Series 45 Frame K and L Open Circuit Axial Piston Pumps
Contents
1. WE Outlet port B System gauge port M2 4 25 10 41 SAE J1926 1 1 3125 12 SAE J1926 1 0 4375 20 Inlet port S SAE J1926 1 1 875 12 P101 635E Case drain port L2 SAE J1926 1 0 875 14 520L0532 Rev AB October 2012 SAUER DANFOSS GENERAL START UP PROCEDURE CAUTION Incorrect shaft alignment may result in damage to drive shaft bearings or seal which can cause external oil leakage Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Initial start up procedures Follow this procedure when starting up a new Series 45 installation or when restarting an installation in which the pump has been removed A WARNING Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Prior to installing the pump inspect for damage incurred during shipping Make2. DEI mE ERAT ER BSS ER Double acting cylinder F i Ma 0 KL Frame Series 45 opencircuitaxial 1 piston pump with 2 t load sensing control il al PVG 32 f mulit section load n sensing i control valve I y e LA i 4 Bi directional gear motor Zi ip TT Les fe teat ce E UCM ee 1 B3 EN System pressure EJ Servo pressure Heat exchanger z F i Actuator pressure Reservoir Filter P Load sense pressure Ng ee S Actuator return Suction case drain POSSE system return Full available flow is a function of pump displacement operating speed and efficiency Refer to Series 45 Axial Piston Open Circuit Pumps Technical Information BLN 10128 for details 520L0532 Rev AB October 2012 7 SAUER DANFOSS GENERAL SPECIFICATIONS Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Technical specifications Type of mounting SAE B mounting flange Auxiliary mounting pad options SAE A SAE B or SAE B B Control options PC Pressure Compensator LS Load Sensing with PC Port options Inlet and system ports SAE flanged ports code 61 or O ring boss ports Axial end ports or radial side ports All other ports SAE straight thread O ring boss Direction of rotation Clockwise or counterclockwise Installation pos
3. to measure system pressure Install a Gauge port M2 pressure gauge in case drain port L1 0 300 bar 0 5000 psi or L2 to measure case pressure 91618 NE M14 9 1 4 in 6mm 2 Startthe prime mover and allow Z 34 68 N m 27 35 Nem fluid to reach normal operating 25 50 Ibf ft 20 26 Ibf ft temperature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 3 Loosen the PC set screw and turn the PC adjustment screw until the desired setting is indicated on the pressure gauge at port M2 Clockwise rotation will increase pressure counterclockwise rotation PC adjustment screw Case drain port L1 will decrease approximate gain 6mm 0 10 bar 0 100 psi 35 bar 507 psi per turn PC set screw 69 7 8 14 8 4mm 3 8 in Note If the pressure does not increase an e 7 11 Nem 6 8 Ibfeft 54 136 Nem external system relief valve may require 40 100 Ibf ft adjustment External system relief valve must be set above the PC setting for proper operation P101 652E Adjustment screw set screw and gauge locations shown 4 While holding the position of the PC adjustment screw torque the PC set screw to 7 11 Nem 6 8 Ibf ft 5 Stopthe prime mover remove the pressure gauges and return the system to its normal operating configuration 1P C setting is ref
4. M 20 LS control Shiattseal replacement scere tetigere reote tacet Eae aire Pee Det retrato Feet re ua aiis Re 22 Auxiliary pad Sissi et 23 ES MAPE CONOIS LE M 24 LS and PC Controls 525 Electric Controls 26 Servo Control Orifice 29 Plugiand fittingsizes and torqli8s 4e titt times ito otine qne PA EE RR ROMA deao ERR TEM QUE a POL Neansai 30 520L0532 Rev AB October 2012 3 SAUER DANFOSS USING THIS MANUAL SAFETY PRECAUTIONS Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction This manual includes information for the normal operation maintenance and service of the Series 45 frame K and L open circuit pumps The manual includes a description of the units and their individual components troubleshooting information adjustment instructions and minor repair procedures Unit warranty obligations should not be affected if maintenance adjustment and minor repairs are performed according to the procedures described in this manual Many service and adjustment activities can be performed without removing the unit from the vehicle or machine However adequate access to the unit must be available and the unit must be thoroughly cleaned before beginning maintenance adjustment or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness
5. Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Action Fill the reservoir to proper level Allow system to warm up before operation or use fluid with the appropriate viscosity grade for expected operating temperatures See Ayaraulic fius Series 45 Technical Information Manual BLN 10128 External relief valve set below PC setting will cause low output flow Adjust external relief valve per manufacturer s recommendation External relief valve setting must be above PC setting for proper operation Low PC setting will prevent the pump from achieving full stroke Low LS setting will limit output flow Adjust PC and LS setting Refer to Adjustments page 20 High inlet vacuum will cause low output flow Correct inlet pressure conditions Low input speeds decrease flow Adjust input speed Incorrect rotational configuration will cause low flow Use pump with appropriate rotational configuration Description Air in system will cause erratic operation Action Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression SYSTEM OPERATING HOT Check fluid level in reservoir Hydraulic fluid viscosity above acceptable limits Check external system relief valve setting LOW PUMP OUTPUT Item FLOW Check fluid level in reservoir Hydraulic fl
6. Eliminate fittings to make path more direct Hydraulic fluid viscosity above acceptable limits High fluid viscosity causes high inlet vacuum Select fluid with appropriate viscosity for expected operating temperature See Hydraulic fluids Series 45 Technical Information Manual BLN 10128 520L0532 Rev AB October 2012 19 SAUER DANFOSS PC CONTROL WARNING Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing CAUTION Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Adjustments PC setting is indicated in the pump model code Refer to the Series 45 Open Circuit Axial Piston PumpsTechnical Information Manual BLN 10128 for more information Note Before performing adjustments read page 14 Pressure measurement for recommendations 1 Install a pressure gauge in port M2 PC control adjustment
7. Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 11 Inspect the control housing for damage Check the spool bores for excessive wear 12 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0532 Rev AB October 2012 SAUER DANFOSS LS AND PC CONTROLS continued Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair Reassembly 13 Install the PC spool spherical end first into the PC bore The PC spool is the shorter of the two Using a new O ring install the plug C103 Torque to 11 14 Nem 8 10 Ibfeft 14 Place the two PC springs onto the spring guide and install into the PC bore Place a new O ring onto the PC adjustment screw and thread it into the PC bore until flush then make another full turn Install and torque the set screw to 7 11 Nem 6 8 Ibf ft Control asser bly c118 Z SF O CT 6mm K cs t fig d Gs 9 num ea il O C116 ilicis c rex C102 pl Note For PC only controls skip steps 15 and 16 15 Install the LS spool spherical end first into the LS bore The LS spool is the longer of the two Using a new O ring install the plug C106 Torque
8. AB October 2012 SAUER O DANFOSS CONTROL OPTIONS continued Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features Electric Proportional Controls PLUS 1 Compliance All Series 45 Electric controls have met and passed the Sauer Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Sauer Danfoss website within the PLUS 1 Guide section 7 COMPLIANT Electric Proportional Control Principle The Electric Proportional Control consists of a proportional solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at any pressure limit between the Load Sense and Pressure Compensation settings by varying the current sent to the solenoid Electric On Off Controls PLUS 1 Compliance All Series 45 Electric controls have met and passed the Sauer Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Sauer Danfoss website within the PLUS 1 Guide section 7 COMPLIANT Electric On Off Control Principle The Electric On Off Control consists of an On Off solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at either the Load Sense pressure setting when On or the Pressure Compensation pressure setting w
9. Danfoss Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations can be made without subsequent changes being necessary in specifications already agreed All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group All rights reserved Printed in U S A 0402H 520L0532 Rev AB October 2012 SAUER DANFOSS PRESSURE MEASUREMENT INITIAL START UP PROCEDURES FLUID AND FILTER MAINTENANCE TROUBLESHOOTING ADJUSTMENTS MINOR REPAIR Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Contents Required tools sssi 14 Port locations and gauge installation 14 Jie X 15 KjCIguitjegelfele e U ar cR 15 RecomiiemdatiODs rennes eaaet eiai riadi i eara n p iranin KR EXER NE AEn 16 Excessive rioise and or vibration nosene nna EE EERO 17 Act atorresponse is sl ggis Msn 17 System operating hot 18 Low pump output flow 18 Pressure or flow instability 18 System pressure not reaching PC setting nee 19 Highiitlet vacuums a uoscee nn teer ee eren OU SUN E ATE ERR ER EXER EAN 19 ders
10. Frame K and L Open Circuit Axial Piston Pumps DANFOSS Service Manual Minor repair NOTES 520L0532 Rev AB October 2012 31 SAUER DANFOSS Products we offer e Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics e Hydraulic Power Steering e Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software e Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Members of the Sauer Danfoss Group Comatrol www comatrol com Schwarzm ller Inverter ww w schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Sauer Danfoss Daikin ww w sauer danfoss daikin com 520L0532 Rev AB October 2012 Sauer Danfoss is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Sauer Danfoss Your Strongest Partner in Mobile Hydraulics Go to www sauer
11. Place a protective Keeping the seal perpindicular to the shaft press the new seal into the housing just far enough to clear the retaining ring groove Install seal with the cupped side 2 Remove the shaft seal K020 from the bore in the pump housing and discard Avoid damaging the pump housing or shaft GA Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal Installation 3 Inspect the pump housing and new Polish the sealing area on the shaft if necessary 4 sleeve over the shaft end to prevent damage to the seal during installation 5 toward the shaft bearing Do not damage the seal during installation 6 Using the appropriate snap ring pliers install the seal retaining ring 7 Remove the installation sleeve 520L0532 Rev AB October 2012 SAUER DANFOSS AUXILIARY PADS Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair Auxiliary mounting pads may be installed on pumps equipped with through drive radial ported endcaps Follow these steps to either remove replace or exchange auxiliary mounting pads Removal 1 Remove two screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its sealing O ring J120 Discard the O ring Remove the drive coupling J140 Remove the four screws J100 retaining the pad adapter J085 to the endcap Discard the
12. bore The LS spool is the longer of the two Install plug C106 Torque to 11 14 Nem 8 10 Ibf ft Place the two LS springs onto the spring guide and install into the LS bore Use a new LS adjustment screw assembly C118 and thread it into the LS bore until flush then make another full turn Install and torque the set screw C102 to 7 11 Nem 6 8 Ibfeft Install plug C107 Torque to 11 14 Nem 8 10 Ibf ft Install plug C105 Torque to 11 14 Nem 8 10 Ibf ft Install filter screen plug C145 and O ring C140 Install the cartridge valve C150 and torque to 24 27 Nem 18 20 Ibf ft DO NOT OVERTORQUE the cartridge valve Install the electric solenoid coil C155 and solenoid coil nut torque the nut to 5 7 Nem 4 5 Ibf ft Install the electric control manifold drain orifice C149 torque to 2 3 4 Nem 18 30 invlb Install plug C108 Torque the plug to 11 14 Nem 8 10 Ibfeft Using petroleum jelly to retain them install the three interface O rings C200 Install the control assembly onto the endcap using the four screws C300 Torque to 15 18 Nem 11 13 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Check and adjust the control setting See Adjustments page 20 520L0532 Rev AB October 2012 SAUER DANFOSS SERVO CONTROL ORIFICE Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly 1 R
13. certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 1 Connect the pump to the prime mover Ensure that pump shaft is properly aligned with the shaft of the prime mover 2 Fill the reservoir with recommended hydraulic fluid Always filter fluid through a 10 micron filter pouring into the reservoir Never reuse hydraulic fluid 3 Fill the main pump housing with clean hydraulic fluid Pour filtered oil directly into the upper most case drain port 4 Fill the inlet line leading from the pump to the reservoir Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks 5 To ensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at port M2 to monitor system pressure during start up Note Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While watching the pressure gauge installed at M2 jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels minimum 11 bar 160psi Once system pressure is established increase to full operating speed If system pressure is not maintained shut down the prime mover determine cause and take corrective action Refer to Troubleshooting page 17 8 Operate the hydraulic system for at least fifteen minutes u
14. relief valve Item Check PC control setting Description System pressure will not rise above PC setting Action Adjust PC to appropriate setting Refer to Adjustments page 20 Check external relief valve External relief valve setting below PC setting will prevent pressure compensation Adjust external relief valve per manufacturer s recommendations External relief valve must be set above PC setting for proper operation Inspect PC control spring Broken damaged or missing spring will cause erratic operation Replace spring as required Inspect PC spool for wear Wear of the PC spool will cause internal leakage in the control Replace the spool as required Inspect PC spool for proper orientation Improper orientation will result in poor operation Correct orientation of spool Check PC control for contamination Contamination may interfere with movement of the PC Spool Clean PC control components take appropriate action to eliminate contamination Item Check fluid temperature Inspect inlet screen Description Low temperature increases viscosity High fluid viscosity causes high inlet vacuum Blocked or restricted inlet screen will cause high inlet vacuum Action Allow system to warm up before operation Clean screen remove blockage Check inlet piping Too many fittings bends or long piping will cause high inlet vacuum
15. requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Sauer Danfoss Authorized Service Centers ASCs is available should major repairs be needed Contact any Sauer Danfoss ASC for details A list of all ASCs can be found in bulletin BLN 2 40527 or in brochure SAW Ident No 698266 or you can locate your nearest ASC using the distributor locator at www sauer danfoss com Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system Unintended machine movement A WARNING Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A WARNING Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A WARNING Escaping hydraulic fluid under pressure can have sufficient force 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 comp
16. the outlet thereby imparting power into the system circuit A small amount of fluid is allowed to leak from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling Case drain ports are provided to return this fluid to the reservoir The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate The swashplate is forced into an inclined position into stroke by the bias spring The servo piston opposes the action of the bias spring forcing the swashplate out of stroke when hydraulic pressure in the control circuit rises above the spring force The pump control by varying the pressure at the servo piston controls the displacement of fluid in the system circuit Controls designed for Pressure Compensation PC or Load Sensing LS are available For a detailed description of control operation refer to Control options operation page 12 Pump and control sectional view LS control attached to endcap LS adjustment screw LS spool PC adjustment screw PC spool Swashplate Bias spring Tapered roller bearing Endcap b axial ported Piston Cylinderblock 59 Slipper retainer P101 659E 520L0532 Rev AB October 2012 SAUER DANFOSS THE SYSTEM CIRCUIT Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction The pump receives fluid directly from the reservoir thro
17. to 11 14 Nem 8 10 Ibfeft 16 Place the two LS springs onto the spring guide and install into the LS bore Place a new O ring and back up rings onto the LS adjustment screw and thread it into the LS bore until flush then make another full turn Install and torque the set screw to 7 11 Nem 6 8 lbfeft 17 Using a new O ring install the plug C107 Torque to 11 14 Nem 8 10 Ibf ft 18 Using petroleum jelly to retain them install the three interface O rings 4mm 7 11 N m 6 8 Ibf ft amp C300 4pl g C107 5mm ES ES 3 16 in 15 18 Nem NE 11 14 Nem 11 13 Ibfft 8 10 Ibf ft AIE y lom 8 C106A li 3 c103A 8 C106 g C103 9 3 16in zen 11 14 Nem 11 14 Nem 8 10 Ibf ft 8 10 Ibf ft boise LS control shown parts C106 and C112 through C118 are not used on PC control C200 in the recesses on the control housing 19 Install the control assembly onto the endcap using the four screws C300 Torque to 15 18 Nem 11 13 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 20 Check and adjust the control setting See Adjustments page 20 520L0532 Rev AB October 2012 25 ELECTRIC CONTROLS 26 SAUER Minor repa
18. SAUER Series 45 G DANFOSS Frame K and L Open Circuit Axial Piston Pumps Service Manual SAUER DANFOSS INTRODUCTION TECHNICAL SPECIFICATIONS FEATURES Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Contents Using this manual Safety precautions Unintended machine movement Flarmmable cleanirig solvents ui riter eser sciret odere EN 4 El id underpressule nensi tire emi aa a ar EHE UON rm en en ETE 4 Personal safety Symbols used in Sauer Danfoss literature General description The Systemmoelt Cult oissecoeses tette prre mesi te tete e een uude inier uu EN EAEn i RRT 7 General specificati oN rone m rm annee E 8 PEO MOUNN Gei aeieea 8 Auxiliary mounting pad options berto i R a A S 8 Control options Port options Direction of rotation Installation POSH Osunn E E A 8 MEE MNIGAlS DECI CALIONS ccpscsnasessazessecsacenssstsstenusodsnnassossbsssasasensiatuxstieseaiansssveasbisspd stsnasoasdtsevedisesnasssstcysadiatisatintiesnadts 8 Hydraulic parameters Inlet pressure Pressure compensator valve setting G ET Noe M 9 EydrauliG ui eme rte nn nine 9 Fluid viscosity Filtration Displacement limiter Auxiliary mounting pads Input shafts enfe erm Ole runtpte E Electric Proportional Controls Electric On Off Controls O 2001 Sauer
19. and The flow demand of the system is sensed by the LS control as a pressure drop across the External Control Valve ECV As the ECV opens and closes the pressure delta across the valve changes When opening the delta decreases When closing the delta increases The LS control then increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjustment screw 7 and spring 8 Cross section LS control System pressure LS pressure 7 8 9 4 5 6 Case pressure Servo pressure P101 664E LS spool shifts to port system pressure to servo piston Typical load sensing control valve Load Return e pressure pressure i Tank Load sense System pressure pressure P101 665E Pressure drop across external control valve defines system demand The LS control consists of two spool valves that connect the servo piston either to pump case or system pressure The PC spool 6 controls the pressure compensating function of the control as described in the previous section The LS spool 9 controls the load sensing function The PC spool has priority over the LS spool Via internal porting system pressure upstream of ECV is applied to the non spring end of the LS spool and via hydraulic line connected at port X LS pressure downstream of ECV is applied to the spring en
20. araulic Fluids Series 45 Technical Information Manual BLN 10128 Check external system valving Malfunctioning valving may not allow system to respond properly Repair or replace system valving as required Check pump case pressure High case pressure will cause the system to be sluggish Correct case drain line restrictions Check pump inlet pressure vacuum High inlet vacuum will cause low output flow Correct inlet pressure conditions 520L0532 Rev AB October 2012 17 SAUER DANFOSS Service Manual Troubleshooting Description Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Series 45 Frame K and L Open Circuit Axial Piston Pumps Action Fill the reservoir to proper level Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or use fluid with the appropriate viscosity grade for expected operating temperatures See Ayaraulic fius Series 45 Technical Information Manual BLN 10128 External relief valve set below PC setting will cause low output flow Adjust external relief valve per manufacturer s recommendation External relief valve setting must be above PC setting for proper Description Insufficient hydraulic fluid will limit output flow and cause internal damage to pump
21. bjected to temperature levels greater that the recommended maximum Note 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 520L0532 Rev AB October 2012 S SAUER EXCESSIVE NOISE AND OR VIBRATION ACTUATOR RESPONSE IS SLUGGISH Series 45 Frame K and L Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Check fluid level in reservoir Check for air in system Description Insufficient hydraulic fluid will cause cavitation Air in system will cause noisy erratic control Action Fill the reservoir to proper level Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Improper inlet conditions will cause erratic behavior and low output flow Correct pump inlet pressure vacuum conditions Refer to Hydraulic parameters page 9 Inspect shaft couplings A loose or incorrect shaft coupling will cause excessive noise and or vibration Repair or replace coupling and ensure that correct coupling is being used Check shaft alignment Misaligned shafts will create excessive noise and or vibration Correct shaft misalignment Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limit
22. d This arrangement allows the LS spool to act on the delta between system pressure and LS pressure The LS spring sets the threshold of operation LS setting Because the swashplate is biased to maximum angle the pump attempts to deliver full flow to the hydraulic system When the flow being delivered exceeds demand the pressure delta across the ECV is great enough to overcome spring force and shift the LS spool porting system pressure to the servo piston The pump de strokes reducing flow until the delta across the ECV becomes equal to the LS setting When flow being delivered is less than demand the delta across the ECV drops below the LS setting and the LS spring shifts the spool connecting the servo piston to pump case The pump strokes increasing flow until the delta across the ECV becomes equal to the LS setting When the external control valve is placed in neutral it connects the LS signal line to drain With no LS pressure acting on the non spring end of the LS spool the pump adjusts stroke to whatever position necessary to maintain system pressure at the LS setting The pump is now in standby mode Because of the series arrangement of the LS and PC spools the PC spool will override the LS spool If at any time system pressure reaches the PC setting the PC spool will shift blocking the passage that connects the LS spool with the servo piston and porting system pressure to the servo piston causing the pump to de stroke 520L0532 Rev
23. danfoss com for further product information Wherever off highway vehicles are at work so is Sauer Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Sauer Danfoss representative nearest you Local address Sauer Danfoss US Company Sauer Danfoss ApS 2800 East 13th Street DK 6430 Nordborg Denmark Ames IA 50010 USA Phone 45 7488 4444 Phone 1 515 239 6000 Fax 45 7488 4400 Fax 1515 2396618 Sauer Danfoss GmbH amp Co OHG Sauer Danfoss Daikin LTD Postfach 2460 D 24531 Neum nster Shin Osaka TERASAKI 3rd Bldg 6F Krokamp 35 D 24539 Neum nster Germany 1 5 28 Nishimiyahara Yodogawa ku Phone 49 4321 8710 Osaka 532 0004 Japan Fax 49 4321 871 122 Phone 81 6 6395 6066 Fax 81 6 6395 8585 www sauer danfoss com
24. emove plug C103 and PC spool C132 from the control housing Keep the O ring Note the orientation of the spool for reassembly Reassembly 1 Ensure the preferred orifice spool C132 is selected 2 Install the PC spool spherical end first into the PC bore Install plug C103 Torque to 11 14 Nem 8 10 Ibfeft 520L0532 Rev AB October 2012 Control assembly C103 P108 671E 3 16 in 11 14 Nem 8 10 Ibf ft 29 SAUER DANFOSS PLUG AND FITTING SIZES AND TORQUES 3 8 in 54 136 Nem 40 100 Ibfeft NIOIE J080 J081 J082 m8 N Z 8mm JAA Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair If any plugs or fittings are removed from the unit during service install and torque as indicated here This drawing is a composite Your configuration may differ but the appropriate wrench size and torque can be found here Plug locations sizes and torques K045 Q de 7 8 o M14 6mm 41 95 Nem 30 70 Ibf ft P101 642 27 35 Nem 20 26 Ibfeft 520L0532 Rev AB October 2012 o Fa P J041 J043 J044 J046 20 26 Ibf ft M14 9 16 in 6mm e 1 4 in 27 35 Nm Z 34 68 Nem 25 50 Ibfeft K040 7 8 in on 3 8 in we 54 136 Nem 6mm 40 100 Ibf ft 27 35 Nem 20 26 Ibf ft eC SAUER Series 45
25. erenced to case pressure Subtract case pressure from system pressure to compute the actual setting 20 520L0532 Rev AB October 2012 SAUER DANFOSS LS CONTROL A WARNING Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing CAUTION Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Adjustments The LS setting is indicated in the pump model code Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual BLN 10128 for more information Note Before performing adjustments read page 14 Pressure measurement for recommendations 1 Install a pressure gauge in port M2 LS control adjustment to measure system pressure Install Gauge port M2 a pressure gauge in drain port L1 or O 0 300 bar 10 5000 psi L2 to measure case pressure Tee in 6 9 16 18 M14 a gauge to the LS remote PC signal 1 4 in 6mm li
26. hen Off 520L0532 Rev AB October 2012 13 SAUER DANFOSS REQUIRED TOOLS PORT LOCATIONS AND GAUGE INSTALLATION 14 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Pressure measurement The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown Calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges Gauge port locations are shown below Recommended pressure gauges and fittings are detailed in the table Gauge and port information Port Purpose Range of gauge Fitting 0 300 bar or 05000 psi 7 16 20 cing fitting IM4 Servo pressure 0 300 bar or 0 5000 psi 7 16 20 o ring fitting 0 10 bar or 100 psi A 7 16 20 o ring fitting LS signal 0 300 bar or 0 5000 x fisso fosoobaroriosooops tee into LS signal line Gauge port locations axial ported units System gauge port M2 SAE J1926 1 0 4375 20 LS signal port X SAE J1926 1 0 4375 20 Outlet port B SAE J1926 1 1 3125 12 Inlet port S SAE J1926 1 1 875 12 Case drain port L1 SAE J1926 1 0 875 14 Case drain port L2 SAE J1926 1 0 875 14 P101 634E Gauge port locations radial ported units Case drain port L1 Ma SAE J1926 1 0 875 14
27. ir Control assembly C150 Cartridge 3 4in 24 27 Nem 18 20 Ibf ft Coil Nut 3 4 in 5 7 Nem 4 5 Ibf ft C300 5mm 15 18 N m 11 13 Ibf ft Disassembly C138 6mm 1 Remove four screws C300 135 E CIS Z Series 45 Frame K and L Open Circuit Axial Piston Pumps DANFOSS Service Manual C200 3pl C102 2pl 4mm ee 7 16 in aes OA 28 39 Nem 21 29 Ibf ft e C149 6mm IU Pd d lt C300 ra G 5mm 9 15 18 Nem z 11 13 Ibfeft 4A C112 A C107 P ud 3 16 in 11 14 N m ae m e 8 8 10 Ibf ft 5 C104 3 16 in C103 11 14 Nem 3 16 in 8 10 Ibf ft 11 14 Nem 8 10 Ibf ft P108 670E 2 Remove the control and discard the three O rings C200 3 Remove set screws C102 PC adjusting screw C138 springs C134 C135 and seat C133 4 Remove plug C103 Remove PC spool C132 Note orientation of the spool for reassembly 520L0532 Rev AB October 2012 eC SAUER Series 45 Frame K and L Open Circuit Axial Piston Pumps gt DANFOSS Service Manual Minor repair Disassembly continued 5 Remove the plug C107 6 Remove the LS set screw C102 LS adjustment screw assembly C118 springs C114 C115 and seat C113 Discard the LS adjustment screw assembly 7 Remove plug C104 and spool C112 Note the orientation of the spool for reassembly 8 Remove the plug C105 9 Remove the solen
28. ition Installation position is discretionary To satisfy inlet pressure conditions it is recom mended that the pump always be located below the lowest level of hydraulic fluid in the reservoir The housing must always be filled with hydraulic fluid Technical specifications Ratings Specification Unt Framel Framek Displacement cm 25753 sores 3812320 45273 Minimum so s so s Input Speed Rated 320 3200 250 365 Maximum _ 3600 3600 2800 2809 bar ips 359 5075 300 4350 350 5075 300 143501 r Psi 26015770 21015045 260 13770 210 13045 Flow at rated speed Vmin gal min 76 2 20 3 90 0 24 0 108 3 28 9 126 0 33 6 Theoretical input torque at Nem bar 0 395 0 477 0 605 0 716 maximum displacement Ibf in 1000psi 243 291 369 437 Mass moment of inertia of internal 0 0016 0 0015 0 0017 0 0020 i kgm Ibm ft rotating components 0 037 0 035 0 040 0 047 PE om on ETE 3 spa 2453 Ca 520L0532 Rev AB October 2012 SAUER DANFOSS HYDRAULIC PARAMETERS Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Technical specifications Inlet pressure Minimum pressure continuous 0 8 bar absolute 23 2 in Hg at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 14 8 in Hg Pressure compensator valve setting Minimum 100 bar 1450 psi Maximum 260 bar 3770 psi Ca
29. l housing discard the O ring Note orientation of the spool for reassembly 5 Remove the plug C107 and O ring C107A discard the O ring Note For PC only controls skip steps 6 and 7 6 Remove the LS set screw C102 LS adjustment screw C118 O ring C116 back up rings C117 springs C114 C115 and seat C113 discard the O ring 7 Remove the plug C106 O ring C106A and LS spool C112 from the control housing discard the O ring Note orientation of the spool for reassembly Inspection Control assembly FT c138 11C136 C133 o C102 2pl ES 4mm 7 11 Nem 6 8 Ibfeft C300 4pl 8 C107 5mm ES ES 3 16 in 15 18 Nem 11 14 Nem 11 13 Ibf ft 8 10 Ibf ft AIE m iuf 8 C106A ii lcio3a 8 cA J C103 9 3 16 in 2 11 14 Nem 11 14 Nem 8 10 Ibf ft 8 10 Ibf ft PIUTGE7 LS control shown parts C106 and C112 through C118 are not used on PC control 8 Inspect the adjustment screws for wear at the tips and where they contact the springs replace as necessary 9 Inspect the springs and spring guides for wear or damage replace as necessary 10
30. ment to 92 This displacement limiter is not adjustable Auxiliary mounting pads are available for all radial ported Series 45 pumps These pads are typically used for mounting auxiliary hydraulic pumps Since the auxiliary pad operates under case pressure an O ring must be used to seal the auxiliary pump mounting flange to the pad The drive coupling is lubricated by oil from the main pump case For details refer to Series 45 Axial Piston Open Circuit Pumps Technical Information BLN 10128 Displacement limiter P101 660 P101 661 Series 45 K and L frame pumps are available with a variety of splined straight keyed and tapered end shafts For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information BLN 10128 520L0532 Rev AB October 2012 SAUER DANFOSS CONTROL OPTIONS Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features The Series 45 Frames K and L have two possible control options a Load Sensing LS control with Pressure Compensator PC or a PC only control Operation Cross section pump General The bias spring 1 acts at all times to push Da the swashplate 2 to maximum angle Z causing the pump to stroke The servo j 4 NS piston 3 acts against the bias spring to g reduce the swashplate angle causing the pump to de stroke Swashplate angle DZ determines pump outle
31. nder light load conditions 9 Checkand adjust control settings as necessary after installation Refer to Adjustments page 20 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M2 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 520L0532 Rev AB October 2012 15 SAUER DANFOSS RECOMMENDATIONS 16 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Fluid and filter maintenance To ensure optimum life of Series 45 products perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Water in the fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Change the fluid and filter per the Fluid and filter change interval vehicle machine manufacturer s recommendations or at these intervals Reservoir Type E gius nterval c Sealed 2000 H Change the fluid more frequently if it oo beat Breather 500 Hours becomes contaminated with foreign matter dirt water grease etc or if the fluid is su
32. ne port X 34 68 Nem 27 35 Nem 25 50 Ibf ft 20 26 Ibf ft LS remote PC 2 Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydraulic function which will demand approximately half flow from the pump but keep system pressure below the PC set point signal port X 3 Loosen the LS set screw While watching the pressure gauges turn BHA LS adjustment screw 4 Case rain porte the LS adjustment screw until the Emm O 0 10 bar 0 100 psi desired pressure differential between pM 69 7 8 14 port M2 and port X is achieved PA amp 3 8 in Clockwise rotation will increase 7 11 Nem 6 8 Ibit 54 136 Nem the setting counterclockwise rotation will decrease approximate gain 12 bar 170 psi per turn P101636E 40 100 Ibfeft Adjustment screw set screw and gauge locations shown 4 While holding the position of the LS adjustment screw torque the LS set screw to 7 11 Nem 6 8 lbfeft 5 Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 6 Loosen the PC set screw and turn the PC adjustment screw until the desired setting is indicated on the pressure gauge at port M2 Clockwise rotation will increase pressure counterclockwise rotation will decrease approximate gain 35 bar 507 psi per turn Note If the pressure does not increase an external system relief valve may require adjustmen
33. oid coil nut and electric solenoid coil C155 Remove the cartridge valve C150 Remove filter screen plug C145 and O ring C140 10 Remove the plug C108 and electric control manifold drain orifice C149 Inspection 1 Inspect the adjusting plugs for wear at the tips and where they contact the springs replace as necessary 2 Inspect the springs and spring guides for wear or damage replace as necessary 3 Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 4 Inspect the control housing for damage Check the spool bores for excessive wear 5 Ensurethe electric control manifold drain orifice is clean Remove debris from orifice if necessary 6 Cleanall parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0532 Rev AB October 2012 27 SAUER DANFOSS ELECTRIC CONTROLS CONTINUED 28 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair Reassembly is Install the PC spool spherical end first into the PC bore The PC spool is the shorter of the two Install plug C103 Torque to 11 14 Nem 8 10 Ibf ft Thread the PC adjustment screw into the PC bore until flush then make another full turn Install and torque the set screw C102 to 7 11 Nem 6 8 Ibfeft Install the LS spool spherical end first into the LS
34. onents 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 520L0532 Rev AB October 2012 SAUER DANFOSS SYMBOLS USED IN SAUER DANFOSS LITERATURE Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction A e f v ds le BI amp y s UE WARNING may result in injury CAUTION may result in damage to product or property Reusable part Non reusable part use a new part Non removable item Option either part may exist Superseded parts are not interchangeable Measurement required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port Deo a Rj be eee oA ej Tip helpful suggestion Lubricate with hydraulic fluid Apply grease petroleum jelly Apply locking compound Inspect for wear or damage Clean area or part Be careful not to 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 can be found in the illustra
35. s or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or use fluid with the appropriate viscosity grade for expected operating temperatures See yaraulic Fluids Series 45 Technical Information Manual BLN 10128 Item Check external system relief valve setting Description Low external relief valve setting will slow down system Action Adjust external relief valve setting per manufacturer s recommendations External relief setting must be above PC setting for proper operation Check PC and LS control setting Low PC setting will prevent the pump from achieving full stroke Low LS setting will limit output flow Adjust PC and LS setting Refer to Adjustments page 20 Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system ensure that proper LS signal is transmitted to the pump Internal system leaks Worn internal parts will not allow the pump to operate properly Refer to Authorized Service Center for repairs as required Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or use fluid with the appropriate viscosity grade for expected operating temperatures See Ay
36. se pressure Maximum continuous 0 5 bar 7 psi Above inlet Intermittent 2 bar 29 psi Cold start Hydraulic fluid Refer to Sauer Danfoss publication Fluids and Filtration BLN 9887 or 520L0463 For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465 See Fluid and filter maintenance page 16 for recommended fluid and filter change intervals Temperature range Intermittent cold start 40 C 40 F Continuous 82 C 180 F Maximum 104 C 220 F Fluid viscosity Viscosity limits o REUS or e E 64 47 intermittent maximum Filtration Required cleanliness level ISO 4406 Class 18 13 or better Refer to Sauer Danfoss publications Fluids and Filtration BLN 9887 or 520L0463 and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465 See Fluid and filter maintenance page 16 for recommended fluid and filter change intervals 1 Hydraulic fluid viscosity must be maintained within the prescribed limits As measured at the hottest point in the system e g drain line 520L0532 Rev AB October 2012 9 SAUER DANFOSS DISPLACEMENT LIMITER AUXILIARY MOUNTING PADS INPUT SHAFTS 10 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features Frame K and L Series 45 pumps are available with an optional maximum displacement limiter If installed this longer servo piston will limit the maximum displace
37. t External system relief valve must be set above the PC setting for proper operation 7 While holding the position of the PC adjustment screw torque the PC set screw to 7 11Nem 6 8 Ibf ft 8 Stopthe prime mover remove the pressure gauges and return the system to its normal operating configuration The LS setting is a differential pressure Subtract pilot pressure at port X from system pressure at port M2 to compute the actual setting PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 520L0532 Rev AB October 2012 21 S SAUER DANFOSS SHAFT SEAL REPLACEMENT CAUTION Premature bearing failure can result if the shaft seal contacts the shaft bearing Press the seal into the housing only far enough to clear the retaining ring 22 groove Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair A lip type shaft seal is used in the Series 45 open circuit variable pumps This seal can be replaced without major disassembly of the unit Replacement of the shaft seal requires removal of the pump from the machine Removal 1 Using the appropriate snap ring pliers remove the retaining ring K010 from the housing Shaft seal and retaining ring seal for damage Inspect the sealing area on the shaft for rust wear or contamination Lubricate the lip of the new shaft seal with clean hydraulic fluid
38. t flow The pump control depending on conditions in the system circuit sets swashplate angle by metering system pressure to the servo E piston 4 A E P101 663 Bias spring and servo piston set swashplate position PC control The PC control is designed to maintain a constant pressure in the hydraulic circuit as flow varies The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as defined by the PC adjustment screw 4 and spring 5 Cross section PC control When system pressure acting on the ystemi pressure non spring end of the PC spool 6 overcomes the force of the PC spring the spool shifts porting system pressure to the servo piston and the swashplate angle decreases When system pressure drops below the PC setting the PC spring shifts the spool in the opposite 4 3 6 direction connecting the servo piston servo pressure POU eee to pump case and the swashplate angle PC spool shifts to port system pressure to EM Sero piston increases The swashplate is maintained at whatever angle is required to keep system pressure at the PC setting Case pressure v2 520L0532 Rev AB October 2012 11 SAUER DANFOSS CONTROL OPTIONS continued 12 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Features LS control The LS control is designed to match pump flow with system dem
39. tions 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 is provided to define each symbol and explain its purpose 520L0532 Rev AB October 2012 SAUER DANFOSS GENERAL DESCRIPTION Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Introduction Sauer Danfoss Series 45 K and L frame open circuit piston pumps convert input torque into hydraulic power Rotational force is transmitted through the input shaft to the cylinder block The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block A lip seal at the front end of the pump prevents leakage where the shaft exits the pump housing The spinning cylinder block contains nine reciprocating pistons Each piston has a brass slipper connected at one end by a ball joint The slippers are held to the swashplate by the spring retainer and block spring The block spring also holds the cylinder block to the valve plate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation Via the valve plate one half of the cylinder block is connected to pump inlet and the other half to pump outlet As each piston cycles in and out of its bore fluid is drawn from the inlet and displaced to
40. two pad adapter O rings J090 J095 Auxiliary mounting pads m J085 i E095 J140 P f Jo90 O Er o im o i E J090 wa bw 2pl J100 4pl 8mm J085 N 47 61 Nem 35 45 Ibf ft O 9 16 in 37 50 Nem 27 37 Ibf ft J100 4pl 8mm 47 61 Nem 35 45 Ibfeft Installation 4 Lubricate new O rings with petroleum jelly Install the pad adapter to the endcap 5 Install the four screws and torque to 47 61 Nem 35 45 Ibfeft 5 Install the drive coupling Q CAUTION Shipping coverisintended 6 Install shipping cover or auxiliary pump with new O ring only to retain coupling during shipmentand 7 Install two screws J130 and torque to 37 50 Nem 27 37 Ibf ft storage Do not operate pump with coupling and shipping cover installed 520L0532 Rev AB October 2012 23 SAUER DANFOSS LS AND PC CONTROLS 24 Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly 1 Remove the four screws C300 holding the control housing onto the end cap 2 Remove the control and discard the three interface O rings C200 3 Remove the PC set screw C102 PC adjustment screw C138 O ring C136 springs C135 C134 and seat C133 Discard the O ring 4 Remove the plug C103 O ring C103A and PC spool C132 from the contro
41. ugh the inlet line A screen placed in the inlet protects the pump from large contaminants The output of the pump is directed to a PVG 32 multi section load sensing directional control valve which directs fluid to the actuators in the system Fluid returning from the system is cooled by a heat exchanger and cleaned by a filter before returning to the reservoir The speed of the actuators in the system depends on the volume of fluid being provided by the pump The operating pressure varies depending on actuator load but is limited to an adjustable maximum setting by the PC section of the pump control and by a system relief valve integrated into the side module of the PVG valve The position of the PVG valve sets the demand for flow in the system and communicates this to the pump control by means of a hydraulic signal load sense signal The pump will provide as much flow to the system as it demands while limiting the maximum pressure Therefore flow and pressure in the system are compensated to meet requirements Pictorial circuit diagram
42. uid viscosity above acceptable limits Check external system relief valve setting Check PC and LS control setting Check pump inlet pressure vacuum Check input speed Check pump rotation PRESSURE OR FLOW Item INSTABILITY Check for air in system Check control spools 18 Sticking control spools will cause erratic operation Inspect spools for free movement in bore Clean or replace as needed 520L0532 Rev AB October 2012 S SAUER PRESSURE OR FLOW INSTABILITY continued SYSTEM PRESSURE NOT REACHING PC SETTING HIGH INLET VACUUM CAUTION High inlet vacuum causes cavitation which can damage internal pump components Series 45 Frame K and L Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Description Action Check LS setting Low LS setting may cause instability Adjust LS setting to proper level See Adjustments page 20 Check LS signal line Blocked LS signal line will interfere with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differential between PC setting and external relief valve Adjust external relief valve or PC control settings to appropriate level Relief valve setting must be above PC setting for proper operation Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace
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