Motors D Series Service Manual 07-2011
Contents
1. D Series Gear Motors v 90 OpencCircuitGear Service Manual D D Series Gear Motors U e 0 Service Manual UM Revision OpenCircuitGear CVISION MEMBER OF THE SAUER DANFOSS GROUP History of Revisions Table of Revisions Date Page Changed Rev November 2010 all Turolla colors BB March 2010 19 Added shaft seal kit number AC February 2010 last Fix Osaka address AB April 2009 First edition AA 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 specifi cations All trademarks in this material are properties of their respective owners Sauer Danfoss Turolla Turolla OpenCircuitGear Turolla 2 L1022962 Rev BB November 2010 Eee OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Introduction Technical Specifications Operating Parameters Pressure Measurements Initial Start Up Procedures Fluid and Filter Maintenance Troubleshooting Minor Repair Repair Parts D Series Gear Motors Service Manual Contents Overview Warranty Safety Pr2. 0 39 9 43 8 49 7 46 1 43 5 41 6 Theoretical power at rated speed hp 31 2 349 376 413 466 532 584 66 3 61 1 58 0 55 5 Bar 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 Case drain pressure maximum a eet et e Oe m psi U25M 725 E5 725 NZ2OM 725 725 72 5 Up 725 e minimum speed at maximum pressure Fluid Specifications Parameter Unit Minimum Continuous Maximum Viscosity mm2 sec cSt 8 10 100 1600 Ratings are based on SUS 36 50 212 7500 operation with premium Temperature C F 40 40 110 230 115 239 petroleum based hydraulic Cleanliness ISO 4406 Class 22 18 13 or better fluids containing oxidation NONAS Filtration efficienc charge filtration rust and foam inhibitors e iid ne Bis20 75 B 210 For detailed filtration information see Sauer Danfoss publication 520L0463 Fluids and Filtration For information on biodegradable fluids see Sauer Danfoss publication 520L0465 Biodegradable Hydraulic Fluids 8 L1022962 Rev BB November 2010 UIfej o OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Overview Pressure D Series Gear Motors Service Manual Operating Parameters Definitions of the D Series motors operating parameters appear below Consult Sauer Danfoss technical support for applications running outside of these parameters Peak pressure Pressure vs time Peak pressure is the highest intermittent pressure allowed The
3. OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Technical Specifications Technical data for D Motors Ratings Units 17 19 21 23 25 29 32 36 38 41 45 cm rev 17 0 19 0 20 5 225 25 4 290 31 8 36 1 38 0 41 0 45 0 Displacement in rev 1 04 1 16 1 25 1 37 558 1 77 1 94 2 20 2 32 250 275 Bar 276 276 276 276 276 276 276 276 276 241 210 Rated pressure psi 4000 4000 4000 4000 4000 4000 4000 4000 4000 3495 3045 Bar 303 303 303 303 303 303 303 303 303 265 231 Peak pressure psi 4400 4400 4400 4400 4400 4400 4400 4400 4400 3843 3350 maximum 3400 3400 3400 3400 3400 3400 3400 3400 3400 3000 3000 Speed at rated pressure minimum 600 600 600 600 600 600 600 600 600 600 600 Start speed at 1000 PSI rpm 400 400 400 400 400 400 400 400 400 400 400 kg 8 53 8 66 8 80 894 9 07 9 38 9 53 9 84 9 93 10 16 10 43 Standard Weight Ib 18 8 19 1 19 4 197 20 0 207 21 0 217 21 9 224 23 0 x10 kom 127 138 146 156 172 191 206 228 239 255 276 Mass moment of inertia x10 slug ft2 94 102 107 115 127 141 152 168 176 188 204 Nem 65 7 73 4 79 2 87 0 98 2 112 1 122 9 139 6 146 9 138 4 132 4 Theoretical torque at rated pressure Ibfeft 48 5 54 2 584 64 2 724 827 907 102 9 108 3 102 1 97 6 kw 23 4 26 1 28 2 31 0 35
4. 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 Fillthe 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 the full level throughout the start up Caution If reservoir is low damage to hydraulic components may occur Maintain sufficient oil in the reservoir at all times 5 Useacommon 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 sta
5. 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 chart 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 L1022962 Rev BB November 2010 Disconnect solenoid coil Fan should go to full speed If fan does not go to full speed replace relief valve 15 M DSeries Gear Motors U e 0 Service Manual Troubleshooting OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP 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 below If fan attains maximum speed follow step 9 Item Description Action 1 Low oil level in reservoir Not enough oil to maintain full system fl
6. 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 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 necessary to change the filter Replace all fluid lost during filter change L1022962 Rev BB November 2010 13 Were OpenCircuitGear D Series Gear Motors Service Manual Troubleshooting 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 conn
7. the proportional relief valve using a Pulse Width Modulated PWM signal Sauer Danfoss fan drives work with engines produced by all the major North American and European engine manufacturers The pump receives fluid directly from the reservoir through the inlet line The output of the pump is connected to a fixed displacement gear motor which has an electrohydraulic proportional valve mounted in the motor s rear cover The valve setting determines the maximum pressure in the system by passing 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 predetermined customer selected maximum pressure setting In a hydraulic fan drive system the predetermined 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 level to minimize air entrainment Baffles in the reservoir diffuse the oil to an acceptable level mix it with the fluid in the reservoir and prevent the oil from flowing immediately back to the pump inlet The return o
8. valve P1 in the E1 position of the model code L1022962 Rev BB November 2010 23 Ure fo OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Our Products Turolla OpenCircuitGear Aluminum Gear Pumps Turolla OCG with more than 60 years of experience in designing and manufacturing gear pumps gear motors and fan drive motors Aluminum Gear Motors of superior quality is the ideal partner ensuring robustness and Cast Iron Gear Pumps reliability to your work functions Cast Iron Gear Motors We are fast and responsive the first to specify a customer product Fan Drive Gear Motors Aluminum the most experienced in providing technical knowledge and support for fan drive solutions Fan Drive Gear Motors Cast Iron 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 Povazsk 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 TurollaoOcCG com L1022962 Rev BB November 2010
9. 16 inch Torque 50 Nem 37 bt P107 963E Item Description Part number Description Part number 1 Shaft nut 5 8 18 UNF 163M2013 PB Key 163M4001 2 Locking washer 163M2428 TK Key 163M4007 3 Key 29620 17 20 L1022962 Rev BB November 2010 UIfe o OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Coil Replacement Valve Replacement D Series Gear Motors Service Manual Minor Repair Refer to the valve drawings on the following pages 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 O ring and coil Install the coil 1 Install new coil 2 Install O ring on the valve stem 3 Install the plastic nut Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft Warning Do not overtorque plastic nut Overtoruque will damage valve 4 Install the wire connector to the coil Remove the valve Remove the valve from the motor Install the valve Install new valve into motor Torque to 45 Nem 33 lbfeft Warning Do not overtorque valve Overtoruque will damage valve L1022962 Rev BB November 2010 21 M DSeries Gear Motors U re le Service Manual Repair Parts OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Valves Proportional Relief Valve Hexagon 22 mm or 28 mm Torque 45 N m 33 Ib ft 12 point socket 26mm Torq
10. R OF THE SAUER DANFOSS GROUP Shaft Seal Replacement 18 D Series Gear Motors Service Manual Minor Repair Tools needed snap ring pliers hammer Replacing the shaft seal awl 2 sheet metal screws 2 wire cutting pliers installation sleeve PVC protector tube approximately 0 5 mm 0 02 in CTS smaller than flange hole diameter wide cellophane packaging tape and grease Dust Seal Remove the shaft seal 1 Remove key from shaft 2 Clean shaft area of all rust dirt and grime 3 Usea needle nose pliers or sharp screwdriver to remove the dust protector E101 262 Use the following instructions to carefully pry out the shaft seal 4 Using a sharp punch or awl punch two holes in the shaft seal date holes In sea Do not drill holes Drilling holes produces contamination P107 971E 5 Turn two sheet metal screws one or two turns into the seal sheet metal L1022962 Rev BB November 2010 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Shaft Seal Replacement continued Seal Kit Kit P N 11078459 D Series Gear Motors Service Manual Minor Repair P107 973E 6 Using side cutting wire pliers remove the seal by prying it out as shown Take care not to damage the shaft 7 Discard the seal Inspect the components Inspect the new seal the motor housing seal bore and the
11. ain pressure as low as possible Maximum case drain pressure allowed is 5 bar 72 5 psi L1022962 Rev BB November 2010 9 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Temperature and Viscosity Hydraulic Fluid 10 D Series Gear Motors Service Manual Operating Parameters Temperature and viscosity requirements must be concurrently satisfied Use petroleum mineral based fluids Temperature High temperature limits apply at the inlet port of the motor The motor should run at or below the maximum continuous temperature Cold oil generally doesn t affect the durability of motor components It may affect the ability of oil to flow and transmit power For this reason keep the temperature at 16 C 60 F above the pour point of the hydraulic fluid Minimum cold start temperature relates to the physical properties of component materials Continuous temperature is the temperature at or below the temperature which normal motor life can be expected Maximum temperature is the highest temperature that is tolerable by the machine for a transient limited time Duty cycle 196 or less Viscosity Minimum viscosity occurs only during brief occasions of maximum fluid temperature and severe duty cycle operation It s the minimum acceptable viscosity to guarantee the motor life Duty cycle 196 or less Maximum viscosity occurs only during cold start at very low temperatures It is the upper limit of viscos
12. e bar psi 3 4 16 SAE J 1926 1 O ring boss 7 8 14 SAE J 1926 1 O ring boss Inlet and outlet 1 1 16 12 SAE J 1926 1 O ring boss System and return 600 10 000 ports A and B 15 16 12 SAE J 1926 1 O ring boss pressure 1 inch split flange 1 1 4 split flange Drain port L1 9 16 18 SAE Case drain 10 100 m External drain L1 9 16 18 SAE Straight thread for 3 8 inch O D tube Note Location can be on opposite side of motor Inlet port and outlet port SAE ORB ports sized identically sizes are 3 4 16 7 8 14 1 1 16 12 p and 1 5 16 12 Radial ports Axial ports External drain drive side Inlet port and outlet port sized identically H Note Location can be on opposite side of motor Inlet port and outlet port Cy sized identically p j Split flange ports Fan drive ports P107 962E L1022962 Rev BB November 2010 11 Were OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP General Start Up Procedure 12 D Series Gear Motors Service Manual Initial Start Up Procedures Follow this procedure when starting up
13. e 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 controller parameters to reduce the current Consult Sauer Danfoss controller documentation 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 controller Replace proportional relief valve After replacing proportional relief valve is there adequate fan speed Check pump 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
14. ecautions Unintended Machine Movement nee 4 Flammable Cleaning Solvents sens 4 Fl id Under Press Ur sansin in ainai 4 Personal Safety EE 4 Hazardous Material m Symbols Used in Sauer Danfoss literature D ier airlBBIieseem e 6 The Systemi CAG UU RU 6 BI me 7 Technical Specifications Fluid SpecifiCations zero ecce ripetere ree tete trit E sey esdessscbusnceasactustscloeres IS mer HEEL PHESSUNG ser Temperature and Viscosity Hydrauli To c Required D lee E 11 Port locations and Gauge Installation em 11 General Start Up Procedure Tune E Le 13 Fan Speed Locked High at High Engine Speed cold conditions EEN 14 High Stand by Fan Speed cold conditions nn 14 Fan Speed Not Controlled by Current to Colle 14 Fan DOSS ee Ul D 15 Fan Too Slow at High Engine rpm EEN 16 Improper Modulation of Control Module 16 System Moise sine Hydraulic System Operating Hot Leaking Motor Shaft Seal Shaft Seal Replacement EENEG 18 ell E Coil Replacement Valve Replacement MED TIMER 22 L1022962 Rev BB November 2010 3 Were OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Overview Warranty Safety Precautions D Series Gear Motors Service Manual Introduction This manual includes inst
15. ect 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 1 Wire disconnected or shorted Any wire on the controller 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 2 Faulty electronics The control module is not sending a current signal to the solenoid No feel of magnetics on proportional relief valve coil Replace the control module Consult engine repair manual verify 12 or 24 VDC is going to the coil 3 Faulty input signal to control module sensors switches PWM signal Sensors either not functioning properly or not properly engaged 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 24VDC going to controller Check for 5VDC across sensors 4 Faulty valve Valve is stuck in closed position Replace valve or complete motor assembly 5 Faulty solenoid coil Coil is either shorted or open No feel of magnetics on coil Replace coil Torque coil nut to 4 to 6 Nem 3 to 4 5 Ibfeft 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 pr
16. el 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 necessary 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 Torque to 45 Nem 33 Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft 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 5 bar 72 psi Replace motor L1022962 Rev BB November 2010 17 Urola OpenCircuitGear MEMBE
17. essure Replace valve Torque to 45 Nem 33 Ibfeft Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft Faulty electronics sensor bad or disconnected PWM signal missing Controller 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 controller Faulty solenoid coil Coil is either shorted or open No feel of magnetics on coil Replace coil Torque coil nut to 4 to 6 Nem 3 to 4 5 Ibfeft Fan Speed Not Controlled by Current to Coil Item Description Action Fan speed proportional to engine speed at all times Blocked or stuck valve causes fan speed to be proportional to engine speed at all times Replace valve Torque to 45 Nem 33 Ibfeft Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft 14 L1022962 Rev BB November 2010 Urola D Series Gear Motors Service Manual ST T Troubleshooting MEMBER OF THE SAUER DANFOSS GROUP Fan Does Not Turn 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 valv
18. here 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 A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Hazardous Material Warning Hydraulic fluid contains hazardous material Avoid prolonged contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations L1022962 Rev BB November 2010 UIfej o OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Symbols Used in Sauer Danfoss literature D Series Gear Motors Service Manual Introduction A e ei v Ix le Ei amp j 8 rg 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
19. il remains in the reservoir long enough to allow any entrained air in the fluid to rise to the surface and dissipate L1022962 Rev BB November 2010 Welle OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Design D Series Gear Motors Service Manual Introduction CANBUS J1939 System Illustration Microcontroller PLUS 1 RESERVOIR case drain D Series D Series gear pump gear motor DIESEL ENGINE P107 929E Sauer Danfoss 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 and dust protector at the front of the motor prevents leakage where the shaft exits the motor housing Cutaway Drawing Optional proportional control valve Specially designed Case drain thrust plates SAE A 2 bolt or SAE B 2 bolt mounting flange Dust protector SAE O ring boss side ports other port options available Heat treated alloy steel H duty low fricti dos AER integral gears and shaft steel backed bronze sleeve bushings Viton seals standard P107 920E L1022962 Rev BB November 2010 7 D D Series Gear Motors U e 0 Service Manual Technical Specifications
20. ity that allows the motor to start Continuous viscosity The viscosity range at which normal motor life can be expected Ratings and data for gear motors are based on operation with premium hydraulic fluids containing oxidation rust and foam inhibitors These fluids must possess good thermal and hydrolytic stability to prevent wear erosion and corrosion of internal components Use only clean fluid in the motor and hydraulic circuit O Caution Never mix hydraulic fluids For more information on hydraulic fluid selection see Sauer Danfoss publications 520L0463 Hydraulic Fluids and Lubricants Technical Information and 520L465 Experience with Biodegradable Hydraulic Fluids Technical Information L1022962 Rev BB November 2010 M DSeries Gear Motors U e 0 Service Manual OpenCircuitGear Pressure Measurements MEMBER OF THE SAUER DANFOSS GROUP Required Tools You can perform the 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 Port locations and Gauge For economical reasons the motors do not contain any designated gauge installation Installation ports Use tee fittings to obtain pressure measurements The table lists locations and gauge sizes D Series Motor Port information Port identifier Size Pressure obtained Gauge siz
21. mproper current to solenoid Consult engine service manual Replace the control module module Faulty proportional relief Valve not shifting properly with current signal from Replace valve assembly valve control module Verify proper current signal to valve Torque to 45 Nem 33 Ibf ft Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft 16 L1022962 Rev BB November 2010 Urola D Series Gear Motors Service Manual ententes Troubleshooting MEMBER OF THE SAUER DANFOSS GROUP System Noise 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 Hydraulic 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 lev
22. n system If pump loses efficiency it may not produce enough Compare performance when oil is hot and cold Measure flow flow coming from pump flow to turn the motor A damaged pump may entering motor Measure steering flow Replace pump if flow is provide flow when oil is cold and viscous but may insufficient 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 8 Inadequate flow coming Restriction in inlet of the pump Strainer or filter in Clean strainer or replace filter in reservoir from the reservoir due to the reservoir plugged Check inlet vacuum at pump inlet Maximum Inlet vacuum restrictions 0 7 bar absolute 10 inches Mercury vacuum 9 Faulty electronic control The control module is sending too high of a current Readjust or replace the control module Verify control module module signal to the solenoid is working properly Troubleshoot control module according to manufacturers instructions Replace control module if necessary Improper Modulation of Control Module Item Description Action Faulty input signal to Sensors either not functioning properly or not Replace or re mount sensor Determine why engine is control module sensors engaged into mounting properly Improper PWM sending faulty PWM signal and fix switches PWM signal signal from engine Faulty electronic control Control module sending i
23. ow Fill reservoir to recommended level Consult operator s manual 2 PRV set to wrong crack PRV may be holding pressure below specifications Replace PRV with one set to appropriate crack pressure pressure The PRV controls the maximum speed of the motor Pressure setting is not externally adjustable 3 Faulty PRV Fan runs at low engine speed at all times Replace valve Torque to 45 Nem 33 Ibfeft Torque coil nut to 4 Nem to 6 Nem 3 to 4 5 Ibfeft 4 Hydraulic oil temperature High oil temperature decreases viscosity and Maintain hydraulic oil at normal operating temperatures 110 C too high affects efficiency 230 F max Ensure cooler is operating properly High oil temperature can also be caused by aeration see below 5 Aeration of oil Air in system decreases efficiency of units and Find location where air is entering into the system and fix controls Noise foaming and hot oil are signs of Check inlet line to pump and repair any leaks Fill reservoir to aeration recommended level Consult operator s manual 6 Damaged motor low Proportional relief valve spool sticking open may Measure system pressure between pump and motor Vary system pressure prevent full flow from going through motor engine speed low to high Does system pressure change Not enough flow from pump 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 7 Inadequate fa
24. relief valve overshoot reaction time determines peak pressure It is assumed to occur for less than 100 ms The illustration to the right shows peak pressure in relation to rated pressure and reaction time 100 ms maximum Peak pressure Rated pressure Pressure Rated pressure Rated pressure is the average regularly occurring operating inlet pressure that should yield satisfactory product life The Time maximum machine load at the motor er shaft determines rated pressure Reaction time 100 ms max System pressure System pressure is the differential between the inlet and outlet ports It is a dominant operating variable affecting hydraulic unit life High system pressure resulting from high load at the motor shaft reduces expected life System pressure must remain at or below rated pressure during normal operation to achieve expected life Back pressure Back pressure is the average regularly occurring operating outlet pressure that should yield satisfactory motor life The hydraulic load demand downstream of the motor determines the back pressure The Fan Drive Gear Motor can work with back pressure up to 10096 of the maximum rated inlet pressure Case drain pressure Case drain pressure is the regularly occurring case drain line pressure that should yield satisfactory motor life It is recommended to design the case drain piping connecting the case drain direct to the tank in order to keep the case dr
25. required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port LENS RAA E 0 D ej Tip helpful suggestion Lubricate with clean 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 L1022962 Rev BB November 2010 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP General Description The System Circuit D Series Gear Motors Service Manual Introduction A Sauer Danfoss electrohydraulic proportional fan drive system consists of a combination of fixed or variable displacement open circuit hydraulic pump and an D gear motor with or without proportional relief valve or standard relief valve and check valve to control fan speed The engine control module or Sauer Danfoss control module drives
26. rt 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 entrainment 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 level 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 motor is going to full speed 9 Checkthat the reservoir is full The motor is now ready for operation L1022962 Rev BB November 2010 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Recommendations D Series Gear Motors Service Manual Fluid and Filter Maintenance Gear 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
27. ructions for the installation maintenance and minor repair of D Series Motors It includes a description of the units and their individual components troubleshooting information and minor repair procedures A worldwide Authorized Service Center network is available for major repairs Sauer Danfoss Authorized Service Centers are trained by the factory and certified on a regular basis You can locate your nearest Authorized Service Center using the distributor locator at www sauer danfoss com Performing installation maintenance and minor repairs according to the procedures in this manual does not affect your warranty Major repairs requiring the removal of a unit s rear cover or front flange voids the warranty Only a Sauer Danfoss Authorized Service Center may perform major repairs Sauer Danfoss trains ASC and certifies their facilities on a regular basis 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 w
28. sealing area on the shaft for rust wear and contamination Polish the shaft and clean the housing if necessary being careful not to allow contamination to fall into the motor Install the new shaft seal 1 Cover the shaft keyway and exposed threads with a shaft cover or packaging tape to protect the shaft and seal during installation Lubricate the inside of the seal Start the shaft seal into the housing with the cupped side of the seal facing the motor Use an installation sleeve to press the seal slowly in place Stop when the seal is seated Using the installation sleeve install the dust protector until it is flush with the motor Installation 0 5 mm sleeve 0 02 in smaller than housing Dust i protector Seal Ae D A Seal Kit K AU EM UU P107 974E Re install the key into the shaft Ensure the top of the key does not interfere with the bottom of the keyway in the fan hub when the fan is installed Thoroughly inspect the operation of the motor after it is installed to ensure no leakage occurs L1022962 Rev BB November 2010 HM D Series Gear Motors U ele Service Manual OpenCircuitGear Minor Repair MEMBER OF THE SAUER DANFOSS GROUP Shaft Repair Parts PB shaft option TK shaft option PB key TK key en Ae D GR l P107 964E SH Hexagon socket 15
29. ue 4 Nem 2 95 Ibfeft um Anti cavitation check valve ES Section A A P107 965E Fixed Relief Valve Hexagon 22 mm or 28 mm Torque 45 Nem 33 Ibf ft Anti cavitation check valve Q Q qu Section A A B _ cc 2 i e 9 e o6 P107 966E 22 L1022962 Rev BB November 2010 Urola OpenCircuitGear MEMBER OF THE SAUER DANFOSS GROUP Valves continued D Series Gear Motors Service Manual Repair Parts Valve Repair Parts Ge Coil Proportional O P d Relief Fixed Valve Relief CO Valve Uv Pilot y et Seal kit ix CH DA Op 73 OQ Le Seal ki 00 eal kit Log P107 968E Seal kit P107 967E Description Part number Description Part number Coil 12 VDC P1 P2 11057054 Seal Kit F 11057062 Coil 24 VDC P3 P4 11057053 Seal Kit G 11057063 Seal Kit P2 P4 11057060 Seal Kit P1 P3 11057061 Pilot seal kit 11057166 Model Code example Fan drive motor A B C D E 12 VDC proportional relief valve 25 GPM or less at 172 Bar curve F A BR CDD PR F G J K VUUU UUU LU ULUL PWUU VUU LUUU LU ULU Above example shows a 12 volt proportional relief
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