Series 45 Frame K And L Open Circuit Axial Piston Pumps .

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Series 45Frame K and LOpen CircuitAxial Piston PumpsService ManualDisplacement PistonPistonSwashplateTapered RollerBearingTapered RollerBearingShaft SealValve PlateCylinder Block Kit

Series 45 Frame K and L Open Circuit Axial Piston PumpsService ManualContentsINTRODUCTIONUsing this manual . 4Safety precautions . 4Unintended machine movement. 4Flammable cleaning solvents . 4Fluid under pressure . 4Personal safety . 4Symbols used in Sauer-Danfoss literature. 5General description . 6Pump and control sectional view . 6The system circuit . 7Pictorial circuit diagram. 7TECHNICALSPECIFICATIONSGeneral specifications . 8Type of mounting. 8Auxiliary mounting pad options. 8Control options . 8Port options. 8Direction of rotation. 8Installation position. 8Technical specifications . 8Ratings . 8Hydraulic parameters. 9Inlet pressure . 9Pressure compensator valve setting . 9Case pressure. 9Hydraulic fluid . 9Temperature range1 . 9Fluid viscosity . 9Viscosity limits. 9Filtration . 9FEATURESDisplacement limiter.10Auxiliary mounting pads .10Input shafts.10Displacement limiter .10Auxiliary mounting pads.10Control options .12Cross-section PC control.12Operation .12General.12PC control.12Cross-section pump .12Cross-section LS control .13LS control .13Typical load-sensing control valve.13 2001 Sauer-Danfoss. Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material. Sauer-Danfossreserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be madewithout subsequent changes being necessary in specifications already agreed. 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. All rights reserved. Printed in U.S.A. (0402H)2BLN-10197 520L0532 April 2002

Series 45 Frame K and L Open Circuit Axial Piston PumpsService ManualContentsPRESSUREMEASUREMENTPort locations and gauge installation.14Required tools .14Gauge and port information.14Gauge port locations, radial ported units .14Gauge port locations, axial ported units .14INITIAL START-UPPROCEDURESGeneral.15Start-up procedure .15FLUID AND FILTERMAINTENANCERecommendations.16Fluid and filter change interval .16TROUBLESHOOTINGExcessive noise and / or vibration .17Actuator response is sluggish.17System operating hot .18Low pump output flow .18Pressure or flow instability.18System pressure not reaching PC setting.19High inlet vacuum.19ADJUSTMENTSPC control.20PC control adjustment .20LS / PC control .21LS control adjustment .21MINOR REPAIRShaft seal replacement.22Removal .22Installation .22Shaft seal and retaining ring.22Auxiliary pads .23Removal .23Auxiliary mounting pads.23Installation .23Control.24Disassembly .24Inspection .24Control assembly .24Reassembly.25Control assembly .25Plug and fitting sizes and torques.26Plug locations, sizes, and torques .26BLN-10197 520L0532 April 20023

Series 45 Frame K and L Open Circuit Axial Piston PumpsService ManualIntroductionUSING THIS MANUALThis manual includes information for the normal operation, maintenance, and serviceof the Series 45 frame K and L open circuit pumps. The manual includes a descriptionof the units and their individual components, troubleshooting information, adjustmentinstructions and minor repair procedures. Unit warranty obligations should not beaffected if maintenance, adjustment and minor repairs are performed according to theprocedures described in this manual.Many service and adjustment activities can be performed without removing the unitfrom the vehicle or machine. However, adequate access to the unit must be available,and the unit must be thoroughly cleaned before beginning maintenance, adjustment,or repair activities. Since dirt and contamination are the greatest enemies of any type ofhydraulic equipment, follow cleanliness requirements strictly. This is especially importantwhen changing the system filter and when removing hoses or plumbing.A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is availableshould major repairs be needed. Contact any Sauer-Danfoss ASC for details. A list of allASCs can be found in bulletin BLN-2-40527, or in brochure SAW (Ident. No. 698266), oryou can locate your nearest ASC using the distributor locator at www.sauer-danfoss.com.SAFETY PRECAUTIONSAlways consider safety precautions before beginning a service procedure. Protectyourself and others from injury. Take the following general precautions whenever servicinga hydraulic 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 or disable/ 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, atall times.4BLN-10197 520L0532 April 2002

Series 45 Frame K and L Open Circuit Axial Piston PumpsService ManualIntroductionSYMBOLS USED INSAUER-DANFOSSLITERATURE 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 grease / petroleum jelly 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 port Pressure measurement / gaugelocation or specificationThe symbols above can be found in the illustrations and text of this manual. They areintended to communicate helpful information at the point where it is most useful to thereader. In most instances, the appearance of the symbol itself denotes its meaning. Thelegend above is provided to define each symbol and explain its purpose.BLN-10197 520L0532 April 20025

Series 45 Frame K and L Open Circuit Axial Piston PumpsService ManualIntroductionGENERAL DESCRIPTIONSauer-Danfoss Series 45 K and L frame open circuit piston pumps convert input torqueinto hydraulic power. Rotational force is transmitted through the input shaft to thecylinder block. The input shaft is supported by tapered roller bearings at the front andrear of the pump and is splined into the cylinder block . A lip-seal at the front end of thepump prevents leakage where the shaft exits the pump housing. The spinning cylinderblock contains nine reciprocating pistons. Each piston has a brass slipper connected atone end by a ball joint. The slippers are held to the swashplate by the spring retainerand block spring. The block spring also holds the cylinder block to the valve plate.The reciprocating movement of the pistons occurs as the slippers slide against theinclined swashplate during rotation. Via the valve plate, one half of the cylinder blockis connected to pump inlet and the other half to pump outlet. As each piston cyclesin and out of its bore, fluid is drawn from the inlet and displaced to the outlet therebyimparting power into the system circuit. A small amount of fluid is allowed to “leak” fromthe cylinder block / valve plate and slipper / swashplate interfaces for lubrication andcooling. Case drain ports are provided 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 biasspring. The servo piston opposes the action of the bias spring forcing the swashplate outof stroke when hydraulic pressure in the control circuit rises above the spring force.The

K/L Frame Series 45 open circuit axial piston pump with load sensing control PVG 32 mulit-section load sensing control valve. P101 658E. Reservoir Filter Heat exchanger Double-acting cylinder Bi-directional gear motor. 1. Full available flow is a function of pump displacement, operating speed, and efficiency. Refer to Series 45 Axial

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