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Product Information - Series 45 Piston Pumps

1. A a 2 7 AS oa B084 132 LE A K132 x 5 4 K110 7 K100 p B082 506 OY Bos BEN Pd M Et P101 062 40 SAUER G SUNDSTRAND Series 45 Service 10 1 57 cc Frame Size continued Parts List Item Description Control C010 Set screw C020 Seal nut C030 Plug C040 O ring C050 Spring seat C060 Spring C070 Spring C080 Spring guide C090 Spool LS or PC C100 Plug C100A O ring C110 Wedge C111 Orifice plug C120 Plug C120A O ring C130 Hex nut Pressure Compensator Valve DO11 Cartridge D012 Poppet D013 Spring D014 Set screw D015 Seal nut D016 O ring D017 Screen D018 Hex nut D019 Set screw K080 O ring K090 Back up ring Pilot Gain Orifice G010 Orifice H010 Orifice Displacement Limiter 1010 1 020 LO20A L030 L040 Servo piston Plug O ring Seal nut Set screw No longer used Qty A o o Lb Exploded Views Item Description Qty Shaft Seal Housing Speed Sensing K010 Snap ring 1 K020 Lip seal 1 K100 O ring 1 K110 Back up ring 1 K120 Plug 1 K120A O ring 1 K122 Plug 1 K122A O ring 1 K124 Plug 1 K124A O ring 1 K130 Plug 1 K130A O ring 1 K132 Plug 1 K132A O ring 1 Auxiliary J040 Plug 2 J040A O ring 2 Common Parts Group B081 Bias piston guide 1 B082 O ring 1 508
2. A WARNING Do not make adjustments or disconnect any hoses until all residual pressure in the system circuit has been released Take necessary precautions to secure the work function of the machine to prevent injury while performing this procedure The pressure compensator setting is indicated in the pump model code Hefer to the Technical Informa tion Manual BLN 10128 for more information 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 If a remote PC control is used disconnect the signal line cap it and plug the port Hefer to Pressure Measurement page 14 Install a pilot hose 6mm 0 25 in diameter mini mum at port X connecting to the reservoir to drain the remote PC port Note Failure to drain port X spring cavity to reservoir may cause additional back pressure on the PC spring resulting in pressure settings above the desired speci fication It is recommended that this procedure be used on all Series 45 57cc pumps however it is particularly vital to 1999 and newer units due to hard ware changes associated with the PC cartridge PC Adjustment Screw 13 mm PC Adjustment Seal Lock Nut 13 mm 23 Nm 17 lof ft 1 Pumps with serial number greater than A 98 21 XXXX will have tamper resistant hardware installed on both the PC and second stage adjustments This will only allow one complete clockwise t
3. N 1 O 13mm EUN 13 1 Pumps with serial number greater than A 98 21 XXXX will have tamper resistant hardware items D018 and D019 installed on the PC adjustment screw This will only allow one complete clockwise turn from the original factory setting lt 28 Nm 17 lbf ft Install the cartridge assembly into the pump housing and torque to 37 Nm 27 Ibf ft Check and adjust the pressure compensator setting before putting the pump back into operation See Adjustments page 22 The control gain orifice plug item H010 and bleed orifice plug item C111 may be removed after remov ing the passage plugs items K120 in the pump housing Inspect orifice plugs for blockage clean as necessary and reassemble Torque orifice plugs to 5 Nm 44 Ibf in passage plugs to 12 Nm 9 Ibfeft 3 16 in lt 12 Nm 9Ibf ft K120 Not used on remote PC P101 0585 2 Pumps with serial number greater than A 97 52 XXXX do not use bleed orifice item C111 The port in the housing is also blocked 33 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 6 Pressure Compensator PC Control Pilot Stage and Gain Orifice continued 9 6 2 74 cc Frame Size Remove the set screw item C102 and the PC adjustment screw item C138 The control springs items C134 and C135 and spring seat item C133 can now be removed from the cavity Remove the plug item C103 from the op
4. a Lp c ce Eo a ac euo E dae tr d a de e gets 11 321 6 Direction of Rotation a ecd AA 11 33 7 Installation Position cere Rc dnce e doe 11 3 2 Circuit DIAg amsn tab n tentes mtr Ut atra Ete SAA 11 3 3 Hydraulic Parameters 12 22 2408 saa eter tet ote rt tape des o Hace CERE D ce a EE o Dee etude ede 12 3 9 1 Inlet PressSUre une Cet Rotes O EE Ee Ree deus 12 3 3 2 Pressure Compensator Valve Setting sse 12 3 3 9 Case PIOSSUTO mir 12 33 4 Hydraulic Fluid sn death ett e Lore et Xe Ye 12 3 3 5 Temperature Range iii 12 3 3 6 Fluid Viscosity Limits ioci RS 12 12 et 6 ER 3 4 Technical Data 3 t eer Anne Doce Tit Done Tx hee ERR Re Lee De ee Ld i e Dae a ee 13 4 Pressure Measurement see 14 4 1 Required TOONS GaSe Foret pa Pes det dene ce dul Ri eee o ovde a Pe E 14 4 2 Port Locations and Pressure Gauge Installation 14 4 2 1 57 c6 Frame Size Sean ARS 14 42 2 74 cc Frame SIZE Saro ee it dicte SAS ens 15 5 Initial Start up Proc dures aOR Aa retenue s pa ane dealer e ae dea dea
5. at maximum pressure and zero flow Turnthe PC adjustment screw until system pressure reaches the desired value as indicated on the gauge at port M2 Clockwise rotation will increase the setting counterclockwise rotation will decrease If the pressure does not increase an external sys tem relief valve may need adjustment External system relief valve should be set above the PC setting for proper operation While holding the position of the PC adjustment screw torque the setscrew to 6 8 Nm 5 1 Stop the prime mover and remove the pressure gauges installed at port M2 and case drain port L1 or L2 Replace the port plugs PC Adjustment Screw 9 6mm P101 053E 23 SAUER 65 SUNDSTRAND Series 45 Service Adjustments 8 2 Load Sensing LS or LB Control Adjustment 8 2 1 57 cc Frame Size A WARNING Do not make adjustments or disconnect any hoses until all residual pressure in the system circuit has been released Take necessary precautions to secure the work function of the machine to prevent injury while performing this procedure The LS or LB Setting is indicated in the pump model code Refer to the Technical Information Manual BLN 10128 for more information 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 Install a pressure gauge in the remote PC port If remote PC is used temporarily remove the
6. below PC setting will cause low flow Low PC setting will preventthe pump from achieving full stroke Low LS setting will prevent adequate flow High inlet vacuum will cause cavita tion and decrease flow Low input speeds decrease flow Pump displacement limiter may be set below desired flow rate Incorrect rotational configuration will cause low flow Restricted control orifice will limit output flow If plug is missing control will not perform correctly Repair as required Allow system to warm up before op eration or use fluid with the appropri ate viscosity grade for expected oper ating temperatures See Hydraulic Fluids Series 45 Technical Informa tion Manual BLN 10128 Repair or replace system valving Correct case drain line restrictions Correct inlet pressure conditions Action Fill the reservoir to proper level Allow system to warm up before opera tion or use fluid with the appropriate viscosity grade for expected operating temperatures See Hyaraulic Fluids Series 45 Technical Information Manual BLN 10128 Correct external relief valve setting Adjust PC and LS setting See Adjust ments page 22 Correct inlet pressure conditions Adjust input speed Adjust displacement limiter to the ap propriate setting See Adjustments page 26 Use pump with appropriate rotational configuration Inspect and clean control orifice Install bleed orifice plug C111 See Minor
7. fittings heat exchanger etc are clean prior to filling with fluid The pump should be connected to the prime mover so that the centers of both shafts are aligned Incor rect alignment may result in eventual damage to the drive shaft drive shaft bearings or the drive shaft seal which can cause external oil leakage Fill the main pump housing with clean hydraulic fluid prior to start up Fill by pouring filtered oil directly into the upper most case drain hole Fillthe reservoir with recommended hydraulic fluid Fluid should always be filtered through a 25 micron filter prior to entering the reservoir Never reuse hydraulic fluid 16 The inlet line leading from the pump to the reservoir must be filled prior to start up Check inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks To ensure the pump stays filled with oil the case drain line should be installed in the upper most case drain port Follow recommendations in the vehicle machine operators manual for prime mover start up proce dures Install a gauge at port M2 to monitor system pressure during start up Jog the prime mover or run at the lowest possible speed until system pressure builds to normal lev els minimum 11 bar 160psi Once system pressure is established increase the speed to full operating RPM If system pressure is not main tained shut down the prime mover determine the cause and take correc
8. remote PC signal line and cap it Leave the LS signal line connected Refer to Pressure Measurement page 14 Start the prime mover and allow fluid to reach normal operating temperature While securing the LS adjustment screw loosen the seal locknut Slowly operate a hydraulic function which will demand approximately half flow from the PC Adjustment Screw 13mm PC Adjustment Seal Lock Nut 13 mm 4e 23 Nm 17 Port X LS Signal 1 Pumps with serial number greater than A 98 21 XXXX will have tamper resistant hardware installed on both the PC and second stage adjustments This will only allow one complete clockwise turn from the original factory setting 24 pump but keep the system pressure below the PC set point While watching the pressure gauges turn the LS adjustment screw until the desired pressure differential between port M2 system pressure and the remote PC port LS signal is achieved Clock wise rotation will increase the setting counterclock wise rotation will decrease While holding the position of the adjustment screw torque the seal locknut to 23 Nm 27 Ibfeft Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow While securing the PC adjustment screw loosen the seal locknut Turn the PC adjustment screw until the desired setting is indicated on the pressure gauge at port M2 Clockwise rotation will increase the setting counte
9. ring Fitting 074 M4 Control 300 bar or 5000 psi gauge X1 LS Signal 300 bar or 5000 psi gauge 7 16 20 o ring Fitting Tee into LS Signal Line 7 16 20 o ring Fitting Case Drain Port L1 e Ue LS Signal Port X LS Signal Port X1 Servo Pressure Gauge Port Port M4 System Pressure Gauge Port Port M2 Case Drain Port L2 Base Unit with PC LS Control and Axial End Cap Ports Shown P101 047E 15 SAUER S SUNDSTRAND Series 45 Service Initial Start up Procedures 5 Initial Start up Procedures The following start up procedure should always be followed when starting up a new Series 45 installa tion or when restarting an installation in which the pump has been removed A WARNING The following procedure may require the vehicle machine to be disabled wheels raised off the ground work function disconnected etc while performing the procedure in order to prevent injury to the technician and bystanders Take necessary safety precau tions before moving the vehicle machine Prior to installing the pump inspect the units for damage incurred during shipping and handling Make certain all system components reservoir hoses valves
10. the displacement limiter setting remove the displacement piston bore plug with its o ring Loosen the seal locknut and turn the displacement limiter adjustment screw counter clockwise until the oppo site end is flush with end of the displacement piston bore plug The setting is now at maximum displace ment Replace the o ring and install the plug into the pump housing Torque the displacement piston plug as indicated Displacement Piston Bore Plug See Table Displacement Limiter Adjustment Screw 96 mm EN Seal Locknut 19 ze 87 Nm 64 Ibf ft Displacement Piston Bore Plug 57 cc 74 cc Hex Wrench 1 in 1 in 230 Nm 170 Ibf ft 176 244 130 180lbfeft 1101 003E Torque Turn the displacement limiter adjustment screw clock wise to set the desired maximum displacement For 57cc pumps the displacement is decreased by 5cc per revolution of the displacement limiter adjustment screw for 74cc pumps 6cc per revolution While holding the position of the displacement limiter adjustment screw torque the seal locknut A WARNING The seal lock nut must be torqued after every adjustment to prevent an unexpected change in pump output and to prevent external leakage during unit operation 57 CC Shown P101 106E 26 SAUER S SUNDSTRAND Series 45 Service Adjustments Notes 27 SAUER 65 SUNDSTRAND Series 45 Service M
11. varies 57 cc 74 cc When the system pressure at the pump outlet drops PC 88 94 1290 42 06 610 below the compensator setting the control will in 7 crease the pump displacement to maximum maxi 2 Stage 17 93 260 mum flow Once the system pressure reaches the T101 092E compensator setting the control will regulate pump displacement to produce an output flow which will maintain system pressure at the compensator setting The pressure compensator setting is adjustable The setting range for the pressure compensator is from 100 to 280 bar 1450 to 4060 psi Refer to Section 8 page 22 for adjustment procedures Note On 57cc pumps built after serial number A 98 21 XXXXX tamper resistant hardware is in stalled onthe PC amp second stage adjustment screws This will allow only one complete clockwise turn from the original factory setting Second Stage Adjustment PC Adjustment Screw Screw 57 cc PC Adjustment AAI lt 2 Screw 74 cc P101 042bE 9 SAUER 65 SUNDSTRAND Series 45 Service Functional Description 2 5 Pump Control Options continued 2 5 2 Load Sensing LS Control The load sensing control is designed to match pump outlet flow and pressure with system demand When the control valve is centered the load sensing port on the pump is drained to the reservoir
12. 3 Spring 1 B084 Bias piston 1 41 SAUER 65 SUNDSTRAND Series 45 Service Exploded Views 10 2 74 cc Frame Size 040 J040A L020 Tg L040 Oy 120 SG L030 2X6 K120A Pa LO20A L020 ME QT P 8 422 LO20A 0 P Bos4 BK Mo 5 B083 K130A K130 gc 0 K100 5 5082 P101 063 8081 808 42 SAUER G SUNDSTRAND Series 45 Service 10 2 74 cc Frame Size continued Parts List Item Description Displacement Limiter L010 Servo piston LO20 Plug LO20A O ring LO30 Seal nut 1040 Set screw Shaft Seal Housing Speed Sensing K010 Snap ring K020 Lip seal K100 O ring K110 Back up ring K120 Plug K120A O ring K130 Plug K130A O ring Auxiliary J040 Plug J040A O ring J030 Cap screw Common Parts Group B081 Bias piston guide B082 O ring 5083 Spring B084 Bias piston Qty ND Pp A N 2 Exploded Views 43 SAUER 65 SUNDSTRAND Exploded Views Series 45 Service 10 2 74 cc Frame Size continued o o E101 000 44 SAUER G SUNDSTRAND Series 45 Service 10 2 74 cc Frame Size continued Parts List Item Description LS PC Control Assembly C100 Control Assembly C101 Housing Control C102 Set Screw C103 Plug C103A O ring C112 Spool LB LS C113 Guide LB LS Spring C114 Spring LB LS Outer C115 Spring LB LS Inne
13. 6 230 Nm 170 Ibfeft 176 244 130 1801bfef T101 003E Torque 29 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 3 Bias Piston Remove the bias piston guide item B081 with the bias spring bias piston o rings and backup washer from the pump housing Remove the bias spring item 8083 and bias piston item 8084 from the piston guide Remove the backup washer item K1 10 small o ring item K100 and large o ring item B082 from the piston guide Inspect the bias piston piston guide and spring for wear or damage 30 Install new o rings and a new backup washer on the piston guide Install the bias spring on the piston guide Lubricate the bias piston with hydraulic oil and install it onto the piston guide Install the piston guide assembly into the pump housing and torque as indicated To keep the 185 piston in position during assembly hold a finger over the hole in the bias piston guide when installing 57cc Shown P101 054E Bias Piston Guide B081 57 cc Hex Wrench 74 cc 1 1 3 in 230 Nm 170 Ibfeft 176 244 130 180 Ibfeft T101 003E lt lt Torque SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 4 Auxiliary Pads If installed remove the screws retaining the auxiliary pump not shown and remove the pump with its sealing
14. Land LB 32 qu lt f SA Gei P C lt 46 Nm 34 Ibf ft Refer to Minor Repair page 35 for instructions on removal and replacement of parts referenced in this procedure After conversion check setting and adjust as neces sary See Adjustments pages 22 and 24 To convert from LS to PC control option 1 Remove LS spool C090 non orificed spool 2 Install PC spool C090 orificed spool 3 Remove pilot orifice G010 With orifice PC C020 13 Ze 23 Nm 17 Ibf ft C130 13mm P101 057E SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 6 Pressure Compensator PC Control Pilot Stage and Gain Orifice 9 6 1 57 cc Frame Size Remove the PC valve cartridge assembly with o rings and backup washer from the pump housing Remove and discard the small o ring item K080 backup washer item K090 and large o ring item D016 found on the cartridge assembly Loosen the seal lock nut item D015 and remove the adjustment screw item D014 spring item D013 and poppet item D012 from the cartridge housing item D011 Inspect all parts for wear or damage Install new o rings and a new backup washer on the cartridge housing Install the poppet spring and adjustment screw with seal lock nut into the car tridge housing PC Valve Cartridge Assembly SN Le 7 gt br 11 16 in 37 Nm 27lbf ft 9 4mm P d
15. Repair page 33 19 SAUER S SUNDSTRAND Series 45 Service Troubleshooting 7 5 Pressure Compensator Not Reaching PC Setting Item Description Action Check PC control setting Check external relief valve Inspect compensator spring Inspect PC poppet 57cc or spool 74cc for wear Inspect compensator spool Check PC control for con tamination Verify bleed orifice plug is installed serial numbers prior to A 97 52 XXXX 7 6 High Inlet Vacuum Item Check oil temperature Inspect inlet screen Check inlet piping Hydraulic oil improper viscosity Pump will not compensate to pres sure settings PC control cannot be set above an external relief valve setting Broken damaged or missing spring will cause erratic operation Abnormal wear of the PC poppet or spool will allow internal leakage in the control Improper orientation will result in poor operation Spool or poppet is held open by contaminants If plug is missing control will not perform correctly Description Cold oil has a higher viscosity Restriction will cause high vacuum Too many fittings bends or long piping will cause high vacuum Hydraulic oil viscosity above ac ceptable limits will cause cavitation 7 7 Pressure or Flow Instability 20 Item Air in system Check control spools Check external relief valve and PC setting Check external relief valve Check gain orifice plug 57
16. SAUER 6 SUNDSTRAND Series 45 Axial Piston Open Circuit Pumps Service Manual SAUER 65 SUNDSTRAND Series 45 Service Introduction 1 Introduction 1 1 Using This Manual This manual includes information for the normal operation maintenance and service ofthe Series 45 family of open circuit pumps The manual includes a description of the units and their individual compo nents troubleshooting information adjustment in structions and minor repair procedures Unit war ranty obligations should not be affected if mainte nance adjustment and minor repairs are performed according to the procedures describedinthis manual Many service and adjustment activities can be per formed without removing the unit from the vehicle or machine However adequate access to the unit must be available and the unit must be thoroughly cleaned 1 2 Safety Precautions Always consider safety precautions before begin ning a service procedure Protect yourself and others from injury Disable Work Function WARNING Certain service procedures may require the vehicle machine to be disabled wheels raised off the ground work function disconnected etc while performing them in order to prevent injury to the technician and bystanders Flammable Cleaning Solvents WARNING Some cleaning solvents are flammable To avoid possible fire do not use cleaning sol vents in an area where a source of ignition may be present C
17. UER 65 SUNDSTRAND Series 45 Service Technical Specifications 3 4 Technical Data Dimension Frame Size 057 074 Displacement cm in 57 3 48 74 4 52 Minimum min rpm 500 500 Rated Input Speed min rpm 2600 2400 Maximum min rpm 3200 2800 Maximum Peak Working Pressure bar psi 350 5075 350 5075 Continuous Working Pressure bar psi 280 4060 280 4060 Flow at Rated Speed l min US gal min 148 2 39 5 177 6 47 4 Theoretical Input Torque at Maximum Displacement Nm bar lbf in 1000 psi 0 907 554 1 178 720 Mass Moment of Inertia of the Internal Rotating Parts kg m2 Ibf ft 0 0043 0 1014 0 0063 0 1500 Axial Ported Units kg lb 24 53 29 63 Weight Radial Ported Units Refer to General Technical Specifications in Series 45 Axial Piston Open Circuit Pumps Technical Information Manual BLN 10128 With pressurized inlet kg Ib 27 60 36 80 T101 119E 13 SAUER 65 SUNDSTRAND Series 45 Service Pressure Measurement 4 Pressure Measurement 4 1 Required Tools The service procedures described in this manual for Series 45 pumps can be performed using common mechanic s hand tools Special tools if required are shown Pressure gauges should be calibrated fre quent
18. ain pressure line 5 Suction line L1 L2 Case drain lines X Load sense line M2 Gauge port for port B M4 Gauge port servo pressure 11 SAUER 65 SUNDSTRAND Series 45 Service 3 3 Hydraulic Parameters 3 3 1 Inlet Pressure Minimum pressure continuous 0 8 bar absolute 23 2 in Hg at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 14 8 in Hg 3 3 2 Pressure Compensator Valve Setting Minimum pressure 100 bar 1450 psi Maximum pressure 280 bar 4060 psi 3 3 3 Case Pressure Maximum continuous 0 5 bar 7 psi Above inlet Intermittent 2 bar 29 psi Cold start 3 3 4 Hydraulic Fluid Refer to Sauer Sundstrand publication BLN 9887 or 697581 Refer to publication ATI E 9101 for informa tion relating to biodegradable fluids 12 Technical Specifications 3 3 5 Temperature Range Intermittent cold start Continuous Maximum at the hottest point i e drain line 40 C 40 F 82 C 180 F 104 C 220 F 1 Hydraulic fluid viscosity must be maintained within the prescribed limits 3 3 6 Fluid Viscosity Limits SUS Saybolt Universal Seconds mm s cSt v min 9 58 min continuous v min 6 4 47 intermittent v max 110 500 max continuous v max 1000 4700 intermittent cold start 3 3 7 Filtration Required cleanliness level ISO 4406 Class 18 13 or better Refer to Sauer Sundstrand publication BLN 9887 or 697581 and ATI E 9201 SA
19. and discard the o ring item C040 from the cavity plug item C030 If necessary remove the seal lock nut item C020 and adjustment screw item C010 from the cavity plug Removethe outer spring seat item C050 fromthe cavity Remove the outer spool spring item C060 and the inner spool spring item C070 Remove the inner spring seat item C080 and the control spool item C090 Note the orientation of the control spool for reassembly If used remove the load sensing pilot orifice item 3010 and bleed orifice item C111 Check for contamination and reinstall torque to 5 Nm 44 Ibfein C120 8 g 1 3 16 n pd 2 12 Nm 9 Ibf ft a 11 lt 2 C100 P 9 3 16 in E3 12 Nm 9 Ibf ft 6010 LS Without orifice LS 3mm or 5 Nm 44 Ibf in Bleed Land LB 1 Pumps with serial number greater than A 98 21 XXXX will have tamper resistant hardware items D018 and D019 installed on the PC adjustment screw This will only allow one complete clockwise turn from the original factory setting n a O 78in 7 2 46 Nm 54 Ibf ft Clean and inspect all parts for wear or damage Check the orifice in the PC second stage spool for obstruction Install the control spool to the cavity insure proper orientation Install the inner spring seat onto the end of the control spool If the spool is not properly oriented the inner spring seat will not fit Install the inne
20. ase etc or if the fluid has been subjected to temperature levels greater that the recommended maximum Never reuse hydraulic fluid Dispose of used hydraulic fluid properly Filters should be changed whenever the fluid is changed or whenever the filter indicator shows that itis necessary to change the filter Replace all fluid lost during filter change 17 SAUER 65 SUNDSTRAND Series 45 Service Troubleshooting 7 Troubleshooting 7 1 Excessive Noise and or Vibration Item Description Action 1 7 2 System Operating Hot 1 Check oil in reservoir Check for air in system Check pump inlet pres sure vacuum Inspect shaft couplings Inspect shaft alignment Hydraulic oil improper vis cosity Item Check oil in reservoir Inspect heat exchanger Check external system re lief valve setting Check pump inlet pres sure vacuum Insufficient hydraulic fluid will lead to cavitation Noisy erratic control Erratic behavior low output flow A loose or incorrect shaft coupling will cause excessive noise and or vibration Misaligned shafts will create exces sive frictional noise and or vibration Hydraulic oil viscosity above accept able limits will cause cavitation at start up Description Insufficient amount of hydraulic oil will not meet cooling demands of system Heat exchanger not sufficiently cool ing system Relief valve setting belo
21. avy Duty Axial Piston Pumps and Motors Heavy Duty Bent Axis Variable Motors Cartridge Motors Compact Wheel Drives Medium Duty Axial Piston Pumps and Motors Microcontrollers and Electrohydraulic Controls Hydrostatic Transmission Packages Genuine Parts Original Ersatzteile 2800 East 13th Street Ames IA 50010 U S A SAUER S SUNDSTRAND Phone 515 239 6000 FAX 515 239 6618 SM OPVAB 8 99 369694A BLN 10129 Revision A August 1999 SAUER SUNDSTRAND COMPANY http www sauer com SAUER SUNDSTRAND GMBH amp CO Postfach 2460 D 24531 Neum nster Krokamp 35 D 24539 Neum nster Germany Phone 04321 871 0 Fax 04321 871 465
22. cc only Description Air in system will cause erratic operation Sticking control spools Insufficient pressure differential be tween pump and external relief valve Chattering external relief valves may be causing unstable feedback to pump Obstructed gain orifice plug option may cause instability Adjust PC to appropriate setting Adjust the external relief valve to the appropriate setting Replace spring Replace PC cartridge or spool Correct orientation of spool Clean PC control components and rid system of contamination Install bleed orifice plug C111 See Minor Repair page 33 Action Allow system to warm up before operation Remove restriction blockage Eliminate fittings to make path more direct Replace existing fluid with the appro priate viscosity grade fluid See Hy draulic Fluids Series 45 Technical Information Manual BLN 10128 Action Activate PC allowing system to bleed air Check inlet line for leaks Inspect spools for free movement in bore Clean or replace as needed Adjust external relief valve or PC control settings to appropriate level Adjust or replace relief valve Clear or change gain orifice plug SAUER S SUNDSTRAND Series 45 Service Troubleshooting Notes 21 SAUER 65 SUNDSTRAND Series 45 Service Adjustments 8 Adjustments 8 1 Pressure Compensator PC Control Adjustments 8 1 1 57 cc Frame Size
23. design with variable displacement 3 1 2 Type of Mounting SAE flange Size C SAE J744 mounting pad SAE flange Size B optional for 57cc pump only 3 1 3 Auxiliary Mounting Pad Options SAE flange Size A B B B or C 3 1 4 Control Options PC Pressure Compensator LS Load Sensing with Pressure Compensator 3 2 Circuit Diagrams Series 45 74 cc variable displacement pump with pressure compensator load sensing control Bo yc iX 9 9 NTI M2 D i e rx jM4 as optional L2 s P101 102 Ports B Main pressure line S Suction line L1 L2 Case drain lines X Load sense line M2 Gauge port for port B M4 Gauge port servo pressure 3 1 5 Port Connections Inlet and pressure ports SAE Flange Ports Code 61 Axial end ports or radial side ports All other SAE straight thread o ring boss 3 1 6 Direction of Rotation Clockwise or counterclockwise 3 1 7 Installation Position Installation position discretionary The housing must always be filled with hydraulic fluid Series 45 57 cc variable displacement pump with pressure compensator load sensing control e inam 4 Fr X MT T optional Lil2 Is P101 103 Ports B M
24. e 2 1 1 Using This Manuale nee nie ee date 2 1 2 Safety Precautions nec Leto ret tit eL htt Dor eu e EO Set Ote ae aia 2 1 3 Symbols Used in Sauer Sundstrand Literature 5 2 Functional Description veca sa d deae de d YR 6 2 1 General Description and Cross Sectional Views 6 2 1 1 Open Circuit Pump Design sise 6 24 2 5886 Pump Operation rhin eee eedem etae ue ee decia vede d 7 2 2 The System Circuit waves dee E gc a 7 2 3 Pump Fealtures iet pee vei pe A e Hex EE 8 2 3 1 Displacement Limiters iii 8 2 3 2 Auxiliary Mounting Pads iii 8 223 2 Input SHAMS irt rd dera PORE Cu Si ed 8 2 5 P mp Gontrol OptlODS cac ice ute ere RE E de nl 9 2 5 1 Pressure Compensator PC Control sisi 9 2 5 2 Load Sensing LS Control sisi 10 3 Technical Specifications 4 ce a dene deine Lact eee a ee ai 11 3 1 General Specifications iii 11 34 1 10631011 2 2 eene tt uet te E Pede Er ae al CORP ue s der leith 11 331 2 Type of MOUNTING 3 SESSA ence rete Re ete Rete d ueste ce e 11 3 1 3 Auxiliary Mounting Pad Options issue 11 3 1 4 Control OPTIONS E C Rats nd Re 11 3 1 5 Port Gonnections icn eani ini
25. e Adjustment Seal Lock Nut O13 mm Ze 23 Nm 17 lbf ft Port X P101 046E 2 The second stage setting is referenced to the pressure at port X During this procedure port X is vented to reservoir 3 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting SAUER G SUNDSTRAND Series 45 Service Adjustments 8 1 Pressure Compensator PC Control Adjustments continued 8 1 2 74 cc Frame Size A WARNING Do not make adjustments or disconnect any hoses until all residual pressure in the system circuit has been released Take necessary precautions to secure the work function of the machine to prevent injury while performing this procedure 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 Refer to Pressure Measurement page 14 Loosen the PC set screw and turn the adjustment screw counter clockwise to release the spring pressure Turn until the end of the screw is flush with the housing PC Set Screw 6 4mm lt 6 8 Nm 5 lbfeft 1 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting Start the prime mover and allow fluid to reach normal operating temperature Operate the prime mover at normal speed Operate a hydraulic function to its full extension loading the pump
26. eat Exchanger Return Filter P101 039E 7 SAUER SUNDSTRAND Series 45 Service 2 3 Pump Features To meet the requirements of various applications the Series 45 pumps are available with various options which change the operation of the pump 2 3 1 Displacement Limiters Series 45 pumps are available with an optional maxi mum displacement limiter This mechanical stop can limit the maximum displacement of the pump to any value from maximum to 75 displacement 2 3 2 Auxiliary Mounting Pads 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 pres sure an o ring must be used to seal the auxiliary pump mounting flange to the pad The driving cou pling is lubricated by oil from the main pump case 2 3 3 Input Shafts Series 45 pumps are available with a variety of splined straight keyed and tapered end shafts Functional Description Adjustment Screw Lock Nut P101 040E P101 041 SAUER 65 SUNDSTRAND Series 45 Service Functional Description 2 5 Pump Control Options 2 5 1 Pressure Compensator PC Control The pressure compensator control is designed to Em b t maintain a constant pressure in the hydraulic circuit ain bar psi per turn as flow
27. ene 16 6 Fluid and Filter Maintenance 8544669999 17 T Troubleshooting teet seite eL deu ne dee 18 7 1 Excessive Noise and or Vibration eene nennen enne nnn 18 7 2 System Operating Flotte dei Pee eR re one a ie 18 7 3 Actuator Response is Sluggish sin 18 7 4 Low Pump Output FOW lantar cL aaa aaa Ede 19 7 5 Pressure Compensator Not Reaching PC Setting ss 20 7 6 high Inlet Vacuum ss eire eed cio e ti ce ce que date dede uk oL Lo a 20 7 7 Pressure or Flow Instability sise 20 SAUER 65 SUNDSTRAND Series 45 Service Introduction Contents continued 8 Adjustments eee ee eee eine eee eene e ep doc Y e ante vn tate una e ee 22 8 1 Pressure Compensator PC Control Adjustments 22 8 151 25766 Erame SIZe ad ann din nn an manie 22 8 1 2 74 0C FrameSIZ SSS AG edi nete desi dent an 23 8 2 Load Sensing LS or LB Control Adjustment ss 24 8 2 S7 CC ETrAame SIZ8 cerni tee ees rate dame a A 24 8 2 2 24 00 Frame SIZE iii cive Tri ie eee ae reda ee ell ana anni o Ha 25 8 3 Displacement Limiter Adjustment sisi 26 9 Minor Repair Instructions nnn nnne eh 444444 renes 28 9 1 Shaft Seal Replacement iii 28 9 2 Displacement Pist
28. h screen in PC cartridge to remove contamination or replace abnormally worn spool SAUER 65 SUNDSTRAND Series 45 Service Troubleshooting 7 3 Actuator Response is Sluggish continued Item Description Action 7 4 Low Pump Output Flow Internal system leaks Hydraulic oil viscosity above acceptable limits Check system valving Check pump case pres sure Check pump inlet pres sure vacuum Item Check oil in reservoir Hydraulic oil viscosity above acceptable limits Check external system re lief valve setting Check PC and LS control setting Check pump inlet pres sure vacuum Check input speed Checkpump displacement limiter Check pump rotation Check pilot orifice in port X Verify bleed orifice plug is installed serial numbers prior to A 97 52 XXXX Worn internal parts will not allow the pump to operate properly Oil viscosity above acceptable limits or low oil temperature will not allow the pump to fill or control to operate properly Malfunctioning valve may not allow System to respond High case pressure will cause the System to be sluggish High inlet vacuum will cause cavita tion and generate heat Description Insufficient hydraulic oil level Oil viscosity above acceptable limits or low oil temperature will not allow the pump to fill or control to operate properly External relief valve set
29. he seal must not contact the shaft bearing 5 33 mm Using the appropriate snap ring pliers install the seal 21 in retaining ring E P101 051 28 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 2 Displacement Piston and Maximum Displacement Limiter Remove the displacement piston bore plug item L020 with its o ring Discard the o ring Re move the displacement piston item L010 from the pump housing If equipped with displacement lim iter loosen the seal lock nut item L030 remove the nut and limiter screw item L040 from the displace ment piston bore plug item L020 Inspect the displacement piston for wear or damage Lubricate the displacement control piston with hy draulic oil and install it into the pump housing with the hole in the end of the piston facing the bore plug 87 Nm 64 Ibf ft Install a new o ring on the piston bore plug and if equipped install the displacement limiter screw and seal locknut Adjust the displacement limiter See Adjustments page 26 Install the piston bore plug into the pump housing Torque the displacement piston plug as indicated A WARNING The seal lock nut must be torqued after every adjustment to prevent an unexpected change in pump output and to prevent external leak age during unit operation 57cc Shown P101 052E Displacement Piston Bore Plug L020 57 cc 74 cc Hex ay CO Wrench 1 0 1 in 2
30. inor Repair 9 Minor Repair Instructions 9 1 Shaft Seal Replacement A lip type shaft seal is used in the Series 45 open circuit variable pumps This seal can be replaced without major disassembly of the unit Replacement of the shaft seal requires removal of the pump from the machine Remove the retaining ring item K010 from the housing After removing the retaining ring carefully remove the shaft seal item K020 from the bore in the pump housing The face of the seal may be punctured with a sharp instrument to aid in prying the seal out or a slide hammer type puller may be used to remove the seal Care must be taken to avoid damaging the pump housing or shaft Discard the shaft seal Inspect the pump housing and the 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 Use a seal protection sleeve or wrap the end of shaft with thin plastic to prevent damage to the seal lip during installation Lubricate the inside diameter of the new seal with petroleum jelly Press the new seal into the housing just far enough to clear the retaining ring groove Keep the shaft seal perpendicular to the shaft The cupped side of the shaft seal must face the shaft bearing Do not dam age the seal during installation CAUTION Do not press the seal into the housing farther than necessary to install the retaining ring T
31. llowing drawing lt 12 Nm 9 Ibf ft K120 Not used with 1 remote PC 3 16 in SR E 12 Nm 9 Ibf ft E C100 85 Not used with LS LAO K130 86 in S 9 8 lt lt 12 Nm 9 6 3 8 in lt 93 Nm 70 Ibf ft 3 t6 in 2 12 Nm 9 Go K120 i 316 Z amp 12 Nm 9 5 9 3 8 in K130 P101 060E 37 SAUER G SUNDSTRAND Minor Repair Series 45 Service 9 8 Plug and Fitting Torques continued 9 8 2 74 cc Frame Size If any plugs or fittings are removed from the unit during service they must be installed and torqued as indicated in the following drawing J040 38 in lt 11 14 Nm 8 10 Ibf ft D I NS K130A K130 JO40A 9 3 4 in 9 1 25 54 68 Nm 40 50 Ibf ft 38 in K130A E 11 14 Nm 8 10 Ibf ft J040 3 8 in gt S 3 Der Nm 8 10 Ibf ft as m PES 0 108 9 7 S 3 8 in 2 11 14 Nm 8 10 Ib ft N Nos K130A K130 3 4 in lt 54 68 Nm 40 50 Ibf ft P101 061E 38 SAUER S SUNDSTRAND Series 45 Service Minor Repair Notes 39 SAUER 65 SUNDSTRAND Series 45 Service Exploded Views 10 Exploded Views 10 1 57 cc Frame Size LO20A ig 180 130 lt K124 KX K124A CS 3 9 CR J040 e d gt
32. ly to ensure accuracy Snubbers are recom mended to protect pressure gauges 4 2 Port Locations and Pressure Gauge Installation The following sections list the gauge ports for each frame size The recommended pressure gauge and fitting are also specified Outline drawings showing port locations follow the tables 4 2 1 57 cc Frame Size M2 System 300 bar or 5000 psi gauge Pressure 7 16 20 o ring Fitting M4 Control 300 bar or 5000 psi gauge 7 16 20 o ring Fitting L1 Case L2 Pressure 10 bar or 100 psi gauge 7 8 14 o ring Fitting 057 300 bar or 5000 psi gauge Tee into LS Signal Line 7 16 20 o ring Fitting Case Drain Port L2 System Output Port B Port M2 Base Unit Shown with PC LS Control and Axial End Cap Ports LH Rotation 14 LS Signal Remote PC Signal Servo Pressure Gauge Port System Inlet Port S Port L1 System Pressure Gauge Port LS Signal Port X This port is plugged on pumps with PC control Case Drain P101 050E SAUER 65 SUNDSTRAND Series 45 Service Pressure Measurement 4 2 Port Locations and Pressure Gauge Installation continued 4 2 2 74 cc Frame Size M2 System 300 bar or 5000 psi gauge L1 Case 10 bar or 100 psi gauge Pressure 7 16 20 o ring Fitting L2 Pressure 7 8 14 o
33. n will increase the setting counterclockwise rotation will decrease If the pressure does not increase an external system relief valve may need to be adjusted External system relief valve should be set above the PC setting for proper operation While holding the position of the PC adjustment screw torque the locking set screw to 6 8 Nm 5 Ibf ft Stop the prime mover remove the pressure gauges and return the system to its normal oper ating configuration LS Locking Set Screw 4mm Ze 6 8 Nm 5 lbfeft LS Adjustment Screw 6mm P101 049E 2 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 25 SAUER 65 SUNDSTRAND Series 45 Service Adjustments 8 3 Displacement Limiter Adjustment If equipped the displacement limiter may be ad justed to achieve a desired maximum flow rate The preferred method for setting the displacement limiter is to make adjustments while operating the pump at full stroke on an appropriate test apparatus equipped with a flow meter and system pressure gauge This allows the pump to be set to a specific maximum flow rate under precise speed and pres sure conditions If test apparatus is not available the following procedure may be used to set an approxi mate maximum displacement Remember to verify that the displacement setting is appropriate by oper ating the pump in its application after adjustment To adjust
34. o ring Discard the o ring Remove the drive coupling item J140 Remove the four screws item J100 retaining the pad adapter item J080 to the pump end cap six screws are used for the SAE C pad Discard the two pad adapter o rings items J090 J095 Install the pad adapter with new o rings Lubricate o rings with petroleum jelly before installation Install and torque the screws to 75 Nm 55 Ibf ft Install the drive coupling If equipped install the auxiliary pump with new o ring 1 Units with serial number prior to A97 42 XXXX do not use item J095 J140 J100 J080 8m A 75 Nm 55 J P101 055E 31 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 5 Control Personality Conversion 57cc Only On the 57cc pump control personalities may be easily converted between load sensing LS and pressure compensating PC options The conver sion steps required are listed below To convert from PC to LS control option 1 Remove PC spool C090 orificed spool 2 Install LS spool C090 non orificed spool 3 Add pilot orifice GO10 Size varies from 8mm to 1 1 mm Refer to Service Parts Manual BLN 2 41689 for orifice part numbers C120 3 16 in cin Ze 12 Nm 9 Ibf ft ie Bin 1 5 lt C100 3 16 in lt 12 Nm 9 Ibf ft 6010 LS Without orifice LS 6 3 or 5 Nm 44 Ibf in Bleed
35. on and Maximum Displacement Limiter 29 9 9 BIAS PISTOTI s sir irt deed dete wet rese Cadden eth ea ee UR LER etum adds Le ERE RAT TA 30 9 4 Auxiliary Pads easi cere e dao 31 9 5 Control Personality Conversion 57cc Only sis 32 9 6 Pressure Compensator PC Control Pilot Stage and Gain Orifice 33 9 6 1 757 60 Frame SIZE i need SSS na AERE 33 36 74 60 Frame SIZE eoe eed AEE E aS 34 9 7 Load Sensing LS or LB Control or Pressure Compensator PC Second Stage 35 9 71 Frame SIZe ioa fiet re ini ede cada db awe eaten 35 Gadd Tan ais te esee te ese and ESE 36 te ACC Frame SIZE 9 8 Plug and Fitting Torques sise 37 9 841 5766 Frame SIZ8 e ie eae a sac 37 9 8 2 Frame Size DSS rete ELT mar CER aaah rene nm Ru Du 38 10 Exploded Views EM 40 OS ESTNE CUN Size 0 eae a E A O E ENE 40 102 7 4 GC Frane SIZ orc ER aS a RATS DURS 42 10 3 Auxiliary Pad Adapters sise 46 SAUER S SUNDSTRAND Series 45 Service Introduction 1 3 Symbols Used in Sauer Sundstrand Literature DANGER May result in injury May result in immediate or prema
36. ontrols are also available 2 2 The System Circuit The pump receives fluid directly from the reservoir without the requirement of a charge pump Fluid is then pumped under pressure to the system and returns directly to the reservoir The speed of the actuator cylinder hydraulic motor etc depends on the volume of fluid being pumped The operating pressure depends onthe actuator load If the actuator is to be reversed a direction control valve is necessary as the pump swashplate oper ates on one side of neutral only and the pump is unidirectional for remote compensators and load sensing sys tems An available displacement adjustment screw allows the maximum flow to be adjusted to match system requirements These controls are designed for low hysteresis and responsive performance When the pump s automatic control is activated fluid is ported to the displacement piston This action destrokes the swashplate reduces pump displace ment to obtain the desired pump flow The control can position the swashplate at any angle between its maximum and zero displacement to provide the pump flow necessary to maintain the setting of the control ai E To System Ed Be E X e T TR 6 2 L OD 7 i 8 S T X lt From System H
37. opyright 1999 Sauer Sundstrand Company All Rights Reserved 2 before beginning maintenance adjustment or repair activities Since dirt and contamination are the great est enemies of any type of hydraulic equipment cleanliness requirements must be strictly followed This is especially important when changing the sys tem filter and during adjustment and repair activities A worldwide network of Sauer Sundstrand Autho rized Service Centers is available should repairs be needed Contact any Sauer Sundstrand Authorized Service Center for details A list of all Service Cen ters can be found in bulletin BLN 2 40527 or in brochure SAW Ident No 698266 The following general precautions should be taken into consideration whenever servicing a hydro static system Fluid Under High Pressure WARNING Use caution when dealing with hydraulic fluid under pressure Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury This fluid may also be hot enough to cause burns Serious infection or reactions can develop if proper medical treatment is not administered immediately Personal Safety WARNING Proper safety equipment including safety glasses should be used at all times Printed in U S A 0899H SAUER G SUNDSTRAND Series 45 Service Introduction Contents 1 Introduction eeepc eet eg ere n cepa Pod e uae e e
38. out of their bores by the angle of a swashplate results in a specific amount of fluid being displaced for every revolution of the cylinder block The displacement per revolution will change as the swashplate angle changes The swashplate angle is controlled by the displacement piston The bias piston acts to return the pump swashplate to max angle Displacement Piston The slipper attaches to the end of the piston by means of a ball and socket joint This allows the slipper to tilt at any angle while maintaining contact with the swashplate The face of the slipper pad slides on a hydrostatic fluid film which uses fluid pressure to balance internal forces Cylinder Block Kit Swashplate Tappered Roller Tappered Roller Bearing Bearing D AAA if CUZ Shaft Seal Valve Plate Slipper Bias Piston Piston P101 038E SAUER S SUNDSTRAND Series 45 Service Functional Description 2 1 General Description and Cross Sectional Views continued 2 1 2 Basic Pump Operation Series 45 pumps utilize a cradle swashplate de sign with a hydraulic control piston Control is provided through a built in compensator valve This compensator will shift the pump displace ment from maximum to minimum when the set pressure is reached C
39. posite end of the control and remove the control spool item C132 Note the orientation of the control spool for reassembly Remove the four control mounting screws item C300 Remove the control and interface o rings items C200 from the housing Remove the control gain orifice item H010 Flush the control cavity and wash all parts with clean solvent Air dry 4 mm lt 7 Nm 5 Ibf ft C300 4 C132 C103 316 Ze 12 Nm 9 Ibfsft pd AY 34 Inspect spool cavity surfaces and all parts for wear or damage Remove any contamination from gain ori fice Replace damaged or worn parts as necessary Install gain orifice torque to 5 Nm 3 7 Ibf ft Install control on pump housing replacing all o rings Install mounting screws torque to 7 Nm 5 lbfeft Install control springs and spring seat in cavity Install adjustment screw and set screw torque set screw to 7 Nm 5 Ibfeft Install control spool and plug torque to 12 Nm 9 Ibf ft Verify orientation of spool before installation Check PC setting and adjust as necessary See Adjustments page 23 C102 4 mm 2 Z 7 Nm 5 lbfett P101 0565 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 7 Load Sensing LS or LB Control or Pressure Compensator PC Second Stage 9 7 1 57 cc Frame Size Remove the cavity plug assembly Items C030 C010 C020 C130 and C110 from the pump housing Remove
40. pressure gauge in drain port L1 or L2 to measure case pressure Install a pressure gauge in port X to measure LS signal pressure Leave the LS signal line connected using the opposite port for the gauge Refer to Pressure Measurement page 14 Startthe prime mover and allow fluid to reach normal operating temperature Loosen the LS locking set screw Slowly operate a hydraulic function which will demand approximately half flow from the pump but keep the system pres Port X 3 16 in lt 12 Nm 9 lbfeft es PC Locking Set Screw 4mm Ze 6 8 Nm 5 lbfeft PC Adjustment Screw 6 6 1 The LS setting is a differential pressure Subtract pilot pressure at port X from system pressure at port M2 to compute the actual setting RPS sure below the PC set point While watching the pressure gauges turn the LS adjustment screw until the desired pressure differential between port M2 system pressure and port X LS signal is achieved Clockwise rotation will increase the setting counter clockwise rotation will decrease While holding the position of the adjustment screw torque the locking set screw to 6 8 Nm 5 Ibf ft Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow While securing the PC adjustment screw loosen the seal locknut Turn the PC adjustment screw until the desired setting is indicated on the pressure gauge at port M2 Clockwise rotatio
41. r C116 O Ring C117 Ring Back Up Packing C118 Plug LB LS Adjusting C132 Spool Control C133 Guide PC Spring C134 Spring PC Outer C135 Spring PC Inner C136 O Ring C138 Plug PC Adjusting C200 O Ring C300 Screw Qty KR u HS S po PRD AH Exploded Views 45 SAUER 65 SUNDSTRAND Series 45 Service 10 3 Auxiliary Pad Adapters p Ya J120 E Le SEM 110 lt 46 Exploded Views E101 019 SAUER G SUNDSTRAND Series 45 Service 10 3 Auxiliary Pad Adapters continued Parts List Item Description Qty Auxiliary Pad Adapters J090 O ring 1 J095 O ring 1 J140 Coupling 1 J080 Adapter flange 1 J100 Screw 4 6 J120 Cover seal 1 J110 Cover plate 1 J130 Screw 2 4 SAE C pad Exploded Views 47 SAUER S SUNDSTRAND Hydraulic Power Systems SAUER SUNDSTRAND Hydraulic Power Systems Market Leaders Worldwide SAUER SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems Research and development resources in both North America and Europe enable SAUER SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology SAUER SUNDSTRAND specializes in integrating a full range of system components to provide vehicle designers with the most advanced total design system SAUER SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems He
42. r and outer spool springs If removed install the adjustment screw and seal lock nut to the cavity plug Hand tighten the seal locknut it must be torqued after adjustment Install a new o ring onto the cavity plug Place the outer spring seat in the plug Install the plug into the cavity and torque to 46 Nm 34 Ibfeft Follow the appropriate adjustment procedure before returning the pump to full operation ments page 22 See adjust With orifice PC C130 Q 13mm P101 057E 2 Pumps with serial number greater than A 97 52 XXXX do not use bleed orifice item C111 Bleed orifice is incorporated into the control spool item C090 The port in the housing is also blocked 35 SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 7 Load Sensing LS or LB Control or Pressure Compensator PC Second Stage continued 9 7 2 74 cc Frame Size Loosen the two set screws items C102 Remove the PC adjustment screw item C138 and o ring item C136 discard o ring Remove control springs items C134 C135 and spring seat item C133 from the cavity Remove the LS adjustment screw item C118 o ring item C116 and back up rings items C117 discard o ring and back up rings Remove control springs item C114 and C115 and spring seat item C113 from the cavity Remove the plugs item C103 from the opposite end of the control housing and remove the control spools item C132 and C112 Note orien
43. rclockwise rotation will decrease If the pressure does not increase an external system relief valve may need to be adjusted External system relief valve should be set above the PC setting for proper operation While holding the position of the PC adjustment screw torque the seal locknut to 23 Nm 17 1 Stop the prime mover remove the pressure gauges and return the system to its normal oper ating configuration Remote PC Port LS Adjustment Screw 13 mm LS Adjustment Seal Lock Nut 13 lt 23 Nm 17 P101 048E 2 The LS setting is a differential pressure Subtract pilot pressure at the remote PC port from system pressure at port M2 to compute the actual setting 3 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting SAUER G SUNDSTRAND Series 45 Service Adjustments 8 2 Load Sensing LS or LB Control Adjustment continued 8 2 2 74 cc Frame Size N WARNING Do not make adjustments or disconnect any hoses until all residual pressure in the system circuit has been released Take necessary precautions to secure the work function of the machine to prevent injury while performing this procedure The LS or LB Setting is indicated in the pump model code Refer to the Technical Information Manual BLN 10128 for more information Install a pressure gauge in port M2 to measure system pressure Install a
44. tation for reassembly Remove the four socket head screws item C300 which hold the control to the housing Remove the control from the housing Remove the interface o rings item C200 and discard Remove the control gain orifice item H010 lt 12 Nm 9 Ibf ft 36 Clean all parts in solvent Air dry Inspect spools cavity surfaces and all parts for wear or damage Remove any contamination from gain orifice Replace damaged or worn parts as necessary Install control housing on pump housing replacing all o rings torque to 7 Nm 5 1 Install springs and spring seats in cavities Replac ing all o rings and back up rings install both adjust ment screws into to the control housing Install LS and PC set screws to control housing After adjustment torque to 7 Nm 5 1 Install control spools in opposite end of control hous ing note proper orientation Replace o rings and install plugs torque to 12 Nm 1 Check and adjust LS and PC settings before return ing pump to operation See Adjustments page 25 4mm e 7 Nm 5 Ibf ft 9 3 16 in 12 Nm 9 lof ft 3 16 in Hoto g3mm lt 5 Nm 44 Ibf in P101 059E SAUER 65 SUNDSTRAND Series 45 Service Minor Repair 9 8 Plug and Fitting Torques 9 8 1 57 cc Frame Size If any plugs or fittings are removed from the unit A during service they must be installed and torqued as 9 3 16 in indicated in the fo
45. through a bleed orifice located either in the control valve or the pump housing This maintains a standby pressure at the pump outlet equal to the load sense setting When the external control valve is actuated the load sensing port sees the load pressure The pump control then adjusts the pump output flow to maintain a constant pressure drop equal to the load sensing setting across the external control valve The pump thereby provides flow to the load as demanded by the external control valve position The load sensing setting is adjustable The setting range for the load sensing control is from 10 to 30 bar 145 to 435 psi Hefer to section 8 page 24 for adjustment procedures LS Port 57 cc Gain bar psi per turn 57 cc 74 cc 88 94 1290 17 93 260 42 06 610 17 24 250 T101 093E Note On 57cc pumps built after serial number A 98 21 XXXXX tamper resistant hardware is in stalled on both the PC amp LS adjustment screws This will allow only one complete counter clockwise turn from original factory setting PC Adjustment Screw RK LS Adjustment Screw 74 cc LS Port 10 PC Adjustment Screw P101 043E SAUER S SUNDSTRAND Series 45 Service Technical Specifications 3 Technical Specifications 3 1 General Specifications 3 1 1 Design Open circuit axial piston pumps of cradle swashplate
46. tive action Refer to Trouble shooting page 18 Operate the hydraulic system for at least fifteen 15 minutes under light load conditions It may be neces sary to check and adjust control settings after installa tion Refer to Adjustments page 22 Shut down the prime mover and remove the pressure gauge Check the fluid level in the reservoir add if necessary The pump is now ready for operation SAUER 65 SUNDSTRAND Series 45 Service Fluid and Filter Maintenance 6 Fluid and Filter Maintenance To ensure optimum service life of Series 45 products regular maintenance of the fluid and filter must be performed Contaminated fluid is the main cause of unit failure Care should be taken to maintain fluid cleanliness while performing any service procedure Check the reservoir daily for proper fluid level the presence of water noted by a cloudy to milky ap pearance or free water in the bottom of the reservoir and rancid fluid odor indicating excessive heat If either of these conditions occur change the fluid and filter immediately It is recommended that the fluid and filter be changed perthe vehicle machine manufacturer s recommendations or at the following intervals Maximum Oil Change Interval Reservoir Type Sealed 2000 Hours Breather 500 Hours T101 097E It may be necessary to change the fluid more fre quently if it becomes contaminated with foreign mat ter dirt water gre
47. ture damage Reusable part Nonreusable part use a new part Non removable item OR in drawing either option may exist Measurement required Flatness specification Parallelism specification External hex head Internal hex head Torx head 2 ta 0 90 9 e Tip helpful suggestion The symbols above can be found in the illustrations and text of this manual They are intended to communicate helpful information at the point where it is most useful to the reader 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 No Press in Pull out with tool Ep Use installation sleeve cone bullet In most instances the appearance of the symbol itself denotes its meaning The legend above is provided to define each symbol and explain its purpose SAUER 65 SUNDSTRAND Series 45 Service Functional Description 2 Functional Description 2 1 General Description and Cross Sectional Views 2 1 1 Open Circuit Pump Design Sauer Sundstrand Series 45 open circuit pumps con vert input torque into hydraulic power A rotating cylin der block containing axial pistons which are forced in and
48. urn from the original factory setting 22 Start the prime mover and run at normal speed While securing the second stage adjustment screw loosen the seal locknut Turn the second stage adjustment screw until a the gauge at port M2 reads 15 bar 220psi Clockwise rotation of the screw will increase pressure counterclockwise rotation will decrease While holding the position of the second stage adjust ment screw torque the seal locknut to 23 Nm 17 Ibfeft Shut down the prime mover Disconnect the pilot hose installed at port X and reinstall the plug Start the prime mover and run at normal speed Operate a hydraulic function to its full extension load ing the pump at maximum pressure and zero flow While securing the PC adjustment screw loosen the seal locknut Turn the PC adjustment screw until the desired setting is indicated on the pres sure gauge at port M2 Clockwise rotation will increase pressure counterclockwise rotation will decrease If the pressure does not increase an external system relief valve may need to be ad justed An external system relief valve should be set above the PC setting for proper operation While holding the position of the PC adjustment screw torque the seal locknut to 23 Nm 17 Ibf ft Stop the prime mover remove the pressure gauges and return the system to its normal oper ating configuration Remote PC Port Second Stage Adjustment Screw 13 mm Second Stag
49. w PC setting will create heat High inlet vacuum will create heat 7 3 Actuator Response is Sluggish 18 Item Check external system re lief valve setting Check PC and LS control setting Check LS control signal pressures PC control not operating properly Description Low external relief valve setting will slow down system Low PC setting will preventthe pump from achieving full stroke Incorrect LS signal will notallow pump to operate correctly PC control with abnormal wear or contamination will not operate properly Fill the reservoir to proper level Purge air and tighten fittings Check inlet for leaks Correct pump inlet pressure vacuum conditions Repair or replace coupling and check that correct coupling is being used Correct shaft misalignment Replace existing fluid with the appropri ate viscosity grade fluid See Hyaraulic Fluids Series 45 Technical Information Manual BLN 10128 Action Fill the reservoir to proper level Verify proper size of reservoir Check air flow and input air tempera ture for the heat exchanger Clean repair or replace heat exchanger Verify proper size of heat exchanger Adjust external system relief valve setting Correct inlet pressure vacuum con ditions Action Adjust external relief valve setting Adjust PC and LS setting Inspect system ensure that proper LS signal is transmitted to the pump Flus

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