45 Series H Frame Service Manual (520L0611 19Sep2005 REV a)

7/27/2019 45 Series H Frame Service Manual (520L0611 19Sep2005 REV a)

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Series 45 H Frame Open Circuit Axial Piston PumpsService Manual

2005 Sauer-Dan oss. All rights reserved. Printed in U.S.A.

Sauer-Dan oss accepts no responsibility or possible errors in catalogs, brochures and other printed material.Sauer-Dan oss reserves the right to alter its products without prior notice. This also applies to productsalready ordered provided that such alterations arent in con ict with agreed specifcations. All trademarks inthis material are properties o their respective owners. Sauer-Dan oss and the Sauer-Dan oss logotype aretrademarks o the Sauer-Dan oss Group.

Front cover illustrations: F101 348, F101 347, F101 3 45, P106 084

OrganizatiOn andheadings

To help you quickly fnd in ormation in this manual, the material is divided into sections,topics, subtopics, and details, with descriptive headings set in red type . Section titlesappear at the top o every page in large red type . Topic headings appear in the le t handcolumn in BOLd red CaPitaL Letters . Subtopic headings appear in the body text inbol p and detail headings in italic red type .

Re erences (example: See Topic xyz , page XX) to sections, headings, or other publications arealso ormatted in red italic type . InPortable d ocument Format ( PdF ) fles, these re erencesrepresent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identifed by titles set in blue italic type above each item. Complementary in ormation such as notes, captions, and drawingannotations are also set in blue type .

Re erences (example: See Illustration abc , page YY) to tables, illustrations, and graphicsare also ormatted in blue italic type . In PDF fles, these re erences represent clickablehyperlinks that jump to the corresponding document pages.

Defned terms and acronyms are set in bol bl ck p in the text that defnes orintroduces them. Therea ter, the terms and acronyms receive no special ormatting.

Black italic type is used in the text to emphasize important in ormation, or to set-o words and terms used in an unconventional manner or alternative context. Red and blueitalics represent hyperlinked text in the PDF version o this document (see above).

An indented t able o Contents ( tOC ) appears on the next page. Tables and illustrationsin the TOC set in blue type . In the PDF version o this document, the TOC entries arehyperlinked to the pages where they appear.

taBLes, iLLustratiOns,and COmPLementaryinFOrmatiOn

sPeCiaL textFOrmatting

taBLe OF COntents

Using this manual


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intrOduCtiOn

teChniCaLsPeCiFiCatiOns

Features

Pressuremeasurement

initiaL start-uPPrOCedures

FLuid and FiLtermaintenanCe

Overview ..................................................................................................................................................Sa ety precautions .....................................................................................................................................

Unintended machine movement .......................................................................................................5Flammable cleaning solvents ...............................................................................................................Fluid under pressure .............................................................................................................................Personal sa ety ......................................................................................................................................

Symbols used in Sauer-Dan oss literature ...........................................................................................General description ...................................................................................................................................System circuit ............................................................................................................................................

General specifcations ............................................................................................................................... Type o mounting .................................................................................................................................Auxiliary mounting pad options .........................................................................................................9Control options .....................................................................................................................................

Port options ..........................................................................................................................................Direction o rotation .............................................................................................................................Installation position ............................................................................................................................. Technical specifcations ........................................................................................................................

General specifcations (continued) ........................................................................................................10Hydraulic parameters .............................................................................................................................

Inlet pressure ........................................................................................................................................Pressure compensator valve setting ................................................................................................10Case pressure .......................................................................................................................................Hydraulic uid ...................................................................................................................................... Temperature range ............................................................................................................................

Hydraulic parameters (continued) .........................................................................................................11Displacement limiter .................................................................................................................................Auxiliary mounting pads ..........................................................................................................................Input sha ts ................................................................................................................................................

Fluid viscosity ......................................................................................................................................Filtration ..............................................................................................................................................

Control options ..........................................................................................................................................Operation ..............................................................................................................................................

Control options ..........................................................................................................................................

Required tools ...........................................................................................................................................Port locations and gauge installation ...................................................................................................14

General ......................................................................................................................................................Start-up procedure .....................................................................................................................................

Recommendations ..................................................................................................................................


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adjustments

minOr rePair

Excessive noise and / or vibration ..........................................................................................................17Actuator response is sluggish ..................................................................................................................17System operating hot .................................................................................................................................18Low pump output ow ..............................................................................................................................18Pressure or ow instability ........................................................................................................................18Pressure or ow instability (continued) ...............................................................................................19System pressure not reaching PC setting ............................................................................................19High inlet vacuum ........................................................................................................................................19

PC second stage control ............................................................................................................................20PC control ........................................................................................................................................................21LS control ........................................................................................................................................................22

Sha t seal replacement ...............................................................................................................................23

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

Auxiliary pads ................................................................................................................................................24Removal ......................................................................................................................................................24Installation .................................................................................................................................................24

Bias piston, servo piston, and optional displacement limiter .......................................................25Pressure compensator valve ....................................................................................................................25

Disassembly ..............................................................................................................................................25Old style .....................................................................................................................................................25New style ..................................................................................................................................................25

Pressure compensator valve (continued) ............................................................................................26Load spring control .....................................................................................................................................26Control ..............................................................................................................................................................26Servo and bias pistons and displacement limiter.............................................................................27Pressure compensator valve ....................................................................................................................27

Reassembly ...............................................................................................................................................27Plug and ftting sizes and torques ..........................................................................................................28

trOuBLeshOOting


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualIntroduction

This manual includes in ormation or the installation, maintenance, and minor repair o the Series 45 rame H open circuit axial piston pumps. The manual includes a descriptiono the units and their individual components, troubleshooting in ormation, and minorrepair procedures. Per orming installation, maintenance, and minor repair o Series 45 HFrame axial piston pumps according to the procedures in this manual will not a ect yourwarranty.

Per orming minor repairs requires the unit to be removed rom the vehicle/machine. Thoroughly clean the unit be ore beginning maintenance, or repair activities. Since dirtand contamination are the greatest enemies o any type o hydraulic equipment, ollowcleanliness requirements strictly. This is especially important when changing the systemflter and when removing hoses or plumbing.

A worldwide network o Sauer-Dan oss a uthorized s ervice Centers (ASCs) is available

or major repairs. Major repairs require the removal o the units endcap, which voidsthe warranty unless done by an ASC. Sauer-Dan oss ASCs are trained by the actory andcertifed on a regular basis. You can locate your nearest ASC using the distributor locatorat www.sauer-dan oss.com

Always consider sa ety precautions be ore beginning a service procedure. Protectyoursel and others rom injury. Take these general precautions whenever servicing ahydraulic system.

u c o Warning

Unintended movement o the machine or mechanism may cause injury to the technicianor bystanders. To protect against unintended movement, secure the machine ordisable / disconnect the mechanism while servicing.

Fl bl cl ol Warning

Some cleaning solvents are ammable. To avoid possible fre, do not use cleaningsolvents in an area where a source o ignition may be present.

Fl p Warning

Escaping hydraulic uid under pressure can have su fcient orce to penetrate your skincausing serious injury and/or in ection. This uid may also be hot enough to cause burns.Use caution when dealing with hydraulic uid under pressure. Relieve pressure in thesystem be ore removing hoses, fttings, gauges, or components. Never use your handor any other body part to check or leaks in a pressurized line. Seek medical attentionimmediately i you are cut by hydraulic uid.

P o l Warning

Protect yoursel rom injury. Use proper sa ety equipment, including sa ety glasses, at alltimes.

Overview

saFety PreCautiOns


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symBOLs used insauer-danFOssLiterature

These symbols are in the illustrations and text o this manual. They communicate help ulin ormation at the point where it is most use ul to the reader.

In most instances, the appearance o the symbol itsel denotes its meaning. The legendbelow defnes the symbol and explains its purpose.

WARNING may result in injury

CAUTION may result in damage toproduct or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option either part may exist

Superseded parts are notinterchangeable

Measurement required

Flatness specifcation

Parallelism specifcation

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, help ul suggestion

Lubricate with hydraulic uid

Apply grease / petroleum jelly

Apply locking compound

Inspect or wear or damage

Clean area or part

Be care ul not to scratch or damage

Note correct orientation

Mark orientation or reinstallation

Torque specifcation

Press in press ft

Pull out with tool press ft

Cover splines with installationsleeve

Pressure measurement / gaugelocation or specifcation


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Sauer-Dan oss Series 45 H Frame open circuit piston pumps convert input torque intohydraulic power. Rotational orce is transmitted through the input sha t to the cylinderblock. The input sha t is supported by tapered roller bearings at the ront and rear o the pump and is splined into the cylinder block. A lip-seal at the ront end o the pumpprevents leakage where the sha t exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one endby a ball joint. The slippers are held to the swashplate by the spring retainer and block spring. The block spring also holds the cylinder block to the valve plate. The reciprocatingmovement o the pistons occurs as the slippers slide against the inclined swashplateduring rotation. One hal o the cylinder block is connected to pump inlet and the otherhal to pump outlet, via the valve plate. As each piston cycles in and out o its bore, uidis drawn rom the inlet and displaced to the outlet thereby imparting power into thesystem circuit. A small amount o uid is allowed to leak rom the cylinder block / valveplate and slipper / swashplate inter aces or lubrication and cooling. Case drain ports are

provided to return this uid to the reservoir.

The volume o uid displaced into the system circuit is controlled by the angle o theswashplate. The swashplate is orced into an inclined position (into stroke) by the biaspiston and spring. The servo piston opposes the action o the bias piston and springorcing the swashplate out o stroke when hydraulic pressure in the control circuit risesabove the spring orce.

The pump control, by varying the pressure at the servo piston, controls the displacemento uid in the system circuit. Controls designed or Pressure Compensation (PC) areavailable. For a detailed description o control operation, re er to Control options,operation , page 13.

generaL desCriPtiOn

Pump and control sectional view

Input shaft

Shaft seal

Tapered roller bearing

Swashplate

Displacement piston

Cylinder block

Valve plate

Slipper retainer

Slipper

PistonBias springBias piston

LS adjustmentPC adjustment

PC cartridge

LS spool

Tapered roller bearing

Integral pump control

P101 984E


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The pump receives uid directly rom the reservoir through the inlet line. A screenplaced in the inlet protects the pump rom large contaminants. The output o the pumpis directed to a PVG-32 multi-section load sensing directional control valve which directsuid to the actuators in the system. Fluid returning rom the system is cooled by a heatexchanger and cleaned by a flter be ore returning to the reservoir.

The speed o the actuators in the system depends on the volume o uid being providedby the pump. The operating pressure varies depending on actuator load, but is limited toan adjustable maximum setting by the PC section o the pump control and by a systemrelie valve integrated into the side module o the PVG valve.

The position o the PVG valve sets the demand or ow in the system and communicatesthis to the pump control by means o a hydraulic signal (load sense signal). The pump willprovide as much ow to the system as it demands 1 while limiting the maximum pressure.

There ore ow and pressure in the system are compensated to meet requirements.

1Full available ow is a unction o pump displacement, operating speed, and e fciency. Re er to Series 45 Axial Piston Open Circuit Pumps Technical In ormation 520L0519 or details.

system CirCuit

Pictorial circuit diagram

System pressure

Servo pressure

Actuator pressure

Load sense pressure

Actuator return

Suction / case drain /system return

PVG 32mulit-sectionloadsensingcontrol

valve

P106 086E

Reservoir FilterHeat exchanger

Double-acting cylinder

Bi-directionalgear motor

H Frame Series 45open circuit axialpiston pump withload sensing control


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Series 45 H Frame Open Circuit Axial Piston PumpsService Manual Technical specifcations

t p o oSAE-C mounting ange.

a l o p op oSAE-A, SAE-B, SAE-B-B, SAE-C, SAE C-C

Co ol op oPC: Pressure CompensatorLS: Load Sensing (with PC)

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

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

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

d c o o o oClockwise or counterclockwise.

i ll o po oInstallation position is discretionary. To satis y inlet pressure conditions, it isrecommended that the pump always be located below the lowest level o hydraulic uidin the reservoir. The housing must always be flled with hydraulic uid.

t c c l p c c o

generaLsPeCiFiCatiOns

Features and options mo lF u h5 B h 5dMaximum Displacement cm [in] 57 [3.48] 75 [4.58]Flow at rated speed (theoretical) l/min

[US gal/min]148.2[39.2]

180[47.5]

Input torque at maximum displacement(theoretical)

Nm/bar[lb in/1000 psi]

0.907[554]

1.194[729]

Mass moment o inertia o internalrotating components

kgm[slug t]

0.00430[0.00318]

0.00420[0.00310]

Weight Axial ports kg [lb] 24 [53]Radial ports 27 [60]

Rotation Clockwise, CounterclockwiseMounting SAE-B, SAE-C

Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-CSystem ports (type) SAE O-ring boss, 4-bolt split angeSystem ports (location) Axial, RadialControl types PC, LS, LS with internal bleedSha ts Splined 13 tooth, 14 tooth, 15 tooth

Tapered 31.75 mm [1.25 in], 1:8 taperStraight 31.75 mm [1.25 in]

Displacement limiters Optional, adjustable


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Series 45 H Frame Open Circuit Axial Piston PumpsService Manual Technical specifcations

F l oRequired cleanliness level: ISO 4406 Class 18/13 or better. Re er to Sauer-Dan osspublications Fluids and Filtration BLN-9887 or 520L0463 and Design Guidelines or Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465. See Fluid and

lter maintenance , page 16 or recommended uid and flter change intervals.

hydrauLiCParameters (co )

Fl co

Fluid viscosity limitsCo o / (cs ) sus

min.continuous 9 58intermittent 6.4 47

max.continuous 110 500intermittent(cold start) 1000 4700

disPLaCement Limiter

auxiLiary mOuntingPads

inPut shaFts Series 45 H Frame pumps are available with a variety o splined and straight keyed sha ts.For in ormation on sha ts re er to Series 45 Axial Piston Open Circuit Pumps Technical In ormation 5 0L051 .

Frame H Series 45 pumps are availablewith an optional adjustable maximumdisplacement limiter. The adjustablestop limits the pumps maximumdisplacement. The displacement changeis 6.5 cc/turn [0.40 in/turn ] o thedisplacement limiter adjustment screw.

Displacement limiter

P104 026

Auxiliary mounting pads are available orall radial ported Series 45 pumps. Thesepads are typically used or mountingauxiliary hydraulic pumps.

Since the auxiliary pad operates undercase pressure, you must use an O-ring toseal the auxiliary pump mounting angeto the pad. Oil rom the main pump caselubricates the drive coupling. For detailsre er to Series 45 Axial Piston Open Circuit Pumps Technical In ormation 5 0L051 .

Auxiliary pad options

P106 023


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualFeatures

The Series 45 Frames H have two possible control options, a Load s ensing (LS) controlwith Pressure Compensator (PC) or a PC only control.

B p o p o plpo o

Cross-section pumpOp oGeneral The bias piston and spring (1) acts atall times to push the swashplate (2) tomaximum angle causing the pump tostroke. The servo piston (3) acts againstthe bias piston and spring to reducethe swashplate angle causing thepump to destroke. Swashplate angledetermines pump outlet ow. The pumpcontrol, depending on conditions in the

system circuit, sets swashplate angleby metering system pressure to theservo piston.

PC control The PC control maintains a constant pressure in the hydraulic circuit as ow varies. ThePC control modulates pump ow to maintain system pressure at the PC setting as the PCadjusting screw defnes.

When system pressure, acting on the non-spring end o the PC spool, overcomes theorce o the PC spring, the spool shi ts porting system pressure to the servo piston andthe swashplate angle decreases. When system pressure drops below the PC setting, thePC spring shi ts the spool in the opposite direction connecting the servo piston to pumpcase and the swashplate angle increases. The swashplate is maintained at the anglerequired to keep system pressure at the PC setting.

COntrOL OPtiOns

PC and Ls pool hift to port y tem pre ure to ervo pi ton

Cross-section PC control

LS adjustmentPC adjustment

PC cartridge

LS spool

Integral pump control

P106 088E

P106 087E12

3


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualFeatures

COntrOL OPtiOns(co )

LS control The LS control matches pump ow with system demand. The LS control senses the owdemand o the system as a pressure drop across the e xternal Control v alve (ECV). Asthe ECV opens and closes, the pressure delta across the valve changes. When opening,the delta decreases. When closing, the delta increases. The LS control then increases ordecreases pump ow to the system until the pressure delta becomes equal to the LSsetting as defned by the LS adjustment.

The LS control consists o two spool valves that connect the servo piston either to pumpcase or system pressure. The PC spool controls the pressure-compensating unction o the control as previously described. The LS spool controls the load-sensing unction. ThePC spool has priority over the LS spool.

Through internal porting, system pressure (upstream o ECV) is applied to the non-

spring end o the LS spool, and through hydraulic line connected at port X. LS pressure(downstream o ECV) is applied to the spring end. This arrangement allows the LS spoolto act on the delta between system pressure and LS pressure. The LS spring sets thethreshold o operation (LS setting).

Because the swashplate is biased to maximum angle, the pump attempts to deliverull ow to the hydraulic system. When the ow being delivered exceeds demand, thepressure delta across the ECV is great enough to overcome spring orce and shi t theLS spool porting system pressure to the servo piston. The pump de-strokes reducingow until the delta across the ECV becomes equal to the LS setting. When ow beingdelivered is less than demand, the delta across the ECV drops below the LS setting andthe LS spring shi ts the spool connecting the servo piston to pump case. The pumpstrokes increasing ow until the delta across the ECV becomes equal to the LS setting.

When the external control valve is placed in neutral, it connects the LS signal line todrain. With no LS pressure acting on the non-spring end o the LS spool, the pumpadjusts stroke to whatever position necessary to maintain system pressure at the LSsetting. The pump is now in standby mode.

Loadpressure

Load sensepressure

Systempressure

Tank

Returnpressure

P101 665E

2

Typical load-sensing control valve

P op c o l co ol l


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualPressure measurement

The service procedures described in this manual can be per ormed using commonmechanics hand tools. Special tools, i required are shown. Calibrate pressure gaugesrequently to ensure accuracy. Use snubbers to protect gauges.

The illustration below shows gauge port locations. Recommended pressure gauges andfttings are in the table.

Gauge port locations

LegendB = Main pressure lineS = Suction lineL1, L2 = Case drain linesX = Load sensing pressure portM2 = Gauge port for port B*M4 = Gauge port servo pressure

*Same pressureX

M2L1

L2

S B

M4

P106 089E

CW CCW

required tOOLs

POrt LOCatiOns andgauge instaLLatiOn

Gauge and port in ormationPo P po r o F

M2 System pressure 0-300 bar [0-5000 psi] 7/16 - 20 O-ring fttingM4 Servo pressure 0-300 bar [0-5000 psi] 7/16 - 20 O-ring fttingL1, L2 Case pressure 0-10 bar [0-100 psi] 7/8 - 14 O-ring ftting

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

(tee into LS signal line)


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualInitial start-up procedures

CautiOnIncorrect sha t alignment

may result in damageto drive sha t, bearings,or seal which can cause

external oil leakage.

generaL

start-uP PrOCedure 1. Connect the pump to the prime mover. Ensure that pump sha t is properly aligned

with the sha t o the prime mover.

2. Fill the reservoir with recommended hydraulic uid. Always flter uid through a 10micron flter pouring into the reservoir. Never reuse hydraulic uid.

3. Fill the main pump housing with clean hydraulic uid. Pour fltered oil directly intothe upper most case drain port.

4. Fill the inlet line leading rom the pump to the reservoir. Check the inlet line orproperly tightened fttings. Be certain it is ree o restrictions and air leaks.

5. To ensure the pump stays flled with oil, install the case drain line in the upper mostcase drain port.

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

Follow recommendations in the vehicle / machine operators manual or prime moverstart up procedures.

7. While watching the pressure gauge installed at M2, jog the prime mover or run atthe lowest possible speed until system pressure builds to normal levels (minimum 11bar [160 psi]). Once system pressure is established, increase to ull operating speed.I system pressure is not maintained, shut down the prime mover, determine cause,and take corrective action. Re er to Troubleshooting , page 17.

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

9. Check and adjust control settings as necessary a ter installation. Re er to Adjustments ,page 20 .

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

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

The pump is now ready or operation.

Follow this procedure when starting-up a new Series 45 installation or when restartingan installation in which the pump has been removed.

WarningUnintended movement o the machine or mechanism may cause injury to the technicianor bystanders. To protect against unintended movement, secure the machine ordisable / disconnect the mechanism while servicing.

Prior to installing the pump, inspect or damage incurred during shipping. Make certainall system components (reservoir, hoses, valves, fttings, heat exchanger, etc.) are cleanprior to flling with uid.


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Series 45 H Frame Open Circuit Axial Piston PumpsService Manual Troubleshooting

exCessive nOise and /Or viBratiOn

aCtuatOr resPOnse issLuggish

i d c p o ac o

Check uid level in reservoir.Insu fcient hydraulic uid causes

cavitation.Fill the reservoir to proper level.

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

Purge air and tighten fttings.Check inlet or leaks.

Check pump inlet pressure /vacuum.

Improper inlet conditions causeerratic behavior and low outputow.

Correct pump inlet pressure /vacuum conditions. Re er toHydraulic parameters , page 10.

Inspect sha t couplings.A loose or incorrect sha t couplingcauses excessive noise and / orvibration.

Repair or replace coupling andensure that correct coupling isused.

Check sha t alignment.Misaligned sha ts create excessivenoise and / or vibration.

Correct sha t misalignment.

Hydraulic uid viscosity aboveacceptable limits.

Hydraulic uid viscosity aboveacceptable limits or low uidtemperature will not allow thepump to fll or control to operateproperly.

Allow system to warm up be oreoperating, or use uid with theappropriate viscosity grade orexpected operating temperatures.See Hydraulic Fluids, Series 45Technical In ormation Manual, 5 0L051 .

i d c p o ac o

Check external system relie valvesetting.

Low external relie valve settingslows down system.

Adjust external relie valvesetting ollowing manu acturersrecommendations. External relie setting must be above PC settingto operate properly.

Check PC and LS control setting.Low PC setting prevents the pumprom achieving ull stroke. Low LSsetting limits output ow.

Adjust PC and LS setting. Re er to Adjustments , page 21.

Check LS control signal pressures.Incorrect LS signal will not allowpump to operate correctly.

Inspect system to ensure thatproper LS signal transmit to pump.

Internal system leaks.Worn internal parts dont allow thepump to operate properly.

Re er to Authorized Service Centeror required repair.


Hydraulic uid viscosity aboveacceptable limits or low uidtemperature will not allow the

pump to fll or control to operateproperly.

Allow system to warm up be oreoperation or use uid with theappropriate viscosity grade orexpected operating temperatures.

See Hydraulic Fluids, Series 45Technical In ormation Manual,5 0L051 .

Check external system valving.Mal unctioning valving may notallow system to respond properly.

Repair or replace system valving asrequired.

Check pump case pressure.High case pressure causes thesystem to be sluggish.

Correct case drain line restrictions.


High inlet vacuum causes lowoutput ow.

Correct inlet pressure conditions.


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system OPerating hOt

LOw PumP OutPutFLOw

Pressure Or FLOwinstaBiLity

i d c p o ac o

Check uid level in reservoir.

Insu fcient volume o hydraulic

uid will not meet coolingdemands o system.

Fill reservoir to proper level. Veri yproper size o reservoir.

Inspect heat exchanger. Check airow and input air temperature orthe heat exchanger.

Insu fcient air ow, high input airtemperature, or undersized heatexchangers will not meet coolingdemands o the system.

Clean, repair, or replace heatexchanger as required. Veri yproper size o heat exchanger.


Fluid passing through relie valveadds heat to system.

Adjust external system relie valvesetting ollowing manu acturersrecommendations. External relie valve setting must be above PCsetting or proper operation.


High inlet vacuum adds heat tosystem.

Correct inlet pressure / vacuumconditions.

i d c p o ac o

Check uid level in reservoir.Insu fcient hydraulic uid will limitoutput ow and cause internaldamage to pump.

Fill the reservoir to proper level.


Fluid viscosity above acceptablelimits or low uid temperaturewill not allow the pump to fll orcontrol to operate properly.

Allow system to warm up be oreoperating, or use uid with theappropriate viscosity grade orexpected operating temperatures.See Hydraulic fuids, Series 45Technical In ormation Manual,5 0L051 .


Eternal relie valve set below PCsetting causes low output ow.

Adjust external relie valveollowing manu acturersrecommendation. External relie valve setting must be above PCsetting to operate properly.

Check PC and LS control setting.Low PC setting prevents the pumprom achieving ull stroke.

Adjust PC and LS setting. Re er to Adjustment , page 20.


High inlet vacuum causes lowoutput ow.

Correct inlet pressure conditions.

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

Check pump rotation.Incorrect rotational confguration

causes low ow.

Use pump with appropriate

rotational confguration.

i d c p o ac o

Check or air in system.Air in system causes erraticoperation.

Activate PC allowing systemto bleed air. Check inlet line orleaks and eliminate source o airingression.

Check control spools.Sticking control spools causeerratic operation.

Inspect spools or ree movementin bore. Clean or replace.


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system Pressure nOtreaChing PC setting

high inLet vaCuum

CautionHigh inlet vacuum causes

cavitation which candamage internal pump

components.

Pressure Or FLOwinstaBiLity (co )

i d c p o ac o

Check LS setting.Low LS setting may cause

instability.

Adjust LS setting to proper level.

See Adjustments , page 20.

Check LS signal line.Blocked LS signal line inter ereswith proper LS operation.

Remove blockage.

Check external relie valve and PCsetting.

Insu fcient pressure di erentialbetween PC setting and externalrelie valve.

Adjust external relie valve or PCcontrol settings to appropriatelevel. Relie valve setting mustbe above PC setting to operateproperly.

Check external relie valve.Chattering external relie valvemay cause unstable eedback topump control.

Adjust or replace relie valve.

i d c p o ac o

Check PC control setting.System pressure will not rise abovePC setting.

Adjust PC to appropriate setting.Re er to Adjustments , page 20.

Check external relie valve.External relie valve setting belowPC setting prevents pressurecompensation.

Adjust external relie valveaccording to manu acturersrecommendations. External relie valve must be set above PC settingto operate properly.

Inspect PC control spring.Broken, damaged, or missingspring will cause erratic operation.

Replace the spring as required.

Inspect PC spool or wear.Wear o PC spool causes internalleakage in the control.

Replace the spool as required.

Inspect PC spool or properorientation.

Improper orientation results inpoor operation.

Correct orientation o spool.

Check PC control orcontamination.

Contamination may inter ere withmovement o the PC spool.

Clean PC control components, takeappropriate action to eliminatecontamination.

i d c p o ac o

Check uid temperature.Low temperature increasesviscosity. High uid viscositycauses high inlet vacuum.

Allow system to warm up be oreoperating.

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

Clean screen / remove blockage.

Check inlet piping. Too many fttings, bends, or longpiping causes high inlet vacuum.

Eliminate fttings to make pathmore direct.


High uid viscosity causes highinlet vacuum.

Select uid with appropriateviscosity or expected operatingtemperature. See Hydraulic fuids,Series 45 Technical In ormationManual ,5 0L051 .


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0 BLN-10237 5 0L0611 August 2005

Series 45 H Frame Open Circuit Axial Piston PumpsService ManualAdjustments

PC seCOnd stageCOntrOL

PC second stage setting is indicated in the pump model code. Re er to the Series 45 OpenCircuit Axial Piston Pumps Technical In ormation Manual 5 0L051 , or more in ormation.

Be ore per orming adjustments, read page 14, Pressure measurement .WarningEscaping hydraulic uid

under pressure canhave su fcient orce

to penetrate your skincausing serious injury

and/or in ection. Relievepressure in the system

be ore removing hoses,fttings, gauges, or

components.

Unintended movement o the machine or mechanism

may cause injury to thetechnician or bystanders.

To protect againstunintended movement,

secure the machine ordisable / disconnect

the mechanism whileservicing.

1. Install a pilot hose (6mm [0.25in] diameter minimum) at port X,connecting to the reservoir to drainthe remote PC port. C

Failure to drain port X (spring cavity)to reservoir may cause additional back pressure on the PC spring, resulting in

pressure settings above the desiredspecifcation. It is recommended thatthis procedure be used on all Series 45,57cc pumps, however it is particularlyvital to 1999 and newer units due tohardware changes associated with thePC cartridge.

2. Start the prime mover and run atnormal speed, While securing thesecond stage adjustment screw,loosen the seal lock nut. Turn the 2ndstage adjustment screw until thegauge at port M2 reads 15 bar [220

PC second stage control adjustment

P106 126E

Gauge port M20 - 300 bar [0 - 4351 psi]3/16 in7/16-2034-68 Nm[25-50 lbfft]

G I B t

Case drain port L10 - 10 bar [0 - 145 psi]3/8 in7/8-1454 - 136 Nm[40 - 100 lbfft]

PC adjuscing screw4 mm

X Port0-300 bar[0-5000 psi]3/16 in7/16-2013-27 Nm[10-20 lbfft]

I

PC second stageadjusting screw4 mm

PC second stagelock nut4 mm

PC lock nut4 mm7.5 - 10.8 Nm[5.5 - 8 lbfft]

h t

CautionContamination can

damage internalcomponents and void themanu acturers warranty.

Take precautions to ensuresystem cleanliness when

removing and reinstallingsystem lines.

4. Shut down the prime mover. Disconnect the pilot hose installed at port X andreinstall the plug.

psi]. Clockwise rotation increases pressure, counterclockwise rotation will decreasepressure.

3. While holding the position o the second stage adjustment screw, torque the seallocknut to 23 Nm [17 lb t].


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1BLN-10237 5 0L0611 August 2005

Series 45 H Frame Open Circuit Axial Piston PumpsService ManualAdjustments

PC COntrOL PC setting is indicated in the pump model code. Re er to the Series 45 Open Circuit Axial Piston Pumps Technical In ormation Manual 5 0L051 , or more in ormation.

Be ore per orming adjustments, read page 14, Pressure measurement .WarningEscaping hydraulic uid

under pressure canhave su fcient orce

to penetrate your skincausing serious injury

and/or in ection. Relievepressure in the system

be ore removing hoses,fttings, gauges, or

components.

Unintended movement o the machine or mechanism

may cause injury to thetechnician or bystanders.

To protect againstunintended movement,

secure the machine ordisable / disconnect

the mechanism whileservicing.

1. Start the prime mover and allowuid to reach normal operatingtemperature. Operate a hydraulicunction to its ull extension, loadingthe pump at maximum pressure andzero ow.

2. While securing the PC adjusting

screw, loosen the PC lock nut andturn the PC adjusting screw untilthe desired setting is indicatedon the pressure gauge at portM21. Clockwise rotation increasespressure, counterclockwise rotationdecreases pressure; approximategain 57 bar [825 psi] per turn.

I the pressure does not increase, anexternal system relie valve may requireadjustment. External system relie valvemust be set above the PC setting orproper operation.

1 P C setting is re erenced to case pressure. Subtract case pressure rom system pressure to compute the actualsetting.

PC control adjustment

P106 090E

Gauge port M20 - 300 bar [0 - 4351 psi]3/16 in7/16-2034-68 Nm[25-50 lbfft]

G I B t

Case drain port L10 - 10 bar [0 - 145 psi]3/8 in7/8-1454 - 136 Nm[40 - 100 lbfft]

PC adjuscing screw4 mm

X Por t0-300 bar[0-5000 psi]3/16 in7/16-2013-27 Nm[10-20 lbfft]

I

LS adjusting screw4 mm

LS lock nut4 mm

PC lock nut4 mm7.5 - 10.8 Nm

[5.5 - 8 lbfft]

h t

CautionContamination can

damage internalcomponents and void themanu acturers warranty.

Take precautions to ensuresystem cleanliness when

removing and reinstallingsystem lines.

3. While holding the position o the PC adjusting screw, torque the PC lock nut to7.5 - 10.8 Nm [5.5 - 8 lb t].

4. Stop the prime mover, remove the pressure gauges, and return the system to itsnormal operating confguration.


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BLN-10237 5 0L0611 August 2005

Series 45 H Frame Open Circuit Axial Piston PumpsService ManualMinor repair

shaFt seaLrePLaCement

The Series 45 open circuit variable pumps use a lip-type sha t seal. You can replace thisseal without major disassembly o the unit. Replacing the sha t seal requires removingthe pump rom the machine.

CautionPremature bearing ailurecan result i the sha t seal

contacts the sha t bearing.Press the seal into the

housing only ar enoughto clear the retaining ring

groove.

r o l1. Using the appropriate snap-ring

pliers, remove the retaining ring(K010) rom the housing.

2. Puncture the ace o the seal (K020)with a packing hook, or use a slide-hammer type puller to remove theseal. C

3 Remove the sha t seal rom the borein the pump housing and discard.

i ll o4. Inspect the pump housing and new

seal or damage. Inspect the sealingarea on the sha t or rust, wear, orcontamination. Polish the sealingarea on the sha t i necessary.

Sha t seal and retaining ring

5. Lubricate the lip o the new sha t seal with clean hydraulic uid. Place a protectivesleeve over the sha t end to prevent damage to the seal during installation.

6. Keeping the seal perpendicular to the sha t, press the new seal into the housing justar enough to clear the retaining ring groove. Install seal with the cupped sidetoward the sha t bearing. Do not damage the seal during installation.

7. Using the appropriate snap ring pliers, install the seal retaining ring.

8. Remove the installation sleeve.

K020

PK010

b

P106 100E

C CautionDont damage the pump

housing or sha t.


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BLN-10237 5 0L0611 August 2005


auxiLiary Pads You may install auxiliary mounting pads on pumps equipped with through-drive radialported end caps. Follow these steps to either remove, replace, or exchange auxiliarymounting pads.

r o l1. Remove the screws (J130), retaining the cover plate (J110) or auxiliary pump (not

shown). Remove the shipping cover or auxiliary pump and its seal (J120).

2. Remove the drive coupling (J140) i present.

3. Remove the 4 screws (J100) retaining the pad adapter (J080) to the endcap. Discardthe pad adapter O-ring (J095) i present.

i ll o

4. Lubricate new O-ring (J095) with petroleum jelly. Install the pad adapter to theendcap.

5. Install the 4 screws (J100 ) and torque to 47.5 - 61 Nm [35 - 45 lb t].

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

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

8. Install the screws (J130) and torque to 94 - 111 Nm [67 - 82 lb t]. I you have anauxiliary A pad, install the screws (J131) and torque to 37 - 50 Nm [27 - 37 lb t].

CautionShipping cover is intended

only to retain couplingduring shipment and

storage. Do not operatepump with coupling andshipping cover installed. Auxiliary mounting pads

J120

J080

J140

dg J090dg J095

J110

J090dg J095J140J080

J120

J110

dg J090dg J095J080

J080

J120

J110

J140

dg J095dg J090

P106 091E

J130h 3 /4 incht 91 - 111 Nm[67 - 82 lbfft]

J130h 3 /4 incht 91 - 111 Nm[67 - 82 lbfft]

J130h 3 /4 incht 91 - 111 Nm[67 - 82 lbfft]

J100I 10 mmt 47.5 - 61 Nm[35 - 45 lbfft]

J100I 10 mmt 47.5 - 61 Nm[35 - 45 lbfft]

J100I 10 mmt 47.5 - 61 Nm[35 - 45 lbfft]


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5BLN-10237 5 0L0611 August 2005


d bl1. Remove the bias guide plug (B081)

using a 1- 3 /8 inch hex wrench. Also,remove the bias spring (B083), andpiston (B084). Discard the O-rings(B082, K100) and backup ring (K110).

2. Remove the servo piston plug (L020)and servo piston (L010) usinga 1-3 /8 inch hex wrench. Discard theO-ring (L020A).

3. Take note o the orientation o theservo piston. The end o the piston

with the hole should be acingupward.

Ol l4. Remove the PC plug (C120) rom the

pump using a 3/16 inch hex wrench.Discard the O-ring (C120A).

5. Remove the PC cartridge using an11/16 inch hex wrench. Discard theO-rings (D016, K080) and backupring (K090).

6. I necessary, loosen the locknuts(D015, D018) on the set screw (D014).

n l7. Remove the PC plug (C120) rom the

pump using a 9/16 inch hex wrench.Discard the O-ring (C120A)

8. The new style is a one-piececartridge. Remove the PC cartridgewith a 11/16 inch hex wrench.Discard the O-rings (D016, K080) andthe backup ring (K090).

E106 096E

d K110d K100B083

d B082

B084

B081

1- 3 /8 in

d L020AL020h 1- 3 /8 in

L030

L040

L010

d D016d K080d K090

D015

D014

D013

D019

D018

D016 d K080 d

K090 d

A98-21

thru

A00-23

E106 097E

New style

Old style

C120

C120A

O

Remove PC valve

Remove servo and bias pistonsBias PistOn, servOPistOn, and OPtiOnaLdisPLaCement Limiter

PressureCOmPensatOr vaLve


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6 BLN-10237 5 0L0611 August 2005


Unscrew the plug (C030) using a 7/8 inchhex wrench. Discard the O-ring (C040).I the springs (C070, C060) remain in thebore, remove them along with the spring

seat (C080) and the PC spool (C090) witha magnet.

C110C130

C020C010

C030

C040C050

C060

C070

C080

C090

P106 098E

Remove the control

9. Inspect the screen in the end o the valve or contamination. It isimportant that the valve is notplugged.

Check the spool or nicks and scratches.Make sure the PC spool orifce is notcontaminated or plugged.

New style

Old style

screen end

screen

E101 340E

C090 i

P106 099E

i

Inspect the control spool and ori ce

Inspect the PC valve

LOad sPring COntrOL

COntrOL

PressureCOmPensatOr vaLve(co )


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BLN-10237 5 0L0611 August 2005


r bl1. Lubricate all sides o the servo

piston (L010) and its respective boreliberally with hydraulic oil. Reinstallthe servo piston with the hole endup. Reinstall the displacement limiterplug (L020) and tighten with a1 3 /8 inch socket to 175-245 Nm[120-170 lb t].

2. Install the set screw (L040) and usea 19 mm hex wrench to torquethe adjustment seal/nut (L030) at78 to 95 Nm [58 to 70 lb t].

3. Lubricate the bias piston (B084) andits respective bore with a liberalcoating o hydraulic oil. Reinstall thebias plug (B081) and spring (B083)with new O-rings. Use a 1 3 /8 inchsocket to tighten to 175-245 Nm[120-170 lb t].

It is extremely important that the biaspiston plug (B081) be correctly torqued,as it may back out at lower torques.

servO and BiasPistOns anddisPLaCement Limiter

d K110d K100

B083

d B082

B084

B081

h 1- 3 /8 in

d L020A

L020

h 1- 1 /4 in

L030

L040

L010

l

P106 101E

Install servo and bias pistons

PressureCOmPensatOr vaLve

D016

K080

K090

P106 102E

New style

C120

C120A d h 9 /16 inch hext 16 Nm[12 lbfft]

Install PC valveNew style4. Using a 9 /16 inch hex wrench, install

short hex plug (C120) with a new O-ring (C120A). Torque this plug to 11-14 Nm [8-10 lb t]. A ter installingthe plug, install the new PC cartridge. Torque to 27-47 Nm [25-35 lb t]with an 11 /16 inch hex wrench. Resetyour pressure compensating settingollowing the Series 45 ServiceManual ,BLn-101 , as these do notcome preset. The new gain or the PCsetting is 825 psi/turn.


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualNotes


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Series 45 H Frame Open Circuit Axial Piston PumpsService ManualNotes


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s -d o mob l Po Co ol s m k L wo l

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45 Series H Frame Service Manual (520L0611 19Sep2005 REV a)

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Transcript of 45 Series H Frame Service Manual (520L0611 19Sep2005 REV a)