45 Series F Frame Service Manual (11005158 Rev AB Sept 2007)

7/27/2019 45 Series F Frame Service Manual (11005158 Rev AB Sept 2007)

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Series 45 Frame F

Open Circuit AxialPiston Pumps

Service Manual


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11005158 Rev. AB September 2007

Series 45 Frame F Open Circuit Axial Piston Pumps

Service Manual

Revisions

2007 Sauer-Danoss. All rights reserved.

Sauer-Danoss accepts no responsibility or possible errors in catalogs, brochures and other printed material.

Sauer-Danoss reserves the right to alter its products without prior notice. This also applies to products

already ordered provided that such alterations arent in conict with agreed specifcations. All trademarks in

this material are properties o their respective owners. Sauer-Danoss and the Sauer-Danoss logotype are

trademarks o the Sauer-Danoss Group.

Front cover illustrations: F101 503, P105265E

Table o Revisions

D P Chd R.

September 2007 28 revision to change per turn or displacement limiter AB

November 2006 - First edition AA

HistoRy o Revisions


3/28



Service Manual

intRoDuCtion

teCHniCal

sPeCiiCations

eatuRes

PRessuRe

measuRement

initial staRt-uP

PRoCeDuRes

luiD anD ilteR

maintenanCe

Overview ...........................................................................................................................................................5

Saety precautions .........................................................................................................................................5

Unintended machine movement .......................................................................................................5Flammable cleaning solvents ...............................................................................................................5

Fluid under pressure ................................................................................................................................5

Personal saety ...........................................................................................................................................5

Symbols used in Sauer-Danoss literature.............................................................................................6

General description ....................................................................................................................................... 7

System circuit ...................................................................................................................................................8

General specifcations ..................................................................................................................................9

Type o mounting ..................................................................................................................................... 9

Auxiliary mounting pad options ......................................................................................................... 9

Control options ..........................................................................................................................................9Port options ................................................................................................................................................9

Direction o rotation ................................................................................................................................9

Installation position .................................................................................................................................9

Technical specifcations ..........................................................................................................................9

Hydraulic parameters..................................................................................................................................10

Inlet pressure ............................................................................................................................................10

Pressure compensator valve setting ................................................................................................10

Case pressure ...........................................................................................................................................10

Hydraulic uid .........................................................................................................................................10

Temperature range.................................................................................................................................11

Fluid viscosity ...........................................................................................................................................11

Filtration ....................................................................................................................................................11

Displacement limiter ...................................................................................................................................12

Auxiliary mounting pads ...........................................................................................................................12

Input shats .....................................................................................................................................................12

Control options .............................................................................................................................................13

Operation ...................................................................................................................................................13

Control options .............................................................................................................................................14

Required tools ...............................................................................................................................................15

Port locations and gauge installation ...................................................................................................15

General .............................................................................................................................................................16

Start-up procedure ......................................................................................................................................16

Recommendations.......................................................................................................................................17


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Service Manual

tRoublesHooting

aDjustments

minoR RePaiR

Excessive noise and / or vibration ..........................................................................................................18

Actuator response is sluggish ..................................................................................................................18

System operating hot .................................................................................................................................19Low pump output ow ..............................................................................................................................19

Pressure or ow instability ........................................................................................................................19

System pressure not reaching PC setting ............................................................................................20

High inlet vacuum ........................................................................................................................................20

PC control ........................................................................................................................................................21

LS control ........................................................................................................................................................22

Shat seal replacement ...............................................................................................................................23

Removal ......................................................................................................................................................23Installation .................................................................................................................................................23

Auxiliary pads ................................................................................................................................................24

Removal ......................................................................................................................................................24

Installation .................................................................................................................................................24

Control..............................................................................................................................................................25

Disassembly ..............................................................................................................................................25

Inspection ..................................................................................................................................................25

Reassembly ...............................................................................................................................................26

Plug and ftting sizes and torques ..........................................................................................................27


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Service Manual

Introduction

This manual includes inormation or the installation, maintenance, and minor repair o

the Series 45 Frame F open circuit axial piston pumps. The manual includes a description

o the units and their individual components, troubleshooting inormation, and minorrepair procedures. Perorming installation, maintenance, and minor repair o Series 45

Frame F axial piston pumps according to the procedures in this manual will not aect

your warranty.

Perorming minor repairs requires the unit to be removed rom the vehicle/machine.

Thoroughly clean the unit beore beginning maintenance, or repair activities. Since dirt

and contamination are the greatest enemies o any type o hydraulic equipment, ollow

cleanliness requirements strictly. This is especially important when changing the system

flter and when removing hoses or plumbing.

A worldwide Global Service Partner Network is available or major repairs. Major repairs

require the removal o the units endcap, which voids the warranty unless done by aGlobal Service Partner. Sauer-Danoss Global Service Partners are trained by the actory

and certifed on a regular basis. You can locate your nearest Global Service Partner using

the distributor locator at www.sauer-danoss.com

Always consider saety precautions beore beginning a service procedure. Protect

yoursel and others rom injury. Take these general precautions whenever servicing a

hydraulic system.

udd ch

WarningUnintended movement o 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.

c

WarningSome cleaning solvents are ammable. To avoid possible fre, do not use cleaning

solvents in an area where a source o ignition may be present.

d dr prr

WarningEscaping hydraulic uid under pressure can have sufcient orce to penetrate your skin

causing serious injury and/or inection. This uid may also be hot enough to cause burns.

Use caution when dealing with hydraulic uid under pressure. Relieve pressure in thesystem beore removing hoses, fttings, gauges, or components. Never use your hand

or any other body part to check or leaks in a pressurized line. Seek medical attention

immediately i you are cut by hydraulic uid.

Pr

WarningProtect yoursel rom injury. Use proper saety equipment, including saety glasses, at all

times.

oveRview

saety PReCautions


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Service Manual

Introduction

symbols useD in

saueR-Danoss

liteRatuRe

These symbols are in the illustrations and text o this manual. They communicate helpul

inormation at the point where it is most useul to the reader.

In most instances, the appearance o the symbol itsel denotes its meaning. The legend

below defnes the symbol and explains its purpose.

WARNING may result in injury

CAUTION may result in damage toproduct or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option either part may exist

Superseded parts are notinterchangeable

Measurement required

Flatness specifcation

Parallelism specifcation

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpul suggestion

Lubricate with hydraulic uid

Apply grease / petroleum jelly

Apply locking compound

Inspect or wear or damage

Clean area or part

Be careul not to scratch or damage

Note correct orientation

Mark orientation or reinstallation

Torque specifcation

Press in press ft

Pull out with tool press ft

Cover splines with installationsleeve

Pressure measurement / gaugelocation or specifcation

waRRanty Perorming installation, maintenance, and minor repairs according to the procedures in

this manual will not aect your warranty. Major repairs requiring the removal o a units

endcap voids the warranty unless done by a Sauer-Danoss Global Service Partner.


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Service Manual

Introduction

Sauer-Danoss Series 45 Frame F open circuit piston pumps convert input torque into

hydraulic power. The input shat transmits rotational orce rom the prime mover to

the cylinder block. Tapered roller bearings support the shat at the ront and rear o thepump. The cylinder block connects to the input shat through splines on the shat. A

lip-seal at the ront end o the pump prevents leakage where the shat 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 o the pistons occurs

as the slippers slide against the inclined swashplate during rotation. The valve plate

connects one hal o the cylinder block to pump inlet and the other hal to pump outlet.

As each piston cycles in and out o its bore, uid is drawn rom the inlet and displaced to

the outlet thereby imparting power into the system circuit. A small amount o uid leaks

rom the cylinder block / valve plate and slipper / swashplate interaces or lubrication

and cooling. Case drain ports return this uid to the reservoir.

The angle o the swashplate controls the volume o uid displaced into the system

circuit. The bias piston orces the swashplate into an inclined position (into stroke). The

servo piston opposes the action o the bias piston and spring, orcing the swashplate out

o stroke when hydraulic pressure in the control circuit rises above the spring orce.

The pump control, by varying the pressure at the servo piston, controls the displacement

o uid in the system circuit. Controls designed or Pressure Compensation (PC) or

load sensing (LS) are available. For a detailed description o control operation, reer to

Control op tions, operation, page 13.

geneRal DesCRiPtion

Pump and control sectional view

Slipper

LS adjustment

PC adjustment

LS spool

PC spool

LS control(attached to endcap)

Servo piston

Swashplate

Taperedrollerbearing

Shaft seal

Tapered rollerbearing

Input shaft

Cylinderblock

Valveplate

Cylinderblockspring

Piston

Slipper retainer

Bias spring

P104 341EBias piston


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8 11005158 Rev. AB September 2007


Service Manual

Introduction

1 Full available ow is a unction o pump displacement, operating speed, and efciency. Reer to Series 45 Frame

F Axial Piston Open Circuit Pumps Technical Inormation,50l098or details.

system CiRCuit

Pictorial circuit diagram

System pressure

Servo pressure

Actuator pressure

Load sense pressure

Actuator return

Suction / case drain /system return

Series 45 F Frameopen circuit axialpiston pump withload sensing control PVG 32

multi-sectionloadsensingcontrol

valve

P106 212E

Reservoir Filter

Heat exchanger

Double-acting cylinder

Bi-directionalgear motor

The pump receives uid directly rom the reservoir through the inlet line. A screen in the

inlet line protects the pump rom large contaminants. The pump outlet eeds a PVG-32

multi-section, load sensing, directional control valve. The PVG valve directs pump ow tothe cylinder and gear motor. A heat exchanger cools the uid returning rom the valve. A

flter cleans the uid beore it returns to the reservoir.

Flow in the circuit determines the speed o the actuators. The position o the PVG valve

determines the ow demand. A hydraulic pressure signal (LS signal) communicates

demand to the pump control. The pump control monitors the pressure dierential

between pump outlet and the LS signal, and regulates servo pressure to control the

swashplate angle. Swashplate angle determines pump ow.

Actuator load determines system pressure. The pump control monitors system pressure

and will decrease the swashplate angle to reduce ow i system pressure reaches the

PC setting. A system relie valve in the PVG valve acts as a back-up to control systempressure.


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Service Manual

Technical specifcations

tp

SAE-C mounting ange.

ar pd p

SAE-A, SAE-B, SAE-B-B, SAE-C, SAE C-C

Cr p

PC: Pressure Compensator

LS: Load Sensing (with PC)

Pr p

Inlet and system ports: SAE anged ports, code 61 Inlet Code 62 outlet.

Axial (end) ports or radial (side) ports.

All other ports: SAE straight thread O-ring boss.

Drc r

Clockwise or counterclockwise.

i p

Installation position is discretionary. To satisy inlet pressure conditions, we recommend

you locate the pump below the lowest level o hydraulic uid in the reservoir. The

housing must always be flled with hydraulic uid.

tchc pcc

geneRal

sPeCiiCations

Features and options md

r u b 90C

Maximum displacement cm [in] 74 [4.52] 90 [5.49]

Flow at rated speed (theoretical) l/min

[US gal/min]

177.6

[46.9]

198

[52.3]

Input torque at maximum displacement

(theoretical)

Nm/bar

[lbin/1000 psi]

1.178

[719]

1.432

[874]

Mass moment o inertia o internal

rotating components

kgm

[slugt]

0.00630

[0.00465]

0.00650

[0.00480]

Weight Axial ports kg [lb] 29 [63]

Radial ports 31.8 [70.1]

Rotation Clockwise, Counterclockwise

Mounting SAE B 2 blot, SAE-C 4 bolt

Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-CSystem ports (type) 4-bolt split ange

System ports (location) Axial, Radial

Control types PC, Remote PC, LS, Electric

Shats Splined 14 tooth, 17 tooth

Straight 31.75 mm [1.25 in]

Displacement limiters Optional, adjustable


10/28


geneRal

sPeCiiCations

(cd)


Service Manual


i prr

Minimum pressure, continuous = 0.8 bar absolute [6.7 inch Hg vacuum]

(at reduced maximum pump speed)

Minimum pressure, cold start = 0.5 bar absolute [15.1 inch Hg vacuum]

Prr cpr

HyDRauliC

PaRameteRs

C prr

Maximum continuous: 0.5 bar [7 psi] above inlet

Intermittent: 2 bar [29 psi] cold start

Hdrc fdReer to Sauer-Danoss publication: Fluids and Filtration50l0. For inormation on

biodegradable uids reer to Biodegradable Hydraulic Fluids,50l05. See Fluid and

lter maintenance, page 17 or recommended uid and flter change intervals.

Ratings md

R u gb g90C

Input speed1 minimum min-1 (rpm) 500 500

continuous 2400 2200

maximum 2800 2600

Working pressure continuous bar [psi] 310 [4495] 260 [3770]

maximum 400 [5800] 350 [5075]

External shat

loads

External moment (Me) Nm [lbin] 300 [2655]

Thrust in (Tin), out (Tout) N [lb ] 2900 [650]

Bearing lie at 140 bar [2030 psi] B10 hours 31 300 17 400

at 210 bar [3045 psi] 1110 5700

at 260 bar [3770 psi] 4810 2490

at 310 bar [4495 psi] 3080 1636

Mounting ange

load moments

Vibratory (continuous) Nm [lbin] 3730 [33 000]

Shock (maximum) 13 220 [117 000]

1. Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs. speedcharts.

PC control setting range

md r p

b 100310 14504495

90C 100260 14503770


11/28


HyDRauliC

PaRameteRs

(cd)


Service Manual


1 Hydraulic uid viscosity must be maintained within the prescribed limits.2 As measured at the hottest point in the system, e.g. drain line.

r

Required cleanliness level: ISO 4406 Class 18/13 or better. Reer to Sauer-Danoss

publications Fluids and Filtration50l0 and Design Guidelines or Selecting and

Maintaining the Required Hydraulic Fluid Cleanliness50l05. See Fluid and lter

maintenance, page 17 or recommended uid and flter change intervals.

tprr r

d c

Fluid viscosity limits

Cd / (cs) sus

min.continuous 9 58

intermittent 6.4 47

max.

continuous 110 500

intermittent(cold start)

1000 4700

Temperature limitsm

(r, cd r)- 40 C [- 40 F]

C 82 C [180 F]

m 104 C [220 F]


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Service Manual

Features

DisPlaCement limiteR

auxiliaRy mounting

PaDs

inPut sHats Series 45 F Frame pumps are available with a variety o splined and straight keyed

shats. For inormation on shats reer to Series 45 F Frame Axial Piston Open Circuit Pumps

Technical Inormation50l098.

Frame F Series 45 pumps are available

with an optional adjustable maximum

displacement limiter. The adjustablestop limits the pumps maximum

displacement. The displacement change

per turn is 6.8 cm/turn [0.47 in/turn] or

the F90C and 6.0 cm/turn [6.1 in/turn]

or the F74B

Displacement limiter

P104 345

Auxiliary mounting pads are available or

all radial ported Series 45 pumps. These

pads are typically used or mountingauxiliary hydraulic pumps.

Since the auxiliary pad operates under

case pressure, you must use an O-ring to

seal the auxiliary pump mounting ange

to the pad. Oil rom the main pump case

lubricates the drive coupling. For details

reer to Series 45 F Frame Axial Piston

Open Circuit Pumps Technical Inormation

50l098.

Auxiliary pad options

P106 262E


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Service Manual

Features

The Series 45 Frame F pumps have two control options, a load sensing (LS) control with

Pressure Compensator (PC) or a PC only control.

b pr d r p hp

p

Cross-section pumpopr

General

The bias piston and spring (1&2) acts at

all times to push the swashplate (4) 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 ow. The pump control,

depending on conditions in the system

circuit, sets swashplate angle by meteringsystem pressure to the servo piston.

PC control

The PC control design maintains a

constant pressure in the hydraulic circuit

as ow varies. The PC control modulates

pump ow accordingly to maintain

system pressure at the PC setting as

the PC adjusting plug (4) and spring (5)

defne.

When system pressure, acting on the

non-spring end o the PC spool (6),

overcomes the orce o the PC spring (5),

the spool shits porting system pressure to the servo piston and the swashplate angle

decreases. When system pressure drops below the PC setting, the PC spring shits 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.

ContRol oPtions

PC spool shifts to port system pressure to

servo piston

Cross-section PC control

P104 049

4

56

P106 261E1

234


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Service Manual

Features

ContRol oPtions

(cd)

LS control

The LS control design matches pump

ow with system demand. The LS controlsenses the ow demand o 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 then increases

or decreases pump ow to the system

until the pressure delta becomes equal

to the LS setting as defned by the LS

adjusting plug (7) and spring (8).

Load

pressure

Load sensepressure

Systempressure

Tank

Return

pressure

P101 665E

Typical load-sensing control valve

Prr drp cr r cr

d dd

The LS control consists o two spool

valves that connect the servo pistoneither to pump case or system pressure.

The PC spool (6) controls the pressure-

compensating unction o the control

as previously described. The LS spool (9)

controls the load-sensing unction. The

PC spool has priority over the LS spool.

Through internal porting, system pressure

(upstream o ECV) is applied to the non-

spring end o the LS spool, and through

hydraulic line connected at port X, LS

pressure (downstream o 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 o operation (LS setting).

Because the swashplate is biased to maximum angle, the pump attempts to deliver

ull ow to the hydraulic system. When the ow being delivered exceeds demand, the

pressure delta across the ECV is great enough to overcome spring orce and shit the

LS spool porting system pressure to the servo piston. The pump de-strokes reducing

ow until the delta across the ECV becomes equal to the LS setting. When ow being

delivered is less than demand, the delta across the ECV drops below the LS setting and

the LS spring shits the spool connecting the servo piston to pump case. The pump

strokes increasing ow 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 todrain. With no LS pressure acting on the non-spring end o 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 o the series arrangement o the LS and PC spools, the PC spool will override

the LS spool. I at any time system pressure reaches the PC setting, the PC spool will shit

blocking the passage that connects the LS spool with the servo piston, thus porting

system pressure to the servo piston causing the pump to destroke.

ls p h pr prr r

p

Cross-section LS control

Spool

Spring

guide

Spring

7LS adjustingplug

LS spring

PC adjusting

plugPlug

Plug

Spool Spring

guide

Spring

(PC heavy)

P104 051

6

89


15/28



Service Manual

Pressure measurement

The service procedures described in this manual can be perormed using common

mechanics hand tools. Special tools, i required are shown. Calibrate pressure gauges

requently to ensure accuracy. Use snubbers to protect gauges.

The illustration below shows gauge port locations. Recommended pressure gauges and

fttings are in the table.

Gauge port locations

P106 263E

LegendB = Main pressure lineS = Suction lineL1, L2 = Case drain linesX = Load sensing pressure portM2 = Gauge port for port BM4 = Gauge port servo pressure

X

M2

L1

L2

SB

M4

RequiReD tools

PoRt loCations anD

gauge installation

Gauge and port inormation

Pr Prp R

M2 System pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring ftting

M4 Servo pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring ftting

L1, L2 Case pressure 0-10 bar [0-100 psi] 7/8 - 14 O-ring ftting

X1 LS signal 0-300 bar [0-5000 psi]7/16 - 20 O-ring ftting

(tee into LS signal line)


16/28



Service Manual

Initial start-up procedures

CautionIncorrect shat alignment

may result in damage

to drive shat, bearings,

or seal which can cause

external oil leakage.

geneRal

staRt-uP PRoCeDuRe 1. Connect the pump to the prime mover. Ensure that pump shat is properly aligned

with the shat o the prime mover. 2. Fill the main pump housing with clean fltered hydraulic uid. Pour fltered oil

directly into the upper most case drain port.

3. To ensure the pump stays flled with oil, install the case drain line in the upper most

case drain port.

4. Fill the inlet line leading rom the pump to the reservoir. Check the inlet line or

properly tightened fttings. Be certain it is ree o restrictions and air leaks.

5. Fill the reservoir with recommended hydraulic uid. Always flter uid through a 10

micron flter pouring into the reservoir. Never reuse hydraulic uid.

6. Install a gauge at port or M2 to monitor system pressure during start up.

Follow recommendations in the vehicle / machine operators manual or 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 [160 psi]). Once system pressure is established, increase to ull operating

speed. I system pressure is not maintained, shut down the prime mover, determine

cause, and take corrective action. Reer to Troubleshooting, page 18.

8. Operate the hydraulic system or at least fteen minutes under light load conditions.

9. Check and adjust control settings as necessary ater installation. Reer to

Adjustments, page 21.

10. Shut down the prime mover and remove the pressure gauge. Replace plug at port M2.

11. Check the uid level in the reservoir; add clean fltered uid i necessary.

The pump is now ready or operation.

Follow this procedure when starting-up a new Series 45 installation or when restarting

an installation in which the pump has been removed.

WarningUnintended movement o 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 or damage incurred during shipping. Make certain

all system components (reservoir, hoses, valves, fttings, heat exchanger, etc.) are clean

prior to flling with uid.


17/28



Service Manual

Fluid and flter maintenance

To ensure optimum lie o Series 45 products, perorm regular maintenance o the uid

and flter. Contaminated uid is the main cause o unit ailure. Take care to maintain uid

cleanliness when servicing.

Check the reservoir daily or proper uid level, the presence o water, and rancid uid

odor. Water in the uid may be noted by a cloudy or milky appearance or ree water

in the bottom o the reservoir. Rancid odor indicates the uid has been exposed to

excessive heat. Change the uid immediately i these conditions occur. Correct the

problem immediately.

ReCommenDations

Change the uid and flter per the

vehicle / machine manuacturers

recommendations or at these intervals:

Change the uid more requently i itbecomes contaminated with oreign

Fluid and lter change interval

Rrr p m ch r

Sealed 2000 hours

Breather 500 hours

matter (dirt, water, grease, etc.) or i the uid is subjected to temperature levels greater

than the recommended maximum.

Dispose o used hydraulic uid properly. Never reuse hydraulic uid.

Change flters whenever the uid is changed or when the flter indicator shows that it is

necessary to change the flter. Replace all uid lost during flter change.


18/28



Service Manual

Troubleshooting

exCessive noise anD /

oR vibRation

aCtuatoR ResPonse is

sluggisH

i Dcrp ac

Check uid level in reservoir.Insufcient hydraulic uid causes

cavitation.Fill the reservoir to proper level.

Check or air in system.Air in system causes noisy, erratic

control.

Purge air and tighten fttings.

Check inlet or leaks.

Check pump inlet pressure /

vacuum.

Improper inlet conditions cause

erratic behavior and low output

ow.

Correct pump inlet pressure /

vacuum conditions. Reer to

Hydraulic parameters, page 10.

Inspect shat couplings.

A loose or incorrect shat coupling

causes excessive noise and / or

vibration.

Repair or replace coupling and

ensure that correct coupling is

used.

Check shat alignment.Misaligned shats create excessive

noise and / or vibration.Correct shat misalignment.

Hydraulic uid viscosity above

acceptable limits.


acceptable limits or low uid

temperature will not allow the

pump to fll or control to operate

properly.

Allow system to warm up beore

operating, or use uid with the

appropriate viscosity grade or

expected operating temperatures.

See Hydraulic Fluids, Series 45

F Frame Technical Inormation

Manual,50l098.

i Dcrp ac

Check external system relie valve

setting.

Low external relie valve setting

slows down system.

Adjust external relie valve

setting ollowing manuacturers

recommendations. External relie

setting must be above PC setting

to operate properly.

Check PC and LS control setting.

Low PC setting prevents the pump

rom achieving ull stroke. Low LS

setting limits output ow.

Adjust PC and LS setting. Reer to

Adjustments, pages 21 and 22.

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 dont allow the

pump to operate properly.

Reer to Sauer-Danoss Global

Service Partner or required repair.


acceptable limits.


acceptable limits or low uid

temperature will not allow the

pump to fll or control to operateproperly.


operation or sue uid with the



See Hydraulic Fluids, Series 45F Frame Technical Inormation

Manual,50l098.

Check external system valves.Malunctioning valves 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.


vacuum.

High inlet vacuum causes low

output ow.Correct inlet pressure conditions.


19/28



Service Manual

Troubleshooting

system oPeRating Hot

low PumP outPut

low

PRessuRe oR low

instability

i Dcrp ac

Check uid level in reservoir.

Insufcient volume o hydraulic

uid will not meet cooling

demands o system.

Fill reservoir to proper level. Veriy

proper size o reservoir.

Inspect heat exchanger. Check air

ow and input air temperature or

the heat exchanger.

Insufcient air ow, high input air

temperature, or undersized heat

exchangers will not meet cooling

demands o the system.

Clean, repair, or replace heat

exchanger as required. Veriy

proper size o heat exchanger.


setting.

Fluid passing through relie valve

adds heat to system.

Adjust external system relie valve

setting ollowing manuacturers


valve setting must be above PC

setting or proper operation.


vacuum.

High inlet vacuum adds heat to

system.

Correct inlet pressure / vacuum

conditions.

i Dcrp ac

Check uid level in reservoir.

Insufcient hydraulic uid will limit

output ow and cause internal

damage to pump.

Fill the reservoir to proper level.


acceptable limits.

Fluid viscosity above acceptable

limits or low uid temperature

will not allow the pump to fll or

control to operate properly.


operating, or use uid with the



See Hydraulic fuids, Series 45

F Frame Technical Inormation

Manual,50l098.


setting.

Eternal relie valve set below PC

setting causes low output ow.


ollowing manuacturers

recommendation. External relie

valve setting must be above PC

setting to operate properly.

Check PC and LS control setting.Low PC setting prevents the pump

rom achieving ull stroke.

Adjust PC and LS setting. Reer to

Adjustment, page 21.


vacuum.

High inlet vacuum causes low

output ow.Correct inlet pressure conditions.

Check input speed. Low input speeds decrease ow. Adjust input speed.

Check pump rotation.Incorrect rotational confguration

causes low ow.

Use pump with appropriate

rotational confguration.

i Dcrp ac

Check or air in system.Air in system causes erratic

operation.

Activate PC allowing system

to bleed air. Check inlet line or

leaks and eliminate source o air

ingression.

Check control spools.Sticking control spools cause

erratic operation.

Inspect spools or ree movement

in bore. Clean or replace.


20/28


PRessuRe oR low

instability

(cd)


Service Manual

Troubleshooting

system PRessuRe not

ReaCHing PC setting

HigH inlet vaCuum

CautionHigh inlet vacuum causes

cavitation which candamage internal pump

components.

i Dcrp ac

Check LS setting.Low LS setting may cause

instability.

Adjust LS setting to proper level.

SeeAdjustments, page 21.

Check LS signal line.Blocked LS signal line intereres

with proper LS operation.Remove blockage.

Check external relie valve and PC

setting.

Insufcient pressure dierential

between PC setting and external

relie valve.

Adjust external relie valve or PC

control settings to appropriate

level. Relie valve setting must

be above PC setting to operate

properly.

Check external relie valve.

Chattering external relie valve

may cause unstable eedback to

pump control.

Adjust or replace relie valve.

i Dcrp ac

Check PC control setting.System pressure will not rise above

PC setting.

Adjust PC to appropriate setting.

Reer toAdjustments, page 21.

Check external relie valve.

External relie valve setting below

PC setting prevents pressure

compensation.


according to manuacturers


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 or wear.Wear o PC spool causes internal

leakage in the control.Replace the spool as required.

Inspect PC spool or proper

orientation.

Improper orientation results in

poor operation.Correct orientation o spool.

Check PC control or

contamination.

Contamination may interere with

movement o the PC spool.

Clean PC control components, take

appropriate action to eliminate

contamination.

i Dcrp ac

Check uid temperature.

Low temperature increases

viscosity. High uid viscosity

causes high inlet vacuum.


operating.

Inspect inlet screen. Blocked or restricted inlet screencauses high inlet vacuum.

Clean screen / remove blockage.

Check inlet piping.Too many fttings, bends, or long

piping causes high inlet vacuum.

Eliminate fttings to make path

more direct.


acceptable limits.

High uid viscosity causes high

inlet vacuum.

Select uid with appropriate

viscosity or expected operating

temperature. See Hydraulic

fuids, Series 45 F Frame Technical

Inormation Manual, 50l098.


21/28



Service Manual

Adjustments

PC ContRol PC setting is indicated in the pump model code. Reer to the Series 45 Frame F Open

Circuit Axial Piston Pumps Technical Inormation Manual,50l098, or more inormation.

Beore perorming adjustments, read page 15, Pressure measurement.WarningEscaping hydraulic uid

under pressure can

have sufcient orce

to penetrate your skin

causing serious injury

and/or inection. Relieve

pressure in the system

beore removing hoses,

fttings, gauges, or

components.

Unintended movement o

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.

1. Install a pressure gauge in port M2

to measure system pressure. Install a

pressure gauge in case drain port L1

or L2 to measure case pressure.C

2. Start the prime mover and allow

uid to reach normal operating

temperature. Operate a hydraulic

unction to its ull extension, loadingthe pump to maximum pressure and

zero ow.

3. Loosen the PC set screw and turn the

PC adjusting plug until the gauge

at port M2 indicates the desired

setting. Clockwise rotation increases

pressure, counterclockwise rotation

decreases; approximate gain 42 bar

[610 psi] per turn.

I the pressure does not increase, an

external system relie valve may require

adjustment. External system relie valve

must be set above the PC setting or

proper operation.

4. While holding the position o the

PC adjusting plug, torque the PC set

screw to 9 Nm [7 lbt].

1 PC setting is reerenced to case pressure. Subtract case pressure rom system pressure to compute the actual

setting.

PC control adjustment

Gauge port M2

0 - 300 bar [0 - 4351 psi]

3/16 in

7/16-20

50 Nm

[37 lbfft]

Case drain port L1

0 - 10 bar [0 - 145 psi]

3/8 in

7/8-14

90 Nm

[67 lbfft]LS set screw

4 mm9 Nm

[7 lbfft]

P106 264E

X Port

0-300 bar

[0-5000 psi]

3/16 in

7/16-20

20 Nm

[51 lbfft]

CautionContamination can

damage internal

components and void the

manuacturers warranty.

Take precautions to ensure

system cleanliness when

removing and reinstalling

system lines.

5. Stop the prime mover, remove the pressure gauges, and return the system to its

normal operating confguration.


22/28



Service Manual

Adjustments

ls ContRol

1. Install a pressure gauge in port 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).C

2. Start the prime mover and allow uid

to reach normal operating temperature.

Slowly operate a hydraulic unctionthat will demand approximately hal

ow rom the pump, but keep system

pressure below the PC set point.

3. Loosen the LS set screw. While

watching the pressure gauges,

turn the LS adjusting plug until the

desired pressure dierential between

port M2 and port X is achieved.

Clockwise rotation increases

the setting, counterclockwise

rotation decreases it; approximate

gain = 17 bar [250 psi] per turn.

4. While holding the position o the

LS adjusting plug, torque the LS set

screw to 9 Nm [7 lbt].

5. Operate a hydraulic unction to its

ull extension loading the pump at

maximum pressure and zero ow.

6. Loosen the PC set screw and turn the

PC adjusting plug until the pressure

WarningEscaping hydraulic uid

under pressure can

have sufcient orce

to penetrate your skin

causing serious injury

and/or inection. Relieve

pressure in the system

beore removing hoses,

fttings, gauges, or

components.

Unintended movement o

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.

LS control adjustment

ad p, cr, d

c h

CautionContamination can

damage internal

components and void the

manuacturers warranty.

Take precautions to ensure

system cleanliness when

removing and reinstalling

system lines.

gauge at port M1 or M2 indicates the desired setting . Clockwise rotation increasespressure, counterclockwise rotation decreases it; approximate gain = 42 bar [610 psi]

per turn.

7. While holding the position o the PC adjusting plug, torque the PC set screw to

9 Nm [7 lbt].

8. Stop the prime mover, remove the pressure gauges, and return the system to its

normal operating confguration.

The LS setting is indicated in the pump model code. Reer to the Series 45 Frame F Open

Circuit Axial Piston Pumps Technical Inormation Manual,50l098, or more inormation.

Beore perorming adjustments, read page 15, Pressure measurement.

I the pressure does not

increase, an externalsystem relie valve may

require adjustment.

External system relie

valve must be set above

the PC setting or proper

operation.

1 The LS setting is a dierential pressure. Subtract pilot pressure at port X rom system pressure at port M2 to

compute the actual setting. PC setting is reerenced to case pressure. Subtract case pressure rom system pressure to compute the actual

setting.

Gauge port M2

0 - 300 bar [0 - 4351 psi]

3/16 in

7/16-20

50 Nm

[37 lbfft]

Case drain port L1

0 - 10 bar [0 - 145 psi]

3/8 in

7/8-14

90 Nm

[67 lbfft]LS set screw

4 mm9 Nm

[7 lbfft]

P106 264E

X Port

0-300 bar

[0-5000 psi]

3/16 in

7/16-20

20 Nm

[51 lbfft]


23/28



Service Manual

Minor repair

sHat seal

RePlaCement

The Series 45 open circuit variable pumps use a lip-type shat seal. You can replace this

seal without major disassembly o the unit. Replacing the shat seal requires removing

the pump rom the machine.

CautionPremature bearing ailure

can result i the shat seal

contacts the shat bearing.

Press the seal into the

housing only ar enough

to clear the retaining ring

groove.

R

1. Using the appropriate snap-ring

pliers, remove the retaining ring

(K010) rom the housing.

2. Remove the shat seal (K020) rom

the bore in the pump housing and

discard. C

Puncture the ace o the seal with a

packing hook, or use a slide-hammertype puller to remove the seal.

i

3. Inspect the pump housing and new

seal or damage. Inspect the sealing

area on the shat or rust, wear, or

contamination. Polish the sealing

area on the shat i necessary.

4. Lubricate the lip o the new shat

seal with clean hydraulic uid.

Shat seal and retaining ring

Place a protective sleeve over the shat end to prevent damage to the seal during

installation.

5. Keeping the seal perpendicular to the shat, press the new seal into the housing just

ar enough to clear the retaining ring groove. Install seal with the cupped sidetoward the shat 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.

K020

K010

E101 254

C CautionDont damage the pump

housing or shat.


24/28



Service Manual

Minor repair

auxiliaRy PaDs You may install auxiliary mounting pads on pumps equipped with through-drive radial

ported end caps. Follow these steps to either remove, replace, or exchange auxiliary

mounting pads.

R

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) i present.

3. Remove the 4 screws (J100) retaining the pad adapter (J080) to the endcap. Discard

the pad adapter O-ring (J090) i present.

i

4. Lubricate new O-ring (J090) with petroleum jelly. Install the pad adapter to theendcap.

5. Install the 4 screws (J100 ) and torque to 55 Nm [40 lbt].

6. Install the drive coupling (J140) i present.

7. Install shipping cover or auxiliary pump with seal (J120).

8. Install the screws (J130) and torque to 105 Nm [77 lbt].

CautionShipping cover is intended

only to retain coupling

during shipment and

storage. Do not operate

pump with coupling and

shipping cover installed. Auxiliary mounting pads

J095

J140

J080J120

J110

J080

J140

J095

J110

J120

P106 267E

J080

J100

J120

J110

J130

J140

J095

J130

J100

105 Nm

[77 lbfft]

55 Nm[40 lbfft]

105 Nm

[77 lbfft]


25/28



Service Manual

Minor repair

ContRol Control assembly

ls cr h; pr C10 hrh C10 d

C11 hrh C118 r d PC cr

D

1. Remove the 4 screws (C300) holding

the control housing onto the endcap.

2. Remove the control and discard the

4 interace O-rings (C200).

3. Remove the PC set screw (C102),

PC adjusting plug (C138), O-ring

(C138A), springs (C134, C135), and

seat (C133). Discard the O-ring.

4. Remove the plug (C103), O-ring

(C103A), and PC spool (C132) rom

the control housing. Discard theO-ring. Note orientation o the spool

or reassembly.

For PC only controls, skip steps 5

through 7

5. Remove the plug (C105) and O-ring

(C105A), or the plug (C106) and

O-ring (C106A). Discard the O-ring

(C105A or C106A).

6. Remove the LS set screw (C102),

LS adjusting plug (C118), O-ring

(C118A), back-up rings (C118B),

springs (C114, C115), and seat (C113).

Discard the O-ring and backup rings.

7. Remove the plug (C104), O-ring

(C104A), and LS spool (C112) rom the control housing; discard the O-ring. Note

orientation o the spool or reassembly.

ipc

8. Inspect the adjusting plugs or wear at the tips and where they contact the seat;

replace as necessary.

9. Inspect the springs and spring guides or wear or damage; replace as necessary.

10. Careully inspect the spools. Ensure the sealing lands are ree o nicks and scratches.

Check the ends that contact the spring guides or wear. Replace spools as necessary.

11. Inspect the control housing or damage. Check the spool bores or excessive wear.

12. Clean all parts and lubricate spools, springs, guides, and new O-rings with clean

hydraulic uid.

12 Nm

[9 lbfft]

12 Nm

[9 lbfft]

12 Nm

[9 lbfft]

6 Nm

[5 lbfft]

12 Nm

[9 lbfft]

9 Nm

[7 lbfft]


26/28



Service Manual

Minor repair

12 Nm

[9 lbfft]

12 Nm

[9 lbfft]

12 Nm

[9 lbfft]

6 Nm

[5 lbfft]

12 Nm

[9 lbfft]

9 Nm

[7 lbfft]

Control assembly

ls cr h; pr C10 hrh C10 d

C11 hrh C118 r d PC cr

R

13. Install the PC spool (C132), spherical

end frst, into the PC bore. Using anew O-ring (C103A), install the plug

(C103). Torque the plug (C103) to

12 Nm [9 lbt].

14. 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 and thread it into

the PC bore until ush, then make

another ull turn. Install and torque

the PC set screw (C102) to 9 Nm[7 lbt].

For PC only controls, skip steps 15

through 17.

15. Install the LS spool (C112), spherical

end frst, into the LS bore. Using a

new O-ring (C105A or C106A), install

the plug (C105 or C106). Torque

the plug (C105 or C106) to 12 Nm

[9 lbt].

16. Using a new O-ring (C104A), install

the plug (C104). Torque the plug to

12 Nm [9 lbt].

17. Place the two LS springs (C114, C115)

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 ush, then make another ull turn. Install and

torque the LS set screw (C102) to 9 Nm [7 lbt].

18. Using petroleum jelly to retain them, install 4 new interace O-rings (C200) in therecesses on the control housing.

19. Install the control assembly onto the endcap using the 4 screws (C300). Torque the

screws to 6 Nm [5 lbt]. Torque screws in a criss-cross pattern and re-torque the frst

screw to ensure proper torque retention.

20. Check and adjust the control setting. SeeAdjustments, page 21.

ContRol

(cd)


27/28



Service Manual

Minor repair

Plug anD itting sizes

anD toRques

I any plugs or fttings are removed rom the unit during service, install and torque as

indicated here. This drawing is a composite. Individual pump confgurations may be

dierent. The illustration below shows the appropriate wrench size and torque or plugsthat may be installed in the pump:

120 Nm

[155 lbfft]

12 Nm

[9 lbfft]

Plug locations, sizes, and torques


28/28

ouR PRoDuCts

Hydrostatic transmissions

Hydraulic power steering

Electric power steering

Electrohydraulic power steering

Closed and open circuit axial pistonpumps and motors

Gear pumps and motors

Bent axis motors

Orbital motors

Transit mixer drives

Planetary compact gears

Proportional valves

Directional spool valves

Cartridge valves

Hydraulic integrated circuits

Hydrostatic transaxles

Integrated systems

Fan drive systems

Electrohydraulics

Microcontrollers and sotware

Electric motors and inverters

Joysticks and control handlesDisplays

Sensors

sr-D m Pr d Cr s

mrk ldr wrdd

Sauer-Danoss is a comprehensive supplier providing complete

systems to the global mobile market.

Sauer-Danoss serves markets such as agriculture, construction, road

building, material handling, municipal, orestry, tur care, and manyothers.

We oer our customers optimum solutions or their needs and

develop new products and systems in close cooperation and

partnership with them.

Sauer-Danoss specializes in integrating a ull range o system

components to provide vehicle designers with the most advanced

total system design.

Sauer-Danoss provides comprehensive worldwide service or its

products through an extensive network o Global Service Partners

strategically located in all parts o the world.

Local address:

Sauer-Danoss (US) Company

2800 East 13th Street

Ames, IA 50010, USA

Phone: +1 515 239-6000

Fax: +1 515 239-6618

Sauer-Danoss ApS

DK-6430 Nordborg, Denmark

Phone: +45 7488 4444

Fax: +45 7488 4400

Sauer-Danoss-Daikin LTD

Sannomiya Grand Bldg. 8F

2-2-21 Isogami-dori, Chuo-ku

Kobe, Hyogo 651-0086, Japan

Phone: +81 78 231 5001

Fax: +81 78 231 5004

Sauer-Danoss GmbH & Co. OHG

Postach 2460, D-24531 Neumnster

Krokamp 35, D-24539 Neumnster, Germany

Phone: +49 4321 871-0

Fax: +49 4321 871 122

45 Series F Frame Service Manual (11005158 Rev AB Sept 2007)

Documents

Transcript of 45 Series F Frame Service Manual (11005158 Rev AB Sept 2007)