SGM2Y, and SGM3Y Fan Drive Motors Service and
Contents
1. m Inlet port A Outlet port B Drain port L1 P106 083E 11022491 June 2010 Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP General Start up procedure SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Initial start up procedures Follow this procedure when starting up a new motor installation or when restarting an installation in which the motor has been removed Prior to installing the motor 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 Ensure that 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 3 Install the gear motor 4 Fill the reservoir with hydraulic fluid of the recommended type and viscosity Use a 10 micron reservoir filler filter After start up the oil level in the reservoir may drop due to filling of the system components Check the oil level in the reservoir to maintain th2. Parameter Unit Displacement cm in 84 0 51 11 0 67 14 0 85 17 1 04 19 1 16 22 1 34 25 1 53 Weight cartridge and SAE A kg Ib 3 0 6 6 3 2 7 0 3 4 7 5 3 5 7 7 3 6 7 9 3 7 8 2 3 8 8 4 Mass moment of 3 in rtiaofrotatin kgem 0 0000324 0 0000384 0 0000473 0 0000533 0 0000592 0 0000681 0 0000741 iner g slug ft 0 0000239 0 0000283 0 0000349 0 0000393 0 0000437 0 0000503 0 0000547 components Theoretical torque Nem bar 0 134 0 175 0 223 0 271 0 302 0 35 0 398 3 81 2 106 6 135 3 165 5 184 6 213 3 243 5 Parameter Unit Displacement cm in 22 1 34 26 1 59 33 2 01 38 2 32 44 4 69 mS cartridgeand ior 7 2 158 7 21158 76 166 770169 7 910174 Mass moment of inertia kg m 0 00001666 0 00001582 0 00001530 0 00002326 0 00002286 of rotating components slug ft 0 00001229 0 00001167 0 00001128 0 00001716 0 00001687 0 40 0 48 0 56 0 60 0 72 Theoretical torque Nem bar 244 293 347 366 439 Parameter Unit Minimum Continuous Maximum Viscosity mm sec cSt 7 10 12 60 1600 SUS 47 60 70 278 7500 Temperature C F 20 4 80 176 90 194 Cleanliness ISO 4406 Class 18 13 or better Filtration efficiency charge filtration Bis20 75 B 21 0 For detailed filtration information see Turolla OCG publication 52
3. 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 necessary to change the filter Replace all fluid lost during filter change L1022491 June 2010 Rev A SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Troubleshooting Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Fan speed locked high at high engine speed cold conditions To determine minimum fan speed at high engine rpm connect coil to battery voltage to lock coil in open position Follow steps 1 3 If fan is still not operating properly follow steps 4 5 Item Description Action Wire disconnected or shorted Any wire on the FDC switches or temperature sensors that is disconnected cut or shorted will lock the fan to full speed Re connect wires or re wire the wiring harness Faulty electronics FDC The FDC or ECM is not sending a current signal to the solenoid No feel of magnetics on proportional relief valve coil Replace the FDC Consult engine repair manual verify 12 or 24 VDC is going to the coil Faulty input signal to FDC sensors switches PWM signal Sensors either not functioning properly or not properly eng
4. SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP ul Urol OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP History of Revisions SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Revisions Table of Revisions Date Page Changed Rev June 2010 First edition A 2010 Turolla OpenCircuitGear All rights reserved Turolla OCG accepts no responsibility for possible errors in catalogs brochures and other printed material Turolla OCG reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations can be made without affecting agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss Turolla Turolla OpenCircuitGear Turolla OCG OpenCircuitGear Fast Lane and PLUS 1 are trademarks of the Sauer Danfoss Group Front cover illustrations F101 489 F301 112 P104 394 L1022491 June 2010 Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Introduction Technical specifications Pressure measurements Initial start up procedures Fluid and filter maintenance Troubleshooting Minor repair repa
5. 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 O Caution Contamination can damage internal components and void the manufac turer s warranty Take precautions to ensure system cleanliness when remov ing and reinstalling system lines 11022491 June 2010 Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Solenoid replacement Valve replacement SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Minor repair Refer to the valve drawings on the following page for wrench sizes and torque specifications Remove the coil 1 Disconnect the electrical connection from the coil 2 Remove the plastic nut holding the coil to the valve 3 Remove the coil and O ring Install the coil 1 Place anew O ring on the valve stem Install the coil 2 Install another new O ring onto the valve stem 3 Install the plastic nut Torque coil nut to 4 Nm to 6 Nm 3 to 4 5 lbf ft 4 Install the wire connector to the coil A Warning Do not overtorque plastic nut Remove the valve Remove the valve from the motor Install the valve Install valve into motor Torque to following specifications SGM2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ibf ft SGM3Y
6. PRV 12 torque to 70 Nem to 75 Nem 51 to 55 Ibf ft A Warning Do not overtorque valve L1022491 June 2010 Rev A ITM rolla OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Repair parts PRV10 Valve 12 point socket 26mm Hexagon 27mm Torque 4 Nem 2 95 Ibf ft Torque 45 to 50 Nem 33 to 36 Ibf ft 7 8 14 UNF 2A L nao ae mH a Position of valve locked in place Do not remove valve or alter position P104 392E SGM2Y Repair parts Proportional valve installed on same side of endcap as return port in body Motor supply Hexagon socket 15 16 inch Torque 45 55 Nem 33 41 Ibf ft Counterclockwise rotation shown P104 395E Item Description Part number Qty 1 Shaft nut 1 2 20 UNF 5722 12 1307 1 2 Locking washer 326 0117 1 00 1 3 Key 5738 03 1005 1 4 Coil nut with O ring 173803668 1 5 Coil 12 Volt 171151719 1 5 Coil 24 Volt 171151819 1 6 Solenoid seal kit 35400071 1 L1022491 June 2010 Rev A m SGM2Y and SGM3Y Fan Drive Motors U Service and Parts Manual OpenCircuitGear Repair parts MEMBER OF THE SAUER DANFOSS GROUP PRV 12 Valve Hexagon 32mm 12 point socket 26mm Torque 70 to 75 Nem 51 to 55 Ibf ft Torque 4 Nem 2 9
7. level fluid level to minimize air entrainment Baffles in the reservoir diffuse the oil to an acceptable level to mix it with the fluid in the reservoir and to prevent the oil from flowing immediately back to the pump inlet The return oil remains in the reservoir long enough to allow any entrained air in the fluid to rise to the surface and dissipate back into the atmosphere 11022491 June 2010 Rev A m SGM2Y and SGM3Y Fan Drive Motors U Service and Parts Manual OpenCircuitGear Introduction MEMBER OF THE SAUER DANFOSS GROUP System circuit diagram Rener Bypass check 7 L Gear pump Suction Heat exchanger screen Filter Electronic fan drive controller Integrated proportional relief valve Gear motor Anti cavitation check valve Pump inlet ll Fan drive pump outlet Return oil Drain P106 043E Design Turolla OCG fixed displacement open circuit gear motors convert hydraulic power into mechanical power Supply flow determines shaft speed Load torque results in system pressure between the pump and motor Bushings at the front and rear of the motor support the shaft The volume between the gear teeth and the pump body defines the displacement of the motor A shaft seal at the front of the motor prevents leakage where the shaft exits the motor housing Cross section view i Drive gear indie W i Teflon backup ring asher Body housin
8. 0L0463 Fluids and Filtration For information on biodegradable fluids see Turolla OCG publication 520L0465 Biodegradable Hydraulic Fluids L1022491 June 2010 e Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Operating parameters SGM2Y Operating parameters SGM3Y SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Technical specifications Parameter Unit Displacement cm in 8 4 0 51 11 0 67 14 0 85 17 1 04 19 1 16 22 1 34 25 1 53 System continuous bar psi 250 230 210 180 160 pressure 3626 3336 3045 2611 2320 maximum 270 250 230 200 180 3916 3626 3336 2901 2611 Speed maximum min 3500 3200 limit rpm Case continuous bar psi 5 70 pressure maximum 8 115 Parameter Unit Displacement cm in 22 1 34 26 1 59 33 2 32 38 2 32 44 0 4 69 System continuous bar psi 210 pressure 3046 maximum 230 3336 Speed limit maximum min rpm 2500 2300 Case continuous bar psi 5 70 pressure maximum 8 115 L1022491 June 2010 Rev A Were OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Required tools Port locations and gauge installation SGM2Y Port locations SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Pressure measurements You can perform t
9. 5 Ibfeft 1 1 16 12 UNF 2A TUA TI Position of valve locked in place Do not remove valve or alter position P104 393E SGMS3Y Repair parts un i Proportional valve installed on same side of endcap as return port in body Hexagon socket 15 16 inch Torque 160 180 Nem 118 133 Ibfeft Clockwise rotation shown P104 396E Item Description Part number Qty 1 Shaft nut 5 8 18 UNF 5722 01 1629 1 2 Locking washer 326 0009 0 00 1 3 Key 930 0018 0 00 1 4 Coil nut with O ring 173803668 1 5 Coil 12 Volt 171151719 1 5 Coil 24 Volt 171151819 1 6 Solenoid seal kit 35400131 1 L1022491 June 2010 Rev A 19 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Our Products Aluminum Gear Pumps Aluminum Gear Motors Cast Iron Gear Pumps Cast Iron Gear Motors Fan Drive Gear Motors Aluminum Fan Drive Gear Motors Cast Iron L1022491 June 2010 Rev A Turolla OpenCircuitGear M Turolla OCG with more than 60 years of experience in designing and manufacturing gear pumps gear motors and fan drive motors of superior quality is the ideal partner ensuring robustness and reliability to your work functions We are fast and responsive the first to specify a customer product the most experienced in provid
10. 6 Nm 3 to 4 5 Ibf ft L1022491 June 2010 Rev A Welle OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP System noise SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Troubleshooting Item Description Action Aeration of the oil Low oil in reservoir 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 Problem is often found in inlet line to pump Fill reservoir Cold oil Low oil temperature increases viscosity and can cause cavitation resulting in system noise Allow the oil to warm up to its normal operating temperature with engine at idle speed Fan hitting shroud Check fan shroud and hydraulic motor mountings Consult owner s manual for proper fastener torques System operating hot Item Description Action Low oil level in reservoir and low supply to pump Insufficient amount of hydraulic fluid will not meet the cooling demands of the system Fill the reservoir to the proper level Faulty or blocked heat exchanger if equipped If the heat exchanger fails or becomes obstructed it may not meet the cooling demands of the system Ensure that heat exchanger is receiving adequate air flow and that the heat exchanger is in good operating condition Repair or replace as ne
11. Y Fan Drive Motors Service and Parts Manual Fluid and filter maintenance Fan drive motors are manufactured using a process known as cut in during which the gears motor body and bearing blocks are allowed to establish a unique relationship to each other Opening a motor and replacing components is not recommended Removal or replacement of some internal components will modify their critical dimensions Because motors are cut in at a specific pressure to ensure maximum efficiency removal or replacement of internal components may be detrimental to motor efficiency Motor conversions are not allowed To ensure optimum 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 Change the fluid and filter per the Fluid and filter change interval vehicle machine manufacturer s Reservoir type Recommended oil recommendations or at these intervals change interval Sealed 2000 hours Change the fluid more frequently if it Breather 500 hours
12. aged in mounting Improper or No PWM signal from engine Replace or re mount sensor Determine why engine is sending faulty signal and fix Verify 12 or 24V going to FDC Check for 5V across sensors Faulty valve Valve is stuck in closed position Replace valve or complete motor assembly Faulty solenoid coil Coil is either shorted or open No feel of magnetics on coil Replace coil o rings and coil nut Torque coil nut to 4 to6 Nm 3 to 4 5 Ibf ft High stand by fan speed cold conditions Item Description Action Blockage in main valve flow passages Blockage in valve flow passages will increase fan speed and system pressure Replace valve SGM2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ibf ft SGM3Y PRV 12 torque to 70 Nem to 75 Nem 51 to 55 Ibf ft Torque coil nut to 4 Nm to 6 Nm 3 to 4 5 Ibf ft Faulty electronics FDC sensor bad or disconnected PWM signal missing FDC is not sending full current signal to the solenoid Sensor bad or disconnected PWM signal missing Replace bad sensor or connect wire Determine reason for missing PWM signal Replace the FDC Faulty solenoid coil Coil is either shorted or open No feel of magnetics on coil Replace coil o rings and coil nut Torque coil nut to 4 to 6 Nm 3 to 4 5 Ibf ft Fan speed not controlled by current to coil Item Description Action Fan speed proportional to en
13. cessary Faulty PRV If a system relief valve becomes unseated for an extended period of time or fails for any other reason the system could become overheated Replace malfunctioning relief valves and verify that the loads on the machine are not excessive SGM2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ibf ft SGM3Y PRV 12 torque to 70 Nem to 75 Nem 51 to 55 bf ft Torque coil nut to 4 Nm to 6 Nm 3 to 4 5 Ibf ft Fan system flow coming from pump is bypassing the motor Proportional relief valve in motor is stuck in open position Disconnect solenoid coil Fan should go to full speed If fan does not go to full speed replace relief valve Proportional valve installed into end cover supply port Install valve into endcover port on return side of motor Leaking motor shaft seal Item Description Action Excessive pressure in case drain line Case drain line from rear of motor restricted No other return lines are tied into motor case drain Verify case drain line is routed directly to reservoir with no restrictions Maximum case pressure limit is 3 bar 45 psi Replace motor Safety precautions Caution High inlet vacuum causes cavitation which can damage internal pump components A Warning Escaping hydraulic fluid under pressure can have sufficient force to pene trate your skin causing serious injury and or infection Relieve pressure in the
14. drives work with engines produced by all the major North American and European engine manufacturers Off highway applications include many other engine options The ECM may control the fan drive motor directly by PWM signal if the signal is suitable or you may use an intermediate control such as the Turolla OCG Fan Drive Controller 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 fixed displacement gear motor which has an electrohydraulic proportional valve mounted in the motor s rear cover The setting of the valve determines the maximum pressure in the system by bypassing oil around the motor s gear set directly to the return port of the motor The proportional valve is normally closed and requires the application of an electrical current to reduce the bypass pressure from a pre determined customer selected maximum pressure setting In a hydraulic fan drive system the pre determined maximum pressure setting determines the maximum pressure to the motor and maximum trim speed of the fan Applying an electrical current to the valve allows the fan to run at speeds below its maximum trim speed regardless of the flow supplied to the pump Oil exiting the motor is directed back to the reservoir through a filter and a heat exchanger Oil returning to the reservoir must enter the reservoir well below the fluid
15. e full level throughout the start up Caution Damage to hydraulic components may occur Maintain sufficient oil in the reservoir at all times 5 Use a common method to disable the engine to prevent the engine from starting Crank the engine 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 unwanted air from the pump outlet line and lubricates the gear motor prior to engine start up Refill the reservoir to recommended full oil level 6 Enable engine to start Start the 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 Caution Cavitation damages hydraulic components Take steps to avoid air entrap ment in the system 7 After initial air removal and ensuring the hydraulic reservoir oil level is correct raise the engine speed enough to increase fan speed to a moderate rpm but not enough to open the bypass relief valve 8 With the engine at high rpm disconnect the PWM wire or a sensor to ensure the fan motor is going to full speed 9 Checkthat the reservoir is full The motor is now ready for operation L1022491 June 2010 Rev A 11 Wreyre OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Recommendations SGM2Y and SGM3
16. ebe terea 12 Fan speed locked high at high engine speed cold conditions High stand by fan speed cold conditions Fan speed not controlled by current to coil eterne nnt Fan TOSS Ot CU FIN rennen nin a RE R a aAa Fan too slow at high engine rpm Improper modulation of FDC or ECM iem System operating MOE urere erm tremere creer remet RRO Leaking motor shaft seal retentione entere nanna naa ees Safety precaution i RR Solenoid replacement unici iter tetas teste beer eoa es aiaei 17 Valve repli ceMm e Mtemani n 17 PR VOW AIM E ANEN E etn E E AEE ES EE AEE RE EAE A EAE SGM2Y Repair parts PRV 12 Valve SGM3Y Repair parts L1022491 June 2010 Rev A 9 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Overview Warranty Safety precautions SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Introduction This manual includes information for the installation maintenance and minor repair of the SGM2Y and SGM3Y Proportional Fan Drive Motors The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures You must remove the unit from the vehicle to perform minor repairs Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type
17. f ft S M3Y PRV 12 torque to 70 Nem to 75 Nem 51 to 55 bf ft Torque coil nut to 4 Nm to 6 Nm 3 to 4 5 Ibf ft Hydraulic oil temperature too high High oil temperature decreases viscosity and affects efficiency Maintain hydraulic oil at normal operating temperatures 85 C 185 F max Ensure cooler is operating properly High oil temperature can also be caused by aeration see below Aeration of oil Air in system decreases efficiency of units and controls Noise foaming and hot oil are signs of aeration Find location where air is entering into the system and fix Check inlet line to pump and repair any leaks Fill reservoir to recommended level Consult operator s manual Damaged motor low system pressure Proportional relief valve spool sticking open may prevent full flow from going through motor Not enough flow from pump Measure system pressure between pump and motor Vary engine speed low to high Does system pressure change Check motor case drain flow Should be maximum 1 2 l min US 0 3 gal min If case drain flow exceeds limits replace motor Inadequate fan system flow coming from pump If pump loses efficiency it may not produce enough flow to turn the motor A damaged pump may provide flow when oil is cold and viscous but may not when oil warms up Systems equipped with steering PFD may be sending too much flow to steering May be sending too much flow to steering Compare performa
18. g Bearing block Outer seal assembly T Shaft seal Pressure seal Rear cover Capscrew Dowel pin P104 393E L1022491 June 2010 Rev A Z Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Overview Features and options Specifications SGM2Y Specifications SGM3Y Fluid specifications Ratings and data are based on operation with premium petroleum based hydraulic fluids containing oxidation rust and foam inhibitors SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Technical specifications Specifications and operating parameters for motors are given here for reference Model SGM2Y SGM3Y Mount SAE A 2 bolt mounting flange European flanges Eurpoean flanges SAE B 2 bolt mounting flange Displacement cm in 8 4 0 51 11 0 67 14 0 85 17 1 04 19 1 16 22 1 34 25 1 53 44 4 69 22 1 34 26 1 59 33 2 01 38 2 32 Rotation Unidirectional direction of rotation is defined in order code Porting SAE O ring boss radial SAE O ring boss split flange European German x European German x see page 13 Output shafts 1 8 taper 0 625 in extended cylindrical keyed 1 8 taper 0 875 in cylindrical keyed 0 625 in cylindrical keyed 1 5 taper 15 0 mm cylindrical keyed shaft Control options Proportional relief valve normally closed 12 V Dc and 24 V Dc
19. gine speed at all times Blocked or stuck valve causes fan speed to be proportional to engine speed at all times Replace valve SGM2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ibf ft SGM3Y PRV 12 torque to 70 Nem to 75 Nem 51 to 55 Ibf ft Torque coil nut to 4 Nm to 6 Nm 3 to 4 5 Ibf ft L1022491 June 2010 Rev A U fe o OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Fan does not turn SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Troubleshooting Item Description Action Not enough flow through motor If engine is left at idle at start up of machine there is not enough flow or pressure to turn fan motor Rev engine a couple times to get flow through motor If the fan begins to turn and continues to turn when the engine returns to idle the pump and motor are OK Delta pressure across proportional valve too low Delta pressure across motor ports should measure approximately 50 psi minimum at engine idle Measure delta pressure across motor ports If it is greater than 150 psi and the motor does not turn replace motor If the delta pressure is between 50 psi and 150 psi and the motor does not turn rev the engine a couple of times to get flow through the motor and check current to the solenoid If current is greater than recommended maximum adjust controller parameters to reduce the current If increasing the engine rpm makes the fan turn adjust co
20. he service procedures described in this manual using common mechanic s hand tools Special tools if required are shown When testing system pressures calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges For economical reasons the motors do not contain any designated gauge installation ports Use tee fittings to obtain pressure measurements The table lists locations and gauge sizes Port information Port identifier Size Pressure obtained Gauge size bar psi Drain port L1 9 16 18 UNF 2B Case drain 10 100 Inlet port A 7 8 14 UNF SAE J 1926 1 O ring boss System pressure 600 10 000 Outlet port B 7 8 14 UNF SAE J 1926 1 O ring boss Return pressure 600 10 000 Inlet port A SGMS3Y Port locations D CE Outlet port B Drain port L1 P106 084E Port information Portidentifier Size Pressure obtained Gauge size bar psi Drain port L1 9 16 18 UNF 2B Case drain 10 100 600 10 000 600 10 000 Inlet port A Outlet port B 1 1 16 12 UN SAE J 1926 1 O ring boss 25 4mm 0 1 5 1 0in 0 0 06 System pressure Return pressure
21. ing technical knowledge and support for fan drive solutions We offer a lean value chain to our partners and customers and the shortest lead time in the market Turolla OCG is member of the Sauer Danfoss Group Local address Turolla OpenCircuitGear Via Villanova 28 40050 Villanova di Castenaso Bologna Italy Phone 39 051 6054411 Fax 39 051 6053033 Turolla OpenCircuitGear Kuku nova 2148 84 01701 Povazska Bystrica Slovakia Phone 421 424 301 544 Fax 421 424 301 626 Turolla OpenCircuitGear 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Fax 1515 2396618 www FUrollaOoCG com
22. ir parts SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Contents GUI H A Warranty Safety precautions Unintended machine movement Flammable cleaning solvents eee terere netten tenente nennt nnns notti nnotttnonas Fluid urider pressure itt eiie terere tteeettos recte reis tasted oe yore a a a Personal safety Symbols used in Turolla OCG literature eerte tenente nnne nontttnnnntttnnnas 5 GeneralidesciltiOn cecidi riii tte tete tede ON I E UR TE EHE Rer e leere erra SEEN 6 Irene 6 DGS IGS 7 OVEN VIOW Features and options Specifications SGM2Y Specifications SGM3Y FLU ic SPOCifiCath OMS m Operating parameters SGM2Y ssssssssscsecnsscssecsseessecnscessccsseessecssecsuecsseesnecesecsuecsseesueenseesseesseesneenseensees 9 Operating parameters SGMBY csssscssscsseccsccssccscessscesccsnscsscesnscesecsnsesscesnecssecsssesseesneenscesssenseesneenseensees 9 Required tools a dieere an de ere ire rv eH re ERR SERE eere te 10 Port locations and gauge installation eese tenerte n 10 Generalmente treni tregua ut ntis tre rei edd 11 kj laeegelroe el r T 11 Recommendations sinsin iadsaii sari Ranui aN eve nU PR d
23. nce when oil is hot and cold Measure flow entering motor Measure steering flow Replace pump if flow is insufficient Inadequate flow coming from the reservoir due to restrictions Restriction in inlet of the pump Strainer or filter in the reservoir plugged Clean strainer or replace filter in reservoir Check inlet vacuum at pump inlet Maximum Inlet vacuum 0 7 bar absolute 10 inches Mercury vacuum Faulty electronics FDC or ECM The FDC or ECM is sending too high of a current signal to the solenoid Readjust or replace the FDC Verify ECM is working properly Troubleshoot ECM according to manufacturers instructions Replace ECM if necessary Improper modulation of FDC or ECM Item Description Action Faulty input signal to FDC or ECM sensors switches PWM signal Sensors either not functioning properly or not engaged into mounting properly Improper PWM signal from engine Replace or re mount sensor Determine why engine is sending faulty PWM signal and fix Faulty electronics FDC or ECM FDC or ECM sending improper current to solenoid Consult engine service manual Replace the FDC Faulty PRV Valve not shifting properly with current signal from FDC Verify proper current signal to valve Replace valve assembly SGM2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ibf ft SGMBY PRV 12 torque to 70 Nem to 75 Nem 51 to 55 Ibf ft Torque coil nut to 4 Nm to
24. ntroller parameters to reduce the current Consult Turolla OCG FDC Tool Box Consult engine service manual Check motor case drain flow Is motor case drain flow greater than 1 2 l min US 0 3 gal min YES Replace motor NO Check proportional relief valve Check proportional relief valve Is there 12 or 24 VDC to coil NO Find out why and repair YES Disconnect coil Check fan speed Did fan speed increase NO Replace proportional relief valve YES Check FDC and ECM Replace proportional relief valve Check pump After replacing proportional relief valve is there adequate fan speed YES System is OK NO With solenoid disconnected measure and record system pressure and fan speed at increasing engine speed i e 700 1200 1500 1800 full throttle Check fan speed and system pressure Is the fan speed and system pressure increasing with engine speed NO Replace pump Inadequate fan system flow coming from pump If pump or motor lose efficiency there may not be enough flow to move the motor Disconnect a sensor wire or battery wire to controller if the fan does not turn check motor bearing flow out of motor case drain line maximum 1 2 l min US 0 3 g min and or with the solenoid disconnected verify system pressures and fan speed while increasing engine speed If the fan does not turn replace the pump if it does turn Repeat troubleshooting chart from the top of this cha
25. o pen etrate 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 fit tings 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 11022491 June 2010 Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Symbols used in Turolla OCG literature SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Introduction ie Lo A Ix le El g e 9 s 8 e 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 D ES EDS a Rj be DA R amp DJ E 0 D ej 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
26. of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide Global Service Partner network is available for major repairs Turolla OCG Global Service Partners are trained by the factory and certified on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www Turolla OCG com 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 Turolla OCG Global Service Partner 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 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 t
27. rt Check engine idle System with Priority Flow Divider PFD for steering may be sending too much flow to steering Check flow to steering unit Replace pump Fan system flow coming from pump is bypassing the motor Proportional relief valve in motor is stuck in open position Disconnect solenoid coil Fan should go to full speed If fan does not go to full speed replace relief valve Proportional valve installed into end cover supply port Install valve into endcover port on return side of motor 11022491 June 2010 Rev A Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Troubleshooting Fan too slow at high engine rpm Disconnect coil to send fan to maximum speed at high engine rpm If problem remains follow steps 1 thru 8 If fan attains maximum speed follow step 9 Item Description Action Low oil level in reservoir Not enough oil to maintain full system flow Fill reservoir to recommended level Consult operator s manual PRV set to wrong crack pressure PRV may be holding pressure below specifications The PRV controls the maximum speed of the motor Replace PRV with one set to appropriate crack pressure Pressure setting is not externally adjustable Faulty PRV Fan runs at low engine speed at all times Replace valve S M2Y PRV 10 torque to 45 Nem to 50 Nem 33 to 36 Ib
28. 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 L1022491 June 2010 Rev A Wreyre OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP General description The system circuit SGM2Y and SGM3Y Fan Drive Motors Service and Parts Manual Introduction A Turolla OCG electrohydraulic proportional fan drive system consists of a fixed or variable displacement open circuit hydraulic pump and an SGM2Y SGM3Y gear motor with integral full flow proportional relief valve to control fan speed The Engine Control Module ECM or Turolla OCG Fan Drive Controller FDC drives the proportional relief valve using a Pulse Width Modulated PWM signal The typical on highway system also includes a second pump or integral priority flow divider PFD to provide flow for power steering The primary on highway applications for this system are diesel rear engine vehicles that provide a proportional fan drive PWM signal Turolla OCG fan
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