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 specications. 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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520L0605 • Rev AB • December 2010
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Fluid under pressure ................................................................................................................................ 5
Personal safety ........................................................................................................................................... 5
Symbols used in Sauer-Danfoss literature .............................................................................................6
General description .......................................................................................................................................7
System circuit ...................................................................................................................................................8
General specications ..................................................................................................................................9
Type of mounting .....................................................................................................................................9
Auxiliary mounting pad options ......................................................................................................... 9
Control options ..........................................................................................................................................9
Port options ................................................................................................................................................9
Direction of rotation ................................................................................................................................9
Installation position ................................................................................................................................. 9
Case pressure ...........................................................................................................................................10
Control options .............................................................................................................................................13
Control options .............................................................................................................................................14
Port locations and gauge installation ...................................................................................................15
General .............................................................................................................................................................16
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
TROUBLESHOOTING
ADJUSTMENTS
MINOR REPAIR
Excessive noise and / or vibration ..........................................................................................................18
Actuator response is sluggish ..................................................................................................................18
System operating hot .................................................................................................................................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
Control ..............................................................................................................................................................25
Control (continued) .....................................................................................................................................26
Plug and tting sizes and torques ..........................................................................................................27
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
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
certied 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 sufcient 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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Introduction
PHASED OUT PRODUCT
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 denes 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 specication
Parallelism specication
External hex head
Internal hex head
Torx head
O-ring boss port
Mark orientation for reinstallation
Torque specication
Press in – press t
Pull out with tool – press t
Cover splines with installation
sleeve
Pressure measurement / gauge
location or specication
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520L0605 • Rev AB • December 2010
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
PHASED OUT PRODUCT
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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520L0605 • Rev AB • December 2010
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
PHASED OUT PRODUCT
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.
1
Full available ow is a function of pump displacement, operating speed, and efciency. Refer to Series 45 Axial
Piston Open Circuit Pumps Technical Information, 520L0519 for details.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
GENERAL
SPECIFICATIONS
Technical specications
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
FeatureUnitG74BG90C
Maximum Displacementcm³ [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
WeightAxial portskg [lb]29 [63]
Radial ports36 [80]
RotationClockwise, Counterclockwise
MountingSAE-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 Splined14 tooth, 17 tooth
Displacement limiters Optional, adjustable
N•m/bar
[lbf•in/1000 psi]
kg•m²
[slug•ft²]
StraightØ 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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Technical specications
PHASED OUT PRODUCT
GENERAL
SPECIFICATIONS
(continued)
HYDRAULIC
PARAMETERS
Ratings
RatingUnitsG74BG90C
Input speed
Working pressure continuousbar [psi]310 [4495]260 [3770]
External shaft
loads
Bearing lifeat 140 bar [2030 psi]B
Mounting ange
load moments
1. Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs. speed charts.
1
minimummin-1 (rpm)500500
continuous24002200
maximum28002600
maximum400 [5800]350 [5075]
External moment (M
Thrust in (T
at 210 bar [3045 psi]90484339
at 260 bar [3770 psi]40621948
at 310 bar [4495 psi]2101—
Vibratory (continuous) N•m [lbf•in]1580 [14 000]
Shock (max)5650 [50 000]
in
) N•m [lbf•in]300 [2655]
e
), out (T
) N [lbf]2900 [650]
out
hours41 38319 847
10
Inlet pressure
Minimum pressure, continuous = 0.8 bar absolute [6.7 inch Hg vac]
Model
(at reduced maximum pump speed)
Minimum pressure, cold start = 0.5 bar absolute [15.1 inch Hg vac]
Pressure compensator valve setting
PC control setting range
Modelbarpsi
G74B100–3101450–4495
G90C100–2601450–3770
Case pressure
Maximum continuous: 0.5 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.
For information on biodegradable uids refer to Biodegradable Hydraulic Fluids,
520L0465. See Fluid and filter maintenance, page 17 for recommended uid and lter
change intervals.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Technical specications
PHASED OUT PRODUCT
PARAMETERS (continued)
Temperature rangeHYDRAULIC
Temperature limits
Minimum
(intermittent, cold start)
Continuous¹82° C [180° F]
Maximum
Fluid viscosity
Fluid viscosity limits
ν min.
ν max.
Filtration
Required cleanliness level: ISO 4406 Class 18/13 or better. 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. See Fluid and
filter maintenance, page 17 for recommended uid and lter change intervals.
2
Conditionmm2/s (cSt)SUS
continuous958
intermittent6.447
continuous110500
intermittent
(cold start)
- 40° C [- 40° F]
104° C [220° F]
10004700
1
Hydraulic uid viscosity must be maintained within the prescribed limits.
2
As measured at the hottest point in the system, e.g. drain line.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Features
P104 026
P106 023
PHASED OUT PRODUCT
DISPLACEMENT LIMITER
AUXILIARY MOUNTING
PADS
Frame G Series 45 pumps are available
with an optional adjustable maximum
displacement limiter. The adjustable
stop limits the pump’s maximum
displacement. The displacement change
is 6.5 cc/turn [0.40 in³/turn ] of the
displacement limiter adjustment screw.
Auxiliary mounting pads are available for
all radial ported Series 45 pumps. These
pads are typically used for mounting
auxiliary hydraulic pumps.
Since the auxiliary pad operates under
case pressure, you must use an O-ring to
seal the auxiliary pump mounting ange
to the pad. Oil from the main pump case
lubricates the drive coupling. For details
refer to Series 45 Axial Piston Open Circuit
Pumps Technical Information 520L0519.
Displacement limiter
Auxiliary pad options
INPUT SHAFTSSeries 45 G Frame pumps are available with a variety of splined and straight keyed shafts.
For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical
Information 520L0519.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Features
P104 049
4
5
6
1
2
3
P106 068E
PHASED OUT PRODUCT
CONTROL OPTIONS
The Series 45 Frames G have two possible control options, a Load Sensing (LS) control with Pressure Compensator (PC) or a PC only control.
Cross-section pumpOperation
General
The bias piston and spring (1) acts at
all times to push the swashplate (2) to
maximum angle causing the pump to
stroke. The servo piston (3) acts against
the bias piston and spring to reduce
the swashplate angle causing the
pump to destroke. Swashplate angle
determines pump outlet ow. The pump
control, depending on conditions in the
system circuit, sets swashplate angle
by metering system pressure to the
servo piston.
Bias spring and servo piston set swashplate
position
PC control
The PC control design maintains a
constant pressure in the hydraulic circuit
as ow varies. The PC control modulates
pump ow accordingly to maintain
system pressure at the PC setting as
the PC adjusting plug (4) and spring (5)
denes.
When system pressure, acting on the
non-spring end of the PC spool (6),
overcomes the force of the PC spring, the
spool shifts porting system pressure to the servo piston and the swashplate angle
decreases. When system pressure drops below 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. The swashplate is maintained at whatever angle is required
to keep system pressure at the PC setting.
Cross-section PC control
PC spool shif ts to port system pressure to
servo piston
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Load
pressure
Load sense
pressure
System
pressure
Tank
Return
pressure
P101 665E
2
2
Spool
Spring
guide
Spring
7LS adjusting
plug
LS spring
PC adjusting
plug
Plug
Plug
Spool
Spring
guide
Spring
(PC heavy)
P104 051
6
8
9
PHASED OUT PRODUCT
Features
CONTROL OPTIONS
(continued)
LS control
The LS control design matches pump
ow with system demand. The LS control
senses the ow demand of the system
as a pressure drop across the External Control Valve (ECV). As the ECV opens
and closes, the pressure delta across
the valve changes. When opening, the
delta decreases. When closing, the delta
increases. The LS control then increases
or decreases pump ow to the system
until the pressure delta becomes equal
to the LS setting as dened by the LS
adjusting plug (7) and spring (8).
Cross-section LS control
LS spool shifts to port system pressure to servo
piston
is applied to the spring end. This arrangement allows the LS spool to act on the delta
between system pressure and LS pressure. The LS spring sets the threshold of operation
(LS setting).
Typical load-sensing control valve
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 PC spool (6) controls the pressurecompensating function of the control
as previously described. The LS spool (9)
controls the load-sensing function. The
PC spool has priority over the LS spool.
Through internal porting, system
pressure (upstream of ECV) is applied
to the non-spring end of the LS spool,
and through hydraulic line connected at
port X. LS pressure (downstream of ECV)
Because the swashplate is biased to maximum angle, the pump attempts to deliver
full ow to the hydraulic system. When the ow being delivered exceeds demand, 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. The pump de-strokes reducing
ow until the delta across the ECV becomes equal to the LS setting. When ow being
delivered is less than demand, the delta across the ECV drops below the LS setting and
the LS spring shifts the spool connecting the servo piston to pump case. The pump
strokes increasing ow until the delta across the ECV becomes equal to the LS setting.
When the external control valve is placed in neutral, it connects the LS signal line to
drain. With no LS pressure acting on the non-spring end of the LS spool, the pump
adjusts stroke to whatever position necessary to maintain system pressure at the LS
setting. The pump is now in standby mode.
Because of the series arrangement of the LS and PC spools, the PC spool will override
the LS spool. If at any time system pressure reaches the PC setting, the PC spool will shift
blocking the passage that connects the LS spool with the servo piston, thus porting
system pressure to the servo piston causing the pump to destroke.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Legend
B = Main pressure line
S = Suction line
L1, L2 = Case drain lines
X = Load sensing pressure port
M2 = Gauge port for port B*
M4 = Gauge port — servo pressure
*Same pressure
X
X
X
M2
L1
L2
S
B
M4
P106 072E
PHASED OUT PRODUCT
Pressure measurement
REQUIRED TOOLS
PORT LOCATIONS AND
GAUGE INSTALLATION
The service procedures described in this manual can be performed using common
mechanic’s hand tools. Special tools, if required are shown. Calibrate pressure gauges
frequently to ensure accuracy. Use snubbers to protect gauges.
The illustration below shows gauge port locations. Recommended pressure gauges and
ttings are in the table.
Gauge and port information
PortPurposeRange of gaugeFitting
M2System pressure0-300 bar [0-5000 psi]9/16 - 18 O-ring tting
M4Servo pressure0-300 bar [0-5000 psi]9/16 - 18 O-ring tting
L1, L2Case pressure0-10 bar [0-100 psi]7/8 - 14 O-ring tting
X1LS signal0-300 bar [0-5000 psi]
Gauge port locations
7/16 - 20 O-ring tting
(tee into LS signal line)
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
GENERAL
START-UP PROCEDURE1. Connect the pump to the prime mover. Ensure that pump shaft is properly aligned
CAUTION
Incorrect shaft alignment
may result in damage
to drive shaft, bearings,
or seal which can cause
external oil leakage.
Initial start-up procedures
Follow this procedure when starting-up a new Series 45 installation or when restarting
an installation in which the pump has been removed.
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.
Prior to installing the pump, inspect for damage incurred during shipping. Make certain
all system components (reservoir, hoses, valves, ttings, heat exchanger, etc.) are clean
prior to lling with uid.
with the shaft of the prime mover.
2. Fill the reservoir with recommended hydraulic uid. Always lter uid through a 10
micron lter pouring into the reservoir. Never reuse hydraulic uid.
3. Fill the main pump housing with clean hydraulic uid. Pour ltered oil directly into
the upper most case drain port.
4. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for
properly tightened ttings. Be certain it is free of restrictions and air leaks.
5. To ensure the pump stays lled with oil, install the case drain line in the upper most
case drain port.
6. Install a gauge at port M1 or M2 to monitor system pressure during start up.
Follow recommendations in the vehicle / machine operator’s manual for prime mover
start up procedures.
7. While watching the pressure gauge installed at M1 or M2, jog the prime mover
or run at the lowest possible speed until system pressure builds to normal levels
(minimum 11 bar [160 psi]). Once system pressure is established, increase to full
operating speed. If system pressure is not maintained, shut down the prime mover,
determine cause, and take corrective action. Refer to Troubleshooting, page 17.
8. Operate the hydraulic system for at least fteen minutes under light load conditions.
9. Check and adjust control settings as necessary after installation. Refer to
Adjustments, page 21.
10. Shut down the prime mover and remove the pressure gauge. Replace plug at port M1
or M2.
11. Check the uid level in the reservoir; add clean ltered uid if necessary.
The pump is now ready for operation.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
RECOMMENDATIONS
Fluid and lter maintenance
To ensure optimum life of Series 45 products, perform regular maintenance of the uid
and lter. Contaminated uid is the main cause of unit failure. Take care to maintain uid
cleanliness when servicing.
Check the reservoir daily for proper uid level, the presence of water, and rancid uid
odor. Water in the uid may be noted by a cloudy or milky appearance or free water
in the bottom of the reservoir. Rancid odor indicates the uid has been exposed to
excessive heat. Change the uid immediately if these conditions occur. Correct the
problem immediately.
Change the uid and lter per the
vehicle / machine manufacturer’s
recommendations or at these intervals:
Change the uid more frequently if it
becomes contaminated with foreign
matter (dirt, water, grease, etc.) or if the uid is subjected to temperature levels greater
than the recommended maximum.
Dispose of used hydraulic uid properly. Never reuse hydraulic uid.
Fluid and filter change interval
Reservoir typeMaximum change interval
Sealed2000 hours
Breather500 hours
Change lters whenever the uid is changed or when the lter indicator shows that it is
necessary to change the lter. Replace all uid lost during lter change.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
PHASED OUT PRODUCT
EXCESSIVE NOISE AND /
OR VIBRATION
ItemDescriptionAction
Check uid level in reservoir.
Check for air in system.
Check pump inlet pressure /
vacuum.
Inspect shaft couplings.
Check shaft alignment.
Hydraulic uid viscosity above
acceptable limits.
Insufcient hydraulic uid causes
cavitation.
Air in system causes noisy, erratic
control.
Improper inlet conditions cause
erratic behavior and low output
ow.
A loose or incorrect shaft coupling
causes excessive noise and / or
vibration.
Misaligned shafts create excessive
noise and / or vibration.
Hydraulic uid viscosity above
acceptable limits or low uid
temperature will not allow the
pump to ll or control to operate
properly.
Fill the reservoir to proper level.
Purge air and tighten ttings.
Check inlet for leaks.
Correct pump inlet pressure /
vacuum conditions. Refer to
Hydraulic parameters, page 10.
Repair or replace coupling and
ensure that correct coupling is
used.
Correct shaft misalignment.
Allow system to warm up before
operating, or use uid with the
appropriate viscosity grade for
expected operating temperatures.
See Hydraulic Fluids, Series 45
Technical Information Manual,
520L0519.
ACTUATOR RESPONSE IS
SLUGGISH
ItemDescriptionAction
Check external system relief valve
setting.
Check PC and LS control setting.
Check LS control signal pressures.
Internal system leaks.
Hydraulic uid viscosity above
acceptable limits.
Check external system valving.
Check pump case pressure.
Check pump inlet pressure /
vacuum.
Low external relief valve setting
slows down system.
Low PC setting prevents the pump
from achieving full stroke. Low LS
setting limits output ow.
Incorrect LS signal will not allow
pump to operate correctly.
Worn internal parts don’t allow the
pump to operate properly.
Hydraulic uid viscosity above
acceptable limits or low uid
temperature will not allow the
pump to ll or control to operate
properly.
Malfunctioning valving may not
allow system to respond properly.
High case pressure causes the
system to be sluggish.
High inlet vacuum causes low
output ow.
Adjust external relief valve
setting following manufacturer’s
recommendations. External relief
setting must be above PC setting
to operate properly.
Adjust PC and LS setting. Refer to
Adjustments, page 20.
Inspect system to ensure that
proper LS signal transmit to pump.
Refer to Authorized Service Center
for required repair.
Allow system to warm up before
operation or sue uid with the
appropriate viscosity grade for
expected operating temperatures.
See Hydraulic Fluids, Series 45
Technical Information Manual,
520L0519.
Repair or replace system valving as
required.
Correct case drain line restrictions.
Correct inlet pressure conditions.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
PHASED OUT PRODUCT
PRESSURE OR FLOW
INSTABILITY (continued)
SYSTEM PRESSURE NOT
REACHING PC SETTING
Troubleshooting
ItemDescriptionAction
Check LS setting.
Check LS signal line.
Check external relief valve and PC
setting.
Check external relief valve.
ItemDescriptionAction
Check PC control setting.
Check external relief valve.
Inspect PC control spring.
Inspect PC spool for wear.
Inspect PC spool for proper
orientation.
Check PC control for
contamination.
Low LS setting may cause
instability.
Blocked LS signal line interferes
with proper LS operation.
Insufcient pressure differential
between PC setting and external
relief valve.
Chattering external relief valve
may cause unstable feedback to
pump control.
System pressure will not rise above
PC setting.
External relief valve setting below
PC setting prevents pressure
compensation.
Broken, damaged, or missing
spring will cause erratic operation.
Wear of PC spool causes internal
leakage in the control.
Improper orientation results in
poor operation.
Contamination may interfere with
movement of the PC spool.
Adjust LS setting to proper level.
See Adjustments, page 21.
Remove blockage.
Adjust external relief valve or PC
control settings to appropriate
level. Relief valve setting must
be above PC setting to operate
properly.
Adjust or replace relief valve.
Adjust PC to appropriate setting.
Refer to Adjustments, page 21.
Adjust external relief valve
according to manufacturer’s
recommendations. External relief
valve must be set above PC setting
to operate properly.
Replace the spring as required.
Replace the spool as required.
Correct orientation of spool.
Clean PC control components, take
appropriate action to eliminate
contamination.
HIGH INLET VACUUM
Caution
High inlet vacuum causes
cavitation which can
damage internal pump
components.
ItemDescriptionAction
Check uid temperature.
Inspect inlet screen.
Check inlet piping.
Hydraulic uid viscosity above
acceptable limits.
Low temperature increases
viscosity. High uid viscosity
causes high inlet vacuum.
Blocked or restricted inlet screen
causes high inlet vacuum.
Too many ttings, bends, or long
piping causes high inlet vacuum.
High uid viscosity causes high
inlet vacuum.
Allow system to warm up before
operating.
Clean screen / remove blockage.
Eliminate ttings to make path
more direct.
Select uid with appropriate
viscosity for expected operating
temperature. See Hydraulic fluids,
Series 45 Technical Information
Manual, 520L0519.
21
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Gauge port M2
0 - 300 bar [0 - 4351 psi]
3/16 in
7/16-20
34-68 N•m
[25-50 lbf•ft]
G
I
B
t
G
I
B
t
Case drain port L1
0 - 10 bar [0 - 145 psi]
3/8 in
7/8-14
54 - 136 N•m
[40 - 100 lbf•ft]
LS adjusting plug
I6 mm
I
t
LS set screw
4 mm
7.5 - 10.8 N•m
[5.5 - 8 lbf•ft]
P106 069E
X Port
0-300 bar
[0-5000 psi]
3/16 in
7/16-20
13-27 N•m
[10-20 lbf•ft]
G
I
B
t
PHASED OUT PRODUCT
Adjustments
PC CONTROLPC setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial
Piston Pumps Technical Information Manual,520L0519, for more information.
Before performing adjustments, read page 14, Pressure measurement.Warning
Escaping hydraulic uid
under pressure can
have sufcient force
to penetrate your skin
causing serious injury
and/or infection. Relieve
pressure in the system
1. Install a pressure gauge in port M1
or M2 to measure system pressure.
Install a pressure gauge in case
drain port L1 or L2 to measure case
pressure. C
PC control adjustment
before removing hoses,
ttings, gauges, or
components.
2. Start the prime mover and allow
uid to reach normal operating
temperature. Operate a hydraulic
Unintended movement of
the machine or mechanism
may cause injury to the
function to its full extension, loading
the pump at maximum pressure and
zero ow.
technician or bystanders.
To protect against
unintended movement,
secure the machine or
disable / disconnect
the mechanism while
servicing.
3. 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 . Clockwise
rotation increases pressure,
counterclockwise rotation decreases;
approximate gain 42 bar [610 psi]
per turn.
Caution
Contamination can
damage internal
components and void the
manufacturer’s warranty.
Take precautions to ensure
system cleanliness when
removing and reinstalling
system lines.
If the pressure does not increase, an
external system relief valve may require
adjustment. External system relief valve
must be set above the PC setting for
proper operation.
4. While holding the position of the PC
adjusting plug, torque the PC set screw to 7.5 - 10.8 N•m [5.5 - 8 lbf•ft].
5. Stop the prime mover, remove the pressure gauges, and return the system to its
normal operating conguration.
1
P C setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual
setting.
22
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Gauge port M2
0 - 300 bar [0 - 4351 psi]
3/16 in
7/16-20
34-68 N•m
[25-50 lbf•ft]
G
I
B
t
G
I
B
t
Case drain port L1
0 - 10 bar [0 - 145 psi]
3/8 in
7/8-14
54 - 136 N•m
[40 - 100 lbf•ft]
LS adjusting plug
I6 mm
I
t
LS set screw
4 mm
7.5 - 10.8 N•m
[5.5 - 8 lbf•ft]
P106 069E
X Port
0-300 bar
[0-5000 psi]
3/16 in
7/16-20
13-27 N•m
[10-20 lbf•ft]
G
I
B
t
PHASED OUT PRODUCT
LS CONTROL
Adjustments
The LS setting is indicated in the pump model code. Refer to the Series 45 Open Circuit
Axial Piston Pumps Technical Information Manual,520L0519, for more information.
Warning
Escaping hydraulic uid
Before performing adjustments, read page 15, Pressure measurement.
under pressure can
have sufcient force
to penetrate your skin
causing serious injury
and/or infection. Relieve
pressure in the system
before removing hoses,
1. Install a pressure gauge in port M1
or M2 to measure system pressure.
Install a pressure gauge in drain port
L1 or L2 to measure case pressure.
Tee-in a gauge to the LS / remote PC
signal line (port X). C
LS control adjustment
ttings, gauges, or
components.
2. Start the prime mover and allow uid
to reach normal operating temperature.
Unintended movement of
the machine or mechanism
may cause injury to the
technician or bystanders.
Slowly operate a hydraulic function
that will demand approximately half
ow from the pump, but keep system
pressure below the PC set point.
To protect against
unintended movement,
secure the machine or
disable / disconnect
the mechanism while
servicing.
3. Loosen the LS set screw. While
watching the pressure gauges,
turn the LS adjusting plug until
the desired pressure differential
between port M1 or M2 and
port X is achieved1. Clockwise
rotation increases the setting,
counterclockwise rotation
will decrease it; approximate
gain = 17 bar [250 psi] per turn.
4. While holding the position of the
LS adjusting plug, torque the LS set
screw to 7.5 - 10.8 N•m [5.5-8 lbf•ft].
5. Operate a hydraulic function to its
full extension loading the pump at
maximum pressure and zero ow.
Adjusting plug, set screw, and gauge
locations shown
6. 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, counterclockwise rotation decreases
it; approximate gain = 42 bar [610 psi] per turn.
7. While holding the position of the PC adjusting plug, torque the PC set screw to
7.5 - 10.8 N•m [5.5-8 lbf•ft].
Contamination can
damage internal
components and void the
manufacturer’s warranty.
Take precautions to ensure
system cleanliness when
removing and reinstalling
If the pressure does not
increase, an external
system relief valve may
require adjustment.
External system relief
valve must be set above
the PC setting for proper
Caution
system lines.
operation.
8. Stop the prime mover, remove the pressure gauges, and return the system to its
normal operating conguration.
1
The LS setting is a differential pressure. Subtract pilot pressure at port X from system pressure at port M2 to
compute the actual setting.
PC setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual
setting.
23
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
lpd
P106 024
b
K010
K020
PHASED OUT PRODUCT
SHAFT SEAL
REPLACEMENT
C Caution
Don’t damage the pump
housing or shaft.
Minor repair
The Series 45 open circuit variable pumps use a lip-type shaft seal. You can replace this
seal without major disassembly of the unit. Replacing the shaft seal requires removing
the pump from the machine.
Removal
1. Using the appropriate snap-ring
pliers, remove the retaining ring
(K010) from the housing.
2. Remove the shaft seal (K020) from
the bore in the pump housing and
discard. C
3 Puncture the face of the seal with a
packing hook, or use a slide-hammer
type puller to remove the seal.
Installation
4. Inspect the pump housing and new
seal for damage. Inspect the sealing
area on the shaft for rust, wear, or
contamination. Polish the sealing
area on the shaft if necessary.
Shaft seal and retaining ring
Caution
Premature bearing failure
can result if the shaft seal
contacts the shaft bearing.
Press the seal into the
housing only far enough
to clear the retaining ring
groove.
5. Lubricate the lip of the new shaft seal with clean hydraulic uid. Place a protective
sleeve over the shaft end to prevent damage to the seal during installation.
6. Keeping the seal perpendicular to the shaft, press the new seal into the housing just
far enough to clear the retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal during installation.
7. Using the appropriate snap ring pliers, install the seal retaining ring.
8. Remove the installation sleeve.
24
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair
J095
J140
J080
J120
J110
J120
J080
J140
J095
J110
J120
P106 029E
J080
J100
J120
J110
J130
J140
J095
J130
h
3
/4 inch
t91 - 111 N•m
[67 - 82 lbf•ft]
J100
I10 mm
t47.5 - 61 N•m
[35 - 45 lbf•ft]
J090 dg
J090 dg
h
3
/4 inch
t91 - 111 N•m
[67 - 82 lbf•ft]
PHASED OUT PRODUCT
AUXILIARY PADSYou may install auxiliary mounting pads on pumps equipped with through-drive radial
ported end caps. Follow these steps to either remove, replace, or exchange auxiliary
mounting pads.
Removal
1. Remove the screws (J130), retaining the cover plate (J110) or auxiliary pump (not
shown). Remove the shipping cover or auxiliary pump and its seal (J120).
2. Remove the drive coupling (J140) if present.
3. Remove the 4 screws (J100) retaining the pad adapter (J080) to the endcap. Discard
the pad adapter O-ring (J090) if present.
Installation
4. Lubricate new O-ring (J090) with petroleum jelly. Install the pad adapter to the
endcap.
5. Install the 4 screws (J100 ) and torque to 47.5 - 61 N•m [35 - 45 lbf•ft].
6. Install the drive coupling (J140) if present.
Caution
7. Install shipping cover or auxiliary pump with seal (J120).
Shipping cover is intended
only to retain coupling
during shipment and
8. Install the screws (J130) and torque to 94 - 115 N•m [67 - 82 lbf•ft]. If you have an
auxiliary A pad, install the screws (J131) and torque to 37 - 50 N•m [27 - 37 lbf•ft].
storage. Do not operate
pump with coupling and
shipping cover installed. Auxiliary mounting pads
25
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair
iC118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
C104
C103
C132 R
C133
C105
C106
dC106A
C135
C134
C138A d
C138 i
C102
C200 d
C103A d
dC104A
E101 226
e
e
C300
I3/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I
3
/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I
3
/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I
3
/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I6 mm
t7.5 - 10.8 N•m
[5.5 - 8 lbf•ft]
I4 mm
t5.4 - 7.5 N•m
[4 - 5.5 lbf•ft]
dC105A
PHASED OUT PRODUCT
CONTROLControl assembly
Disassembly
1. Remove the 4 screws (C300) holding
the control housing onto the
end cap.
2. Remove the control and discard the
4 interface O-rings (C200).
3. Remove the PC set screw (C102),
PC adjusting plug (C138), O-ring
(C138A), springs (C134, C135), and
seat (C133). Discard the O-ring.
4. Remove the plug (C103), O-ring
(C103A), and PC spool (C132) from
the control housing. Discard the
O-ring. Note orientation of the spool
for reassembly.
For PC only controls, skip steps 5
through 7
5. Remove the plug (C105) and O-ring
(C105A), or the plug (C106) and
O-ring (C106A). Discard the O-ring
(C105A or C106A).
6. Remove the LS set screw (C102),
LS adjusting plug (C118), O-ring
(C118A), back-up rings (C118B),
springs (C114, C115), and seat (C113).
Discard the C118A O-ring.
LS control shown; parts C104 through C106 and
C112 through C118 are not used on PC control
7. Remove the C104 plug, C104A O-ring, and C112 LS spool from the control housing;
discard the O-ring. Note orientation of the spool for reassembly.
Inspection
8. Inspect the adjusting plugs for wear at the tips and where they contact the seat;
replace as necessary.
9. Inspect the springs and spring guides for wear or damage; replace as necessary.
10. Carefully inspect the spools. Ensure the sealing lands are free of nicks and scratches.
Check the ends that contact the spring guides for wear. Replace spools as necessary.
11. Inspect the control housing for damage. Check the spool bores for excessive wear.
12. Clean all parts and lubricate spools, springs, guides and new O-rings with clean
hydraulic uid.
26
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair
iC118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
C104
C103
C132 R
C133
C105
C106
dC106A
C135
C134
C138A d
C138 i
C102
C200 d
C103A d
dC104A
E101 226
e
e
C300
I3/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I3/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I
3
/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I
3
/16 inch
t10.8 - 13.5 N•m
[8 - 10 lbf•ft]
I6 mm
t7.5 - 10.8 N•m
[5.5 - 8 lbf•ft]
I4 mm
t5.4 - 7.5 N•m
[4 - 5.5 lbf•ft]
dC105A
PHASED OUT PRODUCT
CONTROL (continued)
Reassembly
Control assembly
13. Install the PC spool (C132), spherical
end rst, into the PC bore. Using a
new O-ring (C103A), install the plug
(C103). Torque the plug (C103) to
10.8 - 13.5 N•m [8 - 10 lbf•ft].
14. Place the two PC springs (C134,
C135) onto the spring guide (C133)
and install into the PC bore. Place
a new O-ring (C138A) onto the
PC adjusting screw and thread it
into the PC bore until ush, then
make another full turn. Install and
torque the PC set screw (C102) to
7.5 - 10.8 N•m [5.5-8 lbf•ft].
For PC only controls, skip steps 15
through 17.
15. Install the LS spool (C112), spherical
end rst, into the LS bore. Using
a new O-ring (C105A or C106A),
install the plug (C105 or C106).
Torque the plug (C105 or C106) to
10.8 - 13.5 N•m [8 - 10 lbf•ft].
16. Using a new O-ring (C104A), install
the plug (C104). Torque the plug to
10.8 - 13.5 N•m [8 - 10 lbf•ft].
17. Place the two LS springs (C134, C135)
onto the spring guide (C113) and
install into the LS bore. Place a new
O-ring (C118A) and back-up rings
LS control shown; parts C104 through C106 and
C112 through C118 are not used on PC control
(C118B) onto the LS adjusting screw
and thread it into the LS bore until ush, then make another full turn. Install and
torque the LS set screw (C102) to 7.5 - 10.8 N•m [5.5-8 lbf•ft].
18. Using petroleum jelly to retain them, install the 4 interface O-rings (C200) in the
recesses on the control housing.
19. Install the control assembly onto the endcap using the 4 screws (C300). Torque the
screws to 5.4 - 7.5 N•m [4 - 5.5 lbf•ft]. Torque screws in a criss-cross pattern and retorque the rst screw to ensure proper torque retention.
20. Check and adjust the control setting. See Adjustments, page 21.
27
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair
J020
J040
B 7/16 inch
I 3/16 inch
t 10.8-13.6 N•m
[8-10 lbf•ft]
J040
B 7/16 inch
I 3/16 inch
t 10.8-13.6 N•m
[8-10 lbf•ft]
K130
B 7/8 inch
I 3/8 inch
t 93 N•m
[70 lbf•ft]
L020
B 1-3/16 inch
h 1-3/8 inch
t 176-244 N•m
[130-180 lbf•ft]
K120
B 7/16 inch
I 3/16 inch
t 10.8-13.5 N•m
[8-10 lbf•ft]
K130
B 7/8 inch
I 3/8 inch
t 93 N•m
[70 lbf•ft]
K120
B 7/16 inch
I 3/16 inch
t 10.8-13.5 N•m
[8-10 lbf•ft]
P106 071E
PHASED OUT PRODUCT
PLUG AND FITTING SIZES
AND TORQUES
If any plugs or ttings are removed from the unit during service, install and torque as
indicated here. This drawing is a composite. Your conguration may differ but here is the
appropriate wrench size and torque:
Sauer-Danfoss is a global manufacturer and supplier of highquality hydraulic and electronic components. We specialize in
providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile o -highway market.
Building on our extensive applications expertise, we work closely
with our customers to ensure exceptional performance for a broad
range of o -highway vehicles.
We help OEMs around the world speed up system development,
reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
Go to www.sauer-danfoss.com for further product information.
Wherever o -highway vehicles are at work, so is Sauer-Danfoss.
We o er expert worldwide support for our customers, ensuring
the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
comprehensive global service for all of our components.
Please contact the Sauer-Danfoss representative nearest you.
Products we o er:
• Bent Axis Motors
• Closed Circuit Axial Piston Pumps
and Motors
• Displays
• Electrohydraulic Power Steering
• Electrohydraulics
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors
• PLUS+1™ GUIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Sauer-Danfoss-Daikin
www.sauer-danfoss-daikin.com
Sauer-Danfoss (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Fax: +1 515 239 6618