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G Frame Series 45 open circuit axial piston pump
Service guide
28 pgs1.79 Mb0

Danfoss G Frame Series 45 open circuit axial piston pump Service guide

Series 45 Frame G
PHASED OUT PRODUCT
Open Circuit Axial Piston Pumps
Service Manual
Series 45 G Frame Open Circuit Axial Piston Pumps
PHASED OUT PRODUCT
Service Manual
HISTORY OF REVISIONS
Revisions
Table of Revisions
Date Page Changed Rev.
December 2010 last New Back Page AB
March 2003 - First revision -
© 2010 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 products already ordered, provided that such alterations can be made without affecting agreed specications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the Sauer-Danfoss Group.
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
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INTRODUCTION
TECHNICAL SPECIFICATIONS
Overview ...........................................................................................................................................................5
Safety precautions ......................................................................................................................................... 5
Unintended machine movement ....................................................................................................... 5
Flammable cleaning solvents ...............................................................................................................5
Fluid under pressure ................................................................................................................................ 5
Personal safety ........................................................................................................................................... 5
Symbols used in Sauer-Danfoss literature .............................................................................................6
General description .......................................................................................................................................7
System circuit ...................................................................................................................................................8
General specications ..................................................................................................................................9
Type of mounting .....................................................................................................................................9
Auxiliary mounting pad options ......................................................................................................... 9
Control options ..........................................................................................................................................9
Port options ................................................................................................................................................9
Direction of rotation ................................................................................................................................9
Installation position ................................................................................................................................. 9
Technical specications ..........................................................................................................................9
General specications (continued) ........................................................................................................10
Hydraulic parameters ..................................................................................................................................10
Inlet pressure ............................................................................................................................................10
Pressure compensator valve setting ................................................................................................10
Case pressure ...........................................................................................................................................10
Hydraulic uid .........................................................................................................................................10
Hydraulic parameters (continued) .........................................................................................................11
Temperature range .................................................................................................................................11
Fluid viscosity ...........................................................................................................................................11
Filtration ....................................................................................................................................................11
FEATURES
PRESSURE MEASUREMENT
INITIAL START-UP PROCEDURES
FLUID AND FILTER MAINTENANCE
Displacement limiter ...................................................................................................................................12
Auxiliary mounting pads ...........................................................................................................................12
Input shafts .....................................................................................................................................................12
Control options .............................................................................................................................................13
Operation ...................................................................................................................................................13
Control options .............................................................................................................................................14
Required tools ...............................................................................................................................................15
Port locations and gauge installation ...................................................................................................15
General .............................................................................................................................................................16
Start-up procedure ......................................................................................................................................16
Recommendations .......................................................................................................................................17
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
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TROUBLESHOOTING
ADJUSTMENTS
MINOR REPAIR
Excessive noise and / or vibration ..........................................................................................................18
Actuator response is sluggish ..................................................................................................................18
System operating hot .................................................................................................................................19
Low pump output ow ..............................................................................................................................19
Pressure or ow instability ........................................................................................................................19
Pressure or ow instability (continued) ...............................................................................................20
System pressure not reaching PC setting ............................................................................................20
High inlet vacuum ........................................................................................................................................20
PC control ........................................................................................................................................................21
LS control ........................................................................................................................................................22
Shaft seal replacement ...............................................................................................................................23
Removal ......................................................................................................................................................23
Installation .................................................................................................................................................23
Auxiliary pads ................................................................................................................................................24
Removal ......................................................................................................................................................24
Installation .................................................................................................................................................24
Control ..............................................................................................................................................................25
Disassembly ..............................................................................................................................................25
Inspection ..................................................................................................................................................25
Control (continued) .....................................................................................................................................26
Reassembly ...............................................................................................................................................26
Plug and tting sizes and torques ..........................................................................................................27
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
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OVERVIEW
SAFETY PRECAUTIONS
Introduction
This manual includes information for the installation, maintenance, and minor repair of the Series 45 frame G 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 G Frame axial piston pumps according to the procedures in this manual will not affect your warranty.
Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system lter and when removing hoses or plumbing.
A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is available for major repairs. Major repairs require the removal of the unit’s endcap, which voids the warranty unless done by an ASC. Sauer-Danfoss ASCs are trained by the factory and certied on a regular basis. You can locate your nearest ASC using the distributor locator at www.sauer-danfoss.com
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take these general precautions whenever servicing a hydraulic system.
Unintended machine movement
Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable / disconnect the mechanism while servicing.
Flammable cleaning solvents
Warning Some cleaning solvents are ammable. To avoid possible re, do not use cleaning solvents in an area where a source of ignition may be present.
Fluid under pressure
Warning Escaping hydraulic uid under pressure can have sufcient force to penetrate your skin causing serious injury and/or infection. This uid may also be hot enough to cause burns. Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the system before removing hoses, ttings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic uid.
Personal safety
Warning Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
Introduction
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SYMBOLS USED IN SAUER-DANFOSS LITERATURE
These symbols are in the illustrations and text of this manual. They communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend below denes the symbol and explains its purpose.
WARNING may result in injury
CAUTION may result in damage to
product or property
Reusable part
Non-reusable part, use a new part
Non-removable item
Option – either part may exist
Superseded – parts are not
interchangeable
Tip, helpful suggestion
Lubricate with hydraulic uid
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
Flatness specication
Parallelism specication
External hex head
Internal hex head
Torx head
O-ring boss port
Mark orientation for reinstallation
Torque specication
Press in – press t
Pull out with tool – press t
Cover splines with installation
sleeve
Pressure measurement / gauge
location or specication
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
Introduction
LS adjustment
PC adjustment
LS spool
PC spool
LS control (attached to endcap)
Displacement piston
Swashplate
Ta pered roller bearing
Shaft seal
Ta pered roller bearing
Input shaft
Bias piston guide
Bias spring
Bias piston
Cylinder block
Valve plate
Cylinder block spring
Piston
Slipper
Slipper retainer
P104 002E
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GENERAL DESCRIPTION
Sauer-Danfoss Series 45 G Frame open circuit piston pumps convert input torque into hydraulic power. Rotational force is transmitted through the input shaft to the cylinder block. The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block . A lip-seal at the front end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one end by a ball joint. The slippers are held to the swashplate by the spring retainer and block spring. The block spring also holds the cylinder block to the valve plate. The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. One half of the cylinder block is connected to pump inlet and the other half to pump outlet, via the valve plate. As each piston cycles in and out of its bore, uid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit. A small amount of uid is allowed to “leak” from the cylinder block / valve plate and slipper / swashplate interfaces for lubrication and cooling. Case drain ports are provided to return this uid to the reservoir.
The volume of uid 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. 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.
The pump control, by varying the pressure at the servo piston, controls the displacement of uid in the system circuit. Controls designed for Pressure Compensation (PC) or Load Sensing (LS) are available. For a detailed description of control operation, refer to
Control options, operation, page 13.
Pump and control sectional view
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
System pressure
Servo pressure
Actuator pressure
Load sense pressure
Actuator return
Suction / case drain / system return
PVG 32 mulit-section load sensing control valve
P106 067E
Reservoir
Filter
Heat exchanger
Double-acting cylinder
Bi-directional gear motor
GFrame Series 45 open circuit axial piston pump with load sensing control
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SYSTEM CIRCUIT
Pictorial circuit diagram
Introduction
The pump receives uid directly from the reservoir through the inlet line. A screen placed in the inlet protects the pump from large contaminants. The output of the pump is directed to a PVG-32 multi-section load sensing directional control valve which directs uid to the actuators in the system. Fluid returning from the system is cooled by a heat exchanger and cleaned by a lter before returning to the reservoir.
The speed of the actuators in the system depends on the volume of uid being provided by the pump. The operating pressure varies depending on actuator load, 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.
The position of the PVG valve sets the demand for ow in the system and communicates this to the pump control by means of a hydraulic signal (load sense signal). The pump will provide as much ow to the system as it demands1 while limiting the maximum pressure. Therefore ow and pressure in the system are compensated to meet requirements.
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Full available ow is a function of pump displacement, operating speed, and efciency. Refer to Series 45 Axial
Piston Open Circuit Pumps Technical Information, 520L0519 for details.
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Series 45 G Frame Open Circuit Axial Piston Pumps Service Manual
PHASED OUT PRODUCT
GENERAL SPECIFICATIONS
Technical specications
Type of mounting
SAE-C mounting ange.
Auxiliary mounting pad options
SAE-A, SAE-B, SAE-B-B, SAE-C, SAE C-C
Control options
PC: Pressure Compensator
LS: Load Sensing (with PC)
Port options
Inlet and system ports: SAE anged ports, code 61 Inlet Code 62 outlet. Axial (end) ports or radial (side) ports.
All other ports: SAE straight thread O-ring boss.
Direction of rotation
Clockwise or counterclockwise.
Installation position
Installation position is discretionary. To satisfy inlet pressure conditions, it is recommended that the pump always be located below the lowest level of hydraulic uid in the reservoir. The housing must always be lled with hydraulic uid.
Technical specifications
Features and options
Feature Unit G74B G90C
Maximum Displacement cm³ [in³] 74 [4.52] 90 [5.49]
Flow at rated speed (theoretical) l/min
[US gal/min]
Input torque at maximum displacement
(theoretical)
Mass moment of inertia of internal
rotating components
Weight Axial ports kg [lb] 29 [63]
Radial ports 36 [80]
Rotation Clockwise, Counterclockwise
Mounting SAE-C
Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-C
System ports (type) 4-bolt split ange
System ports (location) Axial, Radial
Control types PC, Remote PC, LS, LS with internal bleed
Shafts Splined 14 tooth, 17 tooth
Displacement limiters Optional, adjustable
N•m/bar
[lbf•in/1000 psi]
kg•m²
[slug•ft²]
Straight Ø 31.75 mm [1.25 in]
177.6
[46.9]
1.178
[719]
0.00630
[0.00465]
Model
198
[52.3]
1.432
[874]
0.00650
[0.00480]
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