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Series 45 Frame G

Open Circuit Axial
Piston Pumps

Service Manual

Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Revisions
History of Revisions

Table of Revisions
Date

Page

Changed

December 2010
March 2003

last
-

New Back Page
First revision

Rev.
AB
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520L0605 • Rev AB • December 2010

.....................................................................................................................................................................................................................16 Fluid and filter maintenance Recommendations.................................................................................................................................................................................................................................................................................................................................................13 Control options........................................................................................................................... 7 System circuit.................................................................................................................................................................................................................................................... 8 Technical specifications General specifications................................................... 5 Symbols used in Sauer-Danfoss literature............................................Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Introduction Overview................................................................................................................................................................................................................. 9 General specifications (continued).............14 Pressure measurement Required tools....................... 9 Direction of rotation...........12 Auxiliary mounting pads.......................... 9 Type of mounting...................................... 9 Port options...11 Features Displacement limiter..................................................................................................................10 Hydraulic fluid ...................................................................................................................................................................................................................................................... 5 Personal safety................................................................11 Temperature range................................................................................... 9 Installation position........................................................................................13 Operation.................................................................................................................................................................................................................................................................................................................10 Pressure compensator valve setting....................................................................................................................15 Initial start-up procedures General................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................10 Inlet pressure.... 9 Technical specifications..................................................10 Hydraulic parameters................................................................................................. 6 General description................................................................................................................................................................................................................................................ 9 Auxiliary mounting pad options........... 9 Control options......................................................................................................................................................................................10 Case pressure......................................................................................17 520L0605 • Rev AB • December 2010 3 ................... 5 Fluid under pressure............................................................11 Filtration .................................................................................................................................................................................................................................................................................................................................................................................................................................................................................15 Port locations and gauge installation....................11 Fluid viscosity........................................ .......................................10 Hydraulic parameters (continued)............................................................................ 5 Flammable cleaning solvents........................................12 Control options............................................................................................................................................................................................... 5 Unintended machine movement..16 Start-up procedure..........................................12 Input shafts..................................................................................................................................................................................................... 5 Safety precautions..................................................

...............................................................................................26 Plug and fitting sizes and torques...........................................................................................................................................................................................................18 System operating hot............................25 Control (continued)..........................................................................25 Inspection................................................................19 Pressure or flow instability (continued)........................................................19 Low pump output flow.........................................................................................................19 Pressure or flow instability............................................................................................................................................................................................................20 High inlet vacuum..................................................................................................................................20 Adjustments PC control........................................................................................................25 Disassembly......Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Troubleshooting Excessive noise and / or vibration.........................23 Removal........................................................................................................................................22 Minor repair Shaft seal replacement......................................................................................................24 Control.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................21 LS control........20 System pressure not reaching PC setting...........................................................................................................................................................................24 Installation....................24 Removal.............................................23 Installation..................27 4 520L0605 • Rev AB • December 2010 .................................................................................................................................................................................................................................................................................................................................................................................23 Auxiliary pads.....................................................................................................26 Reassembly...................................................................................................................................................18 Actuator response is sluggish......................................................................................................................................................................................................................................................................

Since dirt and contamination are the greatest enemies of any type of hydraulic equipment. To protect against unintended movement. at all times. Use proper safety equipment.sauer-danfoss. gauges. Never use your hand or any other body part to check for leaks in a pressurized line. including safety glasses. Flammable cleaning solvents  Warning Some cleaning solvents are flammable. This fluid may also be hot enough to cause burns.com Safety precautions Always consider safety precautions before beginning a service procedure. and minor repair of Series 45 G Frame axial piston pumps according to the procedures in this manual will not affect your warranty. and minor repair of the Series 45 frame G open circuit axial piston pumps. Seek medical attention immediately if you are cut by hydraulic fluid. This is especially important when changing the system filter and when removing hoses or plumbing. follow cleanliness requirements strictly. Performing installation.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Introduction Overview This manual includes information for the installation. Unintended machine movement  Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Take these general precautions whenever servicing a hydraulic system. or repair activities. You can locate your nearest ASC using the distributor locator at www. troubleshooting information. Personal safety  Warning Protect yourself from injury. maintenance. Thoroughly clean the unit before beginning maintenance. Fluid under pressure  Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. Major repairs require the removal of the unit’s endcap. or components. A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is available for major repairs. 520L0605 • Rev AB • December 2010 5 . Relieve pressure in the system before removing hoses. Protect yourself and others from injury. Use caution when dealing with hydraulic fluid under pressure. which voids the warranty unless done by an ASC. The manual includes a description of the units and their individual components. do not use cleaning solvents in an area where a source of ignition may be present. maintenance. Performing minor repairs requires the unit to be removed from the vehicle/machine. Sauer-Danfoss ASCs are trained by the factory and certified on a regular basis. To avoid possible fire. fittings. and minor repair procedures. secure the machine or disable / disconnect the mechanism while servicing.

helpful suggestion  CAUTION may result in damage to product or property  Lubricate with hydraulic fluid  Reusable part  Non-reusable part.  WARNING may result in injury  Tip. In most instances. They communicate helpful information at the point where it is most useful to the reader. use a new part  Non-removable item  Option – either part may exist  Superseded – parts are not interchangeable  Apply locking compound  Inspect for wear or damage  Clean area or part  Be careful not to scratch or damage  Note correct orientation  Measurement required  Mark orientation for reinstallation  Flatness specification  Torque specification  Parallelism specification  Press in – press fit  External hex head  Pull out with tool – press fit  Internal hex head  Cover splines with installation sleeve  Torx head  O-ring boss port 6  Apply grease / petroleum jelly 520L0605 • Rev AB • December 2010  Pressure measurement / gauge location or specification . The legend below defines the symbol and explains its purpose. the appearance of the symbol itself denotes its meaning.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Introduction Symbols used in Sauer-Danfoss literature These symbols are in the illustrations and text of this manual.

The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. Case drain ports are provided to return this fluid to the reservoir. The pump control. As each piston cycles in and out of its bore. The servo piston opposes the action of the bias piston and spring forcing the swashplate out of stroke when hydraulic pressure in the control circuit rises above the spring force. fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit. For a detailed description of control operation. refer to Control options. Each piston has a brass slipper connected at one end by a ball joint. The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block . The spinning cylinder block contains nine reciprocating pistons. A small amount of fluid is allowed to “leak” from the cylinder block / valve plate and slipper / swashplate interfaces for lubrication and cooling. operation. The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate. The swashplate is forced into an inclined position (into stroke) by the bias piston and spring. page 13. One half of the cylinder block is connected to pump inlet and the other half to pump outlet.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Introduction General description Sauer-Danfoss Series 45 G Frame open circuit piston pumps convert input torque into hydraulic power. Pump and control sectional view LS control (attached to endcap) LS spool LS adjustment PC spool PC adjustment Displacement piston Swashplate Cylinder block Slipper retainer Tapered roller bearing Valve plate Shaft seal Cylinder block spring Tapered roller bearing Input shaft Slipper Piston Bias piston Bias spring Bias piston guide 520L0605 • Rev AB • December 2010 P104 002E 7 . by varying the pressure at the servo piston. controls the displacement of fluid in the system circuit. The block spring also holds the cylinder block to the valve plate. A lip-seal at the front end of the pump prevents leakage where the shaft exits the pump housing. Controls designed for Pressure Compensation (PC) or Load Sensing (LS) are available. The slippers are held to the swashplate by the spring retainer and block spring. via the valve plate. Rotational force is transmitted through the input shaft to the cylinder block.

and efficiency. Refer to Series 45 Axial Piston Open Circuit Pumps Technical Information. 520L0519 for details.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Introduction System circuit The pump receives fluid directly from the reservoir through the inlet line. The output of the pump is directed to a PVG-32 multi-section load sensing directional control valve which directs fluid to the actuators in the system. Therefore flow and pressure in the system are compensated to meet requirements. but is limited to an adjustable maximum setting by the PC section of the pump control and by a system relief valve integrated into the side module of the PVG valve. A screen placed in the inlet protects the pump from large contaminants. operating speed. Fluid returning from the system is cooled by a heat exchanger and cleaned by a filter before returning to the reservoir. The pump will provide as much flow to the system as it demands1 while limiting the maximum pressure. The operating pressure varies depending on actuator load. The speed of the actuators in the system depends on the volume of fluid being provided by the pump. The position of the PVG valve sets the demand for flow in the system and communicates this to the pump control by means of a hydraulic signal (load sense signal). 1 8 520L0605 • Rev AB • December 2010 . Pictorial circuit diagram Double-acting cylinder G Frame Series 45 open circuit axial piston pump with load sensing control PVG 32 mulit-section load sensing control valve Bi-directional gear motor System pressure Servo pressure Heat exchanger Reservoir Filter Actuator pressure Load sense pressure Actuator return Suction / case drain / system return P106 067E Full available flow is a function of pump displacement.

52] 177.00480] 29 [63] 36 [80] Clockwise. Technical specifications Model Features and options Feature Maximum Displacement Flow at rated speed (theoretical) Unit cm³ [in³] l/min [US gal/min] Input torque at maximum displacement N•m/bar (theoretical) [lbf•in/1000 psi] Mass moment of inertia of internal kg•m² rotating components [slug•ft²] Weight Axial ports kg [lb] Radial ports Rotation Mounting Auxiliary mounting System ports (type) System ports (location) Control types Shafts Splined Straight Displacement limiters 520L0605 • Rev AB • December 2010 G74B 74 [4. SAE C-C Control options PC: Pressure Compensator LS: Load Sensing (with PC) Port options Inlet and system ports: SAE flanged ports.6 [46.75 mm [1. Counterclockwise SAE-C SAE-A. Radial PC. Remote PC. SAE-B. All other ports: SAE straight thread O-ring boss. 17 tooth Ø 31. Axial (end) ports or radial (side) ports.432 [874] 0. it is recommended that the pump always be located below the lowest level of hydraulic fluid in the reservoir.178 [719] 0. SAE-B. LS.49] 198 [52. SAE-C 4-bolt split flange Axial.00650 [0. SAE-BB.00630 [0.3] 1. Auxiliary mounting pad options SAE-A. code 61 Inlet Code 62 outlet. SAE-C. To satisfy inlet pressure conditions. SAE-B-B.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications General specifications Type of mounting SAE-C mounting flange.25 in] Optional. LS with internal bleed 14 tooth. adjustable 9 .00465] G90C 90 [5. Installation position Installation position is discretionary. Direction of rotation Clockwise or counterclockwise.9] 1. The housing must always be filled with hydraulic fluid.

For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids.5 bar absolute [15.7 inch Hg vac] (at reduced maximum pump speed) Minimum pressure.1 inch Hg vac] Pressure compensator valve setting PC control setting range Model G74B G90C bar 100–310 100–260 psi 1450–4495 1450–3770 Case pressure Maximum continuous: 0. Inlet pressure Minimum pressure. cold start = 0. page 17 for recommended fluid and filter change intervals. See Fluid and filter maintenance. out (Tout) at 140 bar [2030 psi] at 210 bar [3045 psi] at 260 bar [3770 psi] at 310 bar [4495 psi] Vibratory (continuous) Shock (max) Units min-1 (rpm) bar [psi] N•m [lbf•in] N [lbf ] B10 hours N•m [lbf•in] G74B 500 2400 2800 310 [4495] 400 [5800] G90C 500 2200 2600 260 [3770] 350 [5075] 300 [2655] 2900 [650] 41 383 9048 4062 2101 19 847 4339 1948 — 1580 [14 000] 5650 [50 000] Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs.8 bar absolute [6. 520L0465. speed charts.5 bar [7 psi] Above inlet Intermittent: 2 bar [29 psi] Cold start Hydraulic fluid Refer to Sauer-Danfoss publication Fluids and Filtration BLN-9887 or 520L0463. Hydraulic parameters Model Ratings minimum continuous maximum continuous maximum External moment (Me) Thrust in (Tin). 10 520L0605 • Rev AB • December 2010 . continuous = 0.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications General specifications (continued) Rating Input speed1 Working pressure External shaft loads Bearing life Mounting flange load moments 1.

Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Technical specifications Hydraulic parameters (continued) Temperature range Temperature limits Minimum (intermittent.g. drain line. continuous intermittent continuous intermittent (cold start) mm2/s (cSt) SUS 9 6. cold start) Continuous¹ Maximum2 . As measured at the hottest point in the system.40° F] 82° C [180° F] 104° C [220° F] Fluid viscosity Fluid viscosity limits Condition ν min. 1 2 Hydraulic fluid viscosity must be maintained within the prescribed limits. 520L0605 • Rev AB • December 2010 11 .40° C [. ν max.4 110 58 47 500 1000 4700 Filtration Required cleanliness level: ISO 4406 Class 18/13 or better. See Fluid and filter maintenance. e. Refer to Sauer-Danfoss publications Fluids and Filtration BLN-9887 or 520L0463 and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465. page 17 for recommended fluid and filter change intervals.

12 520L0605 • Rev AB • December 2010 . For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519. P106 023 Input shafts Series 45 G Frame pumps are available with a variety of splined and straight keyed shafts. The adjustable stop limits the pump’s maximum displacement. Oil from the main pump case lubricates the drive coupling.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Features Displacement limiter Frame G Series 45 pumps are available with an optional adjustable maximum displacement limiter. you must use an O-ring to seal the auxiliary pump mounting flange to the pad. The displacement change is 6.5 cc/turn [0. Displacement limiter P104 026 Auxiliary pad options Auxiliary mounting pads Auxiliary mounting pads are available for all radial ported Series 45 pumps.40 in³/turn ] of the displacement limiter adjustment screw. For details refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519. Since the auxiliary pad operates under case pressure. These pads are typically used for mounting auxiliary hydraulic pumps.

Swashplate angle determines pump outlet flow. Cross-section PC control 4 6 5 P104 049 PC spool shifts to port system pressure to When system pressure. acting on the servo piston non-spring end of the PC spool (6). Cross-section pump 3 1 2 P106 068E Bias spring and servo piston set swashplate position PC control The PC control design maintains a constant pressure in the hydraulic circuit as flow varies. a Load Sensing (LS) control with Pressure Compensator (PC) or a PC only control. The servo piston (3) acts against the bias piston and spring to reduce the swashplate angle causing the pump to destroke. the spool shifts porting system pressure to the servo piston and the swashplate angle decreases. The swashplate is maintained at whatever angle is required to keep system pressure at the PC setting. the PC spring shifts the spool in the opposite direction connecting the servo piston to pump case and the swashplate angle increases. sets swashplate angle by metering system pressure to the servo piston. overcomes the force of the PC spring. Operation General The bias piston and spring (1) acts at all times to push the swashplate (2) to maximum angle causing the pump to stroke. When system pressure drops below the PC setting. The pump control. depending on conditions in the system circuit. 520L0605 • Rev AB • December 2010 13 .Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Features Control options The Series 45 Frames G have two possible control options. The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as the PC adjusting plug (4) and spring (5) defines.

When opening. The PC spool (6) controls the pressurecompensating function of the control as previously described. As the ECV opens and closes. LS spool shifts to port system pressure to servo and through hydraulic line connected at piston port X. the pump attempts to deliver full flow to the hydraulic system. The pump strokes increasing flow until the delta across the ECV becomes equal to the LS setting. With no LS pressure acting on the non-spring end of the LS spool. the pressure delta across the ECV is great enough to overcome spring force and shift the LS spool porting system pressure to the servo piston. Through internal porting. This arrangement allows the LS spool to act on the delta between system pressure and LS pressure. The pump is now in standby mode. 6Spool Spring Spring (PC heavy) guide Because the swashplate is biased to maximum angle. The LS spool (9) controls the load-sensing function. Because of the series arrangement of the LS and PC spools. The LS control senses the flow demand of the system as a pressure drop across the External Control Valve (ECV). The LS control then increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjusting plug (7) and spring (8). the PC spool will override the LS spool.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Features Control options (continued) LS control The LS control design matches pump flow with system demand. thus porting system pressure to the servo piston causing the pump to destroke. the pressure delta across the valve changes. If at any time system pressure reaches the PC setting. LS pressure (downstream of ECV) is applied to the spring end. Cross-section LS control 9Spool Plug Plug Spring Spring guide 8 LS spring 7LS adjusting plug PC adjusting plug Typical load-sensing control valve Load 2 pressure Return pressure Tank Load sense pressure System 2 pressure P101 665E Pressure drop across external control valve defines system demand The LS control consists of two spool valves that connect the servo piston either to pump case or system pressure. The LS spring sets the threshold of operation (LS setting). it connects the LS signal line to drain. system pressure (upstream of ECV) is applied P104 051 to the non-spring end of the LS spool. the PC spool will shift blocking the passage that connects the LS spool with the servo piston. When flow being delivered is less than demand. When the flow being delivered exceeds demand. the pump adjusts stroke to whatever position necessary to maintain system pressure at the LS setting. The PC spool has priority over the LS spool. 14 520L0605 • Rev AB • December 2010 . When the external control valve is placed in neutral. the delta decreases. the delta across the ECV drops below the LS setting and the LS spring shifts the spool connecting the servo piston to pump case. When closing. The pump de-strokes reducing flow until the delta across the ECV becomes equal to the LS setting. the delta increases.

Recommended pressure gauges and fittings are in the table.18 O-ring fitting 9/16 . Calibrate pressure gauges frequently to ensure accuracy.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Pressure measurement Required tools The service procedures described in this manual can be performed using common mechanic’s hand tools.14 O-ring fitting 7/16 . if required are shown. Port locations and gauge installation The illustration below shows gauge port locations. L2 Port Purpose System pressure Servo pressure Case pressure Range of gauge 0-300 bar [0-5000 psi] 0-300 bar [0-5000 psi] 0-10 bar [0-100 psi] X1 LS signal 0-300 bar [0-5000 psi] Fitting 9/16 . Use snubbers to protect gauges. Gauge and port information M2 M4 L1. Special tools.20 O-ring fitting (tee into LS signal line) Gauge port locations X X X B S M2 L1 M4 P106 072E 520L0605 • Rev AB • December 2010 L2 Legend B = S = L1.18 O-ring fitting 7/8 . L2 = X = M2 = M4 = Main pressure line Suction line Case drain lines Load sensing pressure port Gauge port for port B* Gauge port — servo pressure *Same pressure 15 .

heat exchanger. inspect for damage incurred during shipping.) are clean prior to filling with fluid. add clean filtered fluid if necessary. 16 520L0605 • Rev AB • December 2010 . shut down the prime mover. Start-up procedure  CAUTION Incorrect shaft alignment may result in damage to drive shaft. 9. 5. increase to full operating speed. valves. Always filter fluid through a 10 micron filter pouring into the reservoir. Once system pressure is established. Be certain it is free of restrictions and air leaks. If system pressure is not maintained. Replace plug at port M1 or M2. 7. Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Follow recommendations in the vehicle / machine operator’s manual for prime mover start up procedures. hoses. etc. bearings. 4. Check the inlet line for properly tightened fittings. Prior to installing the pump. page 17. Fill the inlet line leading from the pump to the reservoir. Check and adjust control settings as necessary after installation.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Initial start-up procedures General Follow this procedure when starting-up a new Series 45 installation or when restarting an installation in which the pump has been removed. Ensure that pump shaft is properly aligned with the shaft of the prime mover. Refer to Troubleshooting. and take corrective action. Never reuse hydraulic fluid.  2. While watching the pressure gauge installed at M1 or M2. Fill the main pump housing with clean hydraulic fluid. Operate the hydraulic system for at least fifteen minutes under light load conditions. 1. Shut down the prime mover and remove the pressure gauge. install the case drain line in the upper most case drain port. To protect against unintended movement. The pump is now ready for operation. 6. Pour filtered oil directly into the upper most case drain port. To ensure the pump stays filled with oil. or seal which can cause external oil leakage. Fill the reservoir with recommended hydraulic fluid. 11. Install a gauge at port M1 or M2 to monitor system pressure during start up. 10. Check the fluid level in the reservoir. secure the machine or disable / disconnect the mechanism while servicing. jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels (minimum 11 bar [160 psi]). 8. 3. fittings. Refer to Adjustments. page 21. determine cause. Connect the pump to the prime mover. Make certain all system components (reservoir.

water. and rancid fluid odor. 520L0605 • Rev AB • December 2010 17 . Dispose of used hydraulic fluid properly. Rancid odor indicates the fluid has been exposed to excessive heat. Contaminated fluid is the main cause of unit failure. Replace all fluid lost during filter change. etc. Change the fluid and filter per the vehicle / machine manufacturer’s recommendations or at these intervals: Fluid and filter change interval Reservoir type Sealed Breather Maximum change interval 2000 hours 500 hours Change the fluid more frequently if it becomes contaminated with foreign matter (dirt.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Fluid and filter maintenance Recommendations To ensure optimum life of Series 45 products. Never reuse hydraulic fluid. Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter. Change the fluid immediately if these conditions occur. Water in the fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir. grease. Check the reservoir daily for proper fluid level. Take care to maintain fluid cleanliness when servicing. Correct the problem immediately. perform regular maintenance of the fluid and filter.) or if the fluid is subjected to temperature levels greater than the recommended maximum. the presence of water.

Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly. 18 520L0605 • Rev AB • December 2010 Description Insufficient hydraulic fluid causes cavitation. Check inlet for leaks. Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures. Repair or replace system valving as required. Description Low external relief valve setting slows down system. Inspect shaft couplings. Check LS control signal pressures. Allow system to warm up before operating. High inlet vacuum causes low output flow. erratic control. Check pump inlet pressure / vacuum. Refer to Hydraulic parameters. Check external system valving. page 10. Correct inlet pressure conditions. Check pump inlet pressure / vacuum. Series 45 Technical Information Manual. Air in system causes noisy. Action Fill the reservoir to proper level. Correct pump inlet pressure / vacuum conditions. Check PC and LS control setting. Action Adjust external relief valve setting following manufacturer’s recommendations. Worn internal parts don’t allow the pump to operate properly. Inspect system to ensure that proper LS signal transmit to pump. 520L0519. or use fluid with the appropriate viscosity grade for expected operating temperatures. Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly. Misaligned shafts create excessive noise and / or vibration. . page 20. Internal system leaks. A loose or incorrect shaft coupling causes excessive noise and / or vibration. Incorrect LS signal will not allow pump to operate correctly. Hydraulic fluid viscosity above acceptable limits. Hydraulic fluid viscosity above acceptable limits. Check for air in system. Correct shaft misalignment. See Hydraulic Fluids. Adjust PC and LS setting. Malfunctioning valving may not allow system to respond properly. Correct case drain line restrictions. Check shaft alignment. Low PC setting prevents the pump from achieving full stroke. Check pump case pressure.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Troubleshooting Excessive noise and / or vibration Item Check fluid level in reservoir. Refer to Authorized Service Center for required repair. Series 45 Technical Information Manual. Repair or replace coupling and ensure that correct coupling is used. See Hydraulic Fluids. Purge air and tighten fittings. High case pressure causes the system to be sluggish. External relief setting must be above PC setting to operate properly. Refer to Adjustments. Actuator response is sluggish Item Check external system relief valve setting. Low LS setting limits output flow. Improper inlet conditions cause erratic behavior and low output flow. 520L0519.

or use fluid with the Fluid viscosity above acceptable appropriate viscosity grade for limits or low fluid temperature expected operating temperatures. Description Action Insufficient hydraulic fluid will limit output flow and cause internal Fill the reservoir to proper level. Inspect heat exchanger. Low pump output flow Check external system relief valve setting. Pressure or flow instability Description Insufficient volume of hydraulic fluid will not meet cooling demands of system. Verify proper size of heat exchanger. Inspect spools for free movement in bore. High inlet vacuum adds heat to system. Clean or replace. Low input speeds decrease flow. Incorrect rotational configuration Use pump with appropriate causes low flow. page 21. Description Check for air in system. Adjustment. Check inlet line for leaks and eliminate source of air ingression. Check pump inlet pressure / vacuum. 520L0605 • Rev AB • December 2010 Action Action Activate PC allowing system to bleed air. High inlet vacuum causes low Correct inlet pressure conditions. valve setting must be above PC setting to operate properly. damage to pump. repair. or undersized heat exchangers will not meet cooling demands of the system. Sticking control spools cause erratic operation. Check pump inlet pressure / vacuum. high input air temperature. Adjust external relief valve following manufacturer’s Eternal relief valve set below PC recommendation. 19 . External relief valve setting must be above PC setting for proper operation. Technical Information Manual. 520L0519.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Troubleshooting System operating hot Item Check fluid level in reservoir. Adjust external system relief valve setting following manufacturer’s recommendations. Check external system relief valve setting. Check pump rotation. Fluid passing through relief valve adds heat to system. Air in system causes erratic operation. or replace heat exchanger as required. Item Check fluid level in reservoir. Item Fill reservoir to proper level. Check air flow and input air temperature for the heat exchanger. Clean. External relief setting causes low output flow. Insufficient air flow. Check PC and LS control setting. Correct inlet pressure / vacuum conditions. output flow. Allow system to warm up before operating. Adjust input speed. Low PC setting prevents the pump Adjust PC and LS setting. Refer to from achieving full stroke. will not allow the pump to fill or See Hydraulic fluids. Check control spools. Verify proper size of reservoir. Check input speed. Series 45 control to operate properly. Hydraulic fluid viscosity above acceptable limits. rotational configuration.

 Caution High inlet vacuum causes cavitation which can damage internal pump components. Insufficient pressure differential between PC setting and external relief valve. Adjust external relief valve or PC control settings to appropriate level. page 21. spring will cause erratic operation. Clean PC control components. Action Adjust LS setting to proper level. Item Check PC control setting. External relief compensation. Check external relief valve. Inspect inlet screen. . page 21. Broken. Action Allow system to warm up before operating. Inspect PC spool for proper orientation. Select fluid with appropriate viscosity for expected operating temperature. Check external relief valve. Relief valve setting must be above PC setting to operate properly. 520L0519. leakage in the control. System pressure not reaching PC setting Check external relief valve and PC setting. Wear of PC spool causes internal Replace the spool as required. Eliminate fittings to make path more direct. contamination. Check PC control for contamination. Refer to Adjustments. Blocked or restricted inlet screen causes high inlet vacuum. Check LS signal line. Inspect PC control spring. or long piping causes high inlet vacuum. See Hydraulic fluids. Too many fittings. Adjust or replace relief valve. take Contamination may interfere with appropriate action to eliminate movement of the PC spool. PC setting. Check inlet piping. High fluid viscosity causes high inlet vacuum. 20 Remove blockage. Hydraulic fluid viscosity above acceptable limits. Series 45 Technical Information Manual.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Troubleshooting Pressure or flow instability (continued) Item Check LS setting. High inlet vacuum Description Low LS setting may cause instability. Description Low temperature increases viscosity. damaged. Adjust external relief valve External relief valve setting below according to manufacturer’s PC setting prevents pressure recommendations. Blocked LS signal line interferes with proper LS operation. 520L0605 • Rev AB • December 2010 Description Action System pressure will not rise above Adjust PC to appropriate setting. Improper orientation results in Correct orientation of spool. High fluid viscosity causes high inlet vacuum. poor operation. or missing Replace the spring as required. Chattering external relief valve may cause unstable feedback to pump control. valve must be set above PC setting to operate properly. Inspect PC spool for wear. bends. See Adjustments. Clean screen / remove blockage. Item Check fluid temperature.

Subtract case pressure from system pressure to compute the actual setting. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. counterclockwise rotation decreases. Operate a hydraulic function to its full extension. remove the pressure gauges. Pressure measurement. secure the machine or disable / disconnect the mechanism while servicing. an external system relief valve may require adjustment.145 psi] I 3/8 in B 7/8-14 t 54 .10.8 lbf•ft] X Port 3. read page 14.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Adjustments PC control Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. 520L0519. for more information.300 bar [0 . C 2. Stop the prime mover.4351 psi] I 3/16 in B 7/16-20 t 34-68 N•m [25-50 lbf•ft] 4. Take precautions to ensure system cleanliness when removing and reinstalling system lines. P C setting is referenced to case pressure. Install a pressure gauge in case drain port L1 or L2 to measure case pressure. To protect against unintended movement. G 0-300 bar [0-5000 psi] I 3/16 in B 7/16-20 t 13-27 N•m [10-20 lbf•ft] P106 069E Gauge port M2 G 0 . approximate gain 42 bar [610 psi] per turn. Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M2 .136 N•m LS adjusting plug I6 mm [40 . Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual. PC control adjustment Case drain port L1 G 0 . Install a pressure gauge in port M1 or M2 to measure system pressure. Start the prime mover and allow fluid to reach normal operating temperature.5 . Before performing adjustments. fittings.5 . loading the pump at maximum pressure and zero flow.8 N•m [5.8 lbf•ft]. torque the PC set screw to 7. Relieve pressure in the system before removing hoses. 1.100 lbf•ft] LS set screw I 4 mm t 7.8 N•m [5. gauges. If the pressure does not increase. PC setting is indicated in the pump model code.5 - 10. 5.5 . Caution Contamination can damage internal components and void the manufacturer’s warranty. 1 520L0605 • Rev AB • December 2010 21 .10 bar [0 . Clockwise rotation increases pressure. While holding the position of the PC adjusting plug. and return the system to its normal operating configuration. External system relief valve must be set above the PC setting for proper operation. or components.

Subtract case pressure from system pressure to compute the actual setting.10 bar [0 . Clockwise rotation increases the setting. C 2. 8. The LS setting is a differential pressure.8 lbf•ft] X Port 3.5 . PC setting is referenced to case pressure. Slowly operate a hydraulic function that will demand approximately half flow from the pump. turn the LS adjusting plug until the desired pressure differential between port M1 or M2 and port X is achieved1. counterclockwise rotation decreases it. Pressure measurement.100 lbf•ft] LS adjusting plug I6 mm LS set screw I 4 mm t 7. Start the prime mover and allow fluid to reach normal operating temperature. set screw.10.4351 psi] I 3/16 in B 7/16-20 t 34-68 N•m [25-50 lbf•ft] Adjusting plug. Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow. Relieve pressure in the system before removing hoses. While holding the position of the PC adjusting plug. Tee-in a gauge to the LS / remote PC signal line (port X).300 bar [0 . External system relief valve must be set above the PC setting for proper operation.8 N•m [5. fittings. but keep system pressure below the PC set point. read page 15. an external system relief valve may require adjustment.5-8 lbf•ft]. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.5 . and gauge locations shown 6. remove the pressure gauges.8 N•m [5. or components.10.5-8 lbf•ft]. approximate gain = 17 bar [250 psi] per turn. Loosen the LS set screw. Caution Contamination can damage internal components and void the manufacturer’s warranty. 1 22 520L0605 • Rev AB • December 2010 . 1. Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M22. Clockwise rotation increases pressure. Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual.136 N•m [40 . Before performing adjustments. and return the system to its normal operating configuration. If the pressure does not increase.5 - 10. While watching the pressure gauges. Case drain port L1 G 0 . 4. To protect against unintended movement. 520L0519. 5. 7. torque the PC set screw to 7. counterclockwise rotation will decrease it. LS control adjustment G 0-300 bar [0-5000 psi] I 3/16 in B 7/16-20 t 13-27 N•m [10-20 lbf•ft] P106 069E Gauge port M2 G 0 .8 N•m [5. for more information. Take precautions to ensure system cleanliness when removing and reinstalling system lines. secure the machine or disable / disconnect the mechanism while servicing. Install a pressure gauge in drain port L1 or L2 to measure case pressure.145 psi] I 3/8 in B 7/8-14 t 54 . Install a pressure gauge in port M1 or M2 to measure system pressure. Subtract pilot pressure at port X from system pressure at port M2 to compute the actual setting. gauges. torque the LS set screw to 7. Stop the prime mover. While holding the position of the LS adjusting plug. approximate gain = 42 bar [610 psi] per turn.5 . The LS setting is indicated in the pump model code.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Adjustments LS control Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection.

Keeping the seal perpendicular to the shaft.  Install seal with the cupped side toward the shaft bearing. or contamination. Polish the sealing area on the shaft if necessary. C Shaft seal and retaining ring K010 lpd K020 b 3 Puncture the face of the seal with a packing hook. Remove the shaft seal (K020) from the bore in the pump housing and discard. Using the appropriate snap ring pliers. Removal 1. 2. Inspect the sealing area on the shaft for rust. Inspect the pump housing and new seal for damage. 8.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Shaft seal replacement The Series 45 open circuit variable pumps use a lip-type shaft seal. install the seal retaining ring. Installation 4. 7. Press the seal into the housing only far enough to clear the retaining ring groove. 520L0605 • Rev AB • December 2010 23 . wear. Using the appropriate snap-ring pliers. You can replace this seal without major disassembly of the unit. Do not damage the seal during installation. Place a protective sleeve over the shaft end to prevent damage to the seal during installation.  Caution Premature bearing failure can result if the shaft seal contacts the shaft bearing. Lubricate the lip of the new shaft seal with clean hydraulic fluid. P106 024 5. 6. Replacing the shaft seal requires removing the pump from the machine. press the new seal into the housing just far enough to clear the retaining ring groove. C Caution Don’t damage the pump housing or shaft. remove the retaining ring (K010) from the housing. Remove the installation sleeve. or use a slide-hammer type puller to remove the seal.

Installation 4. replace.61 N•m [35 .45 lbf•ft].37 lbf•ft]. 3. Remove the 4 screws (J100) retaining the pad adapter (J080) to the endcap. Do not operate pump with coupling and shipping cover installed. 6. Caution Shipping cover is intended only to retain coupling during shipment and storage. If you have an auxiliary A pad. install the screws (J131) and torque to 37 . or exchange auxiliary mounting pads. retaining the cover plate (J110) or auxiliary pump (not shown). Install the drive coupling (J140) if present. Discard the pad adapter O-ring (J090) if present.82 lbf•ft] J100 J120 P106 029E J120 J110 J130 h3/4 inch t91 .5 . Removal 1.45 lbf•ft] J110 J130 J090 dg J095 J120 J110 J080 h3/4 inch t91 . Install the screws (J130) and torque to 94 . 5.5 .82 lbf•ft].50 N•m [27 . Follow these steps to either remove. 7. Install the 4 screws (J100 ) and torque to 47. Lubricate new O-ring (J090) with petroleum jelly. Auxiliary mounting pads J095 J090 dg J140 J080 J120 J095 J080 J100 I10 mm J140 t47. Remove the screws (J130).115 N•m [67 . Remove the shipping cover or auxiliary pump and its seal (J120). Remove the drive coupling (J140) if present. Install shipping cover or auxiliary pump with seal (J120).82 lbf•ft] 24 520L0605 • Rev AB • December 2010 J140 .111 N•m [67 . Install the pad adapter to the endcap.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Auxiliary pads You may install auxiliary mounting pads on pumps equipped with through-drive radial ported end caps.  8. 2.61 N•m [35 .111 N•m [67 .

4 . springs. 2. Remove the control and discard the 4 interface O-rings (C200). Remove the LS set screw (C102). replace as necessary. C115). Carefully inspect the spools.10. Remove the PC set screw (C102). Remove the 4 screws (C300) holding the control housing onto the end cap. Inspect the springs and spring guides for wear or damage. 520L0605 • Rev AB • December 2010 25 . parts C104 through C106 and C112 through C118 are not used on PC control 7. C103A d t10.8 .10 lbf•ft] dC105A C102 I6 mm C300 I4 mm t5.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Control Disassembly 1.5 . LS adjusting plug (C118). and seat (C133). Discard the O-ring (C105A or C106A). O-ring (C118A).5. Remove the C104 plug. guides and new O-rings with clean hydraulic fluid.10 lbf•ft] C132 R e dC104A C105 RC112 I3/16 inch e t10. Discard the O-ring. Inspect the control housing for damage.8 . Inspection 8.8 lbf•ft] C200 d C133 I C135 t10. Check the ends that contact the spring guides for wear. Check the spool bores for excessive wear.5 N•m [4 . skip steps 5 through 7 t10.5 N•m [8 .5 .8 . O-ring (C103A). C135). back‑up rings (C118B).13. 4.8 N•m [5.10 lbf•ft] C104 I /16 inch 3 t7. PC adjusting plug (C138). Inspect the adjusting plugs for wear at the tips and where they contact the seat. 10.13. 6. and PC spool (C132) from the control housing.5 lbf•ft] dC106A C106 For PC only controls. Ensure the sealing lands are free of nicks and scratches. Remove the plug (C105) and O-ring (C105A). or the plug (C106) and O-ring (C106A). Clean all parts and lubricate spools. replace as necessary.13. springs (C134. and seat (C113). Note orientation of the spool for reassembly. 3.10 lbf•ft] C134 3/16 inch C113 C138A d C115 C138 i C114 dC118B E101 226 dC118A dC118B iC118 LS control shown. springs (C114. Discard the O-ring.7. discard the O-ring. Remove the plug (C103).5 N•m [8 .13. 11. Note orientation of the spool for reassembly. 9. 12. and C112 LS spool from the control housing. Discard the C118A O-ring.5 N•m [8 . Control assembly C103 I3/16 inch 5.5 N•m [8 .8 . O-ring (C138A). C104A O-ring. Replace spools as necessary.

10 lbf•ft] dC105A C102 I6 mm C300 I4 mm t5. Install and torque the LS set screw (C102) to 7. install the plug (C103). Torque the plug (C103) to 10.5 N•m [4 .5-8 lbf•ft]. Torque the screws to 5. Torque the plug (C105 or C106) to 10. Torque screws in a criss-cross pattern and retorque the first screw to ensure proper torque retention.5 N•m [8 . 26 520L0605 • Rev AB • December 2010 .7. 20.13.5 .10 lbf•ft]. 14. Place the two PC springs (C134.5 N•m [8 . 15. Torque the plug to 10. parts C104 through C106 and install into the LS bore.8 - 13.5 .5 - 10. 19.8 - 13. then make another full turn. Install the PC spool (C132).5-8 lbf•ft].5 N•m [8 . install the 4 interface O-rings (C200) in the recesses on the control housing.4 . Using petroleum jelly to retain them. C135) onto the spring guide (C133) and install into the PC bore.5 N•m [8 . install the plug (C105 or C106).5 lbf•ft]. into the PC bore.13. Place the two LS springs (C134.10 lbf•ft] C104 I3/16 inch dC106A C106 t7. install the plug (C104). spherical end first.8 .8 N•m [5. See Adjustments. then make another full turn. Install the LS spool (C112). C135) iC118 onto the spring guide (C113) and LS control shown. into the LS bore.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Control (continued) Reassembly 13.8 - 13. Using a new O-ring (C104A).4 .5 - 10. spherical end first.8 lbf•ft] C200 d C133 I C135 t10. C103A d t10.10. Place a new O-ring (C138A) onto the PC adjusting screw and thread it into the PC bore until flush.8 . Using a new O-ring (C103A). Using a new O-ring (C105A or C106A). Control assembly C103 I3/16 inch 16.10 lbf•ft].10 lbf•ft]. Place a new C112 through C118 are not used on PC control O-ring (C118A) and back-up rings (C118B) onto the LS adjusting screw and thread it into the LS bore until flush.5 N•m [8 . skip steps 15 through 17. Check and adjust the control setting.10 lbf•ft] C134 3/16 inch C113 C138A d C115 C138 i C114 dC118B E101 226 dC118A dC118B 17.5.8 . Install the control assembly onto the endcap using the 4 screws (C300). 18.8 N•m [5.5 N•m [4 .8 .5 lbf•ft] For PC only controls.5 N•m [8 .7.5 N•m [8 . page 21.13. t10.10 lbf•ft] C132 R e dC104A C105 RC112 I3/16 inch e t10.5. Install and torque the PC set screw (C102) to 7.13.8 N•m [5.

8-13.6 N•m [8-10 lbf•ft] L020 B 1-3/16 inch h 1-3/8 inch t 176-244 N•m [130-180 lbf•ft] P106 071E J040 B 7/16 inch I 3/16 inch t 10. Your configuration may differ but here is the appropriate wrench size and torque: Plug locations.8-13.5 N•m [8-10 lbf•ft] K130 B 7/8 inch I 3/8 inch t 93 N•m [70 lbf•ft] J020 J040 B 7/16 inch I 3/16 inch t 10.6 N•m [8-10 lbf•ft] K130 B 7/8 inch I 3/8 inch t 93 N•m [70 lbf•ft] 520L0605 • Rev AB • December 2010 K120 B 7/16 inch I 3/16 inch t 10.8-13.8-13.Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual Minor repair Plug and fitting sizes and torques If any plugs or fittings are removed from the unit during service.5 N•m [8-10 lbf•ft] 27 . and torques K120 B 7/16 inch I 3/16 inch t 10. sizes. install and torque as indicated here. This drawing is a composite.

And with an extensive network of Global Service Partners. Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.com Turolla www.com Schwarzmüller-Inverter www. we work closely with our customers to ensure exceptional performance for a broad range of off-highway vehicles.com for further product information. OHG Postfach 2460. so is Sauer-Danfoss.hydro-gear.schwarzmueller-inverter. Yodogawa-ku Osaka 532-0004. Germany Phone: +49 4321 871 0 Fax: +49 4321 871 122 Sauer-Danfoss-Daikin LTD. 6F 1-5-28 Nishimiyahara.sauer-danfoss-daikin. Japan Phone: +81 6 6395 6066 Fax: +81 6 6395 8585 www. We offer expert worldwide support for our customers. Shin-Osaka TERASAKI 3rd Bldg. Building on our extensive applications expertise. Denmark Phone: +45 7488 4444 Fax: +45 7488 4400 Sauer-Danfoss GmbH & Co. • Integrated Systems • Joysticks and Control Handles • Microcontrollers and Software Go to www. reduce costs and bring vehicles to market faster.com Sauer-Danfoss (US) Company 2800 East 13th Street Ames. We help OEMs around the world speed up system development. ensuring the best possible solutions for outstanding performance.Products we offer: • Bent Axis Motors • Closed Circuit Axial Piston Pumps and Motors • Displays • Electrohydraulic Power Steering • Electrohydraulics • Hydraulic Power Steering Sauer-Danfoss is a global manufacturer and supplier of highquality hydraulic and electronic components.sauer-danfoss.turollaocg. D-24539 Neumünster. D-24531 Neumünster Krokamp 35. USA Phone: +1 515 239 6000 Fax: +1 515 239 6618 Sauer-Danfoss ApS DK-6430 Nordborg.com Sauer-Danfoss-Daikin www. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market.comatrol.sauer-danfoss. IA 50010. • Open Circuit Axial Piston Pumps • Orbital Motors • PLUS+1™ GUIDE • Proportional Valves • Sensors • Steering Wherever off-highway vehicles are at work.com Hydro-Gear www. • Transit Mixer Drives Please contact the Sauer-Danfoss representative nearest you. Local address: Members of the Sauer-Danfoss Group: Comatrol www. we also provide comprehensive global service for all of our components.com 520L0605 • Rev AB • December 2010 .