Series 45 E Frame Open Circuit Sauer-Danfoss Axial Piston .

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Series 45E FrameOpen CircuitAxial Piston PumpsService Manual

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualRevisionsHISTORY OF REVISIONSTable of RevisionsDatePageChangedRev.October 2012April 2011November 2010February 2010July 2009March 2008March 200515-1624lastlast2112-add control typescorrection to installation of shipping cover.new last pageFix Osaka addressPressure change - PC adjustment specsadded new displacement limiter specsFirst editionAGAFAEADACABA 2012 Sauer-Danfoss. All rights reserved.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 productsalready ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks inthis material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype aretrademarks of the Sauer-Danfoss Group.2520L0606 Rev AG October 2012

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualINTRODUCTIONOverview. 5Safety precautions. 5Unintended machine movement. 5Flammable cleaning solvents. 5Fluid under pressure. 5Personal safety. 5Symbols used in Sauer-Danfoss literature. 6General description. 7System circuit. 8TECHNICALSPECIFICATIONSGeneral specifications. 9Type of mounting. 9Auxiliary mounting pad options. 9Control options. 9Port options. 9Direction of rotation. 9Installation position. 9Technical specifications. 9Hydraulic parameters.10Inlet pressure.10Pressure compensator valve setting.10Case pressure.10Hydraulic fluid . .10Fluid viscosity.11Filtration .11FEATURESDisplacement limiter.12Auxiliary mounting pads.12Input shafts.12Control options.13PC control.13LS control.14Electric Proportional Controls.15Electric On/Off Controls.15PRESSUREMEASUREMENTRequired tools.16Port locations and gauge installation.16INITIAL START-UPPROCEDURESGeneral.17Start-up procedure.17FLUID AND FILTERMAINTENANCERecommendations.18520L0606 Rev AG October 20123

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualTROUBLESHOOTINGExcessive noise and / or vibration.19Actuator response is sluggish.19System operating hot.20Low pump output flow.20Pressure or flow instability.20System pressure not reaching PC setting.21High inlet vacuum.21ADJUSTMENTSPC control.22LS control.23MINOR REPAIRShaft seal replacement.24Auxiliary pads.25LS and PC Controls.26Electric Controls.28Servo Control Orifice.30Plug and fitting sizes and torques.314520L0606 Rev AG October 2012

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualIntroductionOVERVIEWThis manual includes information for the installation, maintenance, and minor repair ofthe Series 45 frame E open circuit axial piston pumps. The manual includes a descriptionof the units and their individual components, troubleshooting information, and minorrepair procedures. Performing installation, maintenance, and minor repair of Series 45 Eframe axial piston pumps according to the procedures in this manual will not affect yourwarranty.Performing minor repairs requires the unit to be removed from the vehicle/machine.Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirtand contamination are the greatest enemies of any type of hydraulic equipment, followcleanliness requirements strictly. This is especially important when changing the systemfilter and when removing hoses or plumbing.A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is availablefor major repairs. Major repairs require the removal of the unit’s endcap, which voidsthe warranty unless done by an ASC. Sauer-Danfoss ASCs are trained by the factory andcertified on a regular basis. You can locate your nearest ASC using the distributor locatorat www.sauer-danfoss.comSAFETY PRECAUTIONSAlways consider safety precautions before beginning a service procedure. Protectyourself and others from injury. Take these general precautions whenever servicing ahydraulic system.Unintended machine movement WarningUnintended movement of the machine or mechanism may cause injury to the technicianor bystanders. To protect against unintended movement, secure the machine ordisable / disconnect the mechanism while servicing.Flammable cleaning solvents WarningSome cleaning solvents are flammable. To avoid possible fire, do not use cleaningsolvents in an area where a source of ignition may be present.Fluid under pressure WarningEscaping hydraulic fluid under pressure can have sufficient force to penetrate your skincausing serious injury and/or infection. This fluid may also be hot enough to cause burns.Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in thesystem before removing hoses, fittings, gauges, or components. Never use your handor any other body part to check for leaks in a pressurized line. Seek medical attentionimmediately if you are cut by hydraulic fluid.Personal safety WarningProtect yourself from injury. Use proper safety equipment, including safety glasses, at alltimes.520L0606 Rev AG October 20125

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualIntroductionSYMBOLS USED INSAUER-DANFOSSLITERATUREThese symbols are in the illustrations and text of this manual. They communicate helpfulinformation at the point where it is most useful to the reader.In most instances, the appearance of the symbol itself denotes its meaning. The legendbelow defines the symbol and explains its purpose. WARNING may result in injury Tip, helpful suggestion CAUTION may result in damage toproduct or property Lubricate with hydraulic fluid Reusable part Non-reusable part, use a new part Non-removable item Option – either part may exist Superseded – parts are notinterchangeable 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 installationsleeve Torx head O-ring boss port6 Apply grease / petroleum jelly520L0606 Rev AG October 2012 Pressure measurement / gaugelocation or specification

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualIntroductionGENERAL DESCRIPTIONSauer-Danfoss Series 45 E frame open circuit piston pumps convert input torque intohydraulic power. Rotational force is transmitted through the input shaft to the cylinderblock. The input shaft is supported by tapered roller bearings at the front and rear ofthe pump and is splined into the cylinder block . A lip-seal at the front end of the pumpprevents leakage where the shaft exits the pump housing. The spinning cylinder blockcontains nine reciprocating pistons. Each piston has a brass slipper connected at one endby a ball joint. The slippers are held to the swashplate by the spring retainer and blockspring. The block spring also holds the cylinder block to the valve plate. The reciprocatingmovement of the pistons occurs as the slippers slide against the inclined swashplateduring rotation. Via the valve plate, one half of the cylinder block is connected to pumpinlet and the other half to pump outlet. As each piston cycles in and out of its bore, fluidis drawn from the inlet and displaced to the outlet thereby imparting power into thesystem circuit. A small amount of fluid is allowed to “leak” from the cylinder block / valveplate and slipper / swashplate interfaces for lubrication and cooling. Case drain ports areprovided to return this fluid to the reservoir.The volume of fluid displaced into the system circuit is controlled by the angle of theswashplate. The swashplate is forced into an inclined position (into stroke) by the biaspiston and spring. The servo piston opposes the action of the bias piston and springforcing the swashplate out of stroke when hydraulic pressure in the control circuit risesabove the spring force.The pump control, by varying the pressure at the servo piston, controls the displacementof fluid in the system circuit. Controls designed for Pressure Compensation (PC) orLoad Sensing (LS) are available. For a detailed description of control operation, refer toControl options, operation, page 13.Pump and control sectional viewLS control(attached to endcap)LS adjustmentLS spoolPC adjustmentPC spoolLifting lugServo piston guideAdjustabledisplacementlimiterServo pistonSlipper retainerShaft sealValve plateCylinder blockBlockspringInput plateSlipperBias springBias piston guide520L0606 Rev AG October 2012Bias pistonPistonP104001E7

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualIntroductionSYSTEM CIRCUITThe pump receives fluid directly from the reservoir through the inlet line. A screenplaced in the inlet protects the pump from large contaminants. The output of the pumpis directed to a PVG-32 multi-section load sensing directional control valve which directsfluid to the actuators in the system. Fluid returning from the system is cooled by a heatexchanger and cleaned by a filter before returning to the reservoir.The speed of the actuators in the system depends on the volume of fluid being providedby the pump. The operating pressure varies depending on actuator load, but is limited toan adjustable maximum setting by the PC section of the pump control and by a systemrelief valve integrated into the side module of the PVG valve.The position of the PVG valve sets the demand for flow in the system and communicatesthis to the pump control by means of a hydraulic signal (load sense signal). The pump willprovide as much flow to the system as it demands1 while limiting the maximum pressure.Therefore flow and pressure in the system are compensated to meet requirements.Pictorial circuit diagramE Frame Series 45open circuit axialpiston pump withload sensing controlDouble-acting cylinderPVG algear motorSystem pressureServo pressureReservoirFilterHeat exchangerActuator pressureLoad sense pressureActuator returnSuction / case drain /system returnP104 045EFull available flow is a function of pump displacement, operating speed, and efficiency. Refer to Series 45 AxialPiston Open Circuit Pumps Technical Information, 520L0519 for details.18520L0606 Rev AG October 2012

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualTechnical specificationsGENERALSPECIFICATIONSType of mountingSAE-C mounting flange.Auxiliary mounting pad optionsSAE-A, SAE-B, SAE-B-B, SAE-C, SAE C-CControl optionsPC: Pressure CompensatorLS: Load Sensing (with PC)Port optionsInlet and system ports: SAE flanged ports, code 61 Inlet Code 62 outlet.Axial (end) ports or radial (side) ports.All other ports:SAE straight thread O-ring boss.Direction of rotationClockwise or counterclockwise.Installation positionInstallation position is discretionary. To satisfy inlet pressure conditions, it isrecommended that the pump always be located below the lowest level of hydraulic fluidin the reservoir. The housing must always be filled with hydraulic fluid.Technical specificationsModelFeatures and optionsFeatureMaximum DisplacementUnitcm³ [in³]l/minFlow at rated speed (theoretical)[US gal/min]Input torque at maximum displacement N m/bar(theoretical)[lbf in/1000 psi]Mass moment of inertia of internalkg m²rotating components[slug ft²]Axial portskg [lb]WeightRadial portsRotationMountingAuxiliary mountingSystem ports (type)System ports (location)Control typesSplinedShaftsStraightDisplacement limiters520L0606 Rev AG October 2012E100B100 30 [7.93]147 280.0128[0.0094][0.0094]51.3 [113]54.9 [121]Clockwise, CounterclockwiseSAE-CSAE-A, SAE-B, SAE-BB, SAE-C, SAE-CC4-bolt split flangeAxial, RadialPC, Remote PC, LS, LS with internal bleed13-tooth, 14-tooth, 17-toothØ 38.08 mm [1.5 in]Optional, adjustable9

Series 45 E Frame Open Circuit Axial Piston PumpsService ManualTechnical ngInput speed¹Working pressureExternal shaftloadsBearing lifeMounting flangeload umcontinuousmaximumcontinuousmaximumExternal moment (Me)Thrust in (Tin), out (Tout)Thrust 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)min-1 (rpm)bar [psi]N m [lbf in]N [lbf ]B10 hoursN m [lbf in]E100B50024502880310 [4495]400 [5800]455 [4030]2846 [640]7740 [1740]77 20019 80097005400E130B50022002600310 [4495]400 [5800]360 [3190]1735 [390]6672 [1500]32 7008400411623001920 [17 000]6779 [60 000]E147C50021002475260 [3770]350 [5075]396 [3500]2113 [475]7117 [1600]21 60055002700—Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs. speed charts.Inlet pressureMinimum pressure, continuous 0.8 bar absolute [6.7 inch Hg vac](at reduced maximum pump speed)Minimum pressure, cold start 0.5

the Series 45 frame E open circuit axial piston pumps. The manual includes a description of the units and their individual components, troubleshooting information, and minor repair procedures. Performing installation, maintenance, and minor repair of Series 45 E frame axial piston pumps according to the procedures in this manual will not affect .

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