Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual
Contents
1. Minor repair Reassembly Control assembly 13 Install the PC spool C132 spherical end first into the PC bore Using a Fo Fand new O ring C103A install the plug ree C103 Torque the plug C103 to C104 QS IIBER 10 8 13 5 Nem 8 10 lbfeft 6 3heinch Q 7110 8 13 5 Nem C1O3A i 14 Place the two PC springs C134 B 10 Ibf ft i o g C135 onto the spring guide C133 A and install into the PC bore Place l C104A e 105 a new O ring C138A onto the g cu2 d l S J inch PC adjusting screw and thread it CA i Z 10 8 13 5 Nem into the PC bore until flush then 8 10 Ibfft make another full turn Install and iil C105A 111 torque the PC set screw C102 to C102 7 5 10 8 Nem 5 5 8 Ibf ft MC 106 en G mm C106 9 22 7 5 10 8 Nem For PC only controls skip steps 15 3e inch 5 5 8 Ibfeft through 17 10 8 13 5 Nem C200 fi D x 8 10 bfft INS 15 Install the LS spool C112 spherical C300 C113 end first into the LS bore Using eus bd 4 mm a new O ring C105A or C106A B 54 7 5 Nem install the plug C105 or C106 114 8 4 5 5 Ibf ft Torque the plug2. PC spool PC adjustment Lifting lug Servo piston guide Adjustable Servo piston displacement Slipper retainer limiter f zz Valve plate qmm Shaft seal Cylinder block E 77 Input shaft Block BEA spring Tapered 4 roller RAT E uds bearin 4 roller 3 A je bearing Swashplate Slipper Bias spring Piston Bias piston Bias piston guide P104001E 520L0606 Rev AG October 2012 7 SAUER DANFOSS SYSTEM CIRCUIT Pictorial circuit diagram Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Introduction The pump receives fluid directly from the reservoir through the inlet line A screen placed in the inlet protects the pump from large contaminants The output of the pump is directed to a 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
3. P104 048 Bias spring and servo piston set swashplate position PC control Cross section PC control The PC control design maintains 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 the PC adjusting plug 4 and spring 5 defines P104 049 PC spool shifts to port system pressure to When system pressure acting on the servo piston 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 direction connecting the servo piston to pump case and the swashplate angle increases The swashplate is maintained at whatever angle is required to keep system pressure at the PC setting 520L0606 Rev AG October 2012 13 SAUER DANFOSS CONTROL OPTIONS CONTINUED 14 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Features LS control The LS control design matches pump flow with system demand The LS control senses the flow demand of the system 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 the
4. HO Pd P 9 16 inch 1 4 inch 20 5 27 Nem 15 20 lbfeft 9 16 inch 1 4 inch 20 5 27 Nem 15 20 Ibf ft 1 1 16 inch 9 16 inch 95 135 Nem 70 100 Ibf ft P104 060 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 520L0606 Rev AG 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
5. ss Unintended machine movement Flammable cleaning solvents Fluid under pressure rennes ETE Symbols used in Sauer Danfoss literature G n ral description i SYSTEM CIEU En E General specications sistema 9 Type of MOUNN isssssscscosssssossesectissscoasteceassecceassssnataesociasssoatsosociassnaisosoatav enaseagnaiansonissscodsoteadaertoasssecaiacenss 9 Auxiliary mounting pad options rene 9 Control options sss Port OPTIONS Direction of rotation Installation position Technical specifications sens Hydraulic parameters Inlet pressure Pressure compensator valve setting si CAS Wl ET seb dsseayadedscudves nine nine Hydraulic fluid zenenan anaa Rani Fluid viscosity Bl Displacement limiter rte gettin tenerse eere ieii Auxiliary mounting pads m Input iR m Nat en rein an ann it NN Control OptiGns ssssentienennenutnnienminnenanenntenennenneneinniaetee PC control LS control tenes Electric Proportional Controls m sl TaufeejyieSe dot Required tools cicer eese tpe AS Port locations and gauge installation Gerieral AENT I AEA DEALS AE E AEA RU Vere DNE epu LUE 17 Start Up Droced re issues 17 Recommendation Svesse ter nn eds ini ie tentera it 18 520L0606 Rev
6. l Install the orifice G020 and torque to 2 3 4 Nem 18 30 inelb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft Using petroleum jelly to retain them install the four O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 520L0606 Rev AG October 2012 Control assembly P108 669E S SAUER PLUG AND FITTING SIZES AND TORQUES Series 45 E Frame Open Circuit Axial Piston Pumps DANFOSS 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 here is the appropriate wrench size and torque Plug locations sizes and torques 95 135 Nem 70 100 Ibfeft a LO20 M 6 9 3 4 inch 5 16 inch oS 41 95 Nem NN 30 70 Ibf ft J042 9 16 inch 1 4 inch 36 50 Nem 27 37 lbfeft 520L0606 Rev AG October 2012 1 1 1 9 16 inch T RB
7. 11 bar 160 psi 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 18 8 Operate the hydraulic system for at least fifteen minutes under light load conditions 9 Checkand adjust control settings as necessary after installation Refer to Adjustments page 21 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M1 or M2 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 520L0606 Rev AG October 2012 17 SAUER DANFOSS RECOMMENDATIONS 18 Series 45 E Frame 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 interv
8. E frame axial piston pumps according to the procedures in this manual will not affect your warranty Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Sauer Danfoss Authorized Service Centers ASCs is available for major repairs Major repairs require the removal of the unit s endcap which voids the warranty unless done by an ASC Sauer Danfoss ASCs are trained by the factory and certified on a regular basis 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 these 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 s
9. and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465 See Fluid and filter maintenance page 17 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 520L0606 Rev AG October 2012 11 SAUER DANFOSS DISPLACEMENT LIMITER AUXILIARY MOUNTING PADS INPUT SHAFTS 12 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Features Frame E Series 45 pumps are available with an optional adjustable maximum displacement limiter The adjustable stop limits the pump s maximum displacement The displacement change per turn of the displacement limiter adjustment screw is shown below Displacement change 100 cc 130 cc 147 cc 8 4 cc rev 0 513 in3 rev Displacement change older models 100 cc 130 cc 147 cc 6 5 cc rev 0 397 in3 rev 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 you must use an O ring to seal the auxiliary pump mounting flange to the pad Oil from the main pump case lubricates the drive coupling For details refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519 Setting range 100 cc 40
10. 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 i mt C07 eas Series45 Double acting cylinder bi open circuit axial X piston pump with load sensing control PVG32 I multi section load sensing 7 D control 22 N valve LE 9 a D I 7 U iI Bi directional gear motor i i I i x ZUB PEET E ENT T L System pressure EN Servo pressure Heat exchanger z Filter Actuator pressure Reservoir P104 045E eS Load sense pressure pe HE Actuator return Suction case drain 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 520L0519 for details 520L0606 Rev AG October 2012 SAUER DANFOSS GENERA
11. 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 when Off 520L0606 Rev AG October 2012 15 SAUER DANFOSS REQUIRED TOOLS PORT LOCATIONS AND GAUGE INSTALLATION Series 45 E Frame 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 requi
12. 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 Make 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 M1 or M2 to monitor system pressure during start up Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While watching the pressure gauge installed at M1 or M2 jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels minimum
13. nlet pressure vs speed charts HYDRAULIC Inlet pressure PARAMETERS Minimum pressure continuous 0 8 bar absolute 6 7 inch Hg vac at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 15 1 inch Hg vac Pressure compensator valve setting Setting 100 and 130 cc 147 cc Minimum 100 bar 1450 psi Maximum 310 bar 4495 psi 260 bar 3770 psi Case 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 17 for recommended fluid and filter change intervals 10 520L0606 Rev AG October 2012 SAUER DANFOSS Hydraulic parameters continued Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications Temperature range Intermittent cold start 40 C 40 F Continuous 82 C 180 F Maximum 104 C 220 F Fluid viscosity Viscosity limits Rating mm s cSt SUS minimum 9 58 v continuous maximum 110 500 minimum 6 4 47 vintermittent maximum 1000 4700 cold start Filtration Required cleanliness level ISO 4406 Class 18 13 or better Refer to Sauer Danfoss publications Fluids and Filtration BLN 9887 or 520L0463
14. the O ring if it is damaged 4 Remove plug C103 Remove PC spool C132 Note orientation of the spool for reassembly 5 Remove plug G030 and orifice G020 6 Remove LS adjusting plug C118 springs C114 C115 and seat C113 P108 668E 138 7 Remove plug C104 and spool C112 Note the orientation of the spool for reassembly 8 Remove four screws C151 Remove the manifold C152 and discard the two interface O rings C154 9 Forelectric proportional controls only Remove the electric control manifold drain orifice C149 10 Remove plug C153 Remove the cartridge valve nut C125 electric solenoid C155 and cartridge valve C150 from the electric control manifold 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 Remove debris from orifices if necessary Ensure the servo control orifice backup plug is clean and remove debris if necessary 6 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0606 Rev AG October 20
15. to 100 cm 2 44 to 6 1 in3 130 cc 70 to 130 cm 4 27 to 7 93 in3 147 cc 87 to 147 cm 5 31 to 8 97 in3 Displacement limiter s a P107 779E AS Displacement limiter older models ES T vez EY P104 046 Ty Auxiliary pad options P104 047 Series 45 E frame pumps are available with a variety of splined and straight keyed shafts For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519 520L0606 Rev AG October 2012 SAUER DANFOSS CONTROL OPTIONS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Features The Series 45 Frames E have three possible control options a Load Sensing LS control with Pressure Compensator PC a PC only control or an electric control Operation Cross section pump General The bias piston and spring 1 acts at all times to push the swashplate 2 to maximum angle causing the pump to stroke The servo piston 3 acts against the bias piston and spring to reduce the swashplate angle causing the pump to destroke Swashplate angle determines pump outlet flow The pump E control depending on conditions in the LL system circuit sets swashplate angle by metering system pressure to the servo piston D GO
16. 12 SAUER DANFOSS ELECTRIC CONTROLS CONTINUED Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Reassembly 1 10 11 12 13 14 15 Install the servo control orifice G020 and torque to 2 3 4 Nem 18 30 inelb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw C138 and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft Install the LS spool C112 spherical end first into the LS bore Install plug C104 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Place the two LS springs C114 C115 onto the spring guide C113 and install into the LS bore Thread adjusting screw C118 into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibfeft Install the electric control manifold drain orifice C149 and torque to 2 3 4 Nem 18 30 inelb Install the cartridge valve C150 into the electric control manifold C152 Torque to 25 8 28 5 Nem 19 21 Ibf ft DO NOT OVERTORQUE the cartrid
17. AG October 2012 3 SAUER DANFOSS TROUBLESHOOTING ADJUSTMENTS MINOR REPAIR Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Excessive noise and or vibration nn Actuator response is sluggish System operating hot Low pump output flow Pressure or flow instability System pressure not reaching PC setting Higli nlet Vac sen e recette trei rere as dnegausensoustectauseseadsdeceessct os eoncdsdvoebeuencnascecuostertaseennewaeeee PC COl Ol aceite tation unire beet dido SE PUn iere Vk ton EST 22 ESCM E i o bee 23 Shaft seal replacement eiecti totae Frente ii iei NENS event 24 AUXILANY PAGS e n LS and PC Controls Electric Controls eese eee teet tte ntenttn tnnt states ntt ttt ttt stets btts theta tests tetas sss tt boat S rvo COntrol OTNINES RAR EET 30 Plug and fitting sizes and torques inner 31 520L0606 Rev AG October 2012 SAUER DANFOSS OVERVIEW SAFETY PRECAUTIONS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Introduction This manual includes information for the installation maintenance and minor repair of the Series 45 frame E open circuit axial piston pumps The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures Performing installation maintenance and minor repair of Series 45
18. C105 or C106 to il C118B o 10 8 13 5 Nem 8 10 Ibfeft i C118A Gloss 16 Using a new O ring C104A install mm E c c118 the plug C104 Torque the plug to E101 226 SRI ORE LS control shown parts C104 through C106 and 17 Place the two LS springs C134 C135 C112 through C118 are not used on PC control onto the spring guide C113 and install into the LS bore Place a new O ring C118A and back up rings C118B onto the LS adjusting screw and thread it into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft 18 Using petroleum jelly to retain them install the 4 interface O rings C200 in the recesses on the control housing 19 Install the control assembly onto the endcap using the 4 screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 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 21 520L0606 Rev AG October 2012 27 SAUER DANFOSS ELECTRIC CONTROLS 28 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly Control assembly 1 Remove four screws C300 2 Remove the control and discard the four O rings C200 3 Remove set screws C102 PC adjusting plug C138 with O ring C138A springs C134 C135 and seat C133 Discard
19. L SPECIFICATIONS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications Type of mounting SAE C mounting flange Auxiliary mounting pad options SAE A SAE B SAE B B SAE C SAE C C Control options PC Pressure Compensator LS Load Sensing with PC Port options Inlet and system ports SAE flanged ports code 61 Inlet Code 62 outlet Axial end ports or radial side ports All other ports SAE straight thread O ring boss Direction of rotation Clockwise or counterclockwise Installation position Installation position is discretionary To satisfy inlet pressure conditions it is recommended 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 Model Features and options Feature Unit E100B E130B E147C Maximum Displacement cm in3 100 6 10 130 7 93 147 8 97 g l min 245 286 309 Flow at rated speed theoretical US gal min 64 7 75 6 81 6 Input torque at maximum displacement N m bar 1 592 2 069 2 340 theoretical Ibf in 1000 psi 972 1263 1428 Mass moment of inertia of internal kgm 0 0128 0 0128 0 0128 rotating components slug ft2 0 0094 0 0094 0 0094 Axial ports kg lb 51 3 113 Weight p g Ib 113 Radial ports 54 9 121 Rotation Clockwise Counterclockwise Mou
20. SAUER DANFOSS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual SAUER Series 45 E Frame Open Circuit Axial Piston Pumps S DANFOSS Service Manual Revisions HISTORY OF REVISIONS Table of Revisions Date Page Changed Rev October 2012 add control types AG April 2011 correction to installation of shipping cover AF November 2010 new last page AE February 2010 Fix Osaka address AD July 2009 Pressure change PC adjustment specs AC March 2008 added new displacement limiter specs AB March 2005 First edition A O 2012 Sauer Danfoss All rights reserved Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations aren t in conflict with agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group 2 520L0606 Rev AG October 2012 SAUER DANFOSS INTRODUCTION TECHNICAL SPECIFICATIONS FEATURES PRESSURE MEASUREMENT INITIAL START UP PROCEDURES FLUID AND FILTER MAINTENANCE Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual OWEN CW E EE AE EE A E E E Safety precautions
21. 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 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 piston and spring The servo piston opposes the action of the bias piston and 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 13 Pump and control sectional view LS control attached to endcap LS spool LS adjustment
22. al vehicle machine manufacturer s Reservoir type Maximum change interval recommendations or at these intervals Sealed 2000 hours Breather 500 hours Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater that the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replace all fluid lost during filter change 520L0606 Rev AG October 2012 S SAUER EXCESSIVE NOISE AND OR VIBRATION ACTUATOR RESPONSE IS SLUGGISH Series 45 E Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Description Action Check fluid level in reservoir Insufficient hydraulic fluid causes cavitation Fill the reservoir to proper level Check for air in system Air in system causes noisy erratic control Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Improper inlet conditions cause erratic behavior and low output flow Correct pump inlet pressure vacuum conditions Refer to Hydraulic parameters page 10 Inspect shaft couplings A loose or incorrect shaft coupling causes excessive noise and or vibration Repair or replace coupli
23. at exchanger as required Verify proper size of heat exchanger Check external system relief valve setting Fluid passing through relief valve adds heat to system Adjust external system relief valve setting following manufacturer s recommendations External relief valve setting must be above PC setting for proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions Item Description Action Check fluid level in reservoir Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Fill the reservoir to proper level Hydraulic fluid viscosity above acceptable limits 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 operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic fluids Series 45 Technical Information Manual 520L0519 Check external system relief valve setting Eternal relief valve set below PC setting causes low output flow Adjust external relief valve following manufacturer s recommendation External relief valve setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Adjust PC and LS setting R
24. costs and bring vehicles to market faster Sauer Danfoss Your Strongest Partner in Mobile Hydraulics Go to www sauer 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
25. efer to Adjustment page 21 Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions Check input speed Low input speeds decrease flow Adjust input speed Check pump rotation Incorrect rotational configuration causes low flow Use pump with appropriate rotational configuration Item Description Action Check for air in system Air in system causes erratic operation Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression Check control spools Sticking control spools cause erratic operation Inspect spools for free movement in bore Clean or replace 520L0606 Rev AG October 2012 S SAUER PRESSURE OR FLOW INSTABILITY continued SYSTEM PRESSURE NOT REACHING PC SETTING HIGH INLET VACUUM O Caution High inlet vacuum causes cavitation which can damage internal pump components Series 45 E Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual instability Troubleshooting Item Description Action Low LS setting may cause Adjust LS setting to proper level Check LS setting Mr ML d M i Loon dub See Adjustments page 21 Check LS signal line Blocked LS signal line interferes with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differ
26. ential 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 to operate properly Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace relief valve Item Description Action Check PC control setting System pressure will not rise above PC setting Adjust PC to appropriate setting Refer to Adjustments page 21 Check external relief valve External relief valve setting below PC setting presents pressure compensation Adjust external relief valve according to manufacturer s recommendations External relief valve must be set above PC setting to operate properly Inspect PC control spring Broken damaged or missing spring will cause erratic operation Replace the spring as required Inspect PC spool for wear Wear of PC spool causes internal leakage in the control Replace the spool as required Inspect PC spool for proper orientation Improper orientation results 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 Description Action Check fluid temperature Low tempe
27. ge valve Install the electric solenoid C155 and solenoid coil nut C125 Torque to 6 8 9 5 Nem 5 7 lbfeft Install plug C153 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft Using petroleum jelly to retain them install the two interface O rings C154 in the recesses on the electric control manifold Install the manifold assembly onto the control housing using four screws C151 Torque the screws to 5 4 7 5 Nem 4 5 5 lbfeft Torque the screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Using petroleum jelly to retain them install the four interface O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using the four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 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 22 23 520L0606 Rev AG October 2012 29 SAUER DANFOSS SERVO CONTROL ORIFICE 30 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly 1 2 Remove four screws C300 Remove the control and discard the four O rings C200 Remove PC plug C103 and PC spool C132 from the control housing Note the orientation of the spool for reassembly 4 Remove backup plug G030 and orifice GO20 Reassembly
28. ic 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 sue fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids Series 45 Technical Information Manual 520L0519 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 causes the system to be sluggish Correct case drain line restrictions Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions 520L0606 Rev AG October 2012 19 S SAUER SYSTEM OPERATING HOT LOW PUMP OUTPUT FLOW PRESSURE OR FLOW INSTABILITY 20 Series 45 E Frame Open Circuit Axial Piston Pumps DANFOSS Service Manual Troubleshooting Item Description Action Check fluid level in reservoir Insufficient volume of hydraulic fluid will not meet cooling demands of system Fill reservoir to proper level Verify proper size of reservoir Inspect heat exchanger Check air flow and input air temperature for the heat exchanger Insufficient air flow high input air temperature or undersized heat exchanges will not meet cooling demands of the system Clean repair or replace he
29. lug torque the PC set screw to 7 5 10 8 Nem 5 5 8 Ibf ft 5 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration Pressure change Control option PC adjustment LS adjustment LS LD LB LE PC RP 42 bar rev 609 PSI rev BB BC BP BS 36 bar rev 534 PSI rev 17 2 bar rev 250 PSI rev AB AC AD AJ AS 8 5 bar rev 123 PSl rev PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 520L0606 Rev AG 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 If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation Series 45 E Frame Open Circuit A
30. n auxiliary A pad install the screws J131 and torque to 37 50 Nem 27 37 Ibf ft 520L0606 Rev AG October 2012 25 LS AND PC CONTROLS 26 SAUER DANFOSS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Disassembly T Remove the 4 screws C300 holding the control housing onto the end cap Remove the control and discard the 4 interface O rings C200 Remove the PC set screw C102 PC adjusting plug C138 O ring C138A springs C134 C135 and seat C133 Discard the O ring Remove the plug C103 O ring C103A and PC spool C132 from the control housing Discard the O ring Note orientation of the spool for reassembly Control assembly C103 5Ae inch 10 8 13 5 Nem C104 8 10 Ibf ft 9 3e inch o l 4 10 8 13 5 Nem een ul 8 10 Ibfeft dus s M c104A e 1 C105A 8 10 Ibf ft C102 96 6 mm C105 a 8 c4 6inch A T Z 10 8 13 5 Nem be 9 N Lr C106 s 7 7 5 10 8 Nem 9 A6 inch Da For PC only controls skip steps 5 through 7 5 5 8 Ibfeft 10 8 13 5 Nem 00 5 C105A or C106A 6 Remove the LS set screw C102 LS adjusting plug C118 O ring C118A back u
31. n increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjusting plug 7 and spring 8 Cross section LS control Wille Spring Spring PC heavy guide P104 051 LS spool shifts to port system pressure to servo piston Typical load sensing control valve Load Return E pressure pressure Tank D Z Load sense O 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 previously described The LS spool 9 controls the load sensing function The PC spool has priority over the LS spool Through internal porting system pressure upstream of ECV is applied to the non spring end of the LS spool and through hydraulic line connected at port X LS pressure downstream of ECV is applied to the spring end 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 acr
32. ng and ensure that correct coupling is used Check shaft alignment Misaligned shafts create excessive noise and or vibration Correct shaft misalignment 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 operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids Series 45 Technical Information Manual 520L0519 Item Description Action Check external system relief valve setting Low external relief valve setting slows down system Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Low LS setting limits 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 to ensure that proper LS signal transmit to pump Internal system leaks Worn internal parts don t allow the pump to operate properly Refer to Authorized Service Center for required repair Hydraulic fluid viscosity above acceptable limits Hydraul
33. nting SAE C Auxiliary mounting SAE A SAE B SAE BB SAE C SAE CC System ports type 4 bolt split flange System ports location Axial Radial Control types PC Remote PC LS LS with internal bleed Splined 13 tooth 14 tooth 17 tooth Shafts Straight 38 08 mm 1 5 in Displacement limiters Optional adjustable 520L0606 Rev AG October 2012 9 SAUER Series 45 E Frame Open Circuit Axial Piston Pumps S DANFOSS Service Manual Technical specifications GENERAL Ratings Model SPECIFICATIONS Rating Units E100B E130B E147C continued minimum 500 500 500 Input speed continuous min rpm 2450 2200 2100 maximum 2880 2600 2475 continuous 310 4495 310 4495 260 3770 Working pressure bar psi maximum 400 5800 400 5800 350 5075 External moment M Nem lbf in 455 4030 360 3190 396 3500 External shaft Thrust in T out Toa 2846 640 1735 390 2113 475 loads N lbf Thrust out T 7740 1740 6672 1500 7117 1600 at 140 bar 2030 psi 77 200 32 700 21 600 at 210 bar 3045 psi 19 800 8400 5500 Bearing life B o hours at 260 bar 3770 psi 9700 4116 2700 at 310 bar 4495 psi 5400 2300 Mounting flange Vibratory continuous Nem lbfein 1920 17 000 em lbf in load moments Shock max 6779 60 000 1 Input speeds are valid at 1 bar absolute 0 in Hg vac inlet pressure See
34. nts PC setting is indicated in the pump model code Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual 520L0519 for more information Before performing adjustments read page 15 Pressure measurement Install a pressure gauge in port M1 or M2 to measure system pressure Install a pressure gauge in case drain port L1 or L2 to measure case pressure Start the prime mover and allow fluid to reach normal operating temperature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M21 Clockwise rotation increases pressure counterclockwise rotation decreases approximate gain 42 bar 610 psi per turn PC control adjustment PC set screw c 4 mm 76 7 11 Nem 6 8 Ibfeft PC adjusting plug Case drain port L1 0 10 bar 0 145 psi 7 8 14 54 136 Nem 40 100 Ibfeft Gauge M2 If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation D 0 300 bar 0 4351 psi 6 9 16 28 34 68 Nem 25 50 Ibfeft P104 053 4 While holding the position of the PC adjusting p
35. oss 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 destroke 520L0606 Rev AG October 2012 SAUER O DANFOSS CONTROL OPTIONS CONTINUED Series 45 E Frame 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
36. ource 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 components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 520L0606 Rev AG October 2012 5 SAUER DANFOSS SYMBOLS USED IN SAUER DANFOSS LITERATURE Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Introduction These symbols are in the illustrations and text of this manual They 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 below defines the symbol and explains its purpose A e ds e El g 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 Mea
37. p rings C118B springs C114 C115 and seat C113 Discard the C118A O ring Js Inspection 8 replace as necessary 9 Remove the plug C105 and O ring C105A or the plug C106 and O ring C106A Discard the O ring Ss C200 li i No 8 10ibPf S E oe z 4 mm 54 7 5 Nem A 5 5 Ibfeft M C118B o M C118A lc118B8 eos z ci18 7 E101 226 LS control shown parts C104 through C106 and C112 through C118 are not used on PC control Remove the C104 plug C104A O ring and C112 LS spool from the control housing discard the O ring Note orientation of the spool for reassembly Inspect the adjusting plugs for wear at the tips and where they contact the springs Inspect the springs and spring guides for wear or damage replace as necessary 10 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 520L0606 Rev AG October 2012 LS AND PC CONTROLS SAUER DANFOSS continued Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual
38. quipped with through drive radial ported end caps Follow these steps to either remove replace or exchange auxiliary mounting pads Removal 1 Remove the screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its seal J120 2 Remove the drive coupling J140 if present 3 Remove the 4 screws J100 retaining the pad adapter J080 to the endcap Discard the pad adapter O ring J090 if present Auxiliary mounting pads J130 Ol inch 91 111 Nem 67 82 Ibf ft i Caution Shipping cover is intended only to retain coupling during shipment and storage Do not operate pump with coupling and shipping cover installed 6 10 mm N 76 47 5 61 Nem NC 1140 35 45 Ibf ft EM iJ S Y Tos 5 N nao Some auxiliary A pads 9 NC 5120 do not have this coupling Nd ano Shsinch 3110 7637 50 Nem 27 37 Ibf ft P103 37E Installation 4 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 5 Install the 4 screws J100 and torque to 47 5 61 Nem 35 45 Ibfeft 6 Install the drive coupling J140 if present 7 Install shipping cover with seal J120 or auxiliary pump with O ring customer supplied 8 Install the screws J130 and torque to 94 115 Nem 67 82 Ibf ft If you have a
39. rature increases viscosity High fluid viscosity causes high inlet vacuum Allow system to warm up before operating Inspect inlet screen Blocked or restricted inlet screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Too many fittings bends or long piping causes high inlet vacuum 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 520L0519 520L0606 Rev AG October 2012 21 SAUER DANFOSS PC 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 22 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Adjustme
40. red are shown Calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges The illustration below shows gauge port locations Recommended pressure gauges and fittings are in the table Gauge and port information 16 Port Purpose Range of gauge Fitting M1 M2 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting M4 Servo pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting E112 Case drain 0 300 bar 0 5000 psi 1 1 16 12 O ring fitting 7 16 20 O ring fitting X1 LS signal 0 300 bar 0 5000 psi tee into LS signal line Gauge port locations Legend B Main pressure line S Suction line L1 L2 Case drain lines X Load sensing pressure port M1 CW endcap system pressure gauge M2 Gauge portfor port B M4 Gauge port servo pressure Same pressure P104 052 520L0606 Rev AG 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 E Frame 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
41. rt L1 0 10 bar 0 145 psi 699 7 8 14 75 54 136 Nm 40 100 Ibf ft P104 054 Gauge port M2 0 300 bar 0 4351 psi 9 16 18 34 68 Nem 25 50 Ibfeft Adjusting plug set screw and gauge locations shown PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M2 Clockwise rotation increases pressure counterclockwise rotation decreases it approximate gain 42 bar 610 psi per turn While holding the position of the PC adjusting plug torque the PC set screw to 7 5 10 8 Nem 5 5 8 Ibf ft Stop the 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 520L0606 Rev AG October 2012 23 SAUER DANFOSS SHAFT SEAL REPLACEMENT Caution Don t damage the pump housing or shaft 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 groove 24 Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair The Series 45 open circuit variable pumps use a lip
42. surement required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port 520L0606 Rev AG October 2012 LU D e Ee Deo a Ne RJ a 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 SAUER DANFOSS GENERAL DESCRIPTION Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Introduction Sauer Danfoss Series 45 E 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
43. type shaft seal You can replace this seal without major disassembly of the unit Replacing the shaft seal requires removing 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 GP i 2 Remove the shaft seal K020 from the bore in the pump housing and discard al 3 Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal P104 055 Installation 4 Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary 5 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation 6 Keeping the seal perpendicular 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 toward the shaft bearing Do not damage the seal during installation 7 Using the appropriate snap ring pliers install the seal retaining ring 8 Remove the installation sleeve 520L0606 Rev AG October 2012 SAUER DANFOSS AUXILIARY PADS Series 45 E Frame Open Circuit Axial Piston Pumps Service Manual Minor repair You may install auxiliary mounting pads on pumps e
44. xial 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 520L0519 for more information Before performing adjustments read page 15 Pressure measurement 1 Install a pressure gauge in port M1 or M2 to measure system pressure Install a pressure gauge in drain port L1 or L2 to measure case pressure Tee in a gauge to the LS remote PC signal line port X Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydraulic function that will demand approximately half flow from the pump but keep system pressure below the PC set point Loosen the LS set screw While watching the pressure gauges turn the LS adjusting plug until the desired pressure differential between port M1 or M2 and port X is achieved Clockwise rotation increases the setting counterclockwise rotation will decrease it approximate gain 17 bar 250 psi per turn While holding the position of the LS adjusting plug torque the LS set screw to 7 5 10 8 Nem 5 5 8 lbfeft Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow Loosen the PC set screw and turn the LS control adjustment LS set screw 4mm 7 5 10 8 Nm 5 5 8 Ibf ft LS adjusting plug 6 6 mm Case drain po
Download Pdf Manuals
Related Search