Series 45 Frame K and L Open Circuit Axial Piston Pumps. Service Manual. Displacement Piston. Swashplate. Piston. Tapered Roller Bearing

Transcription

1 Series 45 Frame K ad L Ope Circuit Axial Pisto Pumps Displacemet Pisto Pisto Swashplate Tapered Roller Bearig Tapered Roller Bearig Valve Plate Cylider Block Kit Shaft Seal

2 Cotets INTRODUCTION Usig this maual... 4 Safety precautios... 4 Uiteded machie movemet... 4 Flammable cleaig solvets... 4 Fluid uder pressure... 4 Persoal safety... 4 Symbols used i Sauer-Dafoss literature... 5 Geeral descriptio... 6 Pump ad cotrol sectioal view... 6 The system circuit... 7 Pictorial circuit diagram... 7 TECHNICAL SPECIFICATIONS Geeral specificatios... 8 Type of moutig... 8 Auxiliary moutig pad optios... 8 Cotrol optios... 8 Port optios... 8 Directio of rotatio... 8 Istallatio positio... 8 Techical specificatios... 8 Ratigs... 8 Hydraulic parameters... 9 Ilet pressure... 9 Pressure compesator valve settig... 9 Case pressure... 9 Hydraulic fluid... 9 Temperature rage Fluid viscosity... 9 Viscosity limits... 9 Filtratio... 9 FEATURES Displacemet limiter...10 Auxiliary moutig pads...10 Iput shafts...10 Displacemet limiter...10 Auxiliary moutig pads...10 Cotrol optios...12 Cross-sectio PC cotrol...12 Operatio...12 Geeral...12 PC cotrol...12 Cross-sectio pump...12 Cross-sectio LS cotrol...13 LS cotrol...13 Typical load-sesig cotrol valve BLN L0532 April Sauer-Dafoss. Sauer-Dafoss accepts o resposibility for possible errors i catalogs, brochures ad other prited material. Sauer-Dafoss reserves the right to alter its products without prior otice. This also applies to products already ordered provided that such alteratios ca be made without subsequet chages beig ecessary i specificatios already agreed. All trademarks i this material are properties of their respective owers. Sauer-Dafoss ad the Sauer-Dafoss logotype are trademarks of the Sauer-Dafoss Group. All rights reserved. Prited i U.S.A. (0402H)

3 Cotets PRESSURE MEASUREMENT Port locatios ad gauge istallatio...14 Required tools...14 Gauge ad port iformatio...14 Gauge port locatios, radial ported uits...14 Gauge port locatios, axial ported uits...14 INITIAL START-UP PROCEDURES Geeral...15 Start-up procedure...15 FLUID AND FILTER MAINTENANCE Recommedatios...16 Fluid ad filter chage iterval...16 TROUBLESHOOTING Excessive oise ad / or vibratio...17 Actuator respose is sluggish...17 System operatig hot...18 Low pump output flow...18 Pressure or flow istability...18 System pressure ot reachig PC settig...19 High ilet vacuum...19 ADJUSTMENTS PC cotrol...20 PC cotrol adjustmet...20 LS / PC cotrol...21 LS cotrol adjustmet...21 MINOR REPAIR Shaft seal replacemet...22 Removal...22 Istallatio...22 Shaft seal ad retaiig rig...22 Auxiliary pads...23 Removal...23 Auxiliary moutig pads...23 Istallatio...23 Cotrol...24 Disassembly...24 Ispectio...24 Cotrol assembly...24 Reassembly...25 Cotrol assembly...25 Plug ad fittig sizes ad torques...26 Plug locatios, sizes, ad torques...26 BLN L0532 April

4 Itroductio USING THIS MANUAL This maual icludes iformatio for the ormal operatio, maiteace, ad service of the Series 45 frame K ad L ope circuit pumps. The maual icludes a descriptio of the uits ad their idividual compoets, troubleshootig iformatio, adjustmet istructios ad mior repair procedures. Uit warraty obligatios should ot be affected if maiteace, adjustmet ad mior repairs are performed accordig to the procedures described i this maual. May service ad adjustmet activities ca be performed without removig the uit from the vehicle or machie. However, adequate access to the uit must be available, ad the uit must be thoroughly cleaed before begiig maiteace, adjustmet, or repair activities. Sice dirt ad cotamiatio are the greatest eemies of ay type of hydraulic equipmet, follow clealiess requiremets strictly. This is especially importat whe chagig the system filter ad whe removig hoses or plumbig. A worldwide etwork of Sauer-Dafoss Authorized Service Ceters (ASCs) is available should major repairs be eeded. Cotact ay Sauer-Dafoss ASC for details. A list of all ASCs ca be foud i bulleti BLN , or i brochure SAW (Idet. No ), or you ca locate your earest ASC usig the distributor locator at SAFETY PRECAUTIONS Always cosider safety precautios before begiig a service procedure. Protect yourself ad others from ijury. Take the followig geeral precautios wheever servicig a hydraulic system. Uiteded machie movemet WARNING Uiteded movemet of the machie or mechaism may cause ijury to the techicia or bystaders. To protect agaist uiteded movemet, secure the machie or disable / discoect the mechaism while servicig. Flammable cleaig solvets WARNING Some cleaig solvets are flammable. To avoid possible fire, do ot use cleaig solvets i a area where a source of igitio may be preset. Fluid uder pressure WARNING Escapig hydraulic fluid uder pressure ca have sufficiet force to peetrate your ski causig serious ijury ad/or ifectio. This fluid may also be hot eough to cause burs. Use cautio whe dealig with hydraulic fluid uder pressure. Relieve pressure i the system before removig hoses, fittigs, gauges, or compoets. Never use your had or ay other body part to check for leaks i a pressurized lie. Seek medical attetio immediately if you are cut by hydraulic fluid. Persoal safety WARNING Protect yourself from ijury. Use proper safety equipmet, icludig safety glasses, at all times. 4 BLN L0532 April 2002

5 Itroductio SYMBOLS USED IN SAUER-DANFOSS LITERATURE WARNING may result i ijury CAUTION may result i damage to product or property Reusable part No-reusable part, use a ew part No-removable item Optio either part may exist Superseded parts are ot iterchageable Tip, helpful suggestio Lubricate with hydraulic fluid Apply grease / petroleum jelly Apply lockig compoud Ispect for wear or damage Clea area or part Be careful ot to scratch or damage Note correct orietatio Measuremet required Mark orietatio for reistallatio Flatess specificatio Torque specificatio Parallelism specificatio Press i press fit Exteral hex head Pull out with tool press fit Iteral hex head Torx head O-rig boss port Cover splies with istallatio sleeve Pressure measuremet / gauge locatio or specificatio The symbols above ca be foud i the illustratios ad text of this maual. They are iteded to commuicate helpful iformatio at the poit where it is most useful to the reader. I most istaces, the appearace of the symbol itself deotes its meaig. The leged above is provided to defie each symbol ad explai its purpose. BLN L0532 April

6 Itroductio GENERAL DESCRIPTION Sauer-Dafoss Series 45 K ad L frame ope circuit pisto pumps covert iput torque ito hydraulic power. Rotatioal force is trasmitted through the iput shaft to the cylider block. The iput shaft is supported by tapered roller bearigs at the frot ad rear of the pump ad is splied ito the cylider block. A lip-seal at the frot ed of the pump prevets leakage where the shaft exits the pump housig. The spiig cylider block cotais ie reciprocatig pistos. Each pisto has a brass slipper coected at oe ed by a ball joit. The slippers are held to the swashplate by the sprig retaier ad block sprig. The block sprig also holds the cylider block to the valve plate. The reciprocatig movemet of the pistos occurs as the slippers slide agaist the iclied swashplate durig rotatio. Via the valve plate, oe half of the cylider block is coected to pump ilet ad the other half to pump outlet. As each pisto cycles i ad out of its bore, fluid is draw from the ilet ad displaced to the outlet thereby impartig power ito the system circuit. A small amout of fluid is allowed to leak from the cylider block / valve plate ad slipper / swashplate iterfaces for lubricatio ad coolig. Case drai ports are provided to retur this fluid to the reservoir. The volume of fluid displaced ito the system circuit is cotrolled by the agle of the swashplate. The swashplate is forced ito a iclied positio (ito stroke) by the bias sprig. The servo pisto opposes the actio of the bias sprig forcig the swashplate out of stroke whe hydraulic pressure i the cotrol circuit rises above the sprig force. The pump cotrol, by varyig the pressure at the servo pisto, cotrols the displacemet of fluid i the system circuit. Cotrols desiged for Pressure Compesatio (PC) or Load Sesig (LS) are available. For a detailed descriptio of cotrol operatio, refer to Cotrol optios, operatio, page 12. Pump ad cotrol sectioal view LS cotrol (attached to edcap) LS adjustmet screw PC adjustmet screw LS spool PC spool Swashplate Bias sprig Servo pisto Valve plate Tapered roller bearig Edcap (axial ported) Iput shaft Block sprig Cylider block Pisto Slipper retaier Shaft seal Slipper P E 6 BLN L0532 April 2002

7 Itroductio THE SYSTEM CIRCUIT The pump receives fluid directly from the reservoir through the ilet lie. A scree placed i the ilet protects the pump from large cotamiats. The output of the pump is directed to a PVG-32 multi-sectio load sesig directioal cotrol valve which directs fluid to the actuators i the system. Fluid returig from the system is cooled by a heat exchager ad cleaed by a filter before returig to the reservoir. The speed of the actuators i the system depeds o the volume of fluid beig provided by the pump. The operatig pressure varies depedig o actuator load, but is limited to a adjustable maximum settig by the PC sectio of the pump cotrol ad by a system relief valve itegrated ito the side module of the PVG valve. The positio of the PVG valve sets the demad for flow i the system ad commuicates this to the pump cotrol by meas of a hydraulic sigal (load sese sigal). The pump will provide as much flow to the system as it demads 1 while limitig the maximum pressure. Therefore flow ad pressure i the system are compesated to meet requiremets. Pictorial circuit diagram K/L Frame Series 45 ope circuit axial pisto pump with load sesig cotrol PVG 32 mulit-sectio load sesig cotrol valve Double-actig cylider Bi-directioal gear motor System pressure Reservoir Filter Heat exchager Servo pressure Actuator pressure Load sese pressure Actuator retur P E Suctio / case drai / system retur 1 Full available flow is a fuctio of pump displacemet, operatig speed, ad efficiecy. Refer to Series 45 Axial Pisto Ope Circuit Pumps Techical Iformatio, BLN for details. BLN L0532 April

8 Techical specificatios GENERAL SPECIFICATIONS Type of moutig SAE-B moutig flage. Auxiliary moutig pad optios SAE-A, SAE-B, or SAE-B-B Cotrol optios PC: Pressure Compesator LS: Load Sesig (with PC) Port optios Ilet ad system ports: All other ports: SAE flaged ports, code 61 or O-rig boss ports. Axial (ed) ports or radial (side) ports. SAE straight thread O-rig boss. Directio of rotatio Clockwise or couterclockwise. Istallatio positio Istallatio positio is discretioary. To satisfy ilet pressure coditios, it is recommeded that the pump always be located below the lowest level of hydraulic fluid i the reservoir. The housig must always be filled with hydraulic fluid. Techical specificatios Ratigs S pecificatio Displacemet Iput Speed Miimum Rated Maximum Maximum (peak) workig pressure Cotiuous workig pressure U i t F rame L Frame K cm 3 [ i 3 ] 25 [1.53] 30 [1.83] 38 [2.32] 45 [2.75] m i - 1 (rpm ) bar [psi] 3600** 3600* * 2800* * 2800* * 350 [5075] 300 [4350] 350 [5075] 300 [4350] 260 [3770] 210 [3045] 260 [3770] 210 [3045] F low at rated speed l /mi [gal/mi] 76.2 [20.3] 90.0 [24.0] [28.9] [33.6] Theoretical iput torque at maximum displacemet Mass momet of iertia of iteral rotatig compoets Weight Axial ports Radial ports N m/bar [lbf i/1000psi] 2 kg m [ lbm ft 2 ] kg [lbm] [243] [0.037] [291] [0.035] [369] [0.040] [437] [0.047] 19 [42] 19 [42] 19 [42] 19 [42] 24 [53] 24 [53] 24 [53] 24 [53 8 BLN L0532 April 2002

9 Techical specificatios HYDRAULIC PARAMETERS Ilet pressure Miimum pressure, cotiuous = 0.8 bar absolute [23.2 i Hg] (at reduced maximum pump speed) Miimum pressure, cold start = 0.5 bar absolute [14.8 i Hg] Pressure compesator valve settig Miimum: 100 bar [1450 psi] Maximum: 260 bar [3770 psi] Case pressure Maximum cotiuous: 0.5 bar [7 psi] Above ilet Itermittet: 2 bar [29 psi] Cold start Hydraulic fluid Refer to Sauer-Dafoss publicatio Fluids ad Filtratio BLN-9887 or 520L0463. For iformatio o biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465. See Fluid ad filter maiteace, page 16 for recommeded fluid ad filter chage itervals. Temperature rage 1 Itermittet (cold start): - 40 C [- 40 F] Cotiuous: 82 C [180 F] Maximum: C [220 F] Fluid viscosity Viscosity limits R atig mm m /s (cst) [SUS ] ν cotiuou s m iimum 9 [58] m aximum 110 [500] m iimum 6.4 [47] ν itermitte t maximu m (cold start) 1000 [4700] Filtratio Required clealiess level: ISO 4406 Class 18/13 or better. Refer to Sauer-Dafoss publicatios Fluids ad Filtratio BLN-9887 or 520L0463 ad Desig Guidelies for Selectig ad Maitaiig the Required Hydraulic Fluid Clealiess 520L0465. See Fluid ad filter maiteace, page 16 for recommeded fluid ad filter chage itervals. 1 Hydraulic fluid viscosity must be maitaied withi the prescribed limits. 2 As measured at the hottest poit i the system, e.g. drai lie. BLN L0532 April

10 Features DISPLACEMENT LIMITER Frame K ad L Series 45 pumps are available with a optioal maximum displacemet limiter. If istalled, this loger servo pisto will limit the maximum displacemet to 92%. This displacemet limiter is ot adjustable. Displacemet limiter P AUXILIARY MOUNTING PADS Auxiliary moutig pads are available for all radial ported Series 45 pumps. These pads are typically used for moutig auxiliary hydraulic pumps. Auxiliary moutig pads Sice the auxiliary pad operates uder case pressure, a O-rig must be used to seal the auxiliary pump moutig flage to the pad. The drive couplig is lubricated by oil from the mai pump case. For details refer to Series 45 Axial Pisto Ope Circuit Pumps Techical Iformatio BLN P INPUT SHAFTS Series 45 K ad L frame pumps are available with a variety of splied, straight keyed, ad tapered ed shafts. For iformatio o shafts refer to Series 45 Axial Pisto Ope Circuit Pumps Techical Iformatio BLN BLN L0532 April 2002

11 Features NOTES BLN L0532 April

12 Features CONTROL OPTIONS The Series 45 Frames K ad L have two possible cotrol optios, a Load Sesig (LS) cotrol with Pressure Compesator (PC) or a PC oly cotrol. Operatio Geeral The bias sprig (1) acts at all times to push the swashplate (2) to maximum agle causig the pump to stroke. The servo pisto (3) acts agaist the bias sprig to reduce the swashplate agle causig the pump to de-stroke. Swashplate agle determies pump outlet flow. The pump cotrol, depedig o coditios i the system circuit, sets swashplate agle by meterig system pressure to the servo pisto. Cross-sectio pump P Bias sprig ad servo pisto set swashplate positio PC cotrol The PC cotrol is desiged to maitai a costat pressure i the hydraulic circuit as flow varies. The PC cotrol modulates pump flow accordigly to maitai system pressure at the PC settig as defied by the PC adjustmet screw (4) ad sprig (5). Cross-sectio PC cotrol System pressure Case pressure Servo pressure P E PC spool shifts to port system pressure to servo pisto Whe system pressure, actig o the o-sprig ed of the PC spool (6), overcomes the force of the PC sprig, the spool shifts portig system pressure to the servo pisto ad the swashplate agle decreases. Whe system pressure drops below the PC settig, the PC sprig shifts the spool i the opposite directio coectig the servo pisto to pump case ad the swashplate agle icreases. The swashplate is maitaied at whatever agle is required to keep system pressure at the PC settig. 12 BLN L0532 April 2002

13 Features CONTROL OPTIONS (cotiued) LS cotrol The LS cotrol is desiged to match pump flow with system demad. The flow demad of the system is sesed by the LS cotrol as a pressure drop across the Exteral Cotrol Valve (ECV). As the ECV opes ad closes, the pressure delta across the valve chages. Whe opeig, the delta decreases. Whe closig, the delta icreases. The LS cotrol the icreases or decreases pump flow to the system util the pressure delta becomes equal to the LS settig as defied by the LS adjustmet screw (7) ad sprig (8). Cross-sectio LS cotrol System pressure LS pressure Typical load-sesig cotrol valve Load pressure Load sese pressure Retur pressure Tak System pressure P E Pressure drop across exteral cotrol valve defies system demad The LS cotrol cosists of two spool valves that coect the servo pisto either to pump case or system pressure. The PC spool (6) cotrols the pressurecompesatig fuctio of the cotrol as described i the previous sectio. The LS spool (9) cotrols the load-sesig fuctio. The PC spool has priority over the LS spool. 4 5 Case pressure Servo pressure 6 P E LS spool shifts to port system pressure to servo pisto Via iteral portig, system pressure (upstream of ECV) is applied to the o-sprig ed of the LS spool ad via hydraulic lie coected at port X, LS pressure (dowstream of ECV) is applied to the sprig ed. This arragemet allows the LS spool to act o the delta betwee system pressure ad LS pressure. The LS sprig sets the threshold of operatio (LS settig). Because the swashplate is biased to maximum agle, the pump attempts to deliver full flow to the hydraulic system. Whe the flow beig delivered exceeds demad, the pressure delta across the ECV is great eough to overcome sprig force ad shift the LS spool portig system pressure to the servo pisto. The pump de-strokes reducig flow util the delta across the ECV becomes equal to the LS settig. Whe flow beig delivered is less tha demad, the delta across the ECV drops below the LS settig ad the LS sprig shifts the spool coectig the servo pisto to pump case. The pump strokes icreasig flow util the delta across the ECV becomes equal to the LS settig. Whe the exteral cotrol valve is placed i eutral, it coects the LS sigal lie to drai. With o LS pressure actig o the o-sprig ed of the LS spool, the pump adjusts stroke to whatever positio ecessary to maitai system pressure at the LS settig. The pump is ow i stadby mode. Because of the series arragemet of the LS ad PC spools, the PC spool will override the LS spool. If at ay time system pressure reaches the PC settig, the PC spool will shift blockig the passage that coects the LS spool with the servo pisto ad portig system pressure to the servo pisto causig the pump to de-stroke. BLN L0532 April

14 Pressure measuremet REQUIRED TOOLS The service procedures described i this maual ca be performed usig commo mechaic s had tools. Special tools, if required are show. Calibrate pressure gauges frequetly to esure accuracy. Use subbers to protect gauges. PORT LOCATIONS AND GAUGE INSTALLATION Gauge port locatios are show below. Recommeded pressure gauges ad fittigs are detailed i the table. Gauge ad port iformatio M2 M4 L1, L2 X1 P ort P urpos e R age of gaug e Fitti g S ystem pressure bar or [ psi] 7/16-20 o-rig fittig S ervo pressure bar or [ psi] 7/16-20 o-rig fittig C ase pressure 0-10 bar or [0-100 psi] 7/8-14 o-rig fittig L S sigal bar or [ psi] 7/16-20 o-rig fittig (tee ito LS sigal lie) Gauge port locatios, axial ported uits System gauge port M2 SAE J1926/1, LS sigal port X SAE J1926/1, Outlet port B SAE J1926/1, Case drai port L2 SAE J1926/1, Ilet port S SAE J1926/1, Case drai port L1 SAE J1926/1, P E Gauge port locatios, radial ported uits Case drai port L1 SAE J1926/1, Ilet port S Case drai port L2 SAE J1926/1, SAE J1926/1, System gauge port M2 SAE J1926/1, Outlet port B SAE J1926/1, P E 14 BLN L0532 April 2002

15 Iitial start-up procedures GENERAL Follow this procedure whe startig-up a ew Series 45 istallatio or whe restartig a istallatio i which the pump has bee removed. WARNING Uiteded movemet of the machie or mechaism may cause ijury to the techicia or bystaders. To protect agaist uiteded movemet, secure the machie or disable / discoect the mechaism while servicig. Prior to istallig the pump, ispect for damage icurred durig shippig. Make certai all system compoets (reservoir, hoses, valves, fittigs, heat exchager, etc.) are clea prior to fillig with fluid. START-UP PROCEDURE 1. Coect the pump to the prime mover. Esure that pump shaft is properly aliged with the shaft of the prime mover. CAUTION Icorrect shaft aligmet may result i damage to drive shaft, bearigs, or seal which ca cause exteral oil leakage. 2. Fill the reservoir with recommeded hydraulic fluid. Always filter fluid through a 10 micro filter pourig ito the reservoir. Never reuse hydraulic fluid. 3. Fill the mai pump housig with clea hydraulic fluid. Pour filtered oil directly ito the upper most case drai port. 4. Fill the ilet lie leadig from the pump to the reservoir. Check the ilet lie for properly tighteed fittigs ad be certai it is free of restrictios ad air leaks. 5. To esure the pump stays filled with oil, istall the case drai lie i the upper most case drai port. 6. Istall a gauge at port M2 to moitor system pressure durig start up. Note: Follow recommedatios i the vehicle / machie operator s maual for prime mover start up procedures. 7. While watchig the pressure gauge istalled at M2, jog the prime mover or ru at the lowest possible speed util system pressure builds to ormal levels (miimum 11 bar [160psi]). Oce system pressure is established, icrease to full operatig speed. If system pressure is ot maitaied, shut dow the prime mover, determie cause, ad take corrective actio. Refer to Troubleshootig, page Operate the hydraulic system for at least fiftee miutes uder light load coditios. 9. Check ad adjust cotrol settigs as ecessary after istallatio. Refer to Adjustmets, page Shut dow the prime mover ad remove the pressure gauge. Replace plug at port M Check the fluid level i the reservoir; add clea filtered fluid if ecessary. The pump is ow ready for operatio. BLN L0532 April

16 Fluid ad filter maiteace RECOMMENDATIONS To esure optimum life of Series 45 products, perform regular maiteace of the fluid ad filter. Cotamiated fluid is the mai cause of uit failure. Take care to maitai fluid clealiess whe servicig. Check the reservoir daily for proper fluid level, the presece of water, ad racid fluid odor. Water i the fluid may be oted by a cloudy or milky appearace or free water i the bottom of the reservoir. Racid odor idicates the fluid has bee exposed to excessive heat. Chage the fluid immediately if these coditios occur. Correct the problem immediately. Chage the fluid ad filter per the vehicle / machie maufacturer s recommedatios or at these itervals: Fluid ad filter chage iterval Reservoir Type Maximum Chage Iterva terval 2000 Hours Chage the fluid more frequetly if it Sealed becomes cotamiated with foreig Breather 500 Hours matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater that the recommeded maximum. Note: Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid. Chage filters wheever the fluid is chaged or whe the filter idicator shows that it is ecessary to chage the filter. Replace all fluid lost durig filter chage. 16 BLN L0532 April 2002

17 Troubleshootig EXCESSIVE NOISE AND / OR VIBRATION I tem Check fluid level i reservoir. Check for air i system. Check pump ilet pressure / vacuum. Ispect shaft coupligs. Check shaft aligmet. Hydraulic fluid viscosity above acceptable limits. D escriptio Isufficiet hydraulic fluid will cause cavitatio. Air i system will cause oisy, erratic cotrol. Improper ilet coditios will cause erratic behavior ad low output flow. A loose or icorrect shaft couplig will cause excessive oise ad/or vibratio. Misaliged shafts will create excessive oise ad/or vibratio. Hydraulic fluid viscosity above acceptable limits or low fluid temperature will ot allow the pump to fill or cotrol to operate properly. Actio Fill the reservoir to proper level. Purge air ad tighte fittigs. Check ilet for leaks. Correct pump ilet pressure / vacuum coditios. Refer to H ydraulic parameters, page 9. Repair or replace couplig ad esure that correct couplig is beig used. Correct shaft misaligmet. Allow system to warm up before operatio or use fluid with the appropriate viscosity grade for expected operatig temperatures. See Hydraulic Fluids, Series 45 T echical Iformatio Maual, BLN ACTUATOR RESPONSE IS SLUGGISH I tem Check exteral system relief valve settig. Check PC ad LS cotrol settig. Check LS cotrol sigal pressures. Iteral system leaks. Hydraulic fluid viscosity above acceptable limits. Check exteral system valvig. Check pump case pressure. Check pump ilet pressure / vacuum. D escriptio Low exteral relief valve settig will slow dow system. Low PC settig will prevet the pump from achievig full stroke. Low LS settig will limit output flow. Icorrect LS sigal will ot allow pump to operate correctly. Wor iteral parts will ot allow the pump to operate properly. Hydraulic fluid viscosity above acceptable limits or low fluid temperature will ot allow the pump to fill or cotrol to operate properly. Malfuctioig valvig may ot allow system to respod properly. High case pressure will cause the system to be sluggish. High ilet vacuum will cause low output flow. Actio Adjust exteral relief valve settig per maufacturer's recommedatios. Exteral relief settig must be above PC settig for proper operatio. Adjust PC ad LS settig. Refer to A djustmets, page 20. Ispect system, esure that proper LS sigal is trasmitted to the pump. Refer to Authorized Service Ceter for repairs as required. Allow system to warm up before operatio or use fluid with the appropriate viscosity grade for expected operatig temperatures. See Hydraulic Fluids, Series 45 T echical Iformatio Maual, BLN Repair or replace system valvig as required. Correct case drai lie restrictios. Correct ilet pressure coditios. BLN L0532 April

18 Troubleshootig SYSTEM OPERATING HOT I te m Check fluid level i reservoir. Ispect heat exchager. Check air flow ad iput air temperature for the heat exchager. Check exteral system relief valve settig. Check pump ilet pressure / vacuum. D escriptio Isufficiet volume of hydraulic fluid will ot meet coolig demads of system. Isufficiet air flow, high iput air temperature, or udersized heat exchager will ot meet coolig demads of the system. Fluid passig through relief valve adds heat to system. High ilet vacuum adds heat to system. Actio Fill reservoir to proper level. Verify proper size of reservoir. Clea, repair, or replace heat exchager as required. Verify proper size of heat exchager. Adjust exteral system relief valve settig per maufacturer's recommedatios. Exteral relief valve settig must be above PC settig for proper operatio. Correct ilet pressure / vacuum coditios. LOW PUMP OUTPUT FLOW I tem Check fluid level i reservoir. Hydraulic fluid viscosity above acceptable limits. Check exteral system relief valve settig. Check PC ad LS cotrol settig. Check pump ilet pressure / vacuum. D escriptio Isufficiet hydraulic fluid will limit output flow ad cause iteral damage to pump. Fluid viscosity above acceptable limits or low fluid temperature will ot allow the pump to fill or cotrol to operate properly. Exteral relief valve set below PC settig will cause low output flow. Low PC settig will prevet the pump from achievig full stroke. Low LS settig will limit output flow. High ilet vacuum will cause low output flow. Actio Fill the reservoir to proper level. Allow system to warm up before operatio or use fluid with the appropriate viscosity grade for expected operatig temperatures. See Hydraulic fluids, Series 45 T echical Iformatio Maual, BLN Adjust exteral relief valve per maufacturer's recommedatio. Exteral relief valve settig must be above PC settig for proper operatio. Adjust PC ad LS settig. Refer to A djustmets, page 20. Correct ilet pressure coditios. C heck iput speed. L ow iput speeds decrease flow. Adjust iput speed. Check pump rotatio. Icorrect rotatioal cofiguratio will cause low flow. Use pump with appropriate rotatioal cofiguratio. PRESSURE OR FLOW INSTABILITY I tem Check for air i system. Check cotrol spools. D escriptio Air i system will cause erratic operatio. Stickig cotrol spools will cause erratic operatio. Actio Activate PC, allowig system to bleed air. Check ilet lie for leaks ad elimiate source of air igressio. Ispect spools for free movemet i bore. Clea or replace as eeded. 18 BLN L0532 April 2002

19 Troubleshootig PRESSURE OR FLOW INSTABILITY (cotiued) I tem D escriptio C heck LS settig. Low LS settig may cause istability. Check LS sigal lie. Check exteral relief valve ad PC settig. Check exteral relief valve. Blocked LS sigal lie will iterfere with proper LS operatio. Isufficiet pressure differetial betwee PC settig ad exteral relief valve. Chatterig exteral relief valve may cause ustable feedback to pump cotrol. Actio Adjust LS settig to proper level. See A djustmets, page 20. Remove blockage. Adjust exteral relief valve or PC cotrol settigs to appropriate level. Relief valve settig must be above PC settig for proper operatio. Adjust or replace relief valve. SYSTEM PRESSURE NOT REACHING PC SETTING I tem Check PC cotrol settig. Check exteral relief valve. Ispect PC cotrol sprig. Ispect PC spool for wear. Ispect PC spool for proper orietatio. Check PC cotrol for cotamiatio. D escriptio System pressure will ot rise above PC settig. Exteral relief valve settig below PC settig will prevet pressure compesatio. Broke, damaged, or missig sprig will cause erratic operatio. Wear of the PC spool will cause iteral leakage i the cotrol. Improper orietatio will result i poor operatio. Cotamiatio may iterfere with movemet of the PC Spool. Actio Adjust PC to appropriate settig. Refer to A djustmets, page 20. Adjust exteral relief valve per maufacturer's recommedatios. Exteral relief valve must be set above PC settig for proper operatio. Replace sprig as required. Replace the spool as required. Correct orietatio of spool. Clea PC cotrol compoets, take appropriate actio to elimiate cotamiatio. HIGH INLET VACUUM CAUTION High ilet vacuum causes cavitatio which ca damage iteral pump compoets. I tem Check fluid temperature. Ispect ilet scree. Check ilet pipig. Hydraulic fluid viscosity above acceptable limits. D escriptio Low temperature icreases viscosity. High fluid viscosity causes high ilet vacuum. Blocked or restricted ilet scree will cause high ilet vacuum. Too may fittigs, beds, or log pipig will cause high ilet vacuum. High fluid viscosity causes high ilet vacuum. Actio Allow system to warm up before operatio. Clea scree / remove blockage. Elimiate fittigs to make path more direct. Select fluid with appropriate viscosity for expected operatig t emperature. See Hydraulic fluids, Series 45 Techical Iformatio M aual, BLN BLN L0532 April

20 Adjustmets PC CONTROL WARNING Escapig hydraulic fluid uder pressure ca have sufficiet force to peetrate your ski causig serious ijury ad/or ifectio. Relieve pressure i the system before removig hoses, fittigs, gauges, or compoets. Uiteded movemet of the machie or mechaism may cause ijury to the techicia or bystaders. To protect agaist uiteded movemet, secure the machie or disable / discoect the mechaism while servicig. CAUTION Cotamiatio ca damage iteral compoets ad void the maufacturer s warraty. Take precautios to esure system clealiess whe removig ad reistallig system lies. PC settig is idicated i the pump model code. Refer to the Series 45 Ope Circuit Axial Pisto PumpsTechical Iformatio Maual, BLN-10128, for more iformatio. Note: Before performig adjustmets, read page 14, Pressure measuremet, for recommedatios. 1. Istall a pressure gauge i port M2 to measure system pressure. Istall a pressure gauge i case drai port L1 or L2 to measure case pressure. 2. Start the prime mover ad allow fluid to reach ormal operatig temperature. Operate a hydraulic fuctio to its full extesio, loadig the pump at maximum pressure ad zero flow. 3. Loose the PC set screw ad tur the PC adjustmet screw util the desired settig is idicated o the pressure gauge at port M2. Clockwise rotatio will icrease pressure, couterclockwise rotatio will decrease; approximate gai = 35 bar [507 psi] per tur. Note: If the pressure does ot icrease, a exteral system relief valve may require adjustmet. Exteral system relief valve must be set above the PC settig for proper operatio. 4. While holdig the positio of the PC adjustmet screw, torque the PC set screw to 7-11 N m [6-8 lbf ft]. PC cotrol adjustmet PC adjustmet screw 6mm PC set screw 4mm 7-11 N m [6-8 lbf ft] P E Gauge port M bar [ psi] 9/ /4 i N m [25-50 lbf ft] M14 6mm N m [20-26 lbf ft] Case drai port L bar [0-100 psi] 7/8-14 3/8 i N m [ lbf ft] Adjustmet screw, set screw, ad gauge locatios show 5. Stop the prime mover, remove the pressure gauges, ad retur the system to its ormal operatig cofiguratio. 1 P C settig is refereced to case pressure. Subtract case pressure from system pressure to compute the actual settig. 20 BLN L0532 April 2002

21 Adjustmets LS CONTROL WARNING Escapig hydraulic fluid uder pressure ca have sufficiet force to peetrate your ski causig serious ijury ad/or ifectio. Relieve pressure i the system before removig hoses, fittigs, gauges, or compoets. Uiteded movemet of the machie or mechaism may cause ijury to the techicia or bystaders. To protect agaist uiteded movemet, secure the machie or disable / discoect the mechaism while servicig. CAUTION Cotamiatio ca damage iteral compoets ad void the maufacturer s warraty. Take precautios to esure system clealiess whe removig ad reistallig system lies. The LS settig is idicated i the pump model code. Refer to the Series 45 Ope Circuit Axial Pisto Pumps Techical Iformatio Maual, BLN-10128, for more iformatio. Note: Before performig adjustmets, read page 14, Pressure measuremet, for recommedatios. 1. Istall a pressure gauge i port M2 to measure system pressure. Istall a pressure gauge i drai port L1 or L2 to measure case pressure. Tee-i a gauge to the LS / remote PC sigal lie (port X). 2. Start the prime mover ad allow fluid to reach ormal operatig temperature. Slowly operate a hydraulic fuctio which will demad approximately half flow from the pump, but keep system pressure below the PC set poit. 3. Loose the LS set screw. While watchig the pressure gauges, tur the LS adjustmet screw util the desired pressure differetial betwee port M2 ad port X is achieved 1. Clockwise rotatio will icrease the settig, couterclockwise rotatio will decrease; approximate gai = 12 bar [170 psi] per tur. LS cotrol adjustmet Gauge port M bar [ psi] 9/16-18 M14 1/4 i 6mm N m N m [25-50 lbf ft] [20-26 lbf ft] LS adjustmet screw 6mm LS set screw 4mm 7-11 N m [6-8 lbf ft] P E LS/remote PC sigal port X Case drai port L bar [0-100 psi] 7/8-14 3/8 i N m [ lbf ft] Adjustmet screw, set screw, ad gauge locatios show 4. While holdig the positio of the LS adjustmet screw, torque the LS set screw to 7-11 N m [6-8 lbf ft]. 5. Operate a hydraulic fuctio to its full extesio loadig the pump at maximum pressure ad zero flow. 6. Loose the PC set screw ad tur the PC adjustmet screw util the desired settig is idicated o the pressure gauge at port M2 2. Clockwise rotatio will icrease pressure, couterclockwise rotatio will decrease; approximate gai = 35 bar [507 psi] per tur. Note: If the pressure does ot icrease, a exteral system relief valve may require adjustmet. Exteral system relief valve must be set above the PC settig for proper operatio. 7. While holdig the positio of the PC adjustmet screw, torque the PC set screw to 7-11N m [6-8 lbf ft]. 8. Stop the prime mover, remove the pressure gauges, ad retur the system to its ormal operatig cofiguratio. 1 The LS settig is a differetial pressure. Subtract pilot pressure at port X from system pressure at port M2 to compute the actual settig. 2 PC settig is refereced to case pressure. Subtract case pressure from system pressure to compute the actual settig. BLN L0532 April

22 Mior repair SHAFT SEAL REPLACEMENT A lip type shaft seal is used i the Series 45 ope circuit variable pumps. This seal ca be replaced without major disassembly of the uit. Replacemet of the shaft seal requires removal of the pump from the machie. Removal 1. Usig the appropriate sap-rig pliers, remove the retaiig rig (K010) from the housig. Shaft seal ad retaiig rig K020 K Remove the shaft seal (K020) from the bore i the pump housig ad discard. Avoid damagig the pump housig or shaft. Pucture the face of the seal with a packig hook, or use a slide-hammer type puller to remove the seal. P Istallatio 3. Ispect the pump housig ad ew seal for damage. Ispect the sealig area o the shaft for rust, wear, or cotamiatio. Polish the sealig area o the shaft if ecessary. CAUTION Premature bearig failure ca result if the shaft seal cotacts the shaft bearig. Press the seal ito the housig oly far eough to clear the retaiig rig groove. 4. Lubricate the lip of the ew shaft seal with clea hydraulic fluid. Place a protective sleeve over the shaft ed to prevet damage to the seal durig istallatio. 5. Keepig the seal perpidicular to the shaft, press the ew seal ito the housig just far eough to clear the retaiig rig groove. Istall seal with the cupped side toward the shaft bearig. Do ot damage the seal durig istallatio. 6. Usig the appropriate sap rig pliers, istall the seal retaiig rig. 7. Remove the istallatio sleeve. 22 BLN L0532 April 2002

23 Mior repair AUXILIARY PADS Auxiliary moutig pads may be istalled o pumps equipped with through-drive radial ported edcaps. Follow these steps to either remove, replace, or exchage auxiliary moutig pads. Removal 1. Remove two screws (J130) retaiig the cover plate (J110) or auxiliary pump (ot show). Remove the shippig cover or auxiliary pump ad its sealig O-rig (J120). Discard the O-rig. 2. Remove the drive couplig (J140). 3. Remove the four screws (J100) retaiig the pad adapter (J085) to the edcap. Discard the two pad adapter O-rigs (J090, J095). Auxiliary moutig pads J085 J095 J090 J140 J110 J120 J095 J140 J100 (4pl.) 8mm N m [35-45 lbf ft] J090 J085 J095 J085 J130 (2pl.) 9/16 i N m [27-37 lbf ft] J110 J120 J100 (4pl.) 8mm N m [35-45 lbf ft] Istallatio 4. Lubricate ew O-rigs with petroleum jelly. Istall the pad adapter to the edcap. 5. Istall the four screws ad torque to N m [35-45 lbf ft]. CAUTION Shippig cover is iteded oly to retai couplig durig shipmet ad storage. Do ot operate pump with couplig ad shippig cover istalled. 5. Istall the drive couplig. 6. Istall shippig cover or auxiliary pump with ew O-rig. 7. Istall two screws (J130) ad torque to N m [27-37 lbf ft]. BLN L0532 April

24 Mior repair CONTROL Disassembly 1. Remove the four screws (C300) holdig the cotrol housig oto the ed cap. 2. Remove the cotrol ad discard the three iterface O-rigs (C200). 3. Remove the PC set screw (C102), PC adjustmet screw (C138), O-rig (C136), sprigs (C135, C134), ad seat (C133). Discard the O-rig. 4. Remove the plug (C103), O-rig (C103A), ad PC spool (C132) from the cotrol housig; discard the O- rig. Note orietatio of the spool for reassembly. Cotrol assembly C138 6mm C136 C133 C135 C134 C102 (2pl.) 4mm 7-11 N m [6-8 lbf ft] C118 6mm C117 C116 C117 C114 C115 C Remove the plug (C107) ad O-rig (C107A); discard the O-rig. C200 C107A Note: For PC oly cotrols, skip steps 6 ad Remove the LS set screw (C102), LS adjustmet screw (C118), O-rig (C116), back-up rigs (C117), sprigs (C114, C115), ad seat (C113); discard the O-rig. 7. Remove the plug (C106), O-rig (C106A), ad LS spool (C112) from the cotrol housig; discard the O-rig. Note orietatio of the spool for reassembly. C300 (4pl.) 5mm N m [11-13 lbf ft] C132 C103A C103 3/16 i N m [8-10 lbf ft] C107 3/16 i N m [8-10 lbf ft] C112 C106A C106 3/16 i N m [8-10 lbf ft] P LS cotrol show; parts C106 ad C112 through C118 are ot used o PC cotrol Ispectio 8. Ispect the adjustmet screws for wear at the tips ad where they cotact the sprigs; replace as ecessary 9. Ispect the sprigs ad sprig guides for wear or damage; replace as ecessary. 10. Carefully ispect the spools. Esure the sealig lads are free of icks ad scratches. Check the eds that cotact the sprig guides for wear. Replace spools as ecessary. 11. Ispect the cotrol housig for damage. Check the spool bores for excessive wear. 12. Clea all parts ad lubricate spools, sprigs, guides ad ew O-rigs with clea hydraulic fluid. 24 BLN L0532 April 2002

25 Mior repair CONTROL (cotiued) Reassembly 13. Istall the PC spool, spherical ed first, ito the PC bore. The PC spool is the shorter of the two. Usig a ew O-rig, istall the plug (C103). Torque to N m [8-10 lbf ft]. 14. Place the two PC sprigs oto the sprig guide ad istall ito the PC bore. Place a ew O-rig oto the PC adjustmet screw ad thread it ito the PC bore util flush, the make aother full tur. Istall ad torque the set screw to 7-11 N m [6-8 lbf ft]. Note: For PC oly cotrols, skip steps 15 ad Istall the LS spool, spherical ed first, ito the LS bore. The LS spool is the loger of the two. Usig a ew O-rig, istall the plug (C106). Torque to N m [8-10 lbf ft]. 16. Place the two LS sprigs oto the sprig guide ad istall ito the LS bore. Place a ew O-rig ad backup rigs oto the LS adjustmet screw ad thread it ito the LS bore util flush, the make aother full tur. Istall ad torque the set screw to 7-11 N m [6-8 lbf ft]. 17. Usig a ew O-rig, istall the plug (C107). Torque to N m [8-10 lbf ft]. Cotrol assembly C138 6mm C136 C118 6mm C117 C116 C117 LS cotrol show; parts C106 ad C112 through 18. Usig petroleum jelly to retai them, C118 are ot used o PC cotrol istall the three iterface O-rigs (C200) i the recesses o the cotrol housig. C133 C135 C134 C102 (2pl.) 4mm 7-11 N m [6-8 lbf ft] C300 (4pl.) 5mm N m [11-13 lbf ft] C132 C103A C103 3/16 i N m [8-10 lbf ft] C113 C114 C115 C200 C107A C107 3/16 i N m [8-10 lbf ft] C112 C106A C106 3/16 i N m [8-10 lbf ft] P Istall the cotrol assembly oto the edcap usig the four screws (C300). Torque to N m [11-13 lbf ft]. Torque screws i a criss-cross patter ad re-torque the first screw to esure proper torque retetio. 20. Check ad adjust the cotrol settig. See Adjustmets, page 20. BLN L0532 April

26 Mior repair PLUG AND FITTING SIZES AND TORQUES If ay plugs or fittigs are removed from the uit durig service, istall ad torque as idicated here. This drawig is a composite. Your cofiguratio may differ but the appropriate wrech size ad torque ca be foud here. Plug locatios, sizes, ad torques J041/J043/J044/J046 M14 9/16 i 6mm 1/4 i N m [20-26 lbf ft] N m [25-50 lbf ft] K045 7/8 i 3/8 i N m [ lbf ft] J080/J081/J082 M18 M14 8mm 6mm N m [30-70 lbf ft] N m [20-26 lbf ft] P J040 (M14) 6mm N m [20-26 lbf ft] K040 7/8 i 3/8 i N m [ lbf ft] 26 BLN L0532 April 2002

27 Mior repair NOTES BLN L0532 April

28 OUR PRODUCTS Hydrostatic trasmissios Hydraulic power steerig Electric power steerig Closed ad ope circuit axial pisto pumps ad motors Gear pumps ad motors Bet axis motors Radial pisto motors Orbital motors Trasit mixer drives Plaetary compact gears Proportioal valves Directioal spool valves Sauer-Dafoss Hydraulic Power Systems Market Leaders Worldwide Sauer-Dafoss is a comprehesive supplier providig complete systems to the global mobile market. Sauer-Dafoss serves markets such as agriculture, costructio, road buildig, material hadlig, muicipal, forestry, turf care, ad may others. We offer our customers optimum solutios for their eeds ad develop ew products ad systems i close cooperatio ad partership with them. Sauer-Dafoss specializes i itegratig a full rage of system compoets to provide vehicle desigers with the most advaced total system desig. Sauer-Dafoss provides comprehesive worldwide service for its products through a extesive etwork of Authorized Service Ceters strategically located i all parts of the world. Cartridge valves Hydraulic itegrated circuits Hydrostatic trasaxles Itegrated systems Fa drive systems Electrohydraulic cotrols Digital electroics ad software Battery powered iverter Sesors Sauer-Dafoss (US) Compay 2800 East 13th Street Ames, IA 50010, USA Phoe: , Fax: Sauer-Dafoss (Neumüster) GmbH & Co. OHG Postfach 2460, D Neumüster Krokamp 35, D Neumüster, Germay Phoe: , Fax: Sauer-Dafoss (Nordborg) A/S DK-6430 Nordborg, Demark Phoe: , Fax: BLN L0532 April