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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part Numbers

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers

2002, 2005 Sauer-Danfoss. All rights reserved. Printed in U.S.A. Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material. Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations arent in conict with agreed specications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group.
Front cover illustrations: E100 459, E100 460, E100 461, E100 462, E100 463 and E100 464

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Contents
GENERAL INFORMATION Overview .................................................................................................................................................. 4 Tool requirements ................................................................................................................................. 4 Test Equipment ...................................................................................................................................... 4

ORDER CODE ANALYSIS KITS

Codes ......................................................................................................................................................... 5-10

Seal kits ..................................................................................................................................................... 10 Service kits ............................................................................................................................................... 10 Body kits ................................................................................................................................................... 10 Cover kits .................................................................................................................................................. 11 Bearing plate kits ................................................................................................................................... 11 Shaft kits ................................................................................................................................................... 12 Shaft torque limitations ...................................................................................................................... 12 Gear plate kits ......................................................................................................................................... 12 Single pump screw kits ....................................................................................................................... 13 Dual pump screw bolt kits ................................................................................................................. 13 Seal installation tool kit ....................................................................................................................... 13

SINGLE PUMP ASSEMBLY PROCEDURE

Illustration ................................................................................................................................................ 14 Kit requirement ...................................................................................................................................... 14 Assembly .................................................................................................................................................. 14-16

DUAL PUMP ASSEMBLY PROCEDURE

Illustration ................................................................................................................................................ 17 Kit requirement ...................................................................................................................................... 17 Assembly .................................................................................................................................................. 18-21

PUMP IDENTIFICATION TEST PROCEDURE

Pump identication code ................................................................................................................... 22

Pumps without ow divider .............................................................................................................. 22 Cause for rejection ................................................................................................................................ 22 Air pressure test ..................................................................................................................................... 23 Pumps without ow divider schematic......................................................................................... 23 Pressure and ow data ........................................................................................................................ 23

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers General information
GENERAL INFORMATION Overview The Sauer-Danfoss D series kit program is being offered to those distributors that have the in-house capabilities to build, test and service the Sauer-Danfoss D series pumps. Tool requirements, test stand recommendations, component part identication, assembly procedures and product identication codes are covered in the text of this document. Should you have any questions on qualifying for this program, feel free to contact your Sauer-Danfoss representative. Tool requirements The following tools are required to assemble a D series pump: A. Vise with soft jaw inserts (4 jaw opening) or holding xture. B. Rubber or polyurethane mallet C. Socket wrench and 5/16 internal hex socket D. Torque wrench capable of reading lbfft [Nm] E. One set of 1/8 metal stamps (letters and numbers) F. Shaft seal bullet and installation (driving) tool G. Hand press or equivalent device to press in shaft seal The assembly bench and surrounding area must be clean and free of dirt, grease, and other foreign matter. Test equipment The test must be capable of running any pump displacement at rated ow at factory test pressure. Depending on displacement, horsepower requirements at 1800 rpm range from 10 hp to 50 hp. The test stand must include devices to check output ow, speed, inlet pressure and outlet pressure of the pump. Provisions should also be made to regulate temperature. Filtration is necessary on any test stand; 10 micron is recommended. Use a quality grade hydraulic uid the viscosity range of 160 SSU at 110 F (based on Sauer-Danfoss production testing). Periodic maintenance of the oil and lters is recommended, along with calibration of the measuring devices. The gure below illustrates suggested circuitry and options.
E F G L H I J K A. Inlet pressure gage/vacuum gage B. Electric motor - 1800 rpm C. D series test pump D. Relief valve (optional) E. F. Outlet pressure gage Temperature gage

D B

G. Load valve H. Oil cooler I. J. K. L. Filter - 25 micron (optional) Filter - 10 micron Reservoir (ooded inlet - overhead type preferred) Flow measuring device (meter)

A
P100 559

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis
SINGLE SECTION PUMPS

X A B C D E F H J K Z D E 1 L 0 7 S H B B N 1 0 4 N N N 0 0 0 A F A N N N N 2 1 0 2 0 5 999
X A B C D E F H J K Z Distributor code General characteristics Displacement 1(1) / input drive Mounting Rear cover control/port options Control settings Relief valve pressure Screws Nameplate information Special features Date code

DUAL SECTION PUMPS

X
X A B C R S D E F H J K Z

9 9 9 D E 2 L

3 2 S F AA 1 0 4 1 9 N 1 0 1 NNN 0 0 0 A X AN NNN 2 1 0 2 0 5

Distributor code General characteristics Displacement 1(1) / input drive Mounting Porting prior to rear displacement of dual pumps Rear displacement of dual pumps(1) Rear cover control/port options Control settings Relief valve pressure Screws Nameplate information Special features Date code

Notes: 1. This number denotes cubic centimeter displacement per revolution. For example, 32 = 31.8 cubic centimeters per revolution. Theoretical pump delivery (gpm) is determined by multiplying actual cubic inch displacement by pump rpm and dividing by 231.

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis
CODES

X
Code Decription

Distributor code
Use your assigned distributor code

A
D E 1 L

General characteristics
Code
DE1L DE1R DE2L DE2R

Decription
D-series, revision E, single pump, counterclockwise (left hand) rotation D-series, revision E, single pump, clockwise (right hand) rotation D-series, revision E, dual pump, counterclockwise (left hand) rotation D-series, revision E, dual pump, clockwise (right hand) rotation

B
0 7 S F
Code
07 10 13 14 17 19 21 23 25 29 32 38 41

Displacement 1 (B1)
Displacement cm3/rev in3/rev
7.0 9.5 12.6 14.3 17.0 19.0 20.5 22.5 25.4 29.0 31.8 38.0 41.0 0.43 0.58 0.77 0.87 1.04 1.16 1.25 1.37 1.55 1.77 1.94 2.32 2.50

Gear width mm
7.1 9.5 12.7 14.4 17.0 19.0 20.6 22.4 25.4 29.0 31.7 38.0 40.9

in.
0.280 0.375 0.500 0.565 0.670 0.750 0.810 0.883 1.000 1.141 1.250 1.496 1.610

B
0 7 S F

Input drive (B2)


Code PB PD SE SF SH Diameter (in.) 0.875 0.750 0.625 0.750 0.875 Extension (in.) 1.62 2.00 1.25 1.25 1.62 Type Straight key Straight key Spline Spline Spline Description SAE B - 1/4 keyway 3/16 keyway SAE A 9 tooth, 0.75 effective spline 11 tooth, 0.79 effective spline 13 tooth SAE B, 1.18 effective spline

C
B B

Mounting
Code
AA BB

Decription
SAE A ange, 2-bolt SAE B ange, 2-bolt

R
1 0 4

Porting prior to rear displacement (use with dual pumps only)


Code
101 104 113 125 126

Inlet port
1 1/16 - 12 SAE, side 1 5/16 - 12 SAE, side None 1 5/8 - 12 SAE, side None

Outlet port
7/8 - 14 SAE, side 1 1/16 - 12 SAE, side 7/8 - 14 SAE, side 1 1/16 - 12 SAE, side 1 1/16 - 12 SAE, side

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis
CODES

S
1 9
Code
07 10 13 14 17 19 21 23 25 29 32 38 41

Rear displacement (use with dual pumps only)


Displacement cm3/rev in3/rev
7.0 9.5 12.6 14.3 17.0 19.0 20.5 22.5 25.4 29.0 31.8 38.0 41.0 0.43 0.58 0.77 0.87 1.04 1.16 1.25 1.37 1.55 1.77 1.94 2.32 2.50

Gear width mm
7.1 9.5 12.7 14.4 17.0 19.0 20.6 22.4 25.4 29.0 31.7 38.0 40.9

in.
0.280 0.375 0.500 0.565 0.670 0.750 0.810 0.883 1.000 1.141 1.250 1.496 1.610

Rear cover control/port options

D
N 1 0 1

Note: Codes N113 and N126 are for use with dual pumps only

Code
N101 N104 N504 N113 N125 N126

Inlet port
1 1/16 - 12 SAE, side 1 5/16 - 12 SAE, side 1 5/16 - 12 SAE, end None 1 5/8 - 12 SAE, side None

Outlet port
7/8 - 14 SAE, side 1 1/16 - 12 SAE, side 1 1/16 - 12 SAE, end 7/8 - 14 SAE, side 1 1/16 - 12 SAE, side 1 1/16 - 12 SAE, side

E
NNN

Control settings
Code
NNN

Description
No control setting

F
0 0 0

Relief valve pressure


Code
000

Description
No relief valve

H
A F
Displacement Code B1
07 10 13 14 17 19 21 23 25 29 32 38 41

Single pump screws


Rear cover control/port option D N101, N104, and N504 N125
AF AG AG AG AH AH AH AJ AJ AK AK AL AM AJ AJ AJ AK AK AK AL AL AL AM AM AN AP

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis
CODES

H
A X

Dual pump screws


The following tables are to be used to determine the correct code for a dual pump. 1) Select the appropriate table (4 options) corresponding to the desired port codes. 2) Select the row corresponding to the displacement of the front pump. 3) Select the column corresponding to the displacement of the rear pump. 4) Select the 2 digit code where the two displacements meet. Example: D code = N104, R code = 113, front displacement (B) = 21, and rear displacement (S) = 19 indicates the correct screw code H = AW.

This table only used for the following codes: D = N101, N104, N504, N113, or N126 and R = 101, 104, 113, or 126 Do not use this table if D = N125 or R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code)
3 2 S F

07 10 13 14 17 19 21 23 25 29 32 38 41

07 AS AS AS AT AT AT AU AU AU AV AV AW AX

10 AS AS AT AT AU AU AU AU AV AV AW AX AX

13 AS AT AT AU AU AU AV AV AV AW AW AX AY

14 AT AT AU AU AU AV AV AV AW AW AX AY AY

17 AT AU AU AU AV AV AV AW AW AX AX AY AY

19 AT AU AU AV AV AV AW AW AW AX AX AY AZ

21 AU AU AV AV AV AW AW AW AX AX AY AZ AZ

23 AU AU AV AV AW AW AW AW AX AX AY AZ AZ

25 AU AV AV AW AW AW AX AX AX AY AY AZ BA

29 AV AV AW AW AX AX AX AX AY AY AZ BA BA

32 AV AW AW AX AX AX AY AY AY AZ AZ BA BB

38 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC

41 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC

This table only used for the following codes: D = N101, N104, N504, N113, or N126 and R = 125 Do not use this table if D = N125 or R = 101, 104, 113, or 126 Displacement 1 Rear displacement of dual pump code B (refer to S position code)
3 2 S F

07 10 13 14 17 19 21 23 25 29 32 38 41
8

07 AT AT AU AU AV AV AV AV AW AW AX AY AY

10 AT AU AU AV AV AV AV AW AW AX AX AY AZ

13 AU AU AV AV AV AW AW AW AX AX AY AZ AZ

14 AU AV AV AV AW AW AW AX AX AY AY AZ AZ

17 AV AV AV AW AW AW AX AX AX AY AY AZ BA

19 AV AV AW AW AW AX AX AX AY AY AZ BA BA

21 AV AV AW AW AX AX AX AY AY AZ AZ BA BA

23 AV AW AW AX AX AX AY AY AY AZ AZ BA BB

25 AW AW AX AX AX AY AY AY AZ AZ BA BB BB

29 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC

32 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC

38 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD

41 AY AZ AZ AZ BA BA BA BB BB BC BC BD BE

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis
CODES

H
A X

Dual pump screws continued


This table only used for the following codes: D = N125 and R = 101, 104, 113, or 126 Do not use this table if D = N101, N104, N504, N113 or R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code)
3 2 S F

07 10 13 14 17 19 21 23 25 29 32 38 41

07 AU AU AV AV AW AW AW AW AX AX AY AZ AZ

10 AU AV AV AV AW AW AW AX AX AY AY AZ BA

13 AV AV AW AW AW AX AX AX AY AY AZ BA BA

14 AV AV AW AW AX AX AX AY AY AZ AZ BA BA

17 AW AW AW AX AX AX AY AY AY AZ AZ BA BB

19 AW AW AX AX AX AY AY AY AZ AZ BA BB BB

21 AW AW AX AX AY AY AY AY AZ BA BA BB BB

23 AW AX AX AY AY AY AY AZ AZ BA BA BB BC

25 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC

29 AX AY AY AZ AZ AZ BA BA BA BB BB BC BD

32 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD

38 AZ AZ BA BA BA BB BB BB BC BC BD BE BE

41 AZ BA BA BA BB BB BB BC BC BD BD BE BF

This table only used for the following codes: D = N125 and R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code)
3 2 S F

07 10 13 14 17 19 21 23 25 29 32 38 41

07 AV AW AW AW AX AX AX AY AY AZ AZ BA BB

10 AW AW AX AX AX AY AY AY AZ AZ BA BB BB

13 AW AX AX AX AY AY AY AZ AZ BA BA BB BC

14 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC

17 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC

19 AX AY AY AY AZ AZ AZ BA BA BB BB BC BD

21 AX AY AY AZ AZ AZ BA BA BA BB BB BC BD

23 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD

25 AY AZ AZ AZ BA BA BA BB BB BC BC BD BE

29 AZ AZ BA BA BA BB BB BB BC BC BD BE BE

32 AZ BA BA BA BB BB BB BC BC BD BD BE BF

38 BA BB BB BB BC BC BC BD BD BE BE BF BG

41 BB BB BC BC BC BD BD BD BE BE BF BG BG

J
AN

Nameplate information
Code
AN BN

Description
Standard nameplate Standard label (use with rear cover code N504)

K
NNN

Special features
Code
NNN

Description
No special features, standard black paint

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Order code analysis and kits
CODES

Z
2 1 0 2 0 5
Code
DDMMYY

Date code
Decription
The date code must be stamped as indicated on every pump built. The date code structure is as follows: DD = day of month MM = month of assembly YY = year of assembly

SEAL KITS
E100 472

Item ID
163D9118 163D9119 163D9120

Description
Shaft lip seal kit (lip seal only) Seal kit - D pump, single Seal kit - D pump, dual

SERVICE KITS
E100 473

Item ID
163D9277 163D9278 163D9279 163D9280

Description
Service kit - D pump, single, 14 & below Service kit - D pump, single, 17 & above Service kit - D pump, dual, 14 & below Service kit - D pump, dual, 17 & above

BODY KITS

E100 444

Item ID
163D9200 163D9201 163D9202 163D9203

Description
Body kit - right hand rotation pump - SAE A mount (C code AA) Body kit - left hand rotation pump - SAE A mount (C code AA) Body kit - right hand rotation pump - SAE B mount (C code BB) Body kit - left hand rotation pump - SAE B mount (C code BB)

10

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Kits
COVER KITS

E100 445

Item ID
163D9204 163D9205 163D9206 163D9207 163D9307 163D9283

Description
Cover kit - 1 5/16 - 12 side inlet, 1 1/16 - 12 side outlet (D code N104) Cover kit - 1 1/16 - 12 side inlet, 7/8 - 14 side outlet (D code N101) Cover kit - 1 5/16 - 12 end inlet, 1 1/16 - 12 end outlet (D code N504) Cover kit - no inlet, 7/8 - 14 side outlet (D code N113) for single inlet dual pumps only Cover kit - 1 5/8 - 12 side inlet, 1 1/16 - 12 side outlet (D code N125) Cover kit - no inlet, 1 1/16 - 12 side outlet (D code N126) for single inlet dual pumps only

BEARING PLATE KITS (DUAL PUMPS)

E100 446

Item ID
163D9208 163D9281 163D9282

Description
Bearing plate kit - 1 5/16 - 12 side inlet, 1 1/16 - 12 side outlet (R code 104) Bearing plate kit - 1 5/8 - 12 side inlet, 1 1/16 - 12 side outlet (R code 125) Bearing plate kit - no inlet, 1 1/16 - 12 side outlet (R code 126) for single inlet dual pumps only

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Kits
SHAFT KITS
Keyed Splined Idler drive shaft

E100 465E

E100 447E

E100 448E

Pump Size
07 10 13 14 17 19 21 23 25 29 32 38 41

Code PB 0.875 keyed


163D9291 163D9292 163D9289 163D9293 163D9209 163D9210 163D9211 163D9212 163D9213 163D9214 163D9215 163D9216 163D9217

Code PD 0.750 keyed


163D9218 163D9219 163D9220 163D9294 163D9221 163D9222 163D9223 163D9224 163D9225 163D9226 163D9227 163D9303 163D9304

Code SE 0.625 9 tooth


163D9238 163D9239 163D9240 163D9295 163D9241 163D9242 163D9243 163D9297 163D9298 163D9299 163D9300 163D9301 163D9302

Code SF 0.750 11 tooth


163D9228 163D9229 163D9230 163D9296 163D9231 163D9232 163D9233 163D9234 163D9235 163D9236 163D9237 163D9305 163D9306

Code SH 0.875 13 tooth


163D9290 163D9287 163D9284 163D9286 163D9244 163D9245 163D9246 163D9247 163D9248 163D9249 163D9250 163D9251 163D9252

Dual pump idler drive shaft


163D9253 163D9254 163D9255 163D9288 163D9256 163D9257 163D9258 163D9259 163D9260 163D9261 163D9262 163D9263 163D9264

SHAFT TORQUE LIMITATION

The chart to the right indicates the maximum shaft torque rating for the various drive shaft options.

Shaft code
PB PD SE SF SH

Max. continuous torque rating


183 lbfft 117 lbfft 88 lbfft 130 lbfft 183 lbfft

GEAR PLATE KITS

Pump size
07 10 13 14 17 19 21 23 25 29 32 38 41

Gear plate kits


163D9265 163D9266 163D9267 163D9285 163D9268 163D9269 163D9270 163D9271 163D9272 163D9273 163D9274 163D9275 163D9276

E100 450

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Kits
SINGLE PUMP SCREW KITS
Code Screw kits

E100 451

AF 163D9077 AG 163D9078 AH 163D9082 AJ 163D9084 AK 163D9086 AL 163D9087 AM 163D9088 AN 163D9090 AP 163D9091 refer to page 7 to determine appropriate code

DUAL PUMP SCREW KITS

Code

Screw kits

E100 451

AS 163D9093 AT 163D9094 AU 163D9095 AV 163D9096 AW 163D9097 AX 163D9098 AY 163D9099 AZ 163D9100 BA 163D9101 BB 163D9102 BC 163D9103 BD 163D9104 BE 163D9105 BF 163D9106 BG 163D9107 refer to page 8-9 to determine appropriate code

SEAL INSTALLATION TOOL KIT

Item ID
163D9117

Description
Seal installation tool - Seal bullet and driving tool

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Single pump assembly procedure
ILLUSTRATION
Cover assembly Plastic plug Seal ring Screw

Plastic plug

Wear plate Wear plate Drive shaft Load ring Seal ring

Shaft seal

Idler shaft Dowel pin Wear plate Pre-load ring


E100 453E

Gear plate

Body assembly

KIT REQUIREMENT

One body kit One cover kit One drive shaft kit One gear plate kit One screw kit

ASSEMBLY

1. Place body assembly, with E-ring seal grooves facing up, into vise with soft jaws or in holding xture. Extreme caution must be used when using a vise to avoid distorting any parts or damaging mounting pilot.
E100 444

2. Place the rubber seal ring in body groove. 3. Remove the two wear plates, preload seal (black rubber E-ring), and load seal (yellow k-lon E-ring) from the gear plate kit. 4. Place the pre-load seal in the bottom of the body E-ring groove.
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E100 450

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Single pump assembly procedure
ASSEMBLY (CONTINUED) 5. Place the load seal directly on top of the pre-load seal.
Pressure hole

6. Find the wear plate with the .250 diameter pressure hole and NO oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pressure hole located on the e-ring side of the body.

E100 455E

7. Lubricate key or spline end of drive shaft with Aerolube grease or equivalent and carefully insert in correct bearing bore. 8. Insert idler gear in the other bearing bore. 9. Lubricate gearset completely, using clean oil that is compatible with test stand oil. 10. Place cover assembly on assembly bench with machined surface facing up. 11. Place the rubber seal ring in cover seal ring groove. 12. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the cover with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in cover. 13. Place the gear plate onto the cover. 14. Insert the two dowel pins through the gear plate and into the cover. 15. Place cover/gear plate assembly over shaft journals making certain that the pressure holes in the body and cover wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged. 16. Place appropriate screws in the cover holes and turn until thread engages. Use care so that cross threading does not occur. 17. Turn screws evenly with socket wrench to approximately 20 lbfft. Using a torque wrench, torque screws to 47 lbfft in a crossing pattern begining with one of the four center screws. 18. Remove assembly from vise or holding xture and return with drive shaft facing upwards. 19. Place seal bullet over drive shaft, sliding it downward until it bottoms out.
BLN-2-41714 Rev A April 2005

Pressure hole
E100 456E

15

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Single pump assembly procedure
ASSEMBLY (CONTINUED) 20. Apply Aerolube grease or equivalent to sealing lips of shaft seal.
.25

21. Place the shaft seal over seal bullet with spring loaded side facing inward and slide it down. If shaft extension allows, remove bullet when sealing lips of seal are clear of keyway or spline. 22. Place driving tool over bullet and/or shaft and press seal into housing with a smooth uniform pressure. Be certain seal is not cocked when applying pressure. 23. Remove tool and bullet. NOTE: Bullets and driving tools should be inspected frequently for cracks or other imperfections that may cause seal damage. 24. Rotate drive shaft to make sure it turns smoothly.

Install seal with spring loaded side facing inward

SAE 'A' Body


.25 Install seal with spring loaded side facing inward

E100 457E

SAE 'B' Body

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Dual pump assembly procedure
ILLUSTRATION
Cover assembly Plastic plug Seal ring Screw

Idler drive shaft Plastic plug Wear plate Idler shaft Gear plate Plastic plug Coupling Seal ring Pre-load seal Plastic plug Bearing plate assembly Wear plate Dowel pin Gear plate Seal ring Body assembly Shaft seal Idler shaft Load seal Drive shaft Dowel pin Seal ring Wear plate Load seal

E100 454E

Wear plate Pre-load seal

KIT REQUIREMENTS

One body kit One cover kit One drive shaft kit One idler drive shaft kit Two gear plate kits One bearing plate kit One screw kit

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Dual pump assembly procedure
ASSEMBLY 1. Place body assembly, with E-ring seal grooves facing up, into vise with soft jaws or in holding xture. Extreme caution must be used when using a vise to avoid distorting any parts or damaging mounting pilot. 2. Place the rubber seal ring in body groove. 3. Remove the two wear plates, preload seal (black rubber E-ring), and load seal (yellow k-lon E-ring) from the gear plate kit. 4. Place the pre-load seal in the bottom of the body E-ring groove.
E100 450 E100 444

5. Place the load seal directly on top of the pre-load seal. 6. Find the wear plate with the .250 diameter pressure hole and no oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pressure hole located on the E-ring side of the body. 7. Lubricate key or spline end of drive shaft with Aerolube grease or equivalent and carefully insert in correct bearing bore. 8. Insert idler gear in the other bearing bore. 9. Lubricate gear set completely, using clean oil that is compatible with test stand oil. 10. Place bearing plate assembly on assembly bench with E-ring grooved surface facing down. 11. Place the rubber seal ring in bearing plate seal ring groove.
Pressure hole

E100 455E

E100 446

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Dual pump assembly procedure
ASSEMBLY (CONTINUED) 12. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the bearing plate with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in bearing plate. 13. Place the gear plate onto the bearing plate. 14. Insert the two dowel pins through the gear plate and into the bearing plate. 15. Place this bearing plate/gear plate assembly over shaft journals making certain that the pressure holes in the body and bearing plate wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged. 16. Place the rubber seal ring in bearing plate seal ring groove. 17. Remove the two wear plates, preload seal (black rubber E-ring), and load seal (blue k-lon E-ring) from the gear plate kit. 18. Place the pre-load seal in the bottom of the bearing plate E-ring groove. 19. Place the load seal directly on top of the pre-load seal. 20. Find the wear plate with the .250 diameter pressure hole and no oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pressure hole located on the E-ring side of the bearing plate. 21. Insert coupling into spline bore of drive shaft. 22. Place idler drive shaft into the coupling spline bore. The internal spline of the idler drive shaft must engage with the coupling in the drive shaft.
E100 450

Pressure hole
E100 456E

Pressure hole

E100 455E

E100 448E

23. Lubricate gear set completely, using clean oil that is compatible with test stand oil.

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D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Dual pump assembly procedure
ASSEMBLY (CONTINUED) 24. Place cover assembly on assembly bench with machined surface facing up. 25. Place the rubber seal ring in cover seal ring groove. 26. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the cover with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in cover. 27. Place the gear plate onto the cover. 28. Insert the two dowel pins through the gear plate and into the cover. 29. Place cover/gear plate assembly over shaft journals making certain that the pressure holes in the bearing plate and cover wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged. 30. Place appropriate screws in the cover holes and turn until thread engages. Use care so that cross threading does not occur. 31. Turn screws evenly with socket wrench to approximately 20 lbfft. Using a torque wrench, torque screws to 47 lbfft in a crossing pattern begining with one of the four center screws. 32. Remove assembly from vise or holding xture and return with drive shaft facing upwards. 33. Place seal bullet over drive shaft, sliding it downward until it bottoms out. 34. Apply Aerolube grease or equivalent to sealing lips of shaft seal.
E100 445

Pressure hole
E100 456E

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BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Dual pump assembly procedure
ASSEMBLY (CONTINUED) 35. Place the shaft seal over seal bullet with spring loaded side facing inward and slide it down. If shaft extension allows, remove bullet when sealing lips of seal are clear of keyway or spline. 36. Place driving tool over bullet and/or shaft and press seal into housing with a smooth uniform pressure. Be certain seal is not cocked when applying pressure. 37. Remove tool and bullet. NOTE: Bullets and driving tools should be inspected frequently for cracks or other imperfections that may cause seal damage. 38. Rotate drive shaft to make sure it turns smoothly.
.25 Install seal with spring loaded side facing inward

SAE 'A' Body


.25 Install seal with spring loaded side facing inward

E100 457E

SAE 'B' Body

BLN-2-41714 Rev A April 2005

21

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Pump identication and test procedure
PUMP IDENTIFICATION CODE Proper identication of the unit is an important part of the total assembly, for you and your customer. Three items must be stamped on every unit: 1. Your assigned distributor code* 2. Complete order code
-13SH-BB -10

Pump identification code

3. Date code These items are to be stamped across the pilot of the body. For description and order code breakdown, see Order Code Analysis * A three digit distributor code will be assigned to each participating distributor. This code identies you as the builder and suppliers of the unit. If Sauer-Danfoss is contacted about a unit, it allows us to make proper referrals for service or additional units, and will aid us if any problems should arise. PUMPS WITHOUT FLOW DIVIDER

101-NNN-000 -A 1-N -2

AN VN -NN
-21050

999

P100 562E

1. Mount pump to test stand with recommended features. 2. Connect all required lines to pump as shown in gure I on page 23. 3. Maintain oil temperature at 110 F 5 F throughout test. 4. Jog pump to assure priming. 5. Run pump at 1800 rpm in proper rotation at minimum back pressure for one minute. 6. Increase pressure in 500 psi increments up to specied test pressure, running for one minute at each increment. 7. Check for rated ow at specied test pressure as indicated in chart on page 23. 8. Repeat steps 5 and 6 for each section of dual pumps. Connect sections not being tested to tank.

CAUSE FOR REJECTION

1. Failure to meet rated ow. 2. Air in discharge line. 3. External leakage at shaft seal, between sections, or at ports. If pump is rejected, repeat applicable steps from assembly procedure.

22

BLN-2-41714 Rev A April 2005

D Series Hydraulic Gear Pump Kit Program Assembly and Test Procedures with Part numbers Test procedure
AIR PRESSURE TEST 1. Plug pressure port(s). 2. Insert plug with air tting into tank port. Plug other tank port(s) if applicable. 3. Gradually apply air pressure from 0 to 35 psi in 15 to 20 seconds, and then hold for one minute while submerged in a petroleum based solvent. 4. Check for external air leakage. 5. Insert port protectors (cap plugs). 6. Clean exterior of pump 7. Apply rust preventative to all exposed bare metal parts. If pump is rejected, repeat applicable steps from assembly procedure. PUMPS WITHOUT FLOW DIVIDER SCHEMATIC

P100 561E

Figure I

PRESSURE AND FLOW DATA

Pump Size
07 10 13 14 17 19 21 23 25 29 32 38 41

Test pressure (psi)


3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3500 3000

Minimum ow required (GPM)


2.8 3.8 5.1 5.8 6.9 7.7 8.5 9.3 10.5 12.0 13.2 15.7 16.9

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Sauer-Danfoss Hydraulic Power Systems Market Leaders Worldwide Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market. Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others. We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them. Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design. Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000, Fax: +1 515 239 6618 Sauer-Danfoss GmbH & Co. OHG Postfach 2460, D-24531 Neumnster Krokamp 35, D-24539 Neumnster, Germany Phone +49 4321 871-0, Fax: +49 4321 871 122 Sauer-Danfoss A/S DK-6430 Nordborg, Denmark Phone: +45 7488 4444, Fax: +45 7488 4400

BLN-2-41714 Rev A April 2005

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