Gear Pumps and Motors Service Manual Group 2
Contents
1. Leena PNAS Socket Head Capscrew Pressure Seals Rear Flange pumps 7 3 1 General The figure above shows a cross section of a typical group 2 intermediate stage pump An intermediate stage pump can be purchased directly from the factory or it can be made from a single stage pump 7 3 2 Model Code The model code for ordering an intermediate stage pump is SNP2 FR73 x Where X is the type of porting required as ex pressed in the table at the right See Model Code page 8 and 9 30 Not used in converted intermediate stage P101 135 Intermediate stage pumps supplied from the fac tory are pre assembled with two socket head cap screws on the front flange and two in the rear flange When an intermediate stage pump is converted from a single stage pump the socket head capscrews are omitted The front and rear flanges will then be retained by the main studs of the assembled multiple pump Flanged port with threaded holes in X patern German standard ports centered on the body Flanged port with threaded holes in patern European standard ports Threaded SAE o ring boss ports Threaded Gas port BSPP Flanged port with threaded holes in X patern German standard ports offset from center of body T2. Socket Head Capscrew Pressure Seals Not used on converted 7 4 1 General The figure above shows a cross section of a typical FRO3 type pump Even though this pump is a standard single stage pump itis commonly used as a final stage pump This pump can be purchased directly from the factory or it can be made from a single stage pump 7 4 2 Model Code The model code for ordering a final stage pump is SNP2 FRO3 x Where X is the type of porting required as ex pressed in the table at the right See Model Code pages 8 and 9 32 final stage pumps P101 136 Final stage pumps supplied from the factory are pre assembled with two socket head cap screws on the front flange and two in the rear cover When an intermediate stage pump is converted from a single stage pump the socket head capscrews are omitted The front and rear flanges will then be retained by the main studs of the assembled multiple pump Flanged port with threaded holes in X patern German standard ports centered on the body Flanged port with threaded holes in patern European standard ports Threaded SAE o ring boss ports Threaded Gas port BSPP Flanged port with threaded holes in X patern German standard ports offset from center of body
3. T 1 1 Construction Multiple stage pumps may be purchased directly from Sauer Danfoss or individual stages can be purchased and assembled Single pumps can also be converted to multiple stages by replacing the drive gear shaft and front or rear flange Other multiple configurations can be achieved by mixing pumps of different groups however this manual will present information regarding multiple pumps con figured strictly from the group 2 product line Intermediate stages are of the FR43 or FR73 type and final stage is of the FRO3 type A tang output shaft and oldham style coupling connect each stage Since the coupling requires lubrication from the pump inlet the front shaft seal is omitted on all pumps except the first stage P101 133 Socket head capscrews retain the front flange and rear cover of each stage The assembly is held together by hex nuts and studs extending from the rear cover of the final stage to the front flange of the first stage Studs will differ in length depending upon the displacement combination of all pumps in the unit A table of stud lengths for tandems and a formula for calculating stud length of multiples can be found in the appendix section 1 1 2 2 SAUER DANFOSS Gear Pumps and Motors 7 2 First Stage Pump Preparation Rear Flange Shaft Seal Group 2 Drive Gear Front Shaft Socket Head Li
4. 16 5 6 6 0 260 l M 12 x1 25 6G 0 453 11 5 MINIMUM g 0 650 16 500 EXACT AT THIS POINT FULL THREAD TAPER 1 IN 5 ON DIAMETER 6 24 0 246 19 90 0 783 19 30 0 760 0 004 0 039 1 00 x 60 650 0 110 0 016 5 Spline Data B17x14 DIN 5482 9 tooth pitch diameter 14 4 0 567 pressure angle 30 module 1 60 0 118 3 00 P101 143E P101 144E CO02 Taper Shaft Type Key Data Technical Specifications Nut Torque Maximum Shaft Torque SC02 Splined Shaft Type Spline Data Circular Tooth Thickness s Profile Correction Technical Specifications Maximum Shaft Torque Group 2 11 5 2 Shafts Used with 02 Flange 1 5 Taper Shaft 3 x 6 5 ISO 6604 DIN 6888 40 50 Nm 30 37 lbfeft 140 Nm 103 Ibfeft 9 Tooth Spline 17 x 14 DIN 5482 3 206 mm 0 6 130 Nm 96 Ibf ft SAUER DANFOSS Gear Pumps and Motors 11 5 3 Shafts Used with 04 05 Flange CO04 CO05 Taper Shaft Type Key Data Technical Specifications Nut Torque Maximum Shaft Torque SCO04 SC05 Splined Shaft Type Spline Data Circular Tooth Thickness e Profile Correction Technical Specifications Maximum Shaft Torque 1 5 Taper Shaft 3 x 6 5 ISO 6604 DIN 6888 40 50 Nm 30 37 Ibfeft 140 Nm 103 Ibfeft 9 Tooth Spline 17 x 14 DIN 5482 3 206 mm 0 6 130 Nm 96 lbfeft
5. German standard ports SC04 DIN splined shaft German two bolt PTO flange Deutz German standard ports SCO05 DIN splined shaft German two bolt PTO flange Deutz German standard ports SC06 SAE splined shaft SAE A flange SAE O ring boss ports SC36 SAE splined shaft SAE A flange plus SAE A auxiliary mounting pad SAE O ring boss ports FR Sauer Danfoss tang shaft FRO3 Sauer Danfoss tang shaft flanged for multiple configuration German standard ports SAUER DANFOSS Gear Pumps and Motors Group 2 ABCD EE H L P RS EEEE E ELS C B3 Variant Code Three letter code describes valve settings or other variants to standard configuration BBM Variation on 09 flange to accommodate Perkins 900 series engine mounting LEP Variant on standard straight shaft used with CI96 outrigger bearing option LBD Variant on standard tapered shaft used on CO91 outrigger bearing option Ux Integral flow divider Pressure setting at controlled flow bar psi L 60 870 T 140 2030 M 70 1015 C 150 2175 N 80 1160 U 160 2320 O 90 1305 D 170 2465 P 100 1450 V 180 2611 Q 110 1595 E 190 2755 R 120 1740 X 200 2901 S 130 1885 Controlled flow l min US gal min M 8 2 11 J 18 4 75 F 10 2 64 Q 20 5 28 N 12 8 17 K 22 5 80 O 14 3 70 R 24 6 34 P 16 4 23 l 26 6 86 Vick Integral relie
6. SAUER DANFOSS Gear Pumps and Motors Service Manual SAUER DANFOSS Gear Pumps and Motors Group 2 1 Introduction 1 1 Using This Manual The purpose of this manual is to provide useful information concerning assembling and disassem bling of Group 2 pumps and motors In order to obtain the maximum performance from this series of com ponents we recommend special attention be given to the suggestions and recommendations included This manual gives a general description of the design of the units It also details disassembling and assem bling procedures for single units pumps and mo tors It then follows up with the multistage units explaining how to combine or separate into single stages A special section is devoted to describe how 1 2 Safety Precautions Always consult the equipments operator manual for specific safety warnings prior to approaching a ma chine Hydraulic components may be located in close proximity to sharp and or hot components always take appropriate precautions Flammable Cleaning Solvents A WARNING Some cleaning solvents are flammable To re duce risk of fire do no use cleaning solvents in an area where a source of ignition may be present Personal Safety A WARNING Proper safety equipment including safety glasses should be used at all times Copyright 1999 Sauer Danfoss Company to change the rotation of the pump or motor The appendix gives information on
7. 0 127 mm 005 less than standard SAE class 1 fit 75 Nm 55 lbfeft SAUER DANFOSS Gear Pumps and Motors SKP2 SC06 Splined Shaft Type SAE 11 Tooth Spline Spine Data 11T 16 32DP SAE J498b flat root side fit Circular Tooth Thickness 0 127 mm 005 in less than standard SAE class 1 fit Technical Specifications Maximum Shaft Torque 150 Nm 111 lbfeft r 10 5 413 12 472 _ Group 2 mm in _ 38 1 496 _ 6 236 E ES R em E e Q 2 E E 7 Lf P101 149E 59 SAUER DANFOSS Gear Pumps and Motors 11 5 5 FR Tang Shaft The shaft type shown in the drawing is called a tang shaft This shaft is used in conjunction with an Oldham style coupling and is normally connected to another tang shaft on a P T O Power Take Off This shaft is generally supplied with the 03 43 type flange and is used as the front drive for multistage pumps Caution Due to the limited dimensions of the tang shaft and to supply lubricating oil for the coupling the 03 43 pumps are supplied without a front shaft seal A shaft seal must be located on the P T O Technical Specifications 70 Nm 52 lbfeft Maximum Shaft Torque 11 5 6 Mating Design for FRO3 Pumps The sketch of a P T O for the FR03 type pumps is shown The axial dimensions and positions of the shaft must be strictly met They are very important for correct torque transmission The P T O mu
8. 11 SAUER DANFOSS Gear Pumps and Motors Group 2 4 Servicing 4 1 Conversions Group 2is amodular series In particular itis easy to make conversions on the pumps e g changing rotation replacing flange drive shaft seals or assembling a tandem pump from two single pumps On the following page are tables showing the allowable conversions 4 1 1 Recommendations Due to a specific manufacturing process known as cut in during which the gears pump body and bearing blocks are allowed to establish a unique relationship to each other it is gener ally not recommended to open and replace com ponents of a gear pump or motor The removal or replacement of some internal components will unavoidably modify their critical dimensions Because pumps and motors are cut in at a spe cific pressure to ensure maximum efficiency removal or replacement of internal components may be detrimental to the pump or motor effi ciency Pump motor conversions are allowed if the following criteria are followed The following is a list of general recommendations he personnel performing any type of conver sion must be trained The performance of a converted unit is in direct relationship with the quality of the job A trained qualified techni cian by following the procedures in this manual should be able to perform a quality job 4 2 Conversion Tables The tables on the following page summarize the conversion operations whi
9. 250 3625 Minimum Speed at 0 100 bar 600 600 600 900 900 900 Minimum Speed at 100 180 bar 1200 1200 1000 800 750 750 Minimum Speed at 180 bar to rated pressure 1400 1400 1400 1200 1000 1000 Maximum Speed 4000 4000 4000 4000 3500 3000 Peak Pressure 280 4060 280 4060 280 4060 280 4060 280 4060 280 4060 Rated Pressure 250 3625 250 3625 250 3625 250 3625 250 3625 250 3625 Minimum Speed at 0 100 bar 600 600 600 900 900 500 Minimum Speed at 100 180 bar 1200 1200 1000 800 750 750 Minimum Speed at 180 bar to rated pressure 1400 1400 1400 1200 1000 1000 Maximum Speed 4000 4000 4000 4000 3500 3000 Peak Pressure Rated Pressure Minimum Speed at 0 100 bar Minimum Speed at 100 180 bar Minimum Speed at 180 bar to rated pressure Maximum Speed The data below represent mean values for standard configured pumps Weight kg lb DG 5 1 24 5 3 2 5 5 5 27 5 8 2 9 6 3 3 0 6 5 Sm 6 7 3 2 7 0 SES ms Moment of Inertia of rotating components x10 kg m x10 Ibf ft 20 6 489 PO 610 31 5 747 373 885 45 9 1089 51 7 12
10. 40 5 1 594 LA19 1748 19 3 760 ET 7 2 283 687 Group 2 mm in Section A A ee A LO e 3 0 025 1 18 Zeil ge o gt D i EI e Lo 4 88 2 89 EN Zo WER 0o KR LO Q 1 5 26 1 024 gt 13 9 001 gt T LO e LO co Q spline B17x14 DIN 5482 profile offset 0 6 P101 145E P101 146E SAUER DANFOSS Gear Pumps and Motors mm in 7 92 0 312 7 73 0 304 i 24 10 0 949 23 50 0 925 0 020 0 697 17 700 0 688 17 475 x 45 3 995 0 157 3 970 0 156 15 875 0 625 15 850 0 624 Q 2 3 0 091 1 7 0 067 P101 147E 7 73 0 304 24 10 0 949 23 50 0 925 0 toos 609 x 45 40 0 127 015 456 Spline Data SAE J498b 9T 16 32DP FLAT ROOT SIDE FIT 30 pressure angle 14 288 0 563 pitch diameter circular tooth thickness 0 127 0 005 less than standard class 1 fit P101 148E 58 Group 2 11 5 4 Shafts Used with 06 Flange SAE CI06 Parallel Shaft Type Technical Specifications Maximum Shaft Torque SCO06 Splined Shaft Type Spine Data Circular Tooth Thickness Technical Specifications Maximum Shaft Torque SAE A parallel Shaft 80 Nm 59 Ibf ft SAE 9 Tooth Spline 9T 16 32DP SAE J498b flat root side fit
11. Torque 44 54 Nm 32 40 Ibfeft 18 Install socket head capscrews 03 flange and first stage of multiple Using a 4 mm internal hex wrench install the Socket head capscrews to the front flange and rear cover T Torque 2 5 3 4 Nm 22 30 Ibfein If used install new o ring to flange pilot 19 Testing After pump has been disassembled and reas sembled it is suggested that the pump be run in and tested on an appropriate test stand This is done to verify the volumetric efficiency and the integrity of the unit Test specifications and procedure are given in section 1 1 3 25 SAUER DANFOSS Gear Pumps and Motors 20 Prepare the unit for shipment or storage Clean the exterior of the pump and install the following e Port Plugs e Key CI and CO shafts e Shaft protective cap CI and CO shafts e Nut and washer CO shaft 26 Group 2 Port Plug Plug F101 031 SAUER DANFOSS Gear Pumps and Motors Group 2 7 Multi Stage Pumps 7 1 General
12. a Rear Stage Pump cccccccccssseeeceeeeeeeeeeeeeeeeeeeaeeeceeseseeeceeesseeeeeessaeeeeeesesaaeeeeeeas 33 7 4 4 OV ST SION Frode siorse inean EE 33 7 5 Assembly of Multi Stage Pumps ssssessssssssessseseesenn nennen nennen nennen nennen enar n ness e naar nnns 34 7 6 EE eet RT E 35 7 6 1 E EE A AEEA 35 7 6 2 Determining the Direction of Rotation EEN 35 7 6 3 IVS Reie e EE 36 7 6 4 Soi ce gie goto IC 36 SAUER DANFOSS Gear Pumps and Motors Group 2 G ORFA P UDS eet 39 8 1 General INform tON RTT EE 39 8 12 Drive Gear Shaft Differences CNET TET 40 8 1 3 Front and Rear Flange Differences esses nennen nnne nnne nnn nn nnns 40 8 1 1 BS ai IOC dimfo die PE oa T D TEE D OE 40 8 1 4 Bearing Block Differences o sseeeesssesesseseeseeseeeeee nene nennen nnne nnne nnn nnn n nnne nn nnne nnns 41 8 2 Changing breede Eege E 42 SM Ge TK ODTOINS PRENNENT 44 9 1 Rear Cover with Integral Priority Flow Divider Valve cccccsseceecssseeeeceeeeeeeeeueeessuaeeeessaueeessaaeeessaaes 44 9 1 1 General OW He WE 44 9 1 2 Disassembly and HEASSSMDIY sssri A rira x DEVE ERER 44 9 2 Rear Cover with Integral Relief Valve llssssessesssssseseeeeeeeenne nennen nnne nnne nnne 45 9 2 1 Eeler de EE 45 9 2 2 Disassembly and Reassembly eene nnne nnns nnns n nnn nnns 45 TO TOUDE SOO UING oen esie ete sa esa erase qu
13. capscrews and rear cover Remove the capscrews holding the pump together Remove the rear cover and set aside 2 Remove the flow control spool assembly Remove the caps at each end of the spool Remove the dowty washer from the spring end cad Remove the spool and spring 3 Remove the pilot relief valve Remove the cap dowty washer shims spring and plunger from the cavity Caution Shims are required to set the relief pressure Retain all shims for reassembly 4 Inspect flow control orifice Check the flow control orifice located in the prior ity flow port for debris or obstruction Clean as necessary Caution Theflow control orifice is press fit at the factory Do not attempt to remove it 5 Inspect clean and reassemble Inspect components for damage Clean and remove any debris from parts and cavities Reassembly is the reverse of above SAUER DANFOSS Gear Pumps and Motors 9 2 Rear Cover with Integral Relief Valve 9 2 1 General Information Group 2 pumps are offered with an optional adjust able relief valve integrated into the rear cover When necessary the relief valve may be disas sembled for cleaning and inspection 9 2 2 Disassembly and Reassembly 1 Remove the relief valve assembly Using a 24 mm hex wrench remove the relief valve cartridge from the rear cover remove the washer spring spring seat and poppet from the cavity 2 Inspect clean and re
14. cover when changing the direction of rota tion With the SNP2 you must change the front cover and rotate the rear cover when changing the direc tion of rotation SAUER DANFOSS Gear Pumps and Motors Group 2 8 1 4 Bearing Block Differences SKP2 Bearing Blocks SNP2 Bearing Blocks High Pressure In the SKP2 the pressure seal and backup ring are mounted in grooves on the bearing blocks while in the SNP2 the pressure seal and backup ring are mounted in grooves on the front flange and rear cover In the SKP2 the bearing blocks must be installed with the correct orientation to the high and low pressure sides The bearing blocks for the SNP2 are symmetrical with respect to the high and low pressure sides Low Pressure F101 049 41 SAUER DANFOSS Gear Pumps and Motors 8 2 Changing the Rotation of SKP2 i 8 F101 050 F101 051 F101 052 42 Group 2 There is no additional hardware required to change the rotation on an SKP2 pump The instructions given here show the unique steps involved when converting pumps In addition to these follow the assembly and disassembly instruc tions in sections 5 and 6 1 Remove drive gear and front bearing block Remove the capscrews and place the pump on the work bench with the rear cover down Remove the front flange Remove the drive gear shaft and front bearing block only Hold a finger on the idler gear hole to keep it in place while removing the drive
15. gears Ensure these surfaces are free from burrs or scratches If scratches or burrs are found clean them with a flat stone and or very fine emery paper Rewash the gears after this operation 8 Prepare the bearing blocks ae Clean the two bearing blocks vr Inspect the flat surfaces of the bearing blocks for burrs or scratches on the edges If necessary remove burrs with very fine emery paper Then rewash the bearings vr Inspect the DU bushings for wear There should be no bronze showing 6 Using clean hydraulic oil lubricate the inter nal and external surfaces of the bearing blocks 21 SAUER DANFOSS Gear Pumps and Motors 9 Assemble the bearing blocks and gears A Lubricate the journals and the gear faces Assemble the bearing blocks and gears Ensure that the recessed bearing faces are installed adjacent to the gear faces Align all assembly marks made during disassembly Ensure the front and rear bearing blocks occupy the same location with re spect to the housing as before disassembly Ensure that the relative position of the gear mesh is main tained as before disassembly Misalignment of the gear teeth may increase operating noise 10 Install the gear block assembly 8 Install the bearing block and gear assembly into the body cavity Align the assembly marks to ensure that the gear block assembly is installed with the same orientation as bef
16. it must be operated on an appropriate test apparatus Schematic diagram for a typical test apparatus is shown in the figure at the right Ensure that the test apparatus has sufficient power available to meet the demand of the pump under test see specifications page 10 The output flow should meet or exceed the specified value given in the table If the pump does not pass test itis necessary to disassemble the pump and find the cause Refer to Section 10 Troubleshooting page 46 for more information It may be necessary to check some dimensions and replace either incor rect damaged or worn parts 11 3 2 Test Procedure Set up the pump on the test apparatus with suit able shaft couplings and port adaptors Use ap propriate fluid per ISO VG468 Start the prime mover and run the pump until the oil temperature is 40 to 45 C 104 to 113 F as measured in the inlet line Set up the following test parameters e Pump Speed 1500 rpm e Inlet Vacuum 0 15 bar 2 175 psi e Outlet Pressure See Table Run the pump for one minute at the pressure noted in the table and check the output flow at the flow meter For motors check the flow at the drain as well If the pump is in good condition the measured flow rates will meet limits given in the flow limits table 50 Group 2 Test Relief Valve Outlet Pressure Test Pump Inlet Pressure Temperature d L L Reservoir Reservoir P101 132 11 3 3 Tables P
17. 0 118 9177 3 9177 35 9177 35 40 002 40 002 40 002 RO 5 0 020 0 697 5 RO 5 0 020 0 697 5 RO 5 0 020 0 697 5 916 5 25 9165 25 915 456 255 0 65055 RO 1 004 0 650 555 RO 1 004 0 609 555 ry A D D D D D S S S A S S j 4 e s e n 5 we a z F e a e eU o ei _ o e EMEN o c S o 9 LO e Si T e c t e e E 2 2 y 5 2 e E E 2 10 10 10 41 SCH Shaft ga 0 118 SC02 Shaft 93 0 118 SC06 Shaft 03 0 118 ong 3 9177 3 9177 3 0 002 0 002 0 002 R0 5 0 020 Dees R0 7 0 028 uar R0 7 0 028 Des 917 8 28 915 915 875 3 EL RO 1 004 0 609 RO 2 008 1 62525 D i i i J i i e 28 fe F a E S g S S es N i E z c 2 o 7 si Ke Si eo F ei ail ei m o D N 3 A 3 e N 2 E z t i f 1 B c 2 10 10 E 10 FRO3 Shaft 93 0 118 CI01 Shaft 93 0 118 C106 Shaft 93 0 118 RO 1 004 RO 2 008 P101 139E 53 SAUER DANFOSS Gear Pumps and Motors 11 5 Shaft Dimensions This section contains dimensions and specifications for standard shafts 4 m A es 158a 0 5 1 596 7 670 7 5 020 0 025 0 064 36 5 5
18. 1 438 46 05 632 max 003 9 5328 374 836 Section A A M12x1 25 6g 15 7 2050 619 EL CO 36 5 1 438 30 1 182 6 5 256 W 54 M6 Thread 1 16mm 630 deep 18 x P101 140E 004 008 4 8 030 158 t801 16 5 55 1650 Section B B P101 141E Group 2 mm in 11 5 1 Shafts Used with 01 Flange CO01 Tapered Shaft Type Key Data Technical Specifications Nut Torque Maximum Shaft Torque CI01 Parallel Shaft Type Key Data Technical Specifications Maximum Shaft Torque 1 8 Taper Shaft 4 x 6 5 ISO 3912 35 50 Nm 26 37 Ibf ft 150 Nm 111 lbfeft Parallel A 4x4x25 UNI 6604 90 Nm 66 Ibf ft SAUER DANFOSS Gear Pumps and Motors SCO01 Splined Shaft Type Spline Data Circular Tooth Thickness e Profile Correction Technical Specifications Maximum Shaft Torque 9 Tooth Spline 17 x 14 DIN 5482 3 206 mm 0 6 90 Nm 66 Ibf ft 19 5 768 l 10 394 Spline B17x14 DIN 5482 profile offset 0 6 6 5 256 0 004 1216 5 us 1 690 Group 2 mm in P101 142E 55 S mm in 56 0 510 12 96 0 503 12 77 SAUER DANFOSS Gear Pumps and Motors 27 86 1 097 14 86 0 585 14 26 0 561 0 650
19. 101 137E SAUER DANFOSS Gear Pumps and Motors 7 3 8 Converting a Single Stage Pump to an Intermediate Stage Pump To prepare an intermediate stage pump from a single stage pump the following components are required e SNP2 FR03 type pump with the desired porting and rotation e Drive gear shaft for intermediate stage pump Rear flange of the appropriate rotation e Rear shaft seal 7 3 4 Conversion Procedure The instructions given here show the unique steps involved when converting pumps In addition to these follow the assembly and disassembly instruc tions in sections 5 and 6 1 Remove the capscrews rear cover and drive gear shaft 2 Replace the drive gear shaft with the interme diate pump drive gear 3 Lubricate the rear shaft seal with grease and install it into the seal cavity of the rear flange Snap ring is not required to retain the rear shaft seal 4 Lubricate the pressure seals with grease and install into the rear flange 5 Usingassembly grease to retain them install the dowel pins to the pump body 6 Install the rear flange onto the pump body The intermediate stage pump is now ready to be assembled with the other stages Group 2 31 SAUER DANFOSS Gear Pumps and Motors Group 2 7 4 Final Stage Pump Preparation Drive Gear Rear Cover Shaft Front Flange 77 AEN Socket Head PN Coupling Capscrew i
20. 27 57 5 1364 66 2 1571 72 0 1709 Theoretical Flow at Maximum Speed 10 min US gal min 19 6 4 12 24 0 6 34 33 6 8 87 43 2 11 4 50 4 13 3 50 4 13 3 57 6 15 2 68 4 18 0 75 6 20 0 T101 000E SAUER DANFOSS Gear Pumps and Motors 3 2 System Specifications Inlet Pressure bar absolute Recommended Range 0 8 to 3 0 Minimum cold start 06 T101 001E Fluid Viscosity mm s cSt SUS 10 60 12 to 60 66 to 290 1600 7500 T101 002E Minimum Recommended Range Maximum cold start 3 3 Fluids and Filtration To prevent premature wear it is imperative that only clean fluid enter the pump and hydraulic circuit A filter capable of controlling the fluid cleanliness to Class 18 13 per ISO 4406 or better under normal operating conditions is recommended The filter may be located on the pump outlet pres sure filtration inlet suction filtration or the reser voir return return line filtration The selection of a filter depends on a number of factors including the contaminant ingression rate the generation of contaminants in the system the required fluid cleanliness and the desired mainte nance interval Contaminant ingression rate is deter mined among other things by the type of actuators used in the system Hydraulic cylinders normally cause higher levels of contam
21. 35 3626 210 8045 230 3335 3626 210 8045 220 3190 3335 180 2610 210 3045 8045 3481 160 2320 2610 2610 3045 140 2030 2320 2320 2756 7401 145E n addition to the prescribed test procedure it is recommended that the 6cc motor be tested also as a motor This can be done in the application by providing flow to the motor inlet to with no torque on the shaft at start up Motor will be considered to have passed this test if it performs satisfactorily under the application s normal load 51 SAUER DANFOSS Gear Pumps and Motors Group 2 11 4 Tools mm in This section contains drawings useful in fabricating any specialized tools required to service group 2 gear pumps and motors 11 4 1 Shaft Seal Installation Tool 70 2 756 5 0 197 50 1 969 3 0 118 12 0 472 P101 138 52 S SAUER DANFOSS Gear Pumps and Motors 11 4 2 Shaft Seal Protective Sleeves 9177 3 9177 325 0 697 3 9 9174 0 685 R0 1 004 RO 1 004 co Q13 Toj 2 T0 5127 ry ry E ry ry o m A ped SC e e co To co Y 5 g 5 PCR S S e D e S LO y e oe co oO Let E e S e Kand O p S T x k s S D i 1 3 ES 10 e ipx 2 C001 Shaft g310 118 C002 04 Shaft 93
22. 55 in to account for minimum thread engagement Stud length calculated in this manner has a tolerance of 0 to 0 5mm 0 0 02 in 11 2 3 Component Lengths Typical values for component lengths are found in the following tables If the components you are using are not included measure Length BODY SNP SEP SKP 2 l mm in SNP 2 4 1 988 SNP 2 6 2 126 SNP 2 8 2 283 SNP 2 11 2 441 SNP 2 14 2 677 SNP 2 17 2 835 SNP 2 19 2 992 SNP 2 22 3 228 SNP 2 25 3 386 T101 140E 0 748 Intermediate rear flang Intermediate front flange 0 709 Cover mounting face to nut spotface 0 512 T101 141E Group 2 Given as a formula MSL TBL TRFL TFFL RCL 14mm 0 55 in Where MSL Maximum Stud Length TBL Total Length of all Bodies TRFL Total Length of all intermediate Rear Flanges TFFL Total Length of all intermediate Front Flanges RCL Length of Rear Cover from the sealing surface to the nut s spotface F101 060 49 SAUER DANFOSS Gear Pumps and Motors 11 3 Testing the Pumps and Motors 11 3 1 General After assembling a pump it should be tested to verify that volumetric efficiency is sufficient to insure satis factory performance Motors can be tested as pumps Bi directional mo tors should be tested in both directions of rotation Flow rate at drain of motor should be monitored during test In order to test a pump
23. 7 Multiple pumps only change the rear flange Turn the pump over and remove the rear flange Install new pressure seals and shaft seal to the new rear flange Install the new rear flange to the pump body 38 SAUER DANFOSS Gear Pumps and Motors Group 2 8 SKP2 Pumps 8 1 General Information SKP2 Pumps are designed to accommodate an The differences between SKP2 and SNP2 pumps 11 tooth SAE splined shaft for higher torque are described in this section applications Front cover for clockwise and counter clockwise rotation Shaft Seal Snap Ring Backup Ring F101 045 Rubber Pressure Seal Rear cover orientation symmetrical O Ring 39 SAUER DANFOSS Gear Pumps and Motors High Pressure Side Low Pressure Side F101 046 SNP2 Drive Gear i P F101 047 SNP2 Front Cover SNP2 Rear Cover F101 048 SKP2 Rear Cover 40 Group 2 8 1 1 Bearing Block For SKP2 In SKP2 pumps the pressure seals are located on the bearing blocks as shown 8 1 2 Drive Gear Shaft Differences The shaftonthe drive gearforthe SKP2 is larger than the shaft on the drive gear for the SNP2 The journal diameters of the SKP2 shaft are 20 mm 787 in while the shaft of the SNP2 is 18 mm 708 in 8 1 3 Front and Rear Flange Differences In the SKP2 the front and rear cover can be utilized for both clockwise and counter clockwise rotation With the SKP2 itis not necessary to change the front and rear
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25. SNP 2 CO 02 SNP 2 CI 06 SHP 2 CO 02 SNP 2 SC 02 SNP 2 SC 06 SNP 2 FR 03 SNP 2 CO 09 SNP 2 CO 04 SNP 2 CO 09 BBM F101 061 61 SAUER DANFOSS Gear Pumps and Motors Group 2 Notes 62 SAUER DANFOSS Gear Pumps and Motors Notes Group 2 63 SAUER DANFOSS Hydraulic Power Systems SAUER Danfoss Hydraulic Power Systems Market Leaders Worldwide SAUER DANFOSS is a world leader in the design SAUER DANFOSS specializes in integrating a full and manufacture of Hydraulic Power Systems Research range of system components to provide vehicle designers and development resources in both North America and with the most advanced total design system Europe enable SAUER DANFOSS to offer a wide range of design solutions utilizing hydraulic power system SAUER DANFOSS is Your World Source for technology Controlled Hydraulic Power Systems Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors Pumps and Motors Variable Motors Compact Wheel Drives Medium Duty Axial Piston Mikrocontrollers and Hydrostatic Transmissions Pumps and Motors Electrohydraulic Controls Packages Worldwide Service Support SAUER DANFOSS provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world Look to SAUER DANFOSS for the best in WORLDWIDE SERVICE http www sauer co
26. Socket Head oe a MEER EE E NM e d Capscrew Capscrew Pressure Seals R 7 2 1 General The figure above shows a cross section of a typical group 2 first stage pump A first stage pump can be purchased directly from the factory or it can be made from a single stage pump 7 2 2 Model Code The model code for ordering a first stage pump is SNP2 yy4x Where yy is the shaft type CO CI SC FR X is the flange type See Model Code pages 8 and 9 28 Notusedin converted first stage pumps Idler Gear P101 134 First stage pumps supplied from the factory are pre assembled with two socket head cap screws on the front flange and two in the rear flange When a first stage pump is converted from a single pump the socket head capscrews are omitted The front and rear flanges will then be retained by the main capscrews or studs of the assembled multiple pump SAUER DANFOSS Gear Pumps and Motors Group 2 7 2 3 Converting a Single Stage Pump to a First Stage Pump To prepare a first stage unit from a single pump following components are required e Single pump having the same configuration flange and porting as the desired first stage pump Drive gear shaft for the first stage pump Rear flange of the correct ro
27. T101 137E SAUER DANFOSS Gear Pumps and Motors 7 4 3 Converting to a Rear Stage Pump To prepare a final stage pump from a single stage pump the following components are required e SNP2 single stage pump with the desired porting and rotation Final stage drive gear shaft e 03 or 73 type front flange of the appropriate rotation 7 4 4 Conversion Procedure The instructions given here show the unique steps involved when converting pumps In addition to these follow the assembly and disassembly instruc tions in sections 5 and 6 1 Remove the front flange and drive gear shaft from the pump 2 Replace the drive gear shaft with a final stage drive gear 3 Lubricate the pressure seals with grease and install them to the front flange No shaft seal is required on the final stage pump 4 Using assembly grease to retain them install the dowel pins to the pump body 5 Install the front flange onto the pump Ensure that the flange has the appropriate direction of rotation The final stage pump is now ready to be assembled with the other stages Group 2 33 SAUER DANFOSS Gear Pumps and Motors 7 5 Assembly of Multi Stage Pumps F101 030 F101 033 Capscrews shown in place of hex nuts and studs F101 029 34 Group 2 1 Install the coupling Place the first stage pump on the work bench so that the rear flange is in the upward position If necessary remove burrs on t
28. To Aande e 61 S SAUER DANFOSS Gear Pumps and Motors Group 2 1 3 Symbols Used in Sauer Danfoss Literature lsr P tz e Q Z DANGER May result in injury May result in immediate or premature damage Reusable part Nonreusable part use a new part Non removable item OR in drawing either option may exist Measurement required Flatness specification Parallelism specification External hex Internal hex Torx head P101 128 FE amp pu5wWoQ DR AWE F H Lubricate with hydraulic fluid Apply grease petroleum jelly Apply locking compound Inspect for ware or damage Clean area or part Be careful no to scratch or damage Note correct orientation Mark orientation for reinstallation Torque Specification Press in Pull out with tool Use installation sleeve cone bullet P101 129 SAUER DANFOSS Gear Pumps and Motors Group 2 2 General Information 2 1 General Description Group 2 gear products consist of pumps reversible pumps uni and bidirectional motors This group of gear pumps and motors is characterized by a wide selection of components Itis possible to have a wide range of units resulting from a common base of components or processes This manual describes the service procedures that can be applied to all the p
29. ange 03 Flange F101 002 19 SAUER DANFOSS Gear Pumps and Motors 4 Remove front flange Place the pump on the table and slowly remove the front flange Be careful not to damage the shaft seal when removing the flange Avoid contact of the shaft seal lips with keyway edges in tapered and parallel shafts or splined shaft teeth ia Inspect the front flange and seal area Le Clean with shop solvent dry and set aside 5 Remove rear cover Remover rear cover 4 Clean with shop solvent dry and set aside pa Visually inspect rear cover and seal area 16 Group 2 F101 003 F101 004 SAUER DANFOSS Gear Pumps and Motors F101 005 C Teflon Backup Ring Pressure Seal F101 006 Backup Ring F101 007 Group 2 6 Remove bearing blocks and gears Place the pump on its side and carefully remove the bearing block and gear set To accomplish this hold the pump body and push with your fingers on the rear bearing block Mark the relative positions of the gear mesh drive gear tooth to idler gear tooth and the bearing blocks to the body so they can be reas sembled in the same position 7 Remove pressure seals e For SNP 2 SNU 2 SEP 2 SHP 2 vr Check the seal quality Replacement is recommended whenever there are burrs evidence of extrusion or marks caused by overheating If the seals need to be replaced carefully remove
30. assemble Inspect the poppet and mating seat in the housing for damage Clean and remove any debris from parts and cavity Reassemble in reverse order of disassembly T Torque relief valve cartridge to 47 Nm 35 Ibf ft 3 Check and reset relief valve pressure Using an appropriate test stand check and if necessary reset the relief valve to the proper pressure setting The adjustable relief has 4 setting ranges The outside of the valve housing will be stamped with a number as follows e 0 has a range from 3 25 bar 43 5 363 psi 1 has a range from 26 40 bar 377 580 psi e 2 has a range from 41 150 bar 595 2175 psi e 3 has a range from 151 250 bar 2190 3625 psi Turn the adjustment screw clockwise to increase pressure anti clockwise to reduce Refer to the appendix section 11 3 for information on testing pumps Group 2 F101 059 45 SAUER DANFOSS Gear Pumps and Motors Group 2 10 Trouble Shooting 10 1 Low or No Flow From Gear Pump Item Description Action 1 Check oil level in reservoir 2 Check input spline condition 3 Check pressure at pump inlet Recommended inlet pressure 0 8 to 3 0 bar absolute 0 6 Minimum at cold start 4 Check condition of gear faces and bearing blocks 5 Check bushings 10 2 Excessive Noise Item 1 Check oil level in reservoir 2 Checkinlet line for leaks 3 Check pressure at pump inlet Recommended in
31. ch are allowed For any unit component the table shows the possibility of a conversion operation from one pump to another pump from one motor to another motor from pump to motor and from motorto pump For SKP the only conversion allowed is from pump to pump 12 Conversions should be limited to changing the rotation changing the seal kit and replac ing the flange and rear cover Changing the gear set is not advisable When this operation cannot be avoided special care must be taken Whenever possible avoid making conversions to gear motors as the critical dimensions are more sensitive to minor changes Always use new factory supplied parts when making a conversion After any conversion it is recommended that the unit be tested on a suitable test stand in order to confirm its performance Reference the conversion tables given on the next page to ensure the operation is allowed SAUER DANFOSS Gear Pumps and Motors Group 2 Component Conversion Operation YES Allowed NO Not Allowed From From From From N R Allowed but not Pump to Pump Motor to Motor Motor to Pump Pump to Motor recommended Body Bearing Front Flange Rear Flange Tandem Cover Drive Gear Idle Gear Pressure Seals Outer Seal Shaft Seals Snap Rings Dowel Pins Bolts T101 135E The following conversion steps are allowed on the product groups listed below Con
32. e aus ci Dues nasa E OEE O IFUUEL Gv MUS cExM E VuU IUS SUNY AE EEE EEEE 46 10 1 Low or No Flow From Gear Pump ccccccceeeccccceeeeceeeeeeeeeeeeeeeeeceeeeseeeceesseeeeceessseaseeessseeeeeessaeeees 46 10 2 ee ec 46 10 3 External Leakage E 46 Eh OS E 48 11 1 Stud Specifications eiessssesssssseesssseeseee nennen nennen nna nnns nna nnn sss nna sinn siena sinis sena ses ren seras n sans nns 48 11 2 Stud Length For Multi Stage PUMPS aoiceiosioiode avec co ERE niae aeo esee rin Foto Uude ices cashed cades ibas ub cin btu dts 48 11 2 1 Tandem PUAN EON To mm 48 11 2 2 Multi Stage Pumps General Rule cuiii si tot p eopte oo deeg supina Ute tpe seht nonas SSES rite 49 11 2 3 Gomponent MS TAU Scenes acess tese icut stum cui acun tecum ets uem Se eed U D SECULI UM MRID Id A 49 113 Testing UG Pumps and le re 50 s E WIE NN Eo t 50 11 3 2 EIERE 50 11 3 3 Tables 50 11 3 3 TASS CO EE 51 11 4 po m m Q 52 11 4 1 Shalt Seal installation TOO RE 52 11 4 2 Shaft Seal Protective Sleeves ege EE 53 UP EE Eng Rea Ee EEN 54 11 5 1 Shat Used WIIN OT Flange EE 54 11 5 2 ohats Used wiih 02 Fange EE 56 11 5 3 Shafts Used Witlt 047 05 En Le GE 57 11 5 4 Shafts Used with 06 Flange SAE EE 58 11 5 5 FRDO FLU m RE UNE 60 11 5 6 Maing Design LOR FROS UNAS sitmtionteniad reene ae E Era a ia ia i e Rre 60
33. f valve Pressure setting bar psi A No setting O 90 1305 B No valve P 100 1450 C 18 261 Q 110 1595 D 25 363 R 120 1740 E 80 435 S 130 1885 F 95 508 T 140 2030 G 40 580 U 160 2320 K 50 725 V 170 2465 L 60 870 W 180 2611 M 70 1015 X 210 3045 N 80 1160 Z 250 3626 Pump speed for relief valve setting min rpm A Notdefined C 500 E 1000 F 1250 G 1500 K 2000 2250 L 2500 M 2800 N 3000 O 3250 Version Value representing a change to the initial project Initial project 1 9 A Z Reserved to Port Type If other than standard Standard port for the flange type specified Flanged port with threaded holes in X pattern German standard ports centered on the body Flanged port with threaded holes in pattern European Standard Threaded SAE o ring boss port Threaded Gas port BSP Flanged port with threaded holes in X pattern German standard ports offset from center of body o nmoou SAUER DANFOSS Gear Pumps and Motors Pump Model 3 Technical Specifications 3 1 Hardware Specifications Group 2 Displacement cm rev in rev Peak Pressure 280 4060 280 4060 280 4060 280 4060 280 4060 280 4060 Rated Pressure 250 3625 250 3625 250 3625 250 3625 250 3625
34. ft Mounting Flange Port Configuration CO Tapered shafts 1 5 or 1 8 CO01 1 8 tapered shaft European four bolt flange European flanged ports CO02 1 5tapered shaft German four bolt PTO flange German standard ports CO04 1 5tapered shaft German two bolt PTO flange Deutz German standard ports CO05 1 5tapered shaft German two bolt PTO flange Deutz German standard ports CO09 1 8 tapered shaft Perkins 4 236 timing case flange European flanged ports CO09 variant BBM 1 8 tapered shaft Perkins 900 series flange German standard ports COOB 1 8 tapered shaft Perkins 1000 series left side PTO flange European flanged ports CO91 variant LBD 1 8 tapered shaft European four bolt flange European flanged ports equipped with outrigger bearing CO94 1 5tapered shaft German two bolt PTO flange Deutz German standard ports equipped with outrigger bearing CI Parallel shafts 15mm or 15 875mm C101 15mm 591 in parallel shaft European four bolt flange European flanged ports C106 15 875mm 625 in parallel shaft SAE A flange SAE O ring boss ports CI96 variant LEP 19 05mm 750 in parallel shaft SAE A flange SAE O ring boss ports equipped with outrigger bearing SC Splined shafts DIN B17x14 SAE 9T 16 32p or SAE 11T 16 32p SKP 2 only SCO1 DIN splined shaft European four bolt flange European flanged ports SCO02 DIN splined shaft German four bolt PTO flange
35. gear shaft and bearing block Mark the position of the front bearing block relative to the body Also mark the position of the mating gear teeth relative to each other 2 Remove idler gear Remove the idler gear from the body leaving the rear bearing block in place 3 Install idler gear into the opposite position The idler gear that was just removed must now be installed into the other side of the body cavity SAUER DANFOSS Gear Pumps and Motors 4 Install the drive gear shaft Reinstall the drive gear into the free side of the body cavity H Align the assembly marks on the gear teeth 5 Install the front bearing block Install the front bearing block into the body 8 Align the assembly marks on the bearing block and body 6 Install the front flange Rotate 180 and re Install the front flange Group 2 F101 053 F101 054 F101 055 43 SAUER DANFOSS Gear Pumps and Motors Group 2 9 Product Options 9 1 Rear Cover with Integral Priority Flow Divider Valve F101 056 F101 057 F101 058 44 9 1 1 General Information Group 2 pumps are offered with an optional priority flow divider valve integrated into the rear cover Flow and pressure settings are made at the factory and are not adjustable When necessary flow divider covers may be disas sembled for cleaning and inspection only 9 1 2 Disassembly and Reassembly 1 Remove the
36. he flange Blow the surface and cavity of the flange with compressed air to remove any debris before assembly Fit the coupling onto the rear tang of the shaft 2 Install studs and torque Clamp the first stage of the pump in a vice on the front flange side Install the studs Torque to 5 10 Nm 4 7 Ibfeft Stud length tables and guidelines are found in the appendix sections 11 1 and 11 2 3 Assemble the stages If necessary remove burrs from the front flange of the second stage pump then clean with com pressed air Lubricate the pilot and o ring with grease Mount the second stage pump onto the rear pad of the first stage Align the tang of the shaft with the coupling The two tangs must be rotated 90 from each other The coupling will not engage the shaft if itis not properly aligned Press units together until the pilot is fully engaged Repeat this operation for every pump stage 4 Install and torque hex nuts Install the hex nuts T Torque to 50 60 Nm 37 44 Ibfeft Use the torque sequence shown at the left Test and prepare the pump for shipment or storage as shown in steps 19 and 20 on pages 25 and 26 SAUER DANFOSS Gear Pumps and Motors 7 6 Change of Rotation 7 6 1 General The SNP2 pumps are designed with the pressure seals located in grooves on the rear cover and front flange Therefore the front flange must be replaced whenever a changing rotation The fron
37. ination to enter the system T101 003E Fluid Cleanliness Level and Bb Ratio Required Fluid Cleanliness Level per ISO 4406 Recommended p Ratio Suction Filtration Recommended Ratio Pressure or Return Filtration Class 18 13 or better Posas 19 Bag Pisa 79 B 2 10 107 Recommended Inlet Screen Size for Pressure or Return Filtration EENEG T101 004E T101 004E Filters are selected to meet these requirements using rating parameters of efficiency and capacity Filter efficiency may be measured with a Beta ratio B For suction filtration with controlled reservoir ingression a filter with BR gt 75 and D gt 2 or better has been found to be satisfactory For return or pressure filtration filters with an efficiency of Des 75 and B gt 10 are typically required Since each system is unique the filtration require ments for that system will be unique and must be determined by test in each case Filtration system acceptability should be judged by monitoring of proto types evaluation of components and performance throughout the test program See Sauer Danfoss publications BLN 9887 697581 and ATI E 9201 for more information 1 Filter B ratio is a measure of filter efficiency defined by ISO 4572 It is defined as the ratio of the number of particles greater than a given diameter x in microns upstream of the filter to the number of these particles downstream of the filter
38. let pressure 0 8 to 3 0 bar absolute 0 6 Minimum at cold start 10 3 External Leakage Item 1 Check for pinched o rings or backup ring seal 2 Check pressure seals 46 Insufficientoil to supply gear pump Input shaft broken or stripped Clogged suction filter or inlet screen Scored bearing block and gear faces will reduce pump efficiency Overpressure of gear pump will cause idler gear bushing to fail Description Excessive air will cause cavitation sound Excessive air will cause cavitation sound Lower than normal inlet pressure causes excessive pump noise Description Pinched seal will allow leakage Damage to pressure seals is typically caused by reduced stack up in the pump assem bly This may be due to under torqued assembly fasteners or more commonly is attributed to excessive wear on the bearing blocks Reduced stack up will affect seal efficiency possibly to the point of seal extrusion Fill reservoir to proper level Hepair or replace gear pump Replace filter or clean suction Screen Repair or replace gear pump Hepair or replace gear pump Action Fill reservoir to proper level Repair inlet line Return inlet pressure to recom mended levels Action Replace pinched seal Inspect condition of bearing blocks If they are found to be worn repair or replace the pump If bearing blocks are not worn replace pressure seals and re torque pump assemb
39. low if the unit is a pump Against the direction of the flow if the unit is a unidirectional motor e f the unit is a bidirectional motor the arrow does not appear on the cover Ensure that all the pressure seals stay in place during this operation F101 026 15 Prepare pump for front flange assembly Place the pump with the rear cover downwards Ensure that the assembly marks on the bearing block body are properly aligned F101 027 16 Install the front flange S Install a protective sleeve over the shaft The sleeve is used to protect the shaft seal from damage by the shaft splines keyway during front flange assembly Install the flange onto the body then remove the protective sleeve Ensure that the seals remain seated in their grooves during this operation F101 028 24 SAUER DANFOSS Gear Pumps and Motors F101 029 F101 030 Outlet Pressure Test Pump Inlet P l nlet Pressure Prime Mover Temperature Cooler Reservoir Reservoir P101 132 Group 2 17 Torque sequence all except 03 type Wi Note When assembling units with 01 flange and short coupled tandems wash the capscrews and apply Loctite 242 or equivalent thread lock compound to the threads before assembly Install capscrews While observing the torque sequence shown pre tighten the capscrews Then using a torque wrench tighten them to the proper torque T
40. ly fasteners SAUER DANFOSS Gear Pumps and Motors Notes Group 2 47 S SAUER DANFOSS Gear Pumps and Motors Group 2 11 Appendix 11 1 Stud Specifications Studs used to assemble multiple pumps must com mm in ply with the following specifications A Ole 0 220 10 008 A T S ype Stud a S Thread Dimension ISO M10 2 Design Standard DIN 931 i6 A 16 Strength Class minimum 10 9 i i 0 0 a Surface Treatment Blued 1 0 039 x45 10 0 2200 394 0 009 a PEN 20 23 0788 0906 0 591 0 021 E m T A P101 137 MSL Maximum Stud Length see section 11 2 below 11 2 Stud Length For Multi Stage Pumps 11 2 1 Tandem Pumps The table contains a list of stud lengths for any tandem combination of SNP2 pumps Rear Displacement type 11 T101 139E The stud length tolerance is 0 to 0 5 mm 0 to 0 02 in Note 48 The data given in the tables does not include SHP2 pumps which are longer than SNP2 See section 11 2 2 SAUER DANFOSS Gear Pumps and Motors 11 2 2 Multi Stage Pumps General Rule The following is a general rule that explains how to calculate the stud length for any multiple combina tion of the SNP2 SEP2 pump series This calcula tion is essentially the combined length of all compo nents in the stack plus 14mm 0
41. m S AUER SAUER DANFOSS COMPANY SAUER DANFOSS GMBH amp CO 2800 East 13th Street Postfach 2460 D 24531 Neum nster DAN FOSS Ames IA 50010 USA Krokamp 35 D 24539 Neum nster Germany Phone 515 239 6000 Fax 515 239 6618 Phone 04321 871 0 Fax 04321 871 122 S SM GP2 E 06 99 300168 BLN 10168 May 1999
42. mps In addition to these follow the assembly and disassembly instruc tions in sections 5 and 6 1 Remove front flange d Hemove the capscrews and place the pump on the work bench with the rear cover down Remove the front flange Mark the position of the front bearing block for reassembly 2 Remove bearing block and drive gear shaft Remove the front bearing block Mark the relative position of the gear teeth for reassembly Remove the drive gear shaft SAUER DANFOSS Gear Pumps and Motors 2 Remove idler gear Remove the idler gear from the body cavity leaving the rear bearing block in place 3 Move idler gear Install the idler gear into the opposite position in the bearing block 4 Reinstall the drive gear shaft Reinstall the drive gear shaft Align the gear teeth to the assembly marks Group 2 F101 041 oi F101 042 F101 040 3 SAUER DANFOSS Gear Pumps and Motors Group 2 5 Install front bearing block Install the front bearing block into the body cavity Align the assembly marks F101 043 6 Install the new front flange Old Flange CW New Flange CCW Install the seals and assemble the new front flange onto the pump body F101 044 Note Follow step 7 only if converting the first or an intermediate stage of a multiple pump If converting a single pump or the final stage of a multiple pump skip step 7
43. ore disassembly 11 Clean the mating surfaces in Remove any excess lubrication and grease from the mating surfaces of the pump body Ensure that these surfaces are dry and free of contamination before moving on to the next step 22 Group 2 F101 020 E F101 022 F101 023 SAUER DANFOSS Gear Pumps and Motors F101 024 P101 131 F101 025 Group 2 12 Install the dowel pins mi Install four D mm dowel pins into the proper cavities on both sides of the body refer to the illustration Swab the pins with assembly grease or petroleum jelly to retain them during assembly Do not install dowel pins to the rear cover or flange as one of them may drop inside the pump during assembly 13 Clean the mating surfaces Vn Remove any excess lubrication and grease from the mating surfaces of the front flange and rear cover Ensure that these surfaces are dry and free of contamination before moving on to the next step Ensure the pressure seals are seated properly after this operation 23 SAUER DANFOSS Gear Pumps and Motors Group 2 14 Install Rear Cover 8 Mount the cover on the body Ensure the arrow on the back is oriented properly The arrow should be e n the same direction as the f
44. re completely disassem bling a pump The marks allow components to be reassembled in the same relative position This ac tion should be applied to the body bearings and gears Scribing bluing or using a felt tip pen to mark the outside of the body on the inlet side is suggested to indicate the relative position of the front flange and the rear cover to the body Mark the bearing blocks also on the inlet side and the gears position relative to each other DO NOT scribe internal surfaces SAUER DANFOSS Gear Pumps and Motors Group 2 5 1 5 Procedure 1 Clamp the unit Clamp the unit in a vice from the flange side LE Make sure the vice jaws are clean and have smooth surfaces to prevent damage to the pump Clamping the pump on the body is not recommended because serious damage to the surfaces on which the ports are located may occur F101 000 2 Remove capscrews Except Units with 03 Flange CH Use a 17 mm socket wrench and loosen the four capscrews on the cover Next completely un screw the capscrews and remove them vr Inspect the threads of the capscrews for damage F101 001 3 Remove socket head capscrews 06 Flange first stage of multiple pump 03 Flange or Multiple Pump Stages Only Using a 4 mm internal hex wrench loosen and remove the two small socket screws placed in the center of the cover Repeat the same operation for the corresponding screws on the rear fl
45. ressure Seal Teflon Backup Ring Dowel Pin Idler Gear P101 130 7 SAUER DANFOSS Gear Pumps and Motors Group 2 2 3 Model Code ABCD E F H L R S LITIJLILI AO LEJ O LATT COU Type ul SNP2 Standard Gear Pump SKP2 High Torque Gear Pump SHP2 High Pressure Gear Pump SNI 2 Gear Pump with Internal Drain Relief Valve SNE2 Gear Pump with External Drain Relief Valve Valve omit when not used U Priority Flow Divider with Pilot Relief Valve L Priority Flow Divider with Pilot Relief Valve and Static Load Sensing N Priority Flow Divider with Pilot Relief Valve and Dynamic Load Sensing P Priority Flow Divider with Full Flow Relief Valve F Priority Flow Divider with Full Flow Relief Valve and Static Load Sensing V Priority Flow Divider with Full Flow Relief Valve and Dynamic Load Sensing Valve Port Position omit when not used S Side Ports R Rear Ports Displacement cm rev in rev 4 3 9 0 24 6 6 0 0 37 8 8 4 0 51 11 108 0 66 14 144 0 88 17 168 1 02 19 192 1 17 22 228 1 39 25 252 1 54 Direction of Rotation D Right Clockwise S Left Anti clockwise Input Sha
46. roducts of this range The complete range of products detailed in this manual are e SNP 2 Standard gear pump e SEP 2 Gear pump similar to SNP2 without DU Bushings Cost Effective Model SHP2 Gear pump similar to SNP2 with longer shaft journal bearings high performance model SKP2 Gear pump similar to SNP2 with larger shaft specially designed to accommodate SAE 11 tooth spline e SNU2 Unidirectional gear motor similar to SNP2 pump e SNM 2 Standard bidirectional gear motor e SEM2 Bidirectional gear motor similar to SNM2 with lower pressure limits Cost effective model SNR2 Bidirectional gear pump e SHM 2 Bidirectional gear motor similar to SHP2 pumps with longer shaft journal bearings and higher pressure rating than SNM2 Generally all these products follow the same proce dures for assembling disassembling and servicing In this manual the SNP2 will be used as an example for all unidirectional pumps and motors SNP SEP SHP SNU 2 and the SNM2 for all the bi direction pumps and motors SNM SEM SNR SHM 2 SKP assembly anddisassembly information will be handled in a separate section of this manual SAUER DANFOSS Gear Pumps and Motors Group 2 2 2 Design Outer Seal Bearing Block Assembly Drive Gear Body Housing Rear Cover P
47. rs lt Prepare pressure seals by lightly lubricating them with grease Install pressure seals into the grooves on the front flange and rear cover Then install the teflon backup ring The backup ring will fit tightly into the groove Work the backup ring into the groove by hand Begin with the internal portion of the seal then proceed outward until the backup ring is securely pressed into place 5 Prepare the body A Clean the body a Inspect the internal and mating surfaces Ensure the surfaces are free of burrs and scratches Check both the bearing block mating surface and the cut in path The cut in path should be no deeper than 0 1 mm 0 004 in 20 Pressure Seal Nm Pressure Seal Ce F101 014 Backup Ring F101 007 F101 016 SAUER DANFOSS Gear Pumps and Motors F101 017 F101 018 F101 019 Group 2 6 Install outer seal lt Prepare the outer seal by lightly lubricating with grease Install outer seals in the grooves on both sides of the body 7 Prepare the gears Caution The gear surfaces are superfin ished Residue on hands and fingers may be corro sive to this surface Do not touch ae Carefully clean the two gears If the gears are new wash them with shop solvent to remove any anticorrosive grease on the surfaces vr Inspect the journals and the flat faces on the top and bottom of the
48. st have its own shaft seal To withstand the maximum torque capacity the material of the P T O shaft should be case hardened steel as per DIN 17210 or UNI 5331 64 at least 20 MnCr DIN or 20 CrNI UNI or better The pump mounting holes must be threaded per ISOM10 minimum full thread depth 20mm 0 787 in Capscrews used to attach the pump must be strength class 10 9 Torque 50 60 Nm 37 44 Ibfeft 60 7 2 2 0 283 816 3 2 0 1255 _ 2 0 079 Group 2 mm in OR 45 69 1 989 x 2 62 0 103 JI Ree US ei E bs Sis ge as 2 din T SE Ma e Se Siss E Zu LU 8 T ES N E 2 2 6 5 F 0 256 27 0 0 106 ee 2 472 fois CA N a Bg NS i P101 150E 6 5 0 256 2 R0 5 0 020 Max Co i amp NO MSs ow a L 2 53 0 098 59 8 0 315 Min n c oo o GE w SS o elt JA z o ale H 8 xi t d N Wa 2 20 010 0 004 __ 0 5 0 6 0 020 0 024 P101 151E SAUER DANFOSS Gear Pumps and Motors Group 2 11 6 Flange Types SNP 2 CI 01 SNP 2 SC 04 SEP 2 CI 01 SNP 2 CO 01 SEP 2 CO 01 SNP 2 CO 05 SHP 2 CO 01 SNP 2 SC 01 SNP 2 SC 05 SEP 2 SC 01
49. t flange of a pump is oriented for a particular direction of rotation Hear covers except in multiple configurations may be rotated 180 to be used in either direction of rotation Clockwise Rotation F101 035 F101 036 Group 2 7 6 2 Determining the Direction of Rotation The direction of rotation of a given flange can be determined by referencing its part number in the appropriate parts list Direction of rotation can also be determined by the appearance of the flange Compare to the photographs shown on this page The seal groove encloses the high pressure area or outlet of the pump inlet of unidirectional motors When observed from the inside looking at the sealed surface the high pressure area will be on the left side in clockwise pumps and on the right side for anti clockwise rotating pumps Anti Clockwise Rotation F101 037 F101 038 35 SAUER DANFOSS Gear Pumps and Motors 7 6 3 Model code Rotation is expressed in the model code as follows SNP2 x Where x is D Clockwise right hand rotation S Anti clockwise left hand rotation F101 039 F101 040 36 Group 2 7 6 4 Conversion procedure To change rotation of a pump the following compo nents are required e A front flange of the appropriate direction of rotation Arear cover if converting a multistage pump The instructions given here show the unique steps involved when converting pu
50. tation e Hear shaft seal 7 2 4 Conversion Procedure The instructions given here show the unique steps involved when converting pumps In addition to these follow the assembly and disassembly instruc tions in sections 5 and 6 1 Open the pump remove the flange rear cover and gear block 2 Replace the existing drive gear shaft with the appropriate new shaft 3 Lubricate shaft seal with grease and install into the seal cavity of the rear flange Snap ring is not required to retain the rear shaft seal 4 Lubricate the pressure seals with grease and install into the rear flange 5 Using assembly grease to retain them install the dowel pins to the pump body 6 Installthe rear flange Ensure the rear flange has the correct direction of rotation 7 Using aprotective sleeve on the shaft install the front flange The first stage pump is now ready to be assembled with the other stages A first stage pump when converted from a single pump will not require the small socket head capscrews as shown inthe figure The front flange will be retained by the four main capscrews or studs of the multi stage pump 29 SAUER DANFOSS Gear Pumps and Motors Group 2 7 3 Intermediate Stage Pump Preparation Rear Shaft Seal Drive Gear Front Flange Shaft Coupling Socket Head Capscrew
51. testing and relative specifications A list follows including the special tools necessary for the operations described in the previous sections This manual gives only general procedures for ser vicing and does not give part numbers of single products or single components If this information is required please contact Sauer Danfoss All of the information contained in this manual is accurate at the date of printing Sauer Danfoss reserves the right to change any specifications with out prior notice Disable Work Function AN WARNING Certain service procedures may require the vehicle machine to be disabled while perform ing them in order to protect the technician and bystanders Fluid Under High Pressure WARNING Use caution when dealing with hydraulic fluid under pressure Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin causing serious injury This fluid may also be hot enough to burn If cut or burned by hydraulic fluid seek proper medical attention immediately All rights reserved Contents subject to change Printed in U S A 0599H 2 SAUER DANFOSS Gear Pumps and Motors Group 2 Contents Be MOC Te EE 2 1 1 Gano at 2 1 2 Safety Precautions NNMERO O 2 1 9 Symbols Used in Sauer Danfoss Literature scio eterno Fx bre te EFIE EP t Ya eoi t era ridere erar eene PEE tus 5 2 GONE Fal STON AU IN Mm RET 6 2 Ge MeO SSC MONON EE 6 2 2
52. them from the flange cover beginning with the backup ring and then the pressure seal Important Do not use tools with sharp edges to remove the seals as damage to the cover can result D I After removal dispose of damaged seals e For SNM 2 SEM 2 SHM 2 SNR 2 Motors Follow the same recommendations given for the previous item If itis necessary to remove the seals pay close attention to this procedure Do not force the removal of the backup ring remove it gradually to avoid damaging the groove in the flange The pressure seal is very delicate handle it with care D IN Aner removal dispose of damaged seals Important Do not use tools with sharp edges to remove the seals as damage to the cover can result 17 SAUER DANFOSS Gear Pumps and Motors 8 Remove Outer O Ring Seal vr Check the quality of this seal If necessary replace it Follow the same removal recommenda tions given in step 7 H After removal discard the damaged seal Important Do not use tools with sharp edges to remove the seals as damage to the cover can result 9 Remove the snap ring Place the flange on the work surface Using internal snap ring pliers remove the snap ring 10 Remove the shaft seal vr Check the shaft seal quality and remove if necessary C4 To remove pry the bottom of the shaft seal and force it out while rotating the flange to lift it o
53. ump Flow Limits Table Minimum Output Flow l min US gal min 5 6 1 48 8 6 2 27 121 3 20 15 5 4 09 20 7 5 47 24 3 6 42 27 8 7 34 33 0 8 72 36 5 9 64 T101 142E SAUER DANFOSS Gear Pumps and Motors Group 2 11 3 3 Tables cont Motor Flow Limits Table Minimum Output Flow Maximum Drain Flow l min US gal min l min US gal min 8 6 2 27 0 30 0 079 12 0 3 17 0 30 0 079 15 5 4 09 0 35 0 092 20 6 5 44 0 40 0 105 24 1 6 37 0 40 0 105 27 6 7 29 0 40 0 105 39 0 8 72 0 40 0 105 36 5 9 64 0 40 0 105 T101 143E Test Pressure Table Pumps SEP 2 SNP 2 SKP 2 SHP 2 bar psi bar psi bar psi bar psi 225 83265 250 3625 250 3625 NA N A 225 8265 250 8625 250 8625 NAA N A 225 8265 250 8625 250 8625 NA N A 225 8265 250 8625 250 8625 N A N A 180 2611 250 8625 250 8625 NA N A 180 2611 250 8625 250 8625 NA N A N A N A 3045 240 8481 240 8481 N A N A 2610 210 8045 210 3045 N A N A 2320 190 2756 190 2756 Test Pressure Table Motors SEM 2 SNM 2 SNU 2 bar psi bar psi bar psi 210 3045 230 3335 210 8045 230 3335 3626 210 8045 230 33
54. ut evenly WS Do not use the flange pilot to gain leverage damage may result Use a plastic rod or wooden dowel as a fulcrum SN After removal dispose of damaged seal 18 Group 2 F101 008 F101 009 F101 010 SAUER DANFOSS Gear Pumps and Motors Group 2 6 Assembly 1 Prepare the seals Have the entire seal kit available _ Lightly coat all seals with seal grease The grease is needed to adhere the seals to their grooves Do not install dry seals F101 011 2 Install shaft seal into front flange _ Prepare the flange and shaft seal by lightly lubricating with grease n Seat the seal in the flange by hand Then using the shaft seal installation tool shown on page 52 press the seal until the tool stops on the flange This will insure the seal is inserted to the proper depth F101 012 3 Install snap ring Install the snap ring using internal snap ring pliers Ensure the snap ring fits securely in its groove This is necessary to retain the shaft seal F101 013 19 SAUER DANFOSS Gear Pumps and Motors 4 Install pressure seals e Pumps and Uni Directional Motors Prepare the pressure seals by lightly lubri cating them with grease Install pressure seals into the grooves on the front flange and rear cover Then install the teflon backup ring Ensure that the seals are located in the grooves as shown e Bi Directional Moto
55. version Rotation Input Shaft Rear Cover Flow Setting Pressure Setting Front Flange Displacement Mulitple Pumps T101 136E 13 SAUER DANFOSS Gear Pumps and Motors Group 2 5 Disassembly 5 1 General In the following pages a detailed procedure is given for disassembly and assembly of pumps and motors Prior to proceeding it may be necessary to prepare some subassemblies separately The details for preparing each subassembly are given in the following section Also some general recommendations are given below 5 1 1 Cleanliness Cleanliness is a primary factor for reliable pump performance Wash the outside of the pump thoroughly before disassembly and all pieces prior to assembly Cleaning parts with clean shop solvent and air drying is usually adequate 5 1 2 Lubrication of Moving Parts During assembly it is imperative to provide lubrication with clean hydraulic oil to all the running parts of the pump lt It is also necessary to coat the seals with grease The absence of lubrication during assembly can cause the unit to seize after a few minutes of running 14 5 1 3 Care of Surface Treatment A Be careful when handling all the internal surfaces especially bearings gears and body faces Do not touch or score them with metal tools or cutting edges 5 1 4 Marking the Parts L Mark the parts befo
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