Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual
Contents
1. Reservoir P106 212E Heat exchanger Filter HH Si System pressure a Servo pressure Actuator pressure Es Load sense pressure Actuator return Suction case drain system return Full available flow is a function of pump displacement operating speed and efficiency Refer to Series 45 Frame F Axial Piston Open Circuit Pumps Technical Information 520L0948 for details 11005158 Rev AF October 2012 SAUER DANFOSS GENERAL SPECIFICATIONS Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Technical specifications Type of mounting SAE C mounting flange Auxiliary mounting pad options SAE A SAE B SAE B B SAE C SAE C C Control options PC Pressure Compensator LS Load Sensing with PC Port options Genuine Parts Inlet and system ports SAE flanged ports code 61 Inlet Code 62 outlet Axial end ports or radial side ports All other ports Direction of rotation Clockwise or counterclockwise Installation position SAE straight thread O ring boss Installation position is discretionary To satisfy inlet pressure conditions we recommend you locate the pump below the lowest level of hydraulic fluid in the reservoir The housing must always be filled with hydraulic fluid Technical specifications2. eat o C39 26 O ring C106A Discard the O ring C115 gos C105A or C1 064 c14 J1c118B o6 E101 226 6 Remove the LS set screw C102 lcigA e LS adjusting plug C118 O ring css gt C118A back up rings C118B VP springs C114 C115 and seat C113 Discard the O ring and backup rings LS control shown parts C104 through C106 and C112 through C118 are not used on PC control 7 Remove the plug C104 O ring C104A and LS spool C112 from the control housing discard the O ring Note orientation of the spool for reassembly Inspection 8 Inspect the adjusting plugs for wear at the tips and where they contact the seat replace as necessary 9 Inspect the springs and spring guides for wear or damage replace as necessary 10 Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 11 Inspect the control housing for damage Check the spool bores for excessive wear 12 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 11005158 Rev AF October 2012 SAUER DANFOSS LS AND PC CONTROLS continued Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Minor repair Reassembly 13 14 Install t
3. Features and options Model Feature Unit F74B F90C Maximum displacement cm in3 74 4 52 90 5 49 Flow at rated speed theoretical l min 177 6 198 US gal min 46 9 52 3 Input torque at maximum displacement N m bar 1 178 1 432 theoretical Ibf in 1000 psi 719 874 Mass moment of inertia of internal kg m 0 00630 0 00650 rotating components slug ft2 0 00465 0 00480 Weight Axial ports kg Ib 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 C System ports type 4 bolt split flange System ports location Axial Radial Control types PC Remote PC LS Electric Shafts Splined 14 tooth 17 tooth Straight 0 31 75 mm 1 25 in Displacement limiters Optional adjustable 11005158 Rev AF October 2012 S SAUER GENERAL SPECIFICATIONS continued HYDRAULIC PARAMETERS 10 Series 45 Frame F Open Circuit Axial Piston Pumps DANFOSS Service Manual Technical specifications Basi Palts Ratings Model Rating Units G74B G90C Input speed minimum min rpm 500 500 continuous 2400 2200 maximum 2800 2600 Working pressure continuous bar psi 310 4495 260 3770 maximum 400 5800 350 5075 External shaft External moment M Nem lbf in 300 2655 load
4. LS adjusting plug mm IOS LS set screw c 4mm 2 9 Nem 7 lbfeft X Port 0 300 bar 0 5000 psi 3 16 in 7 16 20 20 Nem 51 Ibf ft P106 264E Gauge port M2 0 300 bar 0 4351 psi 3 16 in 3 7 16 20 50 Nem 37 Ibf ft Na 5 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration Pressure change Control option PC adjustment LS adjustment LS LD LB LE PC RP 42 bar rev 609 PSI rev BB BC BP BS 36 bar rev 534 PSI rev 17 2 bar rev 250 PSI rev AB AC AD AJ AS 8 5 bar rev 123 PSl rev PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 11005158 Rev AF October 2012 SAUER DANFOSS LS CONTROL A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Caution Contamination can damage internal components and void
5. Cross section LS control Spring Spring PC heavy guide P104 051 LS spool shifts to port system pressure to servo piston Genuine Parts Typical load sensing control valve O Load Return pressure pressure Tank s GZ Load sense O System pressure pressure P101 665E Pressure drop across external control valve defines system demand The LS control consists of two spool valves that connect the servo piston either to pump case or system pressure The PC spool 6 controls the pressure compensating function of the control as previously described The LS spool 9 controls the load sensing function The PC spool has priority over the LS spool Through internal porting system pressure upstream of ECV is applied to the non spring end of the LS spool and through hydraulic line connected at port X LS pressure downstream of ECV is applied to the spring end This arrangement allows the LS spool to act on the delta between system pressure and LS pressure The LS spring sets the threshold of operation LS setting Because the swashplate is biased to maximum angle the pump attempts to deliver full flow to the hydraulic system When the flow being delivered exceeds demand the pressure delta across the ECV is great enough to overcome spring force and shift the LS spool porting system pressure to the servo piston The pump de strokes reducin
6. A loose or incorrect shaft coupling causes excessive noise and or vibration Repair or replace coupling and ensure that correct coupling is used Check shaft alignment Misaligned shafts create excessive noise and or vibration Correct shaft misalignment Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids Series 45 F Frame Technical Information Manual 520L0948 Item Description Action Check external system relief valve setting Low external relief valve setting slows down system Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Low LS setting limits output flow Adjust PC and LS setting Refer to Adjustments pages 22 and 23 Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system to ensure that proper LS signal transmit to pump Internal system leaks Worn internal parts don t allow the pump to operate properly
7. Refer to Sauer Danfoss Global Service Partner for required repair Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids Series 45 F Frame Technical Information Manual 520L0948 Check external system valves Malfunctioning 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 Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions 11005158 Rev AF October 2012 19 S SAUER Series 45 Frame F Open Circuit Axial Piston Pumps DANFOSS Service Manual SYSTEM OPERATING HOT LOW PUMP OUTPUT FLOW PRESSURE OR FLOW INSTABILITY 20 Troubleshooting Genuine Parts Item Description Action Check fluid level in reservoir Insufficient volume of hydraulic fluid will not meet cooling demands of system Fill reservoir to proper level Verify proper size of reservoir Inspect heat exchanger Check air flow and input air temperature for the heat exc
8. 7 COMPLIANT Electric Proportional Control Principle The Electric Proportional Control consists of a proportional solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at any pressure limit between the Load Sense and Pressure Compensation settings by varying the current sent to the solenoid Electric On Off Controls PLUS 1 Compliance All Series 45 Electric controls have met and passed the Sauer Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Sauer Danfoss website within the PLUS 1 Guide section 7 COMPLIANT Electric On Off Control Principle The Electric On Off Control consists of an On Off solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at either the Load Sense pressure setting when On or the Pressure Compensation pressure setting when Off 11005158 Rev AF October 2012 15 S SAUER DANFOSS REQUIRED TOOLS PORT LOCATIONS AND GAUGE INSTALLATION 16 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Pressure measurement Genuine Parts The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown Calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gau
9. Unintended machine movement Flammable cleaning solvents Fluid under pressure rennes Personal Safety e Warranty Symbols used in Sauer Danfoss literature 6 General description 7 xy classi 8 General specifications rennes Type of mounting retentione tene Nee ie vedere viele reu Auxiliary mounting pad options Control options Port options siisii PI reifelpforreiueee t Installation position nr Technical specifications Hydraulic parameters Inlet pressure Pressure compensator valve setting Case Pr sSUre e Hydraulic fluid Temperature range cete berti recess aa iia Reeve iaa LUI viscosi e t Blige Displacement Miter uuo iter rci re rta eie e e EE Re EVE 12 Auxiliary MOUNTING pads eire trt tentent aan 12 Input shafts sss Control options PC control a LS CONTON sac scscavecdecsssnacascntectsciccusetevacsels an a HH Electric Proportional Controls sssssssssssssssssessssseesessssssssssesereessssnseeseeeeenensssseetereeesssssseseetereeesesssessetereee 15 Electric On Off COMBOS x sizvsisischccesstesccsaveiie descdacsaslesusateosacsestscodeqancuesi ceessvsl a sheveveavecdescecsteedseetictdotacs 15 Required tools za
10. 3 8 inch 2 12 Nem 9 Ibf ft Eee 70 Ibf ft P106 268E 11005158 Rev AF October 2012 31 SAUER DANFOSS Products we offer e Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics e Hydraulic Power Steering e Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software e Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Members of the Sauer Danfoss Group Comatrol www comatrol com Schwarzm ller Inverter ww w schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Sauer Danfoss Daikin ww w sauer danfoss daikin com 11005158 Revision AF October 2012 Sauer Danfoss is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Sauer Danfoss Your Strongest Partner in Mobile Hydraulics Go to www sauer danfoss com for further produc
11. PC adjusting plug 4 and spring 5 define When system pressure acting on the non spring end of the PC spool 6 overcomes the force of the PC spring 5 Cross section pump P106 261E Bias spring and servo piston set swashplate position Cross section PC control P104 049 PC spool shifts to port system pressure to servo piston the spool shifts porting system pressure to the servo piston and the swashplate angle decreases When system pressure drops below the PC setting the PC spring shifts the spool in the opposite direction connecting the servo piston to pump case and the swashplate angle increases The swashplate is maintained at whatever angle is required to keep system pressure at the PC setting 11005158 Rev AF October 2012 13 SAUER DANFOSS Control options continued 14 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Features LS control The LS control design matches pump flow with system demand The LS control senses the flow demand of the system as a pressure drop across the External Control Valve ECV As the ECV opens and closes the pressure delta across the valve changes When opening the delta decreases When closing the delta increases The LS control then increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjusting plug 7 and spring 8
12. coupling and shipping cover installed Auxiliary mounting pads ge no 3hinch 105 Nem 77 Ibf ft IS u cr NC 120 A N 110 J130 O3 inch 105 Nem 77 Ibf ft 11005158 Rev AF October 2012 25 SAUER DANFOSS LS AND PC CONTROLS Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Minor repair Genuine Parts Disassembly Control assembly 1 Remove the 4 screws C300 holding the control housing onto the endcap i Iheinch 12 Nem 2 Remove the control and discard the 9 o an lbi 4 interface O rings C200 A 12 Nem e c103A Ti 9 Ibf ft c8 3 Remove the PC set screw C102 A PC adjusting plug C138 O ring Dlciosa e 7 Cs C138A springs C134 C135 and 8 an f Blinc seat C133 Discard the O ring A 5 12Nm c300 9 lbf ft 4 Remove the plug C103 O ring 4 mm ANS J Ij C105A C103A and PC spool C132 from snm TA the control housing Discard the peer HG EN O ring Note orientation of the spool 7 Ibf ft for reassembly Fi For PC only controls skip steps 5 C106 through 7 he inch ze 12 Nem 9 Ibf ft e 5 Remove the plug C105 and O ring eg C1054 or the plug C106 and
13. lc g T1 C104A e s 7 rC105 8 C112 4 9 3 6 inch 12Nem 9 Ibfeft C300 2 Am aX C105A 16 Nem bw C102 5 Ibf ft i 6 mm Ze 9 Nem 7 7 Ibf ft C106A C106 o 3heinch ze 12 Nem 9 Ibf ft i CHE S C115 _ g Grue c14 i C118B o E101 226 i C11gA 1C118B lcu LS control shown parts C104 through C106 and C112 through C118 are not used on PC control and thread it into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 9 Nem 7 lbfeft Using petroleum jelly to retain them install 4 new interface O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using the 4 screws C300 Torque the screws to 6 Nem 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Check and adjust the control setting See Adjustments page 22 11005158 Rev AF October 2012 27 SAUER DANFOSS ELECTRIC CONTROLS 28 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Minor repair Genuine Parts Disassembly Control assembly 1 Remove four screws C300 C125 X 2 Remove the control and discard the four O rings C200 3 Remove set screws C102 PC adjusting plug C138 with O ring C138A springs C134 C135 and seat C133 Discard the O ring if it is damaged 4 Remove plug
14. the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Adjustments S Genuine Parts The LS setting is indicated in the pump model code Refer to the Series 45 Frame F Open Circuit Axial Piston Pumps Technical Information Manual 520L0948 for more information Before performing adjustments read page 16 Pressure measurement 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 2 Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydraulic function that will demand approximately half flow from the pump but keep system pressure below the PC set point 3 Loosen the LS set screw While watching the pressure gauges turn the LS adjusting plug until the desired pressure differential 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 of the LS adjusting plug to
15. C 220 F Fluid viscosity Fluid viscosity limits Condition mm s cSt SUS continuous 9 58 v min intermittent 6 4 47 continuous 110 500 vmax intermittent cold start 1009 1708 Filtration Genuine Parts Required cleanliness level ISO 4406 Class 18 13 or better Refer to Sauer Danfoss publications Fluids and Filtration 520L0463 and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465 See Fluid and filter maintenance page 18 for recommended fluid and filter change intervals 1 Hydraulic fluid viscosity must be maintained within the prescribed limits As measured at the hottest point in the system e g drain line 11005158 Rev AF October 2012 SAUER DANFOSS DISPLACEMENT LIMITER AUXILIARY MOUNTING PADS INPUT SHAFTS 12 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Features Frame F Series 45 pumps are available with an optional adjustable maximum displacement limiter The adjustable stop limits the pump s maximum displacement The displacement change per turn is 6 8 cm3 turn 0 47 in3 turn for the F90C and 6 0 cm3 turn 6 1 in3 turn for the F74B Auxiliary mounting pads are available for all radial ported Series 45 pumps These pads are typically used for mounting auxiliary hydraulic pumps Since the auxiliary pad operates under case pressure you must use an O ring to seal the auxiliary pump
16. C103 Remove PC spool C132 Note orientation of the spool for reassembly 5 Remove plug G030 and orifice G020 6 Remove LS adjusting plug C118 C springs C114 C115 and seat C113 amp P108 668E Nc138 7 Remove plug C104 and spool C112 Note the orientation of the spool for reassembly 8 Remove four screws C151 Remove the manifold C152 and discard the two interface O rings C154 9 For electric proportional controls only Remove the electric control manifold drain orifice C149 10 Remove plug C153 Remove the cartridge valve nut C125 electric solenoid C155 and cartridge valve C150 from the electric control manifold Inspection 1 Inspect the adjusting plugs for wear at the tips and where they contact the springs replace as necessary 2 Inspect the springs and spring guides for wear or damage replace as necessary 3 Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 4 Inspect the control housing for damage Check the spool bores for excessive wear 5 Remove debris from orifices if necessary Ensure the servo control orifice backup plug is clean and remove debris if necessary 6 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 11005158 Rev AF October 2012 SAUER DANFOSS ELECTRIC CONTROLS continued Serie
17. SAUER DANFOSS a Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual SAUER Series 45 Frame F Open Circuit Axial Piston Pumps S DANFOSS Service Manual Revisions Genuine Parts HISTORY OF REVISIONS Table of Revisions Date Page Changed Rev October 2012 various add electric controls AF November 2010 last new back page AE February 2010 last Fix Osaka address AD July 2009 21 Add Pressure change PC adjustment specs AC September 2007 AB November 2006 s First edition AA 2012 Sauer Danfoss All rights reserved Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations aren t in conflict with agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group 2 11005158 Rev AF October 2012 SAUER DANFOSS INTRODUCTION TECHNICAL SPECIFICATIONS FEATURES PRESSURE MEASUREMENT INITIAL START UP PROCEDURES FLUID AND FILTER MAINTENANCE Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Genuine Parts ONE TEA Safety precautions sss
18. ants The pump outlet feeds a PVG 32 multi section load sensing directional control valve The PVG valve directs pump flow to the cylinder and gear motor A heat exchanger cools the fluid returning from the valve A filter cleans the fluid before it returns to the reservoir Flow in the circuit determines the speed of the actuators The position of the PVG valve determines the flow demand A hydraulic pressure signal LS signal communicates demand to the pump control The pump control monitors the pressure differential between pump outlet and the LS signal and regulates servo pressure to control the swashplate angle Swashplate angle determines pump flow Actuator load determines system pressure The pump control monitors system pressure and will decrease the swashplate angle to reduce flow if system pressure reaches the PC setting A system relief valve in the PVG valve acts as a back up to control system pressure Series 45 F Frame Double acting cylinder open circuit axial piston pump with un pe load sensing control PVG 32 _ multi section ze T load x i sensing cz i control i valve I H T Bi directional gear motor
19. ere with movement of the PC spool Clean PC control components take appropriate action to eliminate contamination Item Description Action Check fluid temperature Low temperature increases viscosity High fluid viscosity causes high inlet vacuum Allow system to warm up before operating Inspect inlet screen Blocked or restricted inlet screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Too many fittings bends or long piping causes high inlet vacuum Eliminate fittings to make path more direct Hydraulic fluid viscosity above acceptable limits High fluid viscosity causes high inlet vacuum Select fluid with appropriate viscosity for expected operating temperature See Hydraulic fluids Series 45 F Frame Technical Information Manual 520L0948 11005158 Rev AF October 2012 21 SAUER DANFOSS PC CONTROL A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Caution Contamination can damage internal components and v
20. ess the new seal into the housing just far enough to clear the retaining ring groove Install seal with the cupped side toward the shaft bearing Do not damage the seal during installation Using the appropriate snap ring pliers install the seal retaining ring Remove the installation sleeve 11005158 Rev AF October 2012 SAUER Series 45 Frame F Open Circuit Axial Piston Pumps S DANFOSS Service Manual Minor repair Genuine Parts 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 Removal 1 Remove the screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its seal J120 2 Remove the drive coupling J140 if present 3 Remove the 4 screws J100 retaining the pad adapter J080 to the endcap Discard the pad adapter O ring J090 if present Installation 4 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 5 Install the 4 screws J100 and torque to 55 Nem 40 Ibfeft 6 Install the drive coupling J140 if present O Caution 7 Install shipping cover or auxiliary pump with seal J120 Shipping cover is intended only to retain coupling 8 Install the screws J130 and torque to 105 Nem 77 Ibf ft during shipment and storage Do not operate pump with
21. estarting an installation in which the pump has been removed A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Prior to installing the pump inspect for damage incurred during shipping Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 6 Connect the pump to the prime mover Ensure that pump shaft is properly aligned with the shaft of the prime mover Fill the main pump housing with clean filtered hydraulic fluid Pour filtered oil directly into the upper most case drain port To ensure the pump stays filled with oil install the case drain line in the upper most case drain port Fill the inlet line leading from the pump to the reservoir Check the inlet line for properly tightened fittings Be certain it is free of restrictions and air leaks Fill the reservoir with recommended hydraulic fluid Always filter fluid through a 10 micron filter pouring into the reservoir Never reuse hydraulic fluid Install a gauge at port or M2 to monitor system pressure during start up Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While watching the pressure gauge installed at M2 jog the prime mover or run at the lo
22. g flow until the delta across the ECV becomes equal to the LS setting When flow being delivered is less than demand the delta across the ECV drops below the LS setting and the LS spring shifts the spool connecting the servo piston to pump case The pump strokes increasing flow until the delta across the ECV becomes equal to the LS setting When the external control valve is placed in neutral it connects the LS signal line to drain With no LS pressure acting on the non spring end of the LS spool the pump adjusts stroke to whatever position necessary to maintain system pressure at the LS setting The pump is now in standby mode Because of the series arrangement of the LS and PC spools the PC spool will override the LS spool If at any time system pressure reaches the PC setting the PC spool will shift blocking the passage that connects the LS spool with the servo piston thus porting system pressure to the servo piston causing the pump to destroke 11005158 Rev AF October 2012 eC SAUER Series 45 Frame F Open Circuit Axial Piston Pumps gt DANFOSS Service Manual Features Genuine Parts CONTROL OPTIONS Electric Proportional Controls CONTINUED PLUS 1 Compliance All Series 45 Electric controls have met and passed the Sauer Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Sauer Danfoss website within the PLUS 1 Guide section
23. ge 22 Check LS signal line Blocked LS signal line interferes with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differential between PC setting and external relief valve Adjust external relief valve or PC control settings to appropriate level Relief valve setting must be above PC setting to operate properly Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace relief valve Item Description Action Check PC control setting System pressure will not rise above PC setting Adjust PC to appropriate setting Refer to Adjustments page 22 Check external relief valve External relief valve setting below PC setting prevents pressure compensation Adjust external relief valve according to manufacturer s recommendations External relief valve must be set above PC setting to operate properly Inspect PC control spring Broken damaged or missing spring will cause erratic operation Replace the spring as required Inspect PC spool for wear Wear of PC spool causes internal leakage in the control Replace the spool as required Inspect PC spool for proper orientation Improper orientation results in poor operation Correct orientation of spool Check PC control for contamination Contamination may interf
24. ges The illustration below shows gauge port locations Recommended pressure gauges and fittings are in the table Gauge and port information Port Purpose Range of gauge Fitting M2 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting M4 Servo pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting L1 L2 Case pressure 0 10 bar 0 100 psi 7 8 14 O ring fitting 7 16 20 O ring fitting X1 LS signal 0 300 bar 0 5000 psi tee into LS signal line Gauge port locations L1 Legend B Main pressure line S Suction line L1 L2 Case drain lines X Load sensing pressure port M2 Gauge port for port B M4 Gauge port servo pressure M4 B s Q O O o O 0 O O O P106 263E 11005158 Rev AF October 2012 SAUER DANFOSS GENERAL START UP PROCEDURE CAUTION Incorrect shaft alignment may result in damage to drive shaft bearings or seal which can cause external oil leakage Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Initial start up procedures Be Follow this procedure when starting up a new Series 45 installation or when r
25. hanger Insufficient air flow high input air temperature or undersized heat exchangers will not meet cooling demands of the system Clean repair or replace heat exchanger as required Verify proper size of heat exchanger Check external system relief valve setting Fluid passing through relief valve adds heat to system Adjust external system relief valve setting following manufacturer s recommendations External relief valve setting must be above PC setting for proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions Item Description Action Check fluid level in reservoir Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Fill the reservoir to proper level Hydraulic fluid viscosity above acceptable limits Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic fluids Series 45 F Frame Technical Information Manual 520L0948 Check external system relief valve setting Eternal relief valve set below PC setting causes low output flow Adjust external relief valve following manufacturer s recommendation External relief valve setting m
26. he PC spool C132 spherical end first into the PC bore Using a new O ring C103A install the plug C103 Torque the plug C103 to 12 Nem 9 Ibfeft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 9 Nem 7 lbfeft For PC only controls skip steps 15 through 17 15 16 17 18 19 20 Install the LS spool C112 spherical end first 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 Nem 9 Ipf ft Using a new O ring C104A install the plug C104 Torque the plug to 12 Nem 9 Ibf ft 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 Genuine Parts Control assembly r C103 6 3Aeinch 12 Nem C104 9 Ibf ft 0 3he inch js Z 12 Nem C103A iil 9 Ibf ft
27. iately Change the fluid and filter per the Fluid and filter change interval vehicle machine manufacturer s Reservoir type Maximum change interval recommendations or at these intervals Sealed 2000 hours Breather 500 hours Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater than the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replace all fluid lost during filter change 11005158 Rev AF October 2012 S SAUER Series 45 Frame F Open Circuit Axial Piston Pumps DANFOSS Service Manual EXCESSIVE NOISE AND OR VIBRATION ACTUATOR RESPONSE IS SLUGGISH Troubleshooting S Genuine Parts Item Description Action Check fluid level in reservoir Insufficient hydraulic fluid causes cavitation Fill the reservoir to proper level Check for air in system Air in system causes noisy erratic control Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Improper inlet conditions cause erratic behavior and low output flow Correct pump inlet pressure vacuum conditions Refer to Hydraulic parameters page 10 Inspect shaft couplings
28. ircuit piston pumps convert input torque into hydraulic power The input shaft transmits rotational force from the prime mover to the cylinder block Tapered roller bearings support the shaft at the front and rear of the pump The cylinder block connects to the input shaft through splines on the shaft A lip seal at the front end of the pump prevents leakage where the shaft exits the pump housing The spinning cylinder block contains nine reciprocating pistons Each piston has a brass slipper connected at one end by a ball joint The slippers are held to the swashplate by the spring retainer and block spring The block spring also holds the cylinder block to the valve plate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation The valve plate connects one half of the cylinder block to pump inlet and the other half to pump outlet As each piston cycles in and out of its bore fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit A small amount of fluid leaks from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling Case drain ports return this fluid to the reservoir The angle of the swashplate controls the volume of fluid displaced into the system circuit The bias piston forces the swashplate into an inclined position into stroke The servo piston opposes the action of the bias piston and sp
29. lenoid coil nut C125 Torque to 6 8 9 5 Nem 5 7 lbfeft Install plug C153 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft Using petroleum jelly to retain them install the two interface O rings C154 in the recesses on the electric control manifold Install the manifold assembly onto the control housing using four screws C151 Torque the screws to 5 4 7 5 Nem 4 5 5 lbfeft Torque the screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Using petroleum jelly to retain them install the four interface O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using the four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Check and adjust the control setting See Adjustments page 23 24 11005158 Rev AF October 2012 29 SAUER Series 45 Frame F Open Circuit Axial Piston Pumps DANFOSS Service Manual Minor repair Genuine Parts SERVO CONTROL ORIFICE Disassembly Control assembly 1 Remove four screws C300 2 Remove the control and discard the four O rings C200 pe 3 Remove PC plug C103 and PC spool C132 from the control housing PN Note the orientation of the spool for Do reassembly Lozo 5 G020 C200 4 Remove backup plug G030 and orifice G020 dioi Reassembl
30. ment of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 11005158 Rev AF October 2012 5 SAUER DANFOSS WARRANTY SYMBOLS USED IN SAUER DANFOSS LITERATURE Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Introduction Genuine Parts Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring the removal of a unit s endcap voids the warranty u
31. mounting flange to the pad Oil from the main pump case lubricates the drive coupling For details refer to Series 45 F Frame Axial Piston Open Circuit Pumps Technical Information 520L0948 Genuine Parts Displacement limiter P104 345 Auxiliary pad options P106 262E Series 45 F Frame pumps are available with a variety of splined and straight keyed shafts For information on shafts refer to Series 45 F Frame Axial Piston Open Circuit Pumps Technical Information 520L0948 11005158 Rev AF October 2012 SAUER O DANFOSS CONTROL OPTIONS Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Features Genuine Parts The Series 45 Frame F pumps have two control options a Load Sensing LS control with Pressure Compensator PC or a PC only control Operation General The bias piston and spring 1 amp 2 acts at alltimes 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 flow The pump control depending on conditions in the system circuit sets swashplate angle by metering system pressure to the servo piston PC control The PC control design maintains a constant pressure in the hydraulic circuit as flow varies The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as the
32. ncludes information for the installation maintenance and minor repair of the Series 45 Frame F open circuit axial piston pumps The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures Performing installation maintenance and minor repair of Series 45 Frame F axial piston pumps according to the procedures in this manual will not affect your warranty Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide Global Service Partner Network is available for major repairs Major repairs require the removal of the unit s endcap which voids the warranty unless done by a Global Service Partner Sauer Danfoss Global Service Partners are trained by the factory and certified on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www sauer danfoss com Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take these general precautions whenever servicing a hydraulic system Unintended machine movement A Warning Unintended move
33. nless done by a Sauer Danfoss Global Service Partner These symbols are in the illustrations and text of this manual They communicate helpful information at the point where it is most useful to the reader In most instances the appearance of the symbol itself denotes its meaning The legend below defines the symbol and explains its purpose A WARNING may result in injury Tip helpful suggestion ie CAUTION may result in damage to Lubricate with hydraulic fluid product or property Apply grease petroleum jelly amp A Reusable part Apply locking compound il Non reusable part use a new part Inspect for wear or damage Non removable item Clean area or part Option either part may exist Be careful not to scratch or damage x le El Superseded parts are not interchangeable Note correct orientation Measurement required Mark orientation for reinstallation Flatness specification Torque specification Parallelism specification Press in press fit External hex head Pull out with tool press fit De EDS a Nee DJ E oA ej Internal hex head Cover splines with installation g o s UE sleeve Torx head O Pressure measurement gauge O ring boss port location or specification 11005158 Rev AF October 2012 SAUER O DANFOSS GENERAL DESCRIPTION Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Introduction Genuine Parts Sauer Danfoss Series 45 Frame F open c
34. oid the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 22 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Adjustments Genuine Parts PC setting is indicated in the pump model code Refer to the Series 45 Frame F Open Circuit Axial Piston Pumps Technical Information Manual 520L0948 for more information Before performing adjustments read page 16 Pressure measurement 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 2 Startthe prime mover and allow fluid to reach normal operating temperature Operate a hydraulic function to its full extension loading the pump to maximum pressure and zero flow 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 If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation 4 While holding the position of the PC adjusting plug torque the PC set screw to 9 Nem 7 Ibf ft PC control adjustment Case drain port L1 0 10 bar 0 145 psi 3 8 in 7 8 14 90 Nem 67 Ibfeft
35. ring forcing the swashplate out of stroke when hydraulic pressure in the control circuit rises above the spring force The pump control by varying the pressure at the servo piston controls the displacement of fluid in the system circuit Controls designed for Pressure Compensation PC or Load Sensing LS are available For a detailed description of control operation refer to Control op tions operation page 13 Pump and control sectional view LS control attached to endcap LS spool M CES LS adjustment PC spool j S PC adjustment F Door SS LE 2 Servo piston Bias sprin Slipper fas SpRIng Piston PP Tapered roller bearing 7 AA TES i iii Vat mme 9 9 EN Li Shaft seal plate S SR ARR 2 2 BDO OLDS Sa Cylinder f block 7 spring OOo KE VA m L Input shaft Tapered SS NS p roller l bearing gt E LS O Z AX AZ Cylinder Swashplate block Bias piston Slipper retainer P104341E 11005158 Rev AF October 2012 7 SAUER DANFOSS SYSTEM CIRCUIT Pictorial circuit diagram Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Introduction Genuine Parts The pump receives fluid directly from the reservoir through the inlet line A screen in the inlet line protects the pump from large contamin
36. rque the LS set screw to 9 Nem 7 Ibf ft 5 Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 6 Loosen the PC set screw and turn the PC adjusting plug until the pressure LS control adjustment Case drain port L1 0 10 bar 0 145 psi 3 8 in 7 8 14 LS adjusting plug 90 Nem 0 6 mm 67 Ibf ft LS set screw 6 4mm Z 9N m 7 Ibf ft X Port 0 300 bar 0 5000 psi 3 16 in 7 16 20 20 N m 51 Ibf ft P106 264E Gauge port M2 0 300 bar 0 4351 psi 3 16 in zt 3 7 16 20 50 Nem 37 Ibf ft Adjusting plug set screw and gauge locations shown gauge at port M1 or M2 indicates the desired setting Clockwise rotation increases pressure counterclockwise rotation decreases it approximate gain 42 bar 610 psi per turn 7 While holding the position of the PC adjusting plug torque the PC set screw to 9 Nem 7 Ibf ft 8 Stopthe prime mover remove the pressure gauges and return the system to its normal operating configuration The LS setting is a differential pressure Subtract pilot pressure at port X from system pressure at port M2 to compute the actual setting PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual se
37. s 45 Frame F Open Circuit Axial Piston Pumps Service Manual Minor repair oii Reassembly 1 10 11 12 13 14 15 Install the servo control orifice G020 and torque to 2 3 4 Nem 18 30 inelb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw C138 and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft Install the LS spool C112 spherical end first into the LS bore Install plug C104 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Place the two LS springs C114 C115 onto the spring guide C113 and install into the LS bore Thread adjusting screw C118 into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibfeft Install the electric control manifold drain orifice C149 and torque to 2 3 4 Nem 18 30 inelb Install the cartridge valve C150 into the electric control manifold C152 Torque to 25 8 28 5 Nem 19 21 Ibf ft DO NOT OVERTORQUE the cartridge valve Install the electric solenoid C155 and so
38. s Thrust in T out T N lbf 2900 650 Bearing life at 140 bar 2030 psi B 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 flange Vibratory continuous Nem Ibfsin 3730 33 000 load moments Shock maximum 13 220 117 000 1 Input speeds are valid at 1 bar absolute 0 in Hg vac inlet pressure See nlet pressure vs speed charts Inlet pressure 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 Pressure compensator valve setting PC control setting range Model bar psi F74B 100 310 1450 4495 F90C 100 260 1450 3770 Case pressure Maximum continuous 0 5 bar 7 psi above inlet Intermittent 2 bar 29 psi cold start Hydraulic fluid Refer to Sauer Danfoss publication Fluids and Filtration 520L0463 For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465 See Fluid and filter maintenance page 17 for recommended fluid and filter change intervals 11005158 Rev AF October 2012 SAUER DANFOSS HYDRAULIC PARAMETERS continued Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Technical specifications Temperature range Temperature limits Minimum intermittent cold start 40 C 40 F a Cher 104
39. t information Wherever off highway vehicles are at work so is Sauer Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Sauer Danfoss representative nearest you Local address Sauer Danfoss US Company Sauer Danfoss ApS 2800 East 13th Street DK 6430 Nordborg Denmark Ames IA 50010 USA Phone 45 7488 4444 Phone 1515 239 6000 Fax 45 7488 4400 Fax 1515 239 6618 Sauer Danfoss GmbH amp Co OHG Sauer Danfoss Daikin LTD Postfach 2460 D 24531 Neum nster Shin Osaka TERASAKI 3rd Bldg 6F Krokamp 35 D 24539 Neum nster Germany 1 5 28 Nishimiyahara Yodogawa ku Phone 49 4321 8710 Osaka 532 0004 Japan Fax 49 4321 871 122 Phone 81 6 6395 6066 Fax 81 6 6395 8585 wwwW Sauer danfoss com
40. t nti ele FPE ERE Erbe eO sT Ea EPE E EAEn EEEN iaia 16 Port locations and gauge installation 16 ETES TA de EIE 17 Start Up procedlle terere ires ise bereit ecce veste vete ov bes eres teta 17 RECOMMENAALtIONS cccccccccssssssssessesssssessesessssssssesssssssssssssesscssssssssssessessssssssssessessessesssssssessssessssasssssssessesseses 18 11005158 Rev AF October 2012 3 SAUER DANFOSS TROUBLESHOOTING ADJUSTMENTS MINOR REPAIR Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Genuine Parts Excessive noise and or vibration nn Actuator response is sluggish System operating hot Low pump output flow Pressure or flow instability System pressure not reaching PC setting Higlinlet Vac sen e reete tree tere RE eer eni voedeuencnaacecuostertaseoneewsceee PE CORIO e EE TET T DEM 22 LES aT A E i o PANEEL EE UE 23 Shaft seal replacement css sscacsavecccasscscssvsesessssctatsssconssatcteatscatlccansscsnssivavsstercdentedissvsckerssiscantccensvedtagsdatcestvccens 24 IAUIXIMANY PAGS rendent nr sine LS and PC Controls Electric CONTTOIS ner Servo COntrol OTNINES RAR EE ne rene AESA 30 Plug and fitting sizes and torques ee inessnennnenn 31 11005158 Rev AF October 2012 SAUER DANFOSS OVERVIEW SAFETY PRECAUTIONS Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Introduction D This manual i
41. tting 11005158 Rev AF October 2012 23 S SAUER DANFOSS SHAFT SEAL REPLACEMENT Caution Don t damage the pump housing or shaft Caution Premature bearing failure can result if the shaft seal contacts the shaft bearing Press the seal into the housing only far enough to clear the retaining ring 24 groove Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Minor repair Genuine Parts The Series 45 open circuit variable pumps use a lip type shaft seal You can replace this seal without major disassembly of the unit Replacing the shaft seal requires removing the pump from the machine Removal Shaft seal and retaining ring l Installation 3 Using the appropriate snap ring k K010 pliers remove the retaining ring CD K010 from the housing Remove the shaft seal K020 from the bore in the pump housing and discard Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Lubricate the lip of the new shaft E101 254 seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation Keeping the seal perpendicular to the shaft pr
42. ust be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Adjust PC and LS setting Refer to Adjustment page 22 Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions Check input speed Low input speeds decrease flow Adjust input speed Check pump rotation Incorrect rotational configuration causes low flow Use pump with appropriate rotational configuration Item Description Action Check for air in system Air in system causes erratic operation Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression Check control spools Sticking control spools cause erratic operation Inspect spools for free movement in bore Clean or replace 11005158 Rev AF October 2012 S SAUER DANFOSS Service Manual PRESSURE OR FLOW INSTABILITY continued SYSTEM PRESSURE NOT REACHING PC SETTING HIGH INLET VACUUM O Caution High inlet vacuum causes cavitation which can damage internal pump components Series 45 Frame F Open Circuit Axial Piston Pumps instability Troubleshooting Genuine Parts Item Description Action Low LS setting may cause Adjust LS setting to proper level Check LS setting Asians d M i o dp xps See Adjustments pa
43. west possible speed until system pressure builds to normal levels minimum 11 bar 160 psi Once system pressure is established increase to full operating speed If system pressure is not maintained shut down the prime mover determine cause and take corrective action Refer to Troubleshooting page 19 Operate the hydraulic system for at least fifteen minutes under light load conditions Check and adjust control settings as necessary after installation Refer to Adjustments page 22 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M2 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 11005158 Rev AF October 2012 17 SAUER DANFOSS RECOMMENDATIONS 18 Series 45 Frame F Open Circuit Axial Piston Pumps Service Manual Fluid and filter maintenance Genuine Parts To ensure optimum life of Series 45 products perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Water in the fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immed
44. y 1 Install the orifice G020 and torque to 2 3 4 Nem 18 30 inelb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb 2 Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibfeft 3 Using petroleum jelly to retain them install the four O rings C200 in the recesses on the control housing 4 Install the control assembly onto the endcap using four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 30 11005158 Rev AF October 2012 SAUER Series 45 Frame F Open Circuit Axial Piston Pumps S DANFOSS Service Manual Minor repair Genuine Parts PLUG AND FITTING SIZES If any plugs or fittings are removed from the unit during service install and torque as AND TORQUES indicated here This drawing is a composite Individual pump configurations may be different The illustration below shows the appropriate wrench size and torque for plugs that may be installed in the pump Plug locations sizes and torques E 130 CD Ge 7 8 inch 3 8 inch Z 93 Nem 70 Ibfeft L020 1 3 16 inch O 1 3 8 inch D 120 Nem e 155 Ibf ft z peedneh 7 8 inch 3 16 inch 6
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