Series 40 Family of Pumps and Motors Series 40 is a family of hydrostatic pumps and motors for "medium power" applications with maximum loads of 345 bar (0 psi). These pumps and motors can be applied together or combined with other products in a system to transfer and control hydraulic power. Series 40 pump + motor transmissions provide an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation. The pumps and motors each come in four frame sizes:,,, and M46. Series 40 pumps are compact, high power density units. All models utilize the parallel axial piston / slipper concept in conjunction with a tiltable swashplate to vary the pump s displacement. Reversing the angle of the swashplate reverses the flow of fluid from the pump and thus reverses the direction of rotation of the motor output. Series 40 -,, and M46 pumps may include an integral charge pump to provide system replenishing and cooling fluid flow, as well as servo control fluid flow on M46 pumps. pumps are designed to receive charge flow from an auxiliary circuit or from a gear pump mounted on the auxiliary mounting pad. Series 40 pumps feature a range of auxiliary mounting pads to accept auxiliary hydraulic pumps for use in complementary hydraulic systems. Series 40 - M46 pumps offer proportional controls with either manual, hydraulic, or electronic actuation. An electric three-position control is also available. The,, and pumps include a trunnion style direct displacement control. Series 40 motors also use the parallel axial piston / slipper design in conjunction with a fixed or tiltable swashplate. There are,,, M46 fixed motor units and,, M46 variable motor units. The and variable motors feature a trunnion style swashplate and direct displacement control. The M46 variable motors utilize a cradle swashplate design and a two-position hydraulic servo control. The M46 variable motor is available in a cartridge flange version, which is designed to be compatible with and CT compact planetary gearboxes. This combination provides a short final drive length for applications with space limitations. 4 Sizes of Variable Pumps 4 Sizes of Tandem Pumps High Performance at Low Cost Efficient Axial Piston Design Complete Family of Control Systems Proven Reliability and Performance Optimum Product Configurations Compact, Lightweight Worldwide Sales and Service Copyright 1988-1998, Sauer-Sundstrand GmbH & Co. All rights reserved. Contents subject to change. All trademarks property of their respective owners. Printed in Germany F002, F002501, F002502
Series 40 Variable Pump Features Auxiliary Pad Trunnion put Shaft Valve Plate Cylinder Roller Bearing Charge Check and High Pressure Relief Valves with Bypass P100 301E Charge Relief Valve Variable Pump () Piston Swashplate P100 304E Charge Check and High Pressure Relief Valves with Bypass Charge Relief Valve Charge Pump Valve Plate Roller Bearing Auxiliary Pad P100 302E Trunnion put Shaft Cylinder Piston Swashplate P100 305E Variable Pump () ( similar) Charge Check/ High Pressure Relief Valve Bypass Valve Charge Relief Valve Control put Shaft Valve Plate Charge Pump Cylinder Cradle Swashplate Auxiliary Pad P100 303E M46 Variable Pump () Piston Roller Bearing P100 306E
System Circuit Description Control handle Heat exchanger bypass Reservoir Filter Cylinder block assembly control valve Heat exchanger Charge relief valve Bypass valve Charge pressure relief valve Fixed Motor Cylinder block assembly Charge pump put shaft Loop flushing module put shaft Variable Pump Check valves with high pressure relief valves Charge pressure Case flow High pressure Servo pressure Suction flow P100 307E A Series 40 - M46 variable pump (left) is shown in a hydraulic circuit with a Series 40 - fixed motor. The pump shown features manual displacement control. A suction filtration configuration is shown. Note the position of the reservoir and heat exchanger. Pump Circuit Schematic control module MDC L2 S M4 M5 A M1 M2 B System Check/Relief Valves L1 filtration adapter M3 (E) P100 308E A Series 40 - M46 variable pump circuit schematic is shown above. The system ports "A" and "B" connect to the high pressure work lines. The pump receives return fluid in its inlet port and discharges pressurized fluid through the outlet port. Flow direction is determined by swashplate position. System port pressure can be gauged through ports M1 and M2. The pump has two case drains (L1 and L2). This pump includes a manual displacement control. 5
Technical Specifications Specifications for Series 40 pumps are listed on these two pages. For definitions of the various specifications, see the related pages in this publication. Not all hardware options General Specifications are available for all configurations; consult the Series 40 Pump Model Code Supplement or Price Book for more information. Product Line Pump Type Direction of put Rotation stallation Position Filtration Configuration Other System Requirements Hardware Specifications Series 40 Pumps -line, axial piston, variable, positive displacement pumps Clockwise () or counterclockwise () availabl e Discretionary, the housing must be filled with hydraulic fluid. Suction or charge pressure filtration dependent braking system, suitable reservoir and heat exchange r T002 150E Model Pump Configuration cm3/rev (in3/rev) 24.6 (1.50) Single Variable Pump 35.0 (2.14) 43.5 (2.65) M46 46.0 (2.81) 24.6 x 2 (1.50 x 2) Tandem Variable Pump 35.0 x 2 (2.14 x 2) 43.5 x 2 (2.65 x 2) M46 46.0 x 2 (2.81 x 2) W eight kg (lb) 19 (41.5) 25 (55) 25 (55) 33 (73) 25 (56) 45 (99) 45 (99) 59 (131) Moment of ertia of the internal rotating parts kgm2 (lbft2) Type of Mounting (SAE flange size per SAE J744) Connections 0.0018 (0.043) 0.0031 (0.072) 0.0030 (0.071) 0.0050 (0.120) 0.0037 (0.088) 0.0061 (0.145) 0.0060 (0.140) 0.0100 (0.240) S AE "B" S AE "B" S AE "B" S AE "B" S AE "B" S AE "B" S AE "B" SAE "B" Twi n Twi n Twi n tegral Charge Pump (std) 11.8 11.8 13.9 16.4 16.4 22.9 cm 3 3 - - / rev (in /rev) (0.72) (0.72) (0.85) (1.00) (1.00) (1.40) Charge Relief Valve Setting (std) bar (psi) 14.0 (200) 14.0 (200) 14.0 (200) 19.5 (285) 14.0 (200) 14.0 (200) 14.0 (200) 19.5 (285) System Pressure Regulation Available Settings: bar (psi) 140-345 (2030-0) Limiters - - - Option - - - Option put Shaft Options Splined, Tapered, or Straight Key Auxiliary Mounting Pad SAE "A" SAE "A" SAE "A" SAE "A" SAE "A" SAE "A" SAE "A" SAE "A" (SAE Pad per SAE J744) SAE "B" SAE "B" SAE "B" SAE "B" SAE "B" SAE "B" Control Options Filtration Configuration - = not availabl e DDC DDC DDC Twi n MDC, HDC, EDC, FNR Twi n DDC Twi n DDC Twi n DDC Suction Filtration or Remote Charge Pressure Filtration Twi n MDC, HDC, EDC, FNR T002 151E
System Parameters Speed Limits min -1 M46 M46 Minimum speed Rated speed at maximum displacement Maximum speed at maximum displacement 4000 3600 3300 4000 4000 3600 3300 4000 0 4 4100 4100 0 4 4100 4100 T002 152E Case Pressure MPa bar psi Continuous pressure 0.17 1. 7 25 Maximum pressure 0.52 5. 2 75 T002 053E System Pressure Range MPa bar psi Rated pressure 21 210 3 000 Maximum pressure 34. 5 345 5 000 T002 055E T heoretical Flow l/min (US gal/min) M46 M46 At rated speed 100 (26.0) 126 (33.4) 145 (37.9) 166 (43.6) 100 (26.0) 126 (33.4) 145 (37.9) 166 43.6) T002 153E let Vacuum bar in Hg Rated pressure 0. 8 5 Minimum pressure (cold start) 0. 7 10 T002 154E Fluid and Filtration Specifications Temperature Range C F termittent (cold start) -40-40 Continuous 82 180 termittent 104 220 T002 056E Viscosity mm 2 / s [SUS] Minimum 7 [ 49] intermittent Recommended operating range 12-60 [70-278] Maximum 1 600 [7 ] intermittent, cold start T002 010E Cleanliness Level and β x -Ratio Required fluid cleanliness level Recommended β x -ratio for suction filtration Recommended β x -ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration ISO 4406 Class 18/13 β 35-45 75 ( = β 10 2) β 15-20 75 ( = β 10 10) 100 µ m -125 µm T002 007E 7
Model Code The model code is a modular description of a specific product and its options. To create an order code to include the specific options desired, see the Series 40 Pump Model Code Supplement or the Series 40 Price Book. Series 40 Variable Pump Series 40 Tandem Pump Name Plate Name Plate Model Number Serial Number Ames, Iowa, U.S.A. Model Code Model No. Neumünster, Germany Typ M025C B A A R A R NN A A BLL DR A FF A CNN Ident Nr. -2001 123456 A 96 26 12345 Serial No. Fabrik-Nr. MADE IN GERMANY Model Code Ident Number Model Number Serial Number Ames, Iowa, U.S.A. Model Code Model No. Neumünster, Germany Typ M025C S R A E NN B A A A BDD DL A FF B C A A BDD DR A FF A CXN Ident Nr. M91-25111 123456 A 96 26 67890 Serial No. Fabrik-Nr. MADE IN GERMANY Model Code Ident Number Place of Manufacture Place of Manufacture Model Code Modules Model Code Modules C D E F M P V 0 2 5 C B A A R Product Type G H J K L M A R N N A A B L L N P R S T D R A F F A C N N C: Swashplate D: Seal Group E: Shaft F: Rotation G: Charge Pump H: Charge Pressure Relief Valve Setting J: Filtration K: L: Bypass Valve M: System Pressure Protection N: Control P: Control Handle Position R: Control Orifice S: Auxiliary Mounting Flange T: Special Hardware E F G H J M P T 0 2 5 C S R A E N N Product S C T C X N Type Front Pump C D K L M N P R B A A A B D D D L A F F Rear Pump Q D U X V Y Z W B C A A B D D D R A F F E: put Shaft F: Rotation G: Charge Pump H: Charge Pressure Relief Valve Setting J: Filtration C & Q: Swashplate D: Seal Group K & U: L & X: Bypass Valve M & V: System Pressure Protection N & Y: Control P & Z: Control Handle Position R & W: Control Orifice S: Auxiliary Mounting Flange T: Special Hardware
Hydraulic Equations for Pump Selection The pump required for a specific application can be calculated using the equations below. Metric-System: Vg n η v Pump Q e = l/min output flow 1000 Vg p put M e = Nm torque 20 π η t M e n Q e p put P e = = kw power 9550 600 η t ch-system: PD PS EV p Pump Q p = gpm output flow 231 PD p put = in lbf torque 2 π ET p PD PS p put HP = hp power 396 000 ET p System Requirements Description: Metric-System: Vg = Pump displacement per rev. cm 3 n = Hydrostatic pump speed rpm p = phd - pnd (different'l pressure) bar η v η t = Pump volumetric efficiency = Pump mechanical - hydraulic (Torque) efficiency ch-system: PD = Pump displacement per rev. in 3 PS = Hydrostatic pump speed rpm p = Differential hydraulic pressure psi EV p ET p = Pump volumetric efficiency = Pump mechanical - hydraulic (Torque) efficiency WARNING The loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration, or neutral mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop. S000 001E Reservoir The reservoir should be designed to accommodate maximum volume changes during all system operating modes and to promote de-aeration of the fluid as it passes through the tank. The reservoir should be designed to accommodate a fluid dwell time of between 30 and 90 seconds to allow entrained air in the fluid to escape. The fluid volume in the reservoir would be 50% of the maximum charge pump flow per minute at 30 seconds dwell and 150% of maximum charge flow at 90 seconds dwell. The reservoir capacity is recommended to be 125% of the fluid volume to accommodate fluid expansion with temperature. The reservoir outlet to the charge pump inlet should be above the bottom of the reservoir to take advantage of gravity separation and prevent large foreign particles from entering the charge inlet line. A 100-125 mm screen covering the outlet port is recommended. The reservoir inlet (fluid return) should be positioned so that flow to the reservoir is discharged below the normal fluid level, and also directed into the interior of the reservoir for maximum dwell and efficient de-aeration. A baffle (or baffles) between the reservoir inlet and outlet ports will promote de-aeration and reduce surging of the fluid. Loop Flushing Circuit Excess heating and/or contamination in the circuit is a concern. A loop flushing valve can be added to draw additional fluid into the cooling and filtration elements of the circuit. As a loop flushing circuit leads to an overall cleaner system, it is recommended for most applications. Series 40 motors offer a loop flushing option that provides this function. Various flow and relief settings can be provided to suit a particular system. See the Series 40 Motors Technical formation for more information. Case Drain Usage for Tandem Pumps On tandem pumps, excess flow from the charge relief valve is routed into the housing of the front pump section. order to ensure adequate case flushing, it is recommended that the rear housing drain ports be used as the case drain. 9
Case Pressure Under normal operating conditions, case pressure must not exceed the continuous case pressure rating. Momentary case pressures exceeding this rating are acceptable under cold start conditions, but still must stay below the maximum case pressure rating. Operation with case pressure in excess of these limits may result in external leakage due to damage to seals, gaskets, and/or housings. Case Pressure MPa bar psi Continuous pressure 0.17 1. 7 25 Maximum pressure 0.52 5. 2 75 T002 053E Speed Limits Rated speed is the speed limit recommended at full power condition and is the highest value at which normal life can be expected. Maximum speed is the highest operating speed permitted and cannot be exceeded without reduction in the life of the product or risking immediate failure and loss of drive line power (which may create a safety hazard). Mobile applications must have an applied speed below the stated maximum speed. Consult Bulletin BLN-9884 ( Pressure and Speed Limits ) when determining speed limits for a particular application. WARNING The loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration, or neutral mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop. S000 001E Speed Limits min -1 M46 M46 Minimum speed Rated speed at maximum displacement Maximum speed at maximum displacement 4000 3600 3300 4000 4000 3600 3300 4000 0 4 4100 4100 0 4 4100 4100 T002 152E System Pressure System pressure is the differential pressure between system ports referenced to case pressure. It is a dominant operating variable affecting hydraulic unit life. High pressure, which results from high load, reduces expected life in a manner similar to many mechanical assemblies such as engines and gear boxes. There are load-to-life relationships for the rotating group and for the shaft bearings. Refer to these sections for more information. Continuous pressure is the average, regularly occurring operating pressure that should yield satisfactory product life. Maximum pressure is the highest intermittent pressure allowed, and is the relief valve setting. It is determined by the maximum machine load demand. For most systems, the load should move at this pressure. Maximum pressure is assumed to occur a small percentage of operating time, usually less than 2% of the total. Both the continuous and maximum pressure limits must be satisfied to achieve the expected life. All pressure limits are differential pressures (referenced to charge pressure) and assume normal charge pressure and no externally applied shaft loads. System Pressure Range MPa bar psi Rated pressure 21 210 3 000 Maximum pressure 34. 5 345 5 000 T002 055E
let Vacuum Charge pump inlet conditions must be controlled in order to achieve expected life and performance. A continuous inlet vacuum of not less than 0.8 abs bar (not more than 5 in Hg vac) is recommended. Normal vacuums less than the maximum inlet vacuum of 0.7 abs bar (greater than 10 in Hg vac) would indicate inadequate inlet design or a restricted filter. Vacuums less than 0.7 abs bar (greater than 10 in Hg vac) during cold start should be expected, but should improve quickly as the fluid warms. let Vacuum bar in Hg Rated pressure 0. 8 5 Minimum pressure (cold start) 0. 7 10 T002 154E Theoretical put The theoretical maximum flow at rated speed is a simple function of pump displacement and speed. This is a good gauge for sizing a companion motor. This does not take into account losses due to leakage or variations in displacement. T heoretical Flow l/min (US gal/min) M46 M46 At rated speed 100 (26.0) 126 (33.4) 145 (37.9) 166 (43.6) 100 (26.0) 126 (33.4) 145 (37.9) 166 43.6) T002 153E Fluid Specifications Hydraulic Fluid Ratings and data are based on operating with hydraulic fluids containing oxidation,rust and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion and corrosion of the internal components. Fire resistant fluids are also suitable at modified operating conditions. Please see SAUER-SUNDSTRAND publication 697581 or BLN-9887 for more information. Rever to publication ATI-9101D for information relating to biodegradable fluids. Suitable Hydraulic fluids: Hydraulic fluids per DIN 51 524, part 2 (HLP) Hydraulic fluids per DIN 51 524, part 3 (HVLP) API CD, CE and CF engine fluids per SAE J183 M2C33F or G automatic transmission fluids (ATF) Dexron II (ATF), which meets the Allison C3- and Caterpillar TO-2 test Agricultural multi purpose oil (STOU) Premium turbine oils It is not permissible to mix hydraulic fluids. For more information contact your SAUER-SUNDSTRAND representative. 11
Temperature and Viscosity Temperature and viscosity requirements must be concurrently satisfied. The data shown at right assumes petroleum-based fluids. The high temperature limits apply at the hottest point in the transmission, which is normally the case drain. The pump should generally be run at or below the continuous temperature. The maximum temperature is based on material properties and should never be exceeded. Cold oil will generally not affect the durability of the transmission components, but it may affect the ability to flow oil and transmit power; therefore temperatures should remain 16 C (30 F) above the pour point of the hydraulic fluid. The minimum temperature relates to the physical properties of component materials. For maximum unit efficiency and bearing life the fluid viscosity should remain in the continuous viscosity range. The minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation. The maximum viscosity should be encountered only at cold start. Heat exchangers should be sized to keep the fluid within these limits. Testing to verify that these temperature limits are not exceeded is recommended. Viscosity mm 2 / s [SUS] Minimum 7 [ 49] intermittent Recommended operating range Temperature Range C F termittent (cold start) -40-40 Continuous 82 180 termittent 104 220 12-60 [70-278] Maximum 1 600 [7 ] T002 056E intermittent, cold start T002 010E Fluid Cleanliness and Filtration To prevent premature wear, it is imperative that only clean fluid enter the hydrostatic transmission circuit. A filter capable of controlling the fluid cleanliness to ISO 4406 Class 18/13 (SAE J1165) or better under normal operating conditions is recommended. The filter may be located either on the inlet (suction filtration) or discharge (charge pressure filtration) side of the charge pump. Series 40 pumps are available with provisions for either suction or charge pressure filtration to filter the fluid entering the charge circuit (see below). The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. Filters are selected to meet the above requirements using rating parameters of efficiency and capacity. Filter efficiency may be measured with a Beta ratio 1 (β x ). For simple closed circuit transmissions with controlled reservoir ingression, a filter with β 35-45 = 75 (and β 10 = 2) or better has been found to be satisfactory. For some open circuit systems, and closed circuits with cylinders being supplied from the same reservoir, a considerably higher filter efficiency is recommended. This also applies to systems with gears or clutches using a common reservoir. For these systems, a filter within the range of β 15-20 = 75 (and β 10 = 10) or better are typically required. Since each system is unique, the filtration requirement for that system will be unique and must be determined by test in each case. It is essential that monitoring of prototypes and evaluation of components and performance throughout the test program be the final criteria for judging the adequacy of the filtration system. See publication BLN- 9887 or 697581 and ATI-E 9201 for more information. (1) Filter ß x -ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given diameter ("x" in microns) upstream of the filter to the number of these particles downstream of the filter. Cleanliness Level and β x -Ratio Required fluid ISO 4406 Class 18/13 cleanliness level Recommended β x -ratio β for suction filtration 35-45 = 75 ( β 10 2) Recommended β x -ratio for charge pressure β 15-20 = 75 ( β 10 10) filtration Recommended inlet screen size for charge 100 µ m -125 µm pressure filtration T002 007E
Suction Filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump as shown in the accompanying illustration. Filter To Low Pressure Side of Loop and Servo Control Strainer Reservoir Charge Relief Valve To Pump Case Charge Pump Suction Filtration P001 603E Charge Pressure Filtration Provision for charge pressure filtration is available on all Series 40 pumps. The pressure filter is remotely mounted and is situated in the circuit after the charge pump, as shown in the accompanying illustration. Reservoir Strainer Filters used in charge pressure filtration circuits must be rated to at least 34.5 bar ( psi) pressure. A 100-125 µm screen located in the reservoir or in the charge inlet line is recommended when using charge pressure filtration. A filter bypass valve is necessary to prevent filter damage and to avoid contaminants from being forced through the filter media by high pressure differentials across the filter. the event of high pressure drop associated with a blocked filter or cold start-up conditions, fluid will bypass the filter. Working with an open bypass for an extended period should be avoided. A visual or electrical dirt indicator is recommended. Proper filter maintenance is mandatory. To Low Pressure Side of Loop and Servo Control Charge Relief Valve To Pump Case Charge Pressure Filtration Filter with Bypass Charge Pump P001 605E 13
System features and conditions that may invalidate the 10% of displacement rule include (but are not limited to): operation at low input speeds (below 1 RPM) shock loadings excessively long system lines auxiliary flow requirements use of high torque low speed motors If a charge pump of sufficient displacement to meet the 10% of displacement rule is not available or if any of the above conditions exist which could invalidate the 10% rule, contact Sauer-Sundstrand Applications Engineering. pumps do not allow for integral charge pumps. Other Series 40 pumps are also available without charge pumps. When an integral charge pump is not used, an external charge supply is required to ensure adequate charge pressure and cooling. Charge Pump put Flow (Flow at standard charge relief setting, 70 C (160 F) inlet) l/min gpm 90 24 75 60 45 30 15 0 20 16 12 8 4 0 M46 M46 0 1000 2000 3000 4000 Speed (rpm) Charge Pump Power Requirements (Power at standard charge relief setting, 70 C (160 F) inlet) P002 562E kw 4 3 2 1 0 hp 6 5 4 3 2 1 M46 M46 0 0 1000 2000 3000 4000 Speed (rev/min) P002 527E 15
Charge Relief Valve An integral charge pressure relief valve provides a relief outlet for charge pressure. This valve, in effect, sets charge pressure. Flow through the valve is ported to case. The charge relief valve for the,, and / is a flat poppet style valve. For the M46 / it is a cone poppet style valve. The nominal charge relief setting is referenced to case pressure. It is factory set at 1800 rev/min with the pump in neutral position. A proper charge relief setting will take into account input speeds and control requirements. Charge Relief Valve Specs M46 Cone Poppet Type Flat Poppet Valve Valve Available 19.5-26.2 bar 7.5-14 bar (110-200 psi) Settings (285-380 psi) A djustment Via Shims side of Valve Cartridge* T002 160E *Shimming offers adjustment over a limited range, a spring change may be required to make a larger adjustment. The charge pressure setting for pumps without an internal charge pump is set with an externally supplied charge flow of 19 l/min (5 gpm). These units must have adequate charge flow supplied to the charge inlet in order to maintain charge pressure at all times. NOTE: correct charge pressure settings may result in the inability to build required system pressure and/or inadequate loop flushing flows. Correct charge pressure must be maintained under all conditions of operation to maintain pump control performance. The charge relief valve is factory set. If necessary, it can be field adjusted with shims. & M46 Charge Relief Valve Location P100 312
Check / High Pressure Relief Valves Circuit pressure is maintained in the proper range by the combination charge check and high pressure relief valves. The check valves allow charge flow to replenish the low pressure side of the working loop. The high pressure relief valves provide pressure protection to the high pressure side of the working loop. There are two cartridge style valves to handle each side of the working loop with flow in either direction. Check / High Pressure Relief Valves Specs Type Cartridge-style poppet valve S ettings 140-345 bar (2030-0 psi) Option Check only - no relief valve T002 161E High pressure relief valves are available in a range of settings. dividual port pressure settings may be specified. Pumps may be equipped with charge circuit check valves only, if high pressure relief valves are not desired. NOTE: High pressure relief valves are intended for transient overpressure protection and are not intended for continuous pressure control. Operation over relief valves for extended periods of time may result in severe heat build up. High flows over relief valves may result in pressure levels exceeding the nominal valve setting and potential damage to system components. Bypass Valves some applications it is desirable to bypass fluid around the variable displacement pump allowing, for example, a vehicle to be moved short distances at low speeds without running the prime mover. This is accomplished by a manually operated bypass valve. When open, this valve connects both sides of the pump/motor circuit and allows the motor to turn. This valve must be fully closed for normal operation. Bypass Valve &,, & : Bypass valves on the,, and and are integral with the check relief valve assemblies. Both assemblies must be opened for bypass operation. Valves are fully open at 4 revolutions. Do not open valves past 4 turns. Plug torque is 41 to 95 Nm (30 to 70 ft lbf). M46: The bypass valve(s) on the M46 or is fully open at 2 revolutions of the valve stem. Do not open valve past 2 turns. Valve closing torque is 9.5 to 14 Nm (7 to 10 ft lbf). Damage to units may result from overtorquing the bypass valve. NOTE: Operate bypass valve only at low speeds for short periods. The motor speed should not surpass 400 rev/min. As a rule of thumb, vehicle applications should be "towed" at less than 10% of typical operating speed. Type Max Motor "Tow" Speed Full Open At M46 Check / High Pressure Relief / Bypass Valves Location Bypass Valve Specs M46 corporated in 2 Check/Relief Valves 400 rev/min Dedicated Needle Valve 4 turns 2 turns P100 313E T002 162E 17
Shaft Options Series 40 pumps are available with a variety of splined, straight keyed, and tapered shaft ends. Nominal shaft sizes and torque ratings are shown in the accompanying table. Torque ratings assume no external radial loading. Continuous (Cont) torque ratings for splined shafts are based on spline tooth wear, and assume the mating spline has a minimum hardness of R c 55 and full spline depth with good lubrication. Maximum torque ratings are based on shaft torsional strength and assume a maximum of 200,000 load reversals. Shaft Options and T orque Ratings Nm (in lbf) Spline 13 tooth, 16/32 pitch Spline 15 tooth, 16/32 pitch Spline 19 tooth, 16/32 pitch Tapered 1 in (25.4 mm) Dia 1/8 (1.5 in/ft) taper Straight Keyed 22.2 mm (0.875 in) Dia Straight Keyed 25.4 mm (1 in) Dia Shaft Availability and Torque Ratings M46 M46 Cont 85 ( 750) 85 ( 750) 124 ( 1100) - 124 ( 1100) - Max 140 ( 1240) 140 ( 1240) 226 ( 2000) - 226 ( 2000) - Cont - - 153 ( 1350) 153 ( 1350) 153 ( 1350) 153 (1350) Max - - 362 ( 3200) 362 ( 3200) 362 ( 3200) 362 (3200) Cont - - - - - 305 (2700) Max - - - - - 734 (6) Max 140 ( 1240) 140 ( 1240) 497 ( 4400) 497 ( 4400) 497 ( 4400) 497 (4400) Max 140 ( 1240) 140 ( 1240) 226 ( 2000) 226 ( 2000) - - Max - - - - 362 ( 3200) 362 (3200) T002 029E NOTE: Recommended mating splines for Series 40 splined output shafts should be in accordance with ANSI B92.1 Class 5. Sauer- Sundstrand external splines are modified Class 5 Fillet Root Side Fit. The external spline Major Diameter and Circular Tooth Thickness dimensions are reduced in order to assure a clearance fit with the mating spline. NOTE: Other shaft options may exist. Contact Sauer- Sundstrand representative for availability. 19
Auxiliary Mounting Pads and Auxiliary Pumps Auxiliary mounting pads are available on all Series 40 pumps. These pads are used for mounting auxiliary hydraulic pumps. A sealed (oil tight) shipping cover is included as standard equipment on all mounting pads. Since the auxiliary mounting pad operates under case pressure, an O-ring must be used to seal the auxiliary pump mounting flange to the pad. The drive coupling is lubricated with oil from the main pump case. Spline specifications and torque ratings are shown in the accompanying table. All auxiliary mounting pads meet SAE J744 specifications. The combination of auxiliary mounting pad shaft torque, plus the main pump torque should not exceed the maximum pump input shaft rating shown in the Shaft Availability and Torque Ratings table on the previous page. All torque values assume a 58 R c shaft spline hardness on mating pump shaft. Continuous (Cont) torque ratings for splines are based on spline tooth wear. Maximum torque is based on maximum torsional strength and 200,000 load reversals. Applications subject to severe vibratory or high G loading may require an additional structural support. This is necessary to prevent leaks and possible mounting flange damage. Refer to the "Mounting Flange Loads" section for additional information. Auxiliary Pump Mounting Dimensions Pad Size SAE A SAE A Special SAE B Spline 9 teeth 16/32 pitch 11 teeth 16/32 pitch 13 teeth 16/32 pitch Min Spline Engagement mm (in) 13,5 (.53) 13,5 (.53) 14,2 (.56) Rated Torque Nm in lbf 51 (450) 90 (800) 124 (1100) Max Torque Nm in lbf 107 (950) 147 (1300) 248 (2200) Available for M46 - T002 164E = Option; - = not availabl e Mating Auxiliary Pumps Dimensions The accompanying drawing provides the dimensions for the auxiliary pump mounting flange and shaft. Pump mounting flanges and shafts with the dimensions noted below are compatible with the auyiliary mounting pads on this pumps Mounting Flange E max. D max. F min. Spline Engagement for Torque Auxiliary Mounting Pad Dimensions Pad Size ø P B C D E F SAE A SAE B max. mm (in) 82.55 (3.25) 101.6 (4.00) max. mm (in) 6.35 (.25) 9.65 (.38) max. mm (in) 12.7 (.50) 15.2 (.60) max. mm (in) 58.2 (2.299 53.1 (2.09) max. mm (in) 15.0 (.59) 17.5 (.69) min. mm (in) 13.5 (.53) 14.2 (.56) T002 198E With Undercut Without Undercut B max. C max. 2.3 (.09) Cutter clearance Coupling R 0.8 (.03) max. 0 ø P -0.05 (+.000) (-.002) P001 614E
Hydraulic Unit Life Hydraulic unit life is defined as the life expectancy of the hydraulic components. Hydraulic unit life is a function of speed and system pressure; however, system pressure is the dominant operating variable affecting hydraulic unit life. High pressure, which results from high load, reduces expected life in a manner similar to many mechanical assemblies such as engines and gear boxes. It is desirable to have a projected machine duty cycle with percentages of time at various loads and speeds. An appropriate design pressure can be calculated by Sauer- Sundstrand from this information. This method of selecting operating pressure is recommended whenever duty cycle information is available. the absence of duty cycle data, an estimated design pressure can usually be established based on normal input power and maximum pump displacement. All pressure limits are differential pressures (referenced to charge pressure) and assume normal charge pressure. Series 40 pumps will meet satisfactory life expectancy if applied within the parameters specified in this bulletin (Refer to sections Technical Specifications and System Requirements). For more detailed information on hydraulic unit life see BLN-9884, "Pressure and Speed Limits". Efficiency Graphs The following performance graph provides typical volumetric and overall efficiencies for Series 40 pumps. These efficiencies apply for all Series 40 pumps. The performance map provides typical pump overall efficiencies at various operating parameters. These efficiencies also apply for all Series 40 pumps. Efficiency % 100 95 90 85 Pump Performance as a Function of Operating Speed Volumetric Efficiency 170 bar (2 psi) Volumetric Efficiency 345 bar (0 psi) Overall Efficiency 170 bar (2 psi) Overall Efficiency 345 bar (0 psi) System Pressure bar 345 270 210 140 70 Pump Performance at Select Operating Parameters psi 0 4000 3000 2000 1000 80% 85% 87% 88% 88% 87% 85% 80% 80 0 25 50 75 100 Speed % of Rated Speed P002 539E 0 0 0 25 50 75 100 Speed % of Rated Speed P002 540E 23
Control Options The Series 40-, and pumps are controlled by a Direct Control (DDC) system. The M46 pumps have a servo control system with a choice of three proportional controls that provide smooth, stepless, and positive control of the transmission in either direction: Manual Control (MDC), Hydraulic Control (HDC), Electrical Control (EDC) or Three-Position Electric Control (FNR). Typical control applications,, M46 Machine Function Direct Control Manual Control Hydraulic Control Electric Control Three-position Control DDC MDC HDC EDC FNR Roller Compactor Asphalt paver Skid steer loader Articulated loader Utility tractor Windrower Trencher Ag sprayer Specialized harvesters (Sod, fruit, nut, etc.) Comercial mower Rock drill Machine tool Drill rig Sweeper Vibratory drive Conveyor drive Chain drive Auxiliary drive Spindle drive Drill drive Pull down Areal lift = suitable configuratio n T002 167E
Direct Control (DDC) The Direct Control can be located on either side of a Series 40 -,, or pump. It provides a simple, positive method of control. Movement of the control shaft causes a proportional swashplate movement, thus varying the pump s displacement from full displacement in one direction to full displacement in the opposite direction. 15 for 16 for 16 for Some applications (generally vehicle propel) will require a provision for non-linear control input to reduce control sensitivity near neutral. Damping or frictional forces may be necessary to produce desirable control feel. Neutral position is not factory set, nor is there any internal neutral return mechanism. The application must include provisions for all control linkage and neutral return fuctionality. DDC on Left Side of Pump 100% P100 320E WARNING With no external forces applied to the swashplate trunnion, internal hydraulic forces may not return the swashplate to the neutral position under all conditions of operation. The DDC is available on variable pumps and tandem pumps (and variable motors). Trunnion Rotation Pump Pump Trunnion Rotation External Control Handle Requirements Maximum allowable trunnion torque is 79.1 Nm (700 in lbf) for,, and. Minimum torque necessary to hold the swashplate at a zero angle for neutral is 2.3 Nm (20 in lbf). Maximum trunnion angle is 15 for and 16 for and. 100% Pump vs Swashplate Rotation DDC put Specs Max Torque Nm (in lbf) 79. 1 (700) Min Torque to Hold Nm (in lbf) 2.3 (20) P002528E M ax Angle M 25: 15 /44: 16 T002 168E put Shaft Rotation Trunnion Trunnion or Front Rear Location Rotation A Flow B Flow C (A) Flow D (B) Flow Pump Flow Direction Right Left Right Refer to pump installation drawings for port locations and control rotation. Left T002 170E 25
Manual Control (MDC) Dimensions on p. 47 The Manual Control converts a mechanical input signal to a hydraulic signal with a spring centered 4- way servo valve, and ports hydraulic pressure to either side of a double acting servo piston. The MDC provides output flow to the servo piston in proportion to the angular position of the control handle. The servo piston tilts the cradle swashplate, thus varying the pump s displacement from full displacement in one direction to full displacement in the opposite direction. Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by the feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position. 20 20 P100 321 P100 321 ("Handle Up" option shown) Features / Benefits The MDC is a high gain control; with only a small movement of the control handle (input signal) the control valve moves to a full open position porting maximum flow to the servo cylinder. This is a high response control system with low input forces. The integral override mechanism allows rapid changes in input signal without damaging the control mechanism. Mechanical feedback senses swashplate reactions to load. Precision parts provide repeatable, accurate displacement settings with a given input signal. Both ends of the double-acting servo piston are drained to case when a mechanical input signal is not present. The servo piston is coupled to a spring centering mechanism. A B MDC on M46 MDC with NSS on M46 control module MDC M4 M5 P100 322 P100 322 These features result in: S MDC Hydraulic Schematic P100 323E Simple-low cost design. Pump output is maintained regardless of load. Pump will return to neutral after prime mover shuts down. Pump returns to neutral if external control linkage becomes disconnected from the control handle or if there is a loss of charge pressure. Response Time The time required for the pump output flow to change from neutral to full flow (acceleration) or full flow to neutral (deceleration) is a function of the size of the supply orifice in the control inlet passage and the size of the drain orifice in the control sleeve. or Front Rear Pump Flow Direction with MDC Control Handle Rotation A Flow B Flow Handle Rotation C Flow D Flow put Shaft Rotation High Servo Gauge M4 M5 M4 M5 T002 171E Refer to pump installation drawings for port locations.
A range of orifice sizes is available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. The table at right shows some sample response times under certain conditions. (These figures assume 1775 rev/min, 140 bar (2000 psi) system pressure, and 19 bar (275 psi) charge pressure.) Testing should be carried out to determine the proper orifice sizes for the desired response. External Control Handle Requirements Rotation of the control handle to reach full pump displacement is 20. Maximum handle rotation is 25. There is a neutral deadband of ±1.5 (±3.0 with NSS option). A nominal control handle torque of 1.2 Nm (11 in lbf) is required to begin handle rotation (1 ) and 1.7 Nm (15 in lbf) is required to reach full stroke (20 handle rotation). An optional high rate return spring is available which requires 2.5 Nm (22 in lbf) and 3.4 Nm (30 in lbs) to reach 1 and 20 respectively. The maximum allowable handle input torque is 17 Nm (150 in lbf). Handle Direction The MDC handle can be configured in either the "up" or "down" positions. The "up" position is shown on the previous page. The"down" position is oriented 180 of the "up" position. Neutral Start Switch (NSS) This safety feature is an option to prevent start-up when the pump is not in neutral. It provides an electrical switch contact which is closed when the control handle is in its neutral (0 ) position. The switch contact will open when the control handle is rotated 1.5 to 2 clockwise () or counterclockwise () from neutral. The switch is rated at 5 amperes inductive load at 12 or 24 VDC. The NSS should be wired in series with the engine starting circuit and is intended to verify the neutral position of the pump before allowing the engine to be started. This switch is available with screw terminals (no connector) or with a Packard Weather-Pack 2-way sealed connector. Orifice Diameter* mm (in) Supply MDC Response Time Drain Average Response Time (seconds) Acceleratio n Deceleratio n 0.9 ( 0.036) 0. 8 ( 0.031) 2. 5 1. 9 0.9 ( 0.036) 1. 2 ( 0.046) 2. 0 1. 4 1.4 ( 0.054) 1. 2 ( 0.046) 1. 2 0. 9 None 6. 4 ( 0.250) 0. 5 0. 4 * Contact Sauer Sundstrand for special orifice combinations MDC put Specs Min Torque for Full Stroke Nm (in lbf) Max Torque on Handle Nm (in lbf) Std T002 173E MDC Signal Required for Swashplate Position Handle Configuration Handle Rotation 100% Pump b a 25 Maximum 25 Maximum Swashplate Position (ref above chart) Swashplate Movement Begins (point "a") degrees Full Reached (point "b") degrees S tandard 1.5 20 W ith NSS 3.0 20 a b Pump 100% Handle Rotation Option 1.7 (15) 3.4 (30) 17 (150) P002 529E Pump vs Control Lever Rotation T002 172-1E T002 172-2E Switch Position in Neutral NSS Specs Closed N eutral Play ± 1.5 ~ 2 VDC 12 or 24 Rated Current (A) 5 Connector Type Screw or Weather-Pac k T002 174E 27
Hydraulic Control (HDC) Dimensions on p. 48 The Hydraulic Control uses a hydraulic input signal to operate a spring centered 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump s displacement from full displacement in one direction to full displacement in the opposite direction. The HDC provides output flow in proportion to a hydraulic command signal. This allows for remote control of the machine with a hydraulic pressure source rather than with mechanical linkage. With no command signal, the control is in or will return to neutral position. Features / Benefits The hydraulic displacement control is a high gain control; with only a small change in the input signal pressure level, the servo valve moves to a full open position, porting maximum flow to the servo cylinder. ternal mechanical stops on the servo valve allow rapid changes in input signal pressure without damaging the control mechanism. Precision parts provide repeatable, accurate displacement settings with a given input signal. Both ends of the double-acting servo piston are drained to case when input signal pressure is not present. The servo piston is coupled to a spring centering mechanism. These features result in: Simple, low-cost design. Pump will return to neutral after prime mover shuts down. Pump will return to neutral if external hydraulic input signal fails or if there is a loss of charge pressure. A B or Front Rear X1 Pump Flow Direction with HDC Control Higher Pressure into Control : A Flow B Flow Higher Pressure into Control : control module M4 C Flow D Flow HDC on M46 X2 M5 put Shaft Rotation X1 X2 X1 X2 X1 X2 X1 X2 High Servo Gauge M4 M5 M4 M5 Refer to pump installation drawings for port locations HDC HDC Hydraulic Schematic S X2 X1 P100 324E P100 325E T002 175E
Response Time The time required for the pump output flow to change from neutral to full flow (acceleration) or full flow to neutral (deceleration) is a function of the size of the orifices in the servo passages. A range of orifice sizes is available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. The table at right shows some sample response times under certain conditions. (These figures assume 1775 rev/min, 140 bar (2000 psi) system pressure, and 19 bar (275 psi) charge pressure.) Testing should be carried out to determine the proper orifice selection for the desired response. Orifice Diameter* mm (in) HDC Response Time Average Response Time (seconds) Acceleration Deceleratio n 0.9 ( 0.037) 1. 6 1. 3 1.4 ( 0.055) 0. 9 0. 7 None 0. 4 0. 3 * Contact Sauer-Sundstrand for special orifice combinations T002 176E Control put Signal Requirements The standard command signal range required to stroke the pump between neutral and full stroke is 1.3 to 11.7 bar (19 to 170 psi) differential. The maximum command pressure must not exceed 27.5 bar (400 psi). HDC Options The HDC can be tailored to respond to a higher signal pressure. Optional heavy spring packs are available that operate in the 3 to 14 bar (44 to 200 psi) range and the 5 to 15 bar (70 to 220 psi) range. See signal table at right. -a Signal Pressure Pump 100% -b a b Pump 100% Signal Pressure P002530E Pump vs Hydraulic Signal HDC Signal Required for Swashplate Position Configuration Swashplate Position (ref above chart) Swashplate Movement Begins (point "a") bar (psid) Full Reached (point "b") bar (psid) S tandard 1.3±0.5 (19±7) 11.7±1.1 (170±16) O ption 3.0±0.7 (44±10) 14.0±1.4 (200±20) O ption 5.0±0.7 (70±10) 15.0±1.4 (220±20) T002 177-1E HDC put Specs Max put Pressure 27.5 bar (psi) (400) T002 177-2E 29
Electrical Control (EDC) The Electrical Control is similar to the Hydraulic Control, but uses an electrohydraulic Pressure Control Pilot (PCP) valve to control the pilot pressure. The PCP valve converts an electrical input signal to a hydraulic signal to operate a spring centered 4- way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump s displacement from full displacement in one direction to full displacement in the opposite direction. The EDC provides output flow in proportion to a DC electrical command signal (current). These controls are suited for applications where remote or automatic control of system function is required, or where closed loop feedback is needed. With no electrical command signal, the control is in or will return to the neutral position. Packard "Weatherpack" Shroud Connector EDC on M46 P100 326E Features / Benefits The EDC is a high gain control; with only a small change in the input current, the servo valve moves to a full open position thus porting maximum flow to the servo cylinder. Oil filled PCP valve case lengthens control life by preventing moisture ingression and dampening component vibrations. ternal mechanical stops on the servo valve allow rapid changes in input signal voltages without damaging the control mechanism. Precision parts provide repeatable accurate displacement settings with a given input signal. Both ends of the double-acting servo piston are drained to case when input signal current is not present. The servo piston is coupled to a spring centering mechanism. These features result in: Simple, low-cost design. Pump will return to neutral after prime mover shuts down. Pump will return to neutral if external electrical input signal fails or if there is a loss of charge pressure. A B or Front Rear Pump Flow Direction with EDC Control Positive to Pin: Positive to Pin: control module M4 Signal A Flow B Flow Signal C Flow M5 PCP put Shaft Rotation A B A B A B A B EDC S EDC Hydraulic Schematic P100 327E D Flow High Servo Gauge M4 M5 M4 M5 T002 178E
Three-Position Electric Control (FNR) The three-position (FNR - "forward-neutral-reverse") electric displacement control uses a solenoid operated 3- position, 4-way valve to move pump displacement from neutral to maximum displacement in either direction. A When a solenoid is energized, charge pressure is directed to one end of the pump servo control cylinder, which results in the pump going to maximum displacement. The direction of pump output flow is determined by which solenoid is energized. (See the accompanying table on next page.) Features/Benefits Electric control. If voltage is lost, the control returns pump to neutral. Simple, low-cost design. Ideal for applications that do not require proportional control. FNR Control on M46 FNR B A M4 M5 control module B P100 328 A B S FNR Hydraulic Schematic P100 329E Pump Flow Direction with FNR Control put Shaft Rotation or Front Rear Solenoid Energized: A Flow B Flow Solenoid Energized: C Flow A B A B A B A B D Flow High Servo Gauge M4 M5 M4 M5 Refer to dimensions for solenoid and port locations T002 181E