LPV Closed Circuit Axial Piston Pumps Service Manual
Contents
1. N VINILI ME ee N Input shaft m TU d 7 ER S Needle bearing Piston swashplate Cylinder block spring Slipper P106 271E 11004904 Rev AA Jan 2007 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual Introd uction Genuine Parts DIRECT DISPLACEMENT The direct displacement control varies the swashplate angle Swashplate angle DRIVE SYSTEM determines pump flow and motor speed Pictorial circuit diagram Reservoir Heat exchanger bypass D Filter Heat exchanger Cylinder block assembly Charge relief valve OMS d orbital ak motor Es e Bypass valve EN Coupa shaft Charge pump L Suction flow shaft Variable i a HPRV valves Loop flushing valve B Charge pressure displacement pump Servo pressure m High pressure Case flow P100 586E The diagram shows an LPV pump driving an OMS motor The system shown uses an external charge pump and external filter Charge pressure relief valves high pressure relief valves and loop flushing valves are shown separated from the pump to provide2. charge pressure relief valve plug OI 1 in H01 Discard O ring HO1A Z 81 Nem 60 be LO a 2 Charge relief valve shims H06 may remain in plug HO1 Remove shims by tapping plug on the workbench 3 Use a magnet to remove the spring H07 4 Usea magnet to remove the charge relief poppet H08 Inspection Inspect charge relief valve plug shims spring and poppet for wear or damage Replace spring if it is warped or bent Reassembly 1 Insert charge relief valve poppet H08 and spring H07 into endcap 2 Install shims H06 into charge relief valve plug HO1 3 Lubricate and install a new O ring H01A onto the charge relief valve plug 4 Install charge relief valve plug using a 1 in hex wrench Torque to 81 203 Nem 60 150 Ibf ft 11004904 Rev AA Jan 2007 29 SAUER DANFOSS LOOP FLUSHING VALVE 30 LPV Closed Circuit Axial Piston Pumps Service Manual Minor repair Removal l 2 3 Using an 11 16 in hex wrench remove the loop flushing valve plugs J06 Discard O ring JO6A Use a magnet to remove springs J07 Use a magnet to remove loop flushing spool J08 Disassemble loop flushing valve JE ous Ge Onnen D Z 45 Nem J06A 33 Ibfeft i E101 442E Inspection Inspect loop flushing valve spool and springs for damage or wear Replac
3. E101 439E 31 SAUER DANFOSS Service Manual Torque chart LPV Closed Circuit Axial Piston Pumps S Genuine Parts FASTENERS AND PLUGS S04 O ring plug 1 1 16 12 N03 N07 H01 Trunnion Charge relief cover screw valve plug ZT M022 M023 f High pressure Tg4 relief valve End cover NK screw h J06 Loopflushing f u valve plug o AY Oo 3 i Neutral return A O pivot l A B J K08 Ly 7 n TN l fL Neutral return E ud seal nut Lo1 S03 J04 Bypass valve O ring plug 1 1 16 12 Endcap screw P106 323E FASTENER SIZE AND Item Fastener Wrench size Torque TORQUE CHART H01 Charge relief valve plug Tin 81 203 N m 60 150 Ibfeft J04 Endcap screw 8 mminternal hex 54 Nem 40 Ibf ft J06 Loop flushing valve plug 11 16 in 45 Nem 33 Ibf ft K02 Neutral return pivot 1 4 in N A K08 Neutral return seal nut 13mm 22 Nem 16 lbfeft L01 Bypass valve 11 16 in 20 Nem 15 Ibfeft M022 M023 High pressure relief valve 5 16
4. P106 286E Caution Excessive speed or extended movement will damage the pump and motor s Avoid excessive speeds and extended load vehicle movement Do not move the load or vehicle more than 2096 of maximum speed or for longer than 3 minutes When the bypass function is no longer needed reseat the bypass valve to the normal operating position An external pump provides charge CPRV pressure to maintain a minimum pressure in the low side of the transmission loop The CPRV regulates charge pressure Case pressure Charge pressure ooodoo loooo P106 274E 11004904 Rev AA Jan 2007 SAUER DANFOSS LOOP FLUSHING VALVE NEUTRAL RETURN MECHANISM LPV Closed Circuit Axial Piston Pumps Service Manual Operation LPV pumps incorporate an optional integral loop flushing valve to remove heat and contaminants from the transmission loop The loop flushing valve resolves low loop pressure and flushes the low side to pump case Internal orificing prevents charge pressure drop The neutral return mechanism uses a spring to mechanically return the pump to zero displacement A cam allows precise zero displacement adjustment Control linkage may also include a redundant neutral return mechanism Neutral return mechanism Swashplate Shaft Adjusting cam 11004904 Rev AA Jan 2007 Genuine Parts Loop flushing valve P106 276E Neutra
5. SAUER DANFOSS LPV Closed Circuit Axial Piston Pumps Service Manual amp S SAUER LPV Closed Circuit Axial Piston Pumps DANFOSS Service Manual 6 HISTORY OF REVISIONS Revisions Genuine Parts Table of Revisions Date Page Changed Rev January 2007 All First printing AA 2006 Sauer Danfoss All rights reserved 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 503 P105265E 11004904 Rev AA Jan 2007 SAUER DANFOSS INTRODUCTION OPERATION TECHNICAL SPECIFICATIONS FLUID AND FILTER RECOMMENDATIONS STARTUP PROCEDURES PRESSURE MEASUREMENTS TROUBLESHOOTING ADJUSTMENTS LPV Closed Circuit Axial Piston Pumps Service Manual 6 Contents Genuine Parts VEN VIQW I En 5 Watra y sant General instructions Safety precautions sss Unintended machine movement Flammable cleaning solvents eee nn 6 Fluid under pressure Personal
6. 4 Remove the shaft seal and discard Carefully drive a small sheet metal screw into the shaft seal D01 to facilitate removal Be careful not to damage the bearing below the seal Attach a slide hammer or appropriate puller to the screw head and pull to remove the seal Shaft removal 1 Removeretaining ring S09 using retaining ring pliers 2 Pull shaft E01 with bearing S07 out of the pump If necessary tap lightly on the shaft to dislodge it from the internal pump components 3 Remove retaining rings S06 8 using retaining ring pliers 4 Press on the inner race to remove bearing from shaft Caution Moving the pump with the shaft removed may dislodge the rotating group making reassembly impossible without removing the endcap Use extreme caution removing the shaft and replace it immediately Do not allow the pump to move while the shaft is out 11004904 Rev AA Jan 2007 Remove shaft seal bearing Co on Do2 NI _7_ D01 DGA fce P d Genuine Parts SAUER DANFOSS INPUT SHAFT AND SEAL continued LPV Closed Circuit Axial Piston Pumps Service Manual 6 Minor repair Genuine Parts Shaft inspection Inspect shaft Ensure the shaft E01 and its splines are straight and free of damage or heavy wear Inspect the shaft surface where it meets the shaft seal Replace the shaft if a groove exists at the sealing land surface that
7. Closed Circuit Axial Piston Pumps Service Manual 6 Fluid and filter recommendations Genuine barts To ensure optimun life 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 Fluid contaminated by water may appear cloudy or milky or free water may settle 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 Inspect vehicle for leaks daily Fluid and filter change interval Change the fluid and filter per the Reservoir type Max oil change interval vehicle machine manufacturer s Sealed 2000 hours recommendations or at these intervals Breather 500 hours We recommend first fluid change at 500 hours Q Caution High temperatures and pressures result in accelerated fluid aging More frequent fluid changes may be required 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 than 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 ne
8. Piston Pumps Service Manual 6 Introduction Genuine Parts This manual includes information for the installation maintenance and minor repair of the LPV pump It includes a description of the unit and its individual components troubleshooting information and minor repair procedures 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 cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Sauer Danfoss Global Service Partners is available for major repairs Sauer Danfoss trains Global Service Partners and certifies them on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www sauer danfoss com Click on the Sales and Service link Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring the removal of a unit s rear cover or front flange voids the warranty unless done by a Sauer Danfoss Global Service Partner Follow these general procedures when repairing Series LPV variable displacement closed circuit pumps A Remove the unit Prior to performing major repairs remove the unit from the
9. clarity to the diagram LPV PUMP SCHEMATIC Charge pressure DIAGRAM me u j f i P106 287E 11004904 Rev AA Jan 2007 9 SAUER DANFOSS HPRV HIGH PRESSURE RELIEF VALVE BYPASS FUNCTION CPRV CHARGE PRESSURE RELIEF VALVE 10 LPV Closed Circuit Axial Piston Pumps Service Manual 6 Operation Genuine Pats LPV pumps have a combination high pressure relief and charge check valve The high pressure relief function is a dissipative with heat generation pressure control valve for the purpose of limiting excessive system pressures The charge check function replenishes the low pressure side of the working loop with charge oil Each side of the transmission loop has a dedicated HPRV valve that is non adjustable with a factory set pressure When system pressure exceeds the factory setting of the valve oil is passed from the high pressure system loop into the charge gallery and into the low pressure system loop via the charge check HPRV valves P106 273E The LPV contains a dedicated bypass Bypass valve valve To activate the bypass valve back out 3 full turns maximum The bypass function allows you to move a machine or load without rotating the pump shaft or prime mover O
10. in internal hex 81 Nem 60 Ibfeft N03 N07 Trunnion cover screw 13mm 33 Nem 24 Ibf ft T04 End cover screw 9 16 in 44 Nem 32 lbfeft PLUG SIZE AND TORQUE Item O ring plug Wrench size Torque CHART sossos run is mmintermalhex 69 Nem 51 Ib 32 11004904 Rev AA Jan 2007 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual Notes 11004904 Rev AA Jan 2007 33 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual Notes 34 11004904 Rev AA Jan 2007 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual Notes 11004904 Rev AA Jan 2007 35 SAUER DANFOSS OUR PRODUCTS Hydrostatic transmissions Hydraulic power steering Electric power steering 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 11004904 Rev AA Jan 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 serv
11. may let dirt into or hydraulic fluid out of the unit Clean the sealing area with a nonabrasive material if necessary Lubricate the shaft with a light coat of hydraulic fluid before re assembly P106291E Bearing inspection Inspect shaft bearing Clean bearing with a solvent and lubricate with hydraulic fluid Inspect for wear or pitting The bearing should rotate smoothly Any roughness you Se can feel while rotating is cause for replacement P106 292E 11004904 Rev AA Jan 2007 25 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual M l n or re pa r Genuine Parts INPUT SHAFT AND SEAL Reassembly Install shaft seal bearing continued 1 Install first bearing retaining ring Fe D03 S06 using retaining ring pliers i _ D02 2 Lubricate bearing S07 with hydraulic fluid Press bearing onto M shaft by applying force to inner race ogee NS Oe 3 Install second bearing retaining ring A S09 S08 using retaining ring pliers C 7 gm radit m S08 4 For protection cover end of shaft C with installation sleeve or packaging tape O Caution 5 Install shaft S01 with bearing into Do not damage the housing Ensure the shaft splines housing bore shaft or rear engage the block splines and the bearing when installing shaft end slides smoothly into the the shaft and shaft seal rear bear
12. ports type 1 1 16 12 UNF 2B ORB System ports location Twin radial Control types Direct displacement control Shafts Splined Splined SAE 13 tooth 15 tooth Case drain ports 1 1 16 12 SAE ORB Displacement Operating parameters Rating 30 Input speed minimum min rpm continuous maximum 4150 Working pressure continuous bar psi 210 3045 175 2540 140 2030 maximum 345 5000 External shaft External moment M Nem lbf in 7 7 68 loads Thrust in T out Ta N Ibf 750 169 Bearing life B o hours 120 000 37 000 max swashplate angle and max continuous speed at 210 bar 3045 psi Charge pressure minimum bar psi 6 87 maximum 20 300 Case pressure rated bar psi 2 29 maximum 6 87 12 11004904 Rev AA Jan 2007 SAUER DANFOSS SPECIFICATIONS continued LPV Closed Circuit Axial Piston Pumps Service Manual Technical specifications S Genuine Parts Sound levels dB A 100 bar 1450 psi 200 bar 2900 psi 300 bar 3451 psi Displ cm in3 1000 min rpm 1000 min rpm 1000 min rpm 25 1 53 62 66 68 35 2 14 61 66 69 dB A 100 bar 1450 psi 200 bar 2900 psi 300 bar 3451 psi Displ cm in3 3000 min rpm 3000 min rpm 3000 min rpm 25 1 53 70 74 76 35 2 14 71 75 80 1 Sound data was collected in a semi anech
13. properly Install a 50 bar 1000 psi pressure gauge tee in at the charge pressure inlet port Install a 10 bar 100 psi gauge at one of the case pressure ports Operate the system with the pump in neutral zero displacement when measuring charge pressure Verify correct charge pressure per model code Pressure measurements assume 19 l min 5 US gal min charge flow reservoir temperature of 50 C 120 F and are referenced to case pressure Pressure listed in model code assumes a charge flow of 19 l min 5 US gal min At higher charge flows the charge pressure will rise over the rated setting Charge pressure relief valve H01 4 If measured pressure is not correct disassemble valve and look for signs of wear or contamination Refer to Minor repair page 29 for wrench sizes and torque settings If valve is worn replace entire valve If necessary adjust valve by adding or removing shims H06 Kit is available refer to service parts manual When the desired charge pressure setting is achieved remove the gauges 11004904 Rev AA Jan 2007 1in 81 Nem 60 Ibfeft 21 SAUER DANFOSS SYSTEM CHECK AND HPRV LOOP FLUSHING VALVE 22 LPV Closed Circuit Axial Piston Pumps Service Manual Adjustments Genuine Parts Whenever an HPRV valve has been replaced or opened operate the pump in its full range of functions to ensure proper machine opera
14. OLS USED IN SAUER DANFOSS LITERATURE LPV Closed Circuit Axial Piston Pumps Service Manual Introduction A e f v x le El amp j 8 m3 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 H Torx head O ring boss port E Em ES a Rj be DA N DJ E oA ej Genuine Parts Tip helpful suggestion Lubricate with hydraulic fluid Apply grease petroleum jelly Apply locking compound Inspect for wear or damage Clean 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 The symbols above appear in the illustrations and text of this manual They are intended to 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 above defines each symbol and explains its purpose 11004904 Rev AA Jan 2007 SAUER DANFOSS DESIGN LPV C
15. SAFETY PRECAUTIONS LPV Closed Circuit Axial Piston Pumps Service Manual 6 Introduction Genuine Parts Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system Unintended machine movement 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 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 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 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 Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 11004904 Rev AA Jan 2007 SAUER DANFOSS SYMB
16. ating improperly Action Repair replace control linkage Malfunctioning high pressure relief valve Exchange the high pressure relief valves If the problem changes direction replace the valve that does not operate correctly Bypass valve open Open bypass will cause either direction to be inoperative SYSTEM NOISE OR VIBRATION Close repair bypass function Item Description Action Reservoir oil level Low oil level leads to cavitation Fill reservoir Aeration of the oil pump inlet vacuum Air in system decreases efficiency of units and controls Air in system is indicated by excessive noise in pump foaming in oil and hot oil Find location where air is entering into the system and fix Check that inlet line is not restricted and is proper size Cold oil If oil is cold it may be too viscous for proper function and cause cavitation Allow the oil to warm up to its normal operating temperature with engine at idle speed Pump inlet vacuum Shaft couplings Shaft alignment Charge system relief valves High inlet vacuum causes noise cavitation A loose shaft coupling will cause excessive noise Misaligned shafts creates noise Unusual noise may indicate sticking valves Possible contamination Check that inlet line is not restricted and is proper size Check filter and bypass valves if present Replace loose shaft coupling Replace pump or motor Al
17. cessary to change the filter Replace all fluid lost during filter change Hazardous material Warning Hydraulic fluid is hazardous material Avoid contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11004904 Rev AA Jan 2007 SAUER DANFOSS GENERAL START UP PROCEDURE LPV Closed Circuit Axial Piston Pumps Service Manual 6 Startup procedures Genuine Parts Follow this procedure when starting up a new pump installation or when restarting an installation in which you have removed and re installed the pump Ensure pump has been thoroughly tested on a test stand before installing on a machine 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 that may have occurred during shipping 1 Ensure the machine hydraulic oil and system components reservoir hoses valves fittings and heat exchanger are clean and free of any foreign material 2 Install new system filter element s if necessary Check that inlet line fittings are properly tightened and free of air leaks 3 Install the pump Install a 50 bar 1000 psi gauge in the charge pressure gauge port M3 4 Fillthe housing by adding filtered oil to the upper ca
18. e activity Refer to Pressure measurements page 17 for location of gauge ports and suggested gauge size O Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 1 With the prime mover off thoroughly clean the outside of the pump 2 If removing the pump tag each hydraulic line connected to the pump If hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not get into the pump 3 Ensurethe surrounding areas are clean and free of contaminants such as dirt and grime 4 Inspect the system for contamination 5 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles 6 If there are signs of contamination in the hydraulic fluid replace all filters drain the hydraulic system and fill with the correct hydraulic fluid 7 Flush the lines before replacing the hydraulic fluid 11004904 Rev AA Jan 2007 SAUER DANFOSS CHARGE PRESSURE RELIEF VALVE ADJUSTMENTS LPV Closed Circuit Axial Piston Pumps Service Manual Adjustments Genuine Parts The following procedure explains how to check proper operation of the charge pressure relief valve Charge pressure is the measured pressure minus case drain pressure 1 2 Validate that external charge pump is operating
19. e parts as necessary Reassembly im 2 3 Lubricate and insert loop flush spool J08 into endcap Install springs JO7 Lubricate and install new O rings J06A onto loop flushing valve plug J06 Thread the loop flushing valve plugs into the housing and torque to 45 Nem 33 Ibf ft using an 11 16 in hex wrench 11004904 Rev AA Jan 2007 Genuine Parts SAUER DANFOSS BYPASS VALVE COUPLING LPV Closed Circuit Axial Piston Pumps Service Manual Minor repair Removal Using a 5 8 in hex wrench remove the bypass valve cartridge L01 Discard O ring 1003 and backup ring 1002 Inspection Inspect cartridge Replace as necessary Reassembly 1 Lubricate and install new O ring 1003 and backup ring 1002 onto cartridge 2 Install the bypass valve cartridge LO1 using a 5 8 in hex wrench Torque to 20 Nem 15 lbfeft Removal 1 Position pump so endcap is on top 2 Remove auxiliary pump or cover not shown 3 Remove coupling T03 Use a small hook if necessary Inspection Check coupling splines for fretting or abnormal excessive wear Look for cracks that indicate coupling fatigue If wear or damage is found replace coupling Reassembly 1 Lubricate and install coupling T03 2 Replace auxiliary pump or cover 11004904 Rev AA Jan 2007 Genuine Parts Bypass valve 5 8 in 20 Nm 15 Ibf ft E101 443E
20. edures Genuine Parts STARTUP PROCEDURE 9 When adequate charge pressure is established increase engine speed to normal continued operating rpm to further purge residual air from the system 10 Shut off engine Connect pump control Start engine checking to be certain pump remains in neutral Run engine at normal operating speed and carefully check for forward and reverse control operation 11 Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop Normal charge pressure fluctuation may occur during forward and reverse operation 12 Check that the reservoir is full Remove charge pressure gauge The pump is now ready for operation 16 11004904 Rev AA Jan 2007 G SAUER DANFOSS LPV Closed Circuit Axial Piston Pumps Service Manual S Pressure measurements Genuine Parts REQUIRED TOOLS The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown When testing system pressures calibrate pressure gauges frequently to ensure accuracy PORT LOCATIONS AND The following table and drawing show the port locations and gauge sizes needed Use GAUGE INSTALLATION snubbers to protect gauges Port information Port identifier Port size Wrench size Pressure obtained Gauge size bar psi Case d
21. es 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 Global Service Partners strategically located in all parts of the world Local address Sauer Danfoss US Company Sauer Danfoss ApS 2800 East 13th Street DK 6430 Nordborg Denmark Ames IA 50010 USA Phone 45 7488 4444 Phone 1 515 239 6000 Fax 45 7488 4400 Fax 1 515 239 6618 Sauer Danfoss GmbH amp Co OHG Sauer Danfoss Daikin LTD Postfach 2460 D 24531 Neum nster Sannomiya Grand Bldg 8F Krokamp 35 D 24539 Neum nster Germany 2 2 21 Isogami dori Chuo ku Phone 49 4321 871 0 Kobe Hyogo 651 0086 Japan Fax 49 4321 871 122 Phone 81 78 231 5001 Fax 81 78 231 5004 www sauer danfoss com
22. ign shafts Clean replace valves and test pump May be a normal condition 18 11004904 Rev AA Jan 2007 S SAUER LPV Closed Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting SYSTEM WILL NOT OPERATE IN EITHER DIRECTION S Genuine Parts Item Description Action Open bypass valve If bypass valve is open the system loop will be depressurized Close bypass valve Low charge pressure with pump in neutral Low charge pressure insufficient to recharge system loop Measure charge pressure with the pump in neutral If pressure is low go to Pump charge relief valve Low charge pressure with pump in stroke Low charge pressure resulting from elevated loop leakage Isolate pump from motor by blocking system ports With pump in partial stroke and engaged for only a few seconds check pump charge pressure Low charge pressure indicates a malfunctioning pump Continue to next step Good charge pressure indicates a malfunctioning motor or other system component Check motor charge relief operation if present Pump charge relief valve A pump charge relief valve that is leaky or contaminated or set too low will depressurize the system Adjust or replace pump charge relief valve as necessary Charge pump inlet filter A clogged filter will under supply system loop Inspect filter and replace if necessary Charge pump A malfunctioning cha
23. ing It may be necessary All components should fit to tap the shaft to seat the bearing together smoothly Do not force the shaft through the block or into the rear bearing If the shaft does not go into the pump refer to a Sauer Danfoss Global Service Partner for major repair 6 Using retaining ring pliers install shaft bearing retaining ring S09 7 Lubricate the seal D01 using hydraulic fluid Press seal into housing until it bottoms out Press evenly to avoid binding and damaging the seal 8 Install the seal support washer D02 9 Install the seal retaining ring D03 using retaining ring pliers 26 11004904 Rev AA Jan 2007 SAUER DANFOSS TRUNNION SEAL LPV Closed Circuit Axial Piston Pumps Service Manual 6 Minor repair Genuine Parts Removal 1 Remove four trunnion cover bolts N03 using a 13 mm hex wrench 2 Remove trunnion cover N01 Remove and discard O ring N04 3 Press the lip seal N02 out of the trunnion cover N01 discard Inspection Remove trunnion cover and seal Inspect seal land on trunnion shaft N03 and trunnion cover for rust wear or 13mm N contamination Polish seal land on 33 Nem d trunnion shaft if necessary 24 Ibf ft Reassembly N 1 Press new trunnion seal N02 into E N02 cover N03 2 Install new O ring NO4 Retain with petroleum jelly 3 Coverthe trunnion shaf
24. l return adjusting cam Adjusting cam N o Lock seal nut ANS om P106 277E W 9 m Neutral return P106 278E SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual G Technical specifications PS SPECIFICATIONS General specifications Design Axial piston pump of trunnion swashplate design with variable displacement Direction of rotation Clockwise counter clockwise pipe connections Main pressure ports SAE straight thread O ring boss Recommended Pump installation recommended with control position on the top or side installation position Consult Sauer Danfoss for non conformance to these guidelines The housing must always be filled with hydraulic fluid Physical properties Displacement Feature Unit 25 30 35 Maximum Displacement cm in3 25 1 53 30 1 83 35 2 14 Flow at rated speed theoretical l min 85 2 104 9 137 0 US gal min 22 5 27 7 36 2 Input torque at maximum displacement Nem bar 0 4 0 5 0 6 theoretical Ibf in 1000 psi 244 291 340 Mass moment of inertia of internal kg m 0 001670 0 001580 0 001530 rotating components slug ft2 0 0012 0 00120 0 00113 Weight kg lb 23 51 Rotation Clockwise Counter clockwise Mounting SAE B 2 bolt Auxiliary mounting SAE J744 A OT SPCL 11T System
25. losed Circuit Axial Piston Pumps Service Manual 6 Introduction Genuine Paris Series LPV is a family of hydrostatic pumps for low to medium power applications with maximum pressures up to 345 bar 5000 psi You can apply these pumps with other products in a system to transfer and control hydraulic power LPV pumps provide an infinitely variable speed range between zero and maximum in both forward and reverse LPV pumps come in three displacements 25 cm 1 53 in 30 cm 1 83 in and 35 cm 2 32 in LPV pumps are compact high power density units All models use the parallel axial piston slipper concept in conjunction with a tiltable swashplate to vary the pump s displacement Reversing the angle of the swashplate reverses the flow of fluid from the pump reversing the direction of rotation of the motor output LPV pumps have an internal neutral return mechanism and are available with optional loop flushing LPV pumps receive charge flow from an auxiliary circuit or from a gear pump mounted on the auxiliary pad LPV pumps feature an SAE A auxiliary mounting pad to accept a pump s for system charge or complementary systems LPV pumps use a trunnion style direct displacement control LPV cross section Trunion X Tapered roller bearing Cylinder block Valve plate nl L f y Ball bearing lin aaeaa T
26. oic chamber Values have been adjusted 3 dB to reflect anechoic levels Fluid specifications Feature Unit Displacement cm in 25 1 53 30 1 83 35 2 14 Viscosity Minimum 7 47 Recommended range mm s 12 60 66 278 Maximum SUS 1600 7500 Temperature Minimum 40 40 Range Rated C F 82 180 Maximum intermittent 100 212 Filtration Cleanliness per ISO 4406 22 18 13 Efficiency charge pressure Bisa 75 B 2 10 filtration B ratio Efficiency suction filtration Ba545 75 B 02 2 Recommended inlet screen um 100 125 mesh size 2 Atthe hottest point normally case drain port Mounting flange allowable overhung parameters Mounting flange G factors for sample applications Continuous load moment Shock load moment Continuous Maximum M M o vibratory shock Application Nem Ibfein Nem Ibfsin acceleration acceleration 361 3200 617 5470 Go G3 Skid steer loader 6 10 Trencher 6 8 rubber tires Asphalt paver 6 6 Applications experiencing extreme Windrower 6 5 resonant vibrations may require Aerial lift 6 4 additional pump support Refer to Turf care vehicle 6 4 520L0954 LPV Technical Information for baton roller B 19 information concerning mounting flange loads 11004904 Rev AA Jan 2007 13 SAUER DANFOSS FLUID AND FILTER RECOMMENDATIONS 14 LPV
27. on page 5 and precautions related to your specific equipment SYSTEM OPERATING HOT Item Description Action Oil level in reservoir Insufficient hydraulic fluid will not meet cooling demands of system Fill reservoir to proper level Heat exchanger Heat exchanger not sufficiently cooling the system Check air flow and input air temperature for heat exchanger Clean repair or replace heat exchanger Charge pressure System relief pressure settings Charge pump inlet vacuum Low charge pressure will overwork system High inlet vacuum will overwork system A dirty filter will increase the inlet vacuum Inadequate line size will restrict flow If the system relief valves are worn contaminated or valve settings are too low the relief valves will be overworked Measure charge pressure Inspect and adjust or replace charge relief valve Inspect charge pump Repair or replace charge pump Check charge inlet vacuum If high inspect inlet filter and replace as necessary Check for adequate line size length or other restrictions Verify settings of high pressure relief valves and replace valves as necessary System pressure Frequent or long term operation over system relief setting will create heat in system Measure system pressure If pressure is too high reduce loads TRANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY Item Control linkage Description Control linkage oper
28. rain 1 1 16 12 UNF 2B 15 mm internal hex Case drain 10 100 Port A Port B 1 1 16 12 UNF 2B N A System pressure 600 10 000 Charge inlet 7 8 14 UNF 2B N A Charge pressure 50 1000 Port locations 7 8 14 SAE straight thread 11 16 12 oting boss SAE straight thread charge inlet O ring boss case drain T 11 16 12 t SAE straight thread l O ring boss system port A vi 11 16 12 SAE straight thread O ring boss system port B 11 16 12 SAE straight thread O ring boss case drain alternate P106 323E 11004904 Rev AA Jan 2007 17 SAUER DANFOSS LPV Closed Circuit Axial Piston Pumps Service Manual Troubleshooting S Genuine Parts OVERVIEW This section provides general steps to follow if you observe undesirable system conditions Follow these steps until you solve the problem Some of the items are system specific For areas this manual covers we reference the section Always observe the safety precautions listed in the Introduction secti
29. rge pump will provide insufficient charge flow Repair or replace the charge pump System pressure Low system pressure does not provide enough power to move load Measure system pressure Continue to next step System relief valves Defective high pressure relief valves cause system pressure to be low Repair or replace high pressure relief valves SLUGGISH SYSTEM RESPONSE Item Oil level in reservoir Description Low oil level causes sluggish response Action Fill reservoir High pressure relief valves Incorrect pressure settings will affect system reaction time Adjust or replace high pressure relief valves Low prime mover speed Low engine speed will reduce system performance Adjust engine speed Air in system Air in system will produce sluggish system response Fill tank to proper level Cycle system slowly for several minutes to remove air from system Pump inlet vacuum Inlet vacuum is too high resulting in reduced system pressure Measure charge inlet vacuum Inspect line for proper sizing Replace filter Confirm proper bypass operation 11004904 Rev AA Jan 2007 19 SAUER DANFOSS PUMP ADJUSTMENT STANDARD PROCEDURES 20 LPV Closed Circuit Axial Piston Pumps Service Manual 6 Adjustments Genuine Pats This section offers instruction on adjustment of pump components Read through the entire topic before beginning a servic
30. s 23 11004904 Rev AA Jan 2007 3 SAUER DANFOSS MINOR REPAIR TORQUE CHART LPV Closed Circuit Axial Piston Pumps Service Manual 6 Contents Genuine Parts Input shaft and seal rennes Shaft seal removal Shaft removal Shaft inspection Bearing inspection REASSEMMDIY e R M Trunnion Seal MIL M Inspection REASSEMMDIY P 27 High pressure relief valves inner 28 Removal z aola 410 0 assists AREA O M MELIA 9 Charge pressure relief valve Removal Inspection REASSEMMDIY e Loop flushing VAE cis Remowval Inspection Reassembly S Bypass VAE ner died ies ete ceu tU IDE Mr Inspection REASSEMMDIY e COUPIINO C een REMOVE m i TRES POC 410 t REASSEMMDIY c Fasteners aridiplugs aprubahan E E USE Fastener size and torque chart Pl g size and torque Chart erret riarann R 11004904 Rev AA Jan 2007 SAUER DANFOSS OVERVIEW WARRANTY GENERAL INSTRUCTIONS LPV Closed Circuit Axial
31. safety Y Symbols used in Sauer Danfoss literature 7 Pip 8 Direct displacement drive System sense 9 LPV Pump schematic diagram ttti titt eerta tuek tr onte teen erba 9 HPRV High pressure relief Valve rene Bypass function CPRV Charge pressure relief valve Loop flushing ValVe ssssssssssnmnninenmnnmmanannnnNntannnnanenmne Neutral return mechanism rene serneusie 12 Fluid and filter recommendations sens 14 Hazardo s material sssssssrerssnenininiinnenmemannannndiannetnitinintenente 14 IEISATSIS TERRE EA 15 StartUp procedure e 15 Required tools nonet tiit etes pte NEU Oe peti esie eee eH HOHER teta ep eel eq Port locations and gauge installation e C System operating hot Transmission operates normally in one direction only System noise or vibration System will not operate in either direction Sluggish system respohse ss Pump adjustment 20 Standard procedUresssesannenrannmrnenenenauitntenanendionnetenen eniensiie 20 Charge pressure relief valve adjustments testen tenent ttnnnnttnnncis 21 System check and hprv MerejoRiUCBlum m nn ARR Checking for proper HPRV valve operation inner 22 Neutral return mechanism renne
32. se drain port 5 Fill the reservoir with hydraulic fluid of the recommended type and viscosity Use a 10 micron filler filter Ensure inlet line from reservoir to pump is filled After start up the oil level in the reservoir may drop due to filling of the system components Check the level in the reservoir to maintain a full oil level throughout the start up Warning Damage to hydraulic components may occur if the oil supply is not maintained 6 Disconnect the pump from control linkage 7 Use a common method to disable the engine to prevent the engine from starting Crank the starter for several seconds Do not to exceed the engine manufacturer s recommendation Wait 30 seconds and then crank the engine a second time as stated above This operation helps remove air from the system lines Refill the reservoir to recommended full oil level 8 When charge pressure begins to appear enable and start engine Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system Check for leaks at all line connections and listen for cavitation Check for proper fluid level in reservoir Caution Air entrapment in oil under high pressure may damage hydraulic components Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered 11004904 Rev AA Jan 2007 15 LPV Closed Circuit Axial Piston P SAUER SS Pact ante M LE Startup proc
33. t while holding the adjustment screw secure If creep cannot be eliminated then the pump requires major repair Remove the unit and refer to Sauer Danfoss Global Service Partner for repairs 11004904 Rev AA Jan 2007 Genuine Parts The neutral return mechanism returns the pump to zero displacement in the absence of control input If machine does not return to neutral first disconnect control linkage and check for creep If creep is not present with control linkage disconnected refer to machine adjustment service procedures for control linkage adjustment If creep is still present with control linkage disconnected follow this procedure for pump neutral adjustment SUA iN N Neutral return om P106 278E Neutral return adjustment Neutral return adjustment P106 336E Neutral return adjusting screw Adjusting cam Lock seal nut P106 277E NS 23 S SAUER DANFOSS INPUT SHAFT AND SEAL 24 Caution Do not damage the housing bore shaft or bearing when removing the shaft and shaft seal LPV Closed Circuit Axial Piston Pumps Service Manual Minor repair Shaft seal removal 1 Orient pump with the shaft pointing up 2 Remove retaining ring D03 using retaining ring pliers to release the shaft seal components 3 Remove the seal support washer D02 Use a packing hook if necessary
34. t with an installation sleeve or wrap with packaging tape to prevent damage to seal 4 Install trunnion cover and seal assembly N01 to housing 5 Install four trunnion cover bolts using a 13mm hex wrench Torque to 33 Nem 24 Ibf ft 11004904 Rev AA Jan 2007 27 SAUER DANFOSS HIGH PRESSURE RELIEF VALVES 28 LPV Closed Circuit Axial Piston Pumps Service Manual 6 Minor repair Genuine Parts Removal 1 Mark the location of each valve for proper reassembly 2 Using a 5 16 internal hex wrench remove the valves M10 and M20 3 Remove and discard O rings M022 and M023 Disassemble system check relief valves li E101 441E Inspection Inspect plug and internal parts of cartridge If parts are worn or damaged replace entire cartridge Reassembly 1 Lubricate and install new O rings M022 and M023 onto each valve M10 and M20 2 Install the valves in their original location as noted during disassembly 3 Use a 5 16 in internal hex wrench to torque valves to 81 Nem 60 Ibf ft 11004904 Rev AA Jan 2007 SAUER LPV Closed Circuit Axial Piston Pumps S DANFOSS Service Manual i Minor repair Genuine Parts CHARGE PRESSURE Removal Charge pressure relief valve RELIEF VALVE 1 Using a 1 in hex wrench remove the Ho1
35. tion The HPRV valves are pre set at the factory no adjustment is possible Checking for proper HPRV valve operation For suspected HPRV valve malfunction replace valve with identical relief setting and test operation of pump The loop flushing valve is not adjustable If loop flushing malfunction is suspected disassemble valve and check for worn damaged or scored components Replace parts if necessary Refer to Minor repair page 30 for disassembly procedures 11004904 Rev AA Jan 2007 HPRV valves cnp G amp ES Bl i a amp HPRV valves P106 333E Loop flushing valve Loop flushing valve P106 335E SAUER DANFOSS NEUTRAL RETURN MECHANISM LPV Closed Circuit Axial Piston Pumps Service Manual Adjustments Neutral return mechanism Swashplate Shaft N Adjusting cam For propel applications raise the wheels off the ground and secure the vehicle so you can operate it safely Other applications take necessary steps to ensure you can operate the machine safely during this procedure Remove the control linkage and check for creep If the wheels mechanism move while the control linkage is disconnected loosen the locknut and turn the adjusting screw clockwise or counterclockwise You will achieve maximum adjustment with only 1 4 turn in either direction If creep is eliminated by adjustment torque the locknut to 22 Nem 16 Ibf f
36. vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses after removal to prevent contamination y Keep it clean Cleanliness is a primary means of assuring satisfactory pump life on either new or repaired units Clean the outside of the pump thoroughly before disassembly Take care to avoid contamination of the system ports Cleaning parts by using a clean solvent wash and air drying is usually adequate As with any precision equipment you must keep all parts free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the pump with a protective layer of plastic fa Lubricate moving parts During assembly coat all moving parts with a film of clean hydraulic oil This assures that these parts will be lubricated during start up ii Replace all O rings and gaskets We recommend you replace all O rings seals and gaskets during repair Lightly lubricate all O rings with clean petroleum jelly prior to assembly 2 Secure the unit For major repair place the unit in a stable position with the shaft pointing downward It will be necessary to secure the pump while removing and torquing the endcap bolts 11004904 Rev AA Jan 2007 5 SAUER DANFOSS
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