriate setting Refer to Adjustments page 20 Check external relief valve External relief valve setting below PC setting presents pressure compensation Adjust external relief valve according to manufacturer s recommendations
35. section load sensing Z control valve i x x 22 gear motor f Bi directional Reservoir P104 366E B E System pressure E Filter Heat exchanger MU mE Servo pressure Actuator pressure EN Load sense pressure W Actuator return Suction case drain system return 1 Full available flow is a function of pump displacement operating speed and efficiency Refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0676 for details 520L0607 Rev AB March 2007 SAUER Series 45 J Frame Open Circuit Axial Piston Pumps S DANFOSS Service Manual Technical specifications GENERAL Features and options Model SPECIFICATIONS Feature Unit J45B J51B J60B J65C J75C Maximum Displacement cm in3 45 2 751 51 3 11 60 3 66 65 3 97 75 4 58 l min
36. stem Action Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Low LS setting limits output flow Adjust PC and LS setting Refer to Adjustments page 20 Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system to ensure that proper LS signal transmit to pump Internal system leaks Worn internal parts don t allow the pump to operate properly Refer to Authorized Service Center for required repair Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Check external system valving Malfunctioning valving may not allow system to respond properly Repair or replace system valving as required Check pump case pressure Check pump inlet pressure vacuum High case pressure causes the system to be sluggish High inlet vacuum causes low output flow Correct case drain line restrictions
37. tem circuit A small amount of fluid is allowed to leak from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling Case drain ports are provided to return this fluid to the reservoir The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate The swashplate is forced into an inclined position into stroke by the bias piston and spring The servo piston opposes the action of the bias piston and spring forcing the swashplate out of stroke when hydraulic pressure in the control circuit rises above the spring force The pump control by varying the pressure at the servo piston controls the displacement of fluid in the system circuit Controls designed for Pressure Compensation PC or Load Sensing LS are available For a detailed description of control operation refer to Control options operation page 12 Pump and control sectional view LS control attached to endcap LS spool LS adjustment PC adjustment PC spool Bias spring Servo piston R 2 Slipper Piston p Shaft seal Valve plate Ars shaft Block 4 pm spring Tapered J Tapered roller roller bearing P bearing x ZU I Cylinder block Swashplate Slipper retainer
38. wise rotation increases pressure counterclockwise rotation decreases approximate gain 42 bar 610 psi per turn If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation 4 While holding the position of the PC adjusting plug torque the PC set screw to 7 5 10 8 Nem 5 5 8 lbfeft 5 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration PC control adjustment Gauge port M1 T 0 300 bar 0 4351 psi PC set screw 69 9 16 28 0 300 bar 0 4351 psi 9 16 28 ZC 34 68 Nem 25 50 Ibfeft Z 34 68 Nem 25 50 Ibfft ayy gt PC adjusting plug D 0 300 bar 0 4351 psi 6 9 16 28 34 68 Nem 25 50 Ibf ft Case drain port L1 0 300 bar 0 4351 psi 9 16 28 Z 34 68 Nem 25 50 Ibf ft P104 365E Pressure change Control option PC adjustment LS adjustment LS LD LB LE PC RP 42 bar rev 609 PSI rev JFrame BB BC BP BS 42 bar rev 609 PSI rev 17 2 bar rev 250 PSI rev AB AC AD AJ AS 42 bar rev 609 PSI rev PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 520L0607 Rev AB March 2007 SAUER DANFOSS LS CONTROL A W
Download Pdf Manuals
Related Search