Sauer Danfoss 45 Series User manual

Series 45 Frame G
Open Circuit Axial
Piston Pumps
Service Manual
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2520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Revisions
Table of Revisions
Date Page Changed Rev.
December 2010 last New Back Page AB
March 2003 - First revision -
HISTORY OF REVISIONS
© 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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
INTRODUCTION
TECHNICAL
SPECIFICATIONS
FEATURES
PRESSURE
MEASUREMENT
INITIAL START-UP
PROCEDURES
FLUID AND FILTER
MAINTENANCE
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
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
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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
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.
OVERVIEW
SAFETY PRECAUTIONS
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Introduction
SYMBOLS USED IN
SAUER-DANFOSS
LITERATURE
These symbols are in the illustrations and text of this manual. 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
 Measurement required
 Flatness specication
 Parallelism specication
 External hex head
 Internal hex head
 Torx head
 O-ring boss port
 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
 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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Introduction
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.
GENERAL DESCRIPTION
Pump and control sectional view
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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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
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 efciency. Refer to Series 45 Axial
Piston Open Circuit Pumps Technical Information,520L0519 for details.
SYSTEM CIRCUIT
Pictorial circuit diagram
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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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
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
GENERAL
SPECIFICATIONS
Features and options Model
Feature Unit G74B G90C
Maximum Displacement cm³ [in³] 74 [4.52] 90 [5.49]
Flow at rated speed (theoretical) l/min
[US gal/min]
177.6
[46.9]
198
[52.3]
Input torque at maximum displacement
(theoretical)
N•m/bar
[lbf•in/1000 psi]
1.178
[719]
1.432
[874]
Mass moment of inertia of internal
rotating components
kg•m²
[slug•ft²]
0.00630
[0.00465]
0.00650
[0.00480]
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
Straight Ø 31.75 mm [1.25 in]
Displacement limiters Optional, adjustable
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Technical specications
Inlet pressure
Minimum pressure, continuous = 0.8 bar absolute [6.7 inch Hg vac]
(at reduced maximum pump speed)
Minimum pressure, cold start = 0.5 bar absolute [15.1 inch Hg vac]
Pressure compensator valve setting
HYDRAULIC
PARAMETERS
GENERAL
SPECIFICATIONS
(continued)
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.
Ratings Model
Rating Units G74B G90C
Input speed1minimum min-1 (rpm) 500 500
continuous 2400 2200
maximum 2800 2600
Working pressure continuous bar [psi] 310 [4495] 260 [3770]
maximum 400 [5800] 350 [5075]
External shaft
loads
External moment (Me)N•m [lbf•in] 300 [2655]
Thrust in (Tin), out (Tout)N [lbf] 2900 [650]
Bearing life at 140 bar [2030 psi] B10 hours 41 383 19 847
at 210 bar [3045 psi] 9048 4339
at 260 bar [3770 psi] 4062 1948
at 310 bar [4495 psi] 2101 —
Mounting ange
load moments
Vibratory (continuous) N•m [lbf•in] 1580 [14 000]
Shock (max) 5650 [50 000]
1. Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs.speed charts.
PC control setting range
Model bar psi
G74B 100–310 1450–4495
G90C 100–260 1450–3770
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Technical specications
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.
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.
Temperature rangeHYDRAULIC
PARAMETERS (continued)
Fluid viscosity
Fluid viscosity limits
Condition mm2/s (cSt) SUS
ν min. continuous 9 58
intermittent 6.4 47
ν max.
continuous 110 500
intermittent
(cold start) 1000 4700
Temperature limits
Minimum
(intermittent, cold start) - 40° C [- 40° F]
Continuous¹ 82° C [180° F]
Maximum2104° C [220° F]
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Features
DISPLACEMENT LIMITER
AUXILIARY MOUNTING
PADS
INPUT SHAFTS Series 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.
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.
Displacement limiter
P104 026
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.
Auxiliary pad options
P106 023
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Features
The Series 45 Frames G have two possible control options, a Load Sensing (LS) control
with Pressure Compensator (PC) or a PC only control.
Bias spring and servo piston set swashplate
position
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.
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)
denes.
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.
CONTROL OPTIONS
PC spool shifts to port system pressure to
servo piston
Cross-section PC control
P104 049
4
5
6
12
3
P106 068E
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
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 dened by the LS
adjusting plug (7) and spring (8).
Load
pressure
Load sense
pressure
System
pressure
Tank
Return
pressure
P101 665E
2
2
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 pressure-
compensating 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)
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).
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.
LS spool shifts to port system pressure to servo
piston
Cross-section LS control
Spool
Spring
guide
Spring
7LS adjusting
plug
LS spring
PC adjusting
plug
Plug
Plug
SpoolSpring
guide
Spring
(PC heavy)
P104 051
6
8
9
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Pressure measurement
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 port locations
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
XX
X
M2
L1 L2
SB
M4
P106 072E
REQUIRED TOOLS
PORT LOCATIONS AND
GAUGE INSTALLATION
Gauge and port information
Port Purpose Range of gauge Fitting
M2 System pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring tting
M4 Servo pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring tting
L1, L2 Case pressure 0-10 bar [0-100 psi] 7/8 - 14 O-ring tting
X1 LS signal 0-300 bar [0-5000 psi] 7/16 - 20 O-ring tting
(tee into LS signal line)
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Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Initial start-up procedures
CAUTION
Incorrect shaft alignment
may result in damage
to drive shaft, bearings,
or seal which can cause
external oil leakage.
GENERAL
START-UP PROCEDURE 1. Connect the pump to the prime mover. Ensure that pump shaft is properly aligned
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.
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.
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520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
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.
RECOMMENDATIONS
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
Fluid and filter change interval
Reservoir type Maximum change interval
Sealed 2000 hours
Breather 500 hours
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.
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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18 520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
EXCESSIVE NOISE AND /
OR VIBRATION
ACTUATOR RESPONSE IS
SLUGGISH
Item Description Action
Check uid level in reservoir. Insufcient hydraulic uid causes
cavitation. Fill the reservoir to proper level.
Check for air in system. Air in system causes noisy, erratic
control.
Purge air and tighten ttings.
Check inlet for leaks.
Check pump inlet pressure /
vacuum.
Improper inlet conditions cause
erratic behavior and low output
ow.
Correct pump inlet pressure /
vacuum conditions. Refer to
Hydraulic parameters, page 10.
Inspect shaft couplings.
A loose or incorrect shaft coupling
causes excessive noise and / or
vibration.
Repair or replace coupling and
ensure that correct coupling is
used.
Check shaft alignment. Misaligned shafts create excessive
noise and / or vibration. Correct shaft misalignment.
Hydraulic uid viscosity above
acceptable limits.
Hydraulic uid viscosity above
acceptable limits or low uid
temperature will not allow the
pump to ll or control to operate
properly.
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.
Item Description Action
Check external system relief valve
setting.
Low external relief valve setting
slows down system.
Adjust external relief valve
setting following manufacturer’s
recommendations. External relief
setting must be above PC setting
to operate properly.
Check PC and LS control setting.
Low PC setting prevents the pump
from achieving full stroke. Low LS
setting limits output ow.
Adjust PC and LS setting. Refer to
Adjustments, page 20.
Check LS control signal pressures. Incorrect LS signal will not allow
pump to operate correctly.
Inspect system to ensure that
proper LS signal transmit to pump.
Internal system leaks. Worn internal parts don’t allow the
pump to operate properly.
Refer to Authorized Service Center
for required repair.
Hydraulic uid viscosity above
acceptable limits.
Hydraulic uid viscosity above
acceptable limits or low uid
temperature will not allow the
pump to ll or control to operate
properly.
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.
Check external system valving. Malfunctioning valving may not
allow system to respond properly.
Repair or replace system valving as
required.
Check pump case pressure. High case pressure causes the
system to be sluggish. Correct case drain line restrictions.
Check pump inlet pressure /
vacuum.
High inlet vacuum causes low
output ow. Correct inlet pressure conditions.
PHASED OUT PRODUCT

19
520L0605 • Rev AB • December 2010
Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
SYSTEM OPERATING HOT
LOW PUMP OUTPUT
FLOW
PRESSURE OR FLOW
INSTABILITY
Item Description Action
Check uid level in reservoir.
Insufcient volume of hydraulic
uid will not meet cooling
demands of system.
Fill reservoir to proper level. Verify
proper size of reservoir.
Inspect heat exchanger. Check air
ow and input air temperature for
the heat exchanger.
Insufcient air ow, high input air
temperature, or undersized heat
exchangers will not meet cooling
demands of the system.
Clean, repair, or replace heat
exchanger as required. Verify
proper size of heat exchanger.
Check external system relief valve
setting.
Fluid passing through relief valve
adds heat to system.
Adjust external system relief valve
setting following manufacturer’s
recommendations. External relief
valve setting must be above PC
setting for proper operation.
Check pump inlet pressure /
vacuum.
High inlet vacuum adds heat to
system.
Correct inlet pressure / vacuum
conditions.
Item Description Action
Check uid level in reservoir.
Insufcient hydraulic uid will limit
output ow and cause internal
damage to pump.
Fill the reservoir to proper level.
Hydraulic uid viscosity above
acceptable limits.
Fluid viscosity above acceptable
limits or low uid temperature
will not allow the pump to ll or
control to operate properly.
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.
Check external system relief valve
setting.
Eternal relief valve set below PC
setting causes low output ow.
Adjust external relief valve
following manufacturer’s
recommendation. External relief
valve setting must be above PC
setting to operate properly.
Check PC and LS control setting. Low PC setting prevents the pump
from achieving full stroke.
Adjust PC and LS setting. Refer to
Adjustment, page 21.
Check pump inlet pressure /
vacuum.
High inlet vacuum causes low
output ow. Correct inlet pressure conditions.
Check input speed. Low input speeds decrease ow. Adjust input speed.
Check pump rotation. Incorrect rotational conguration
causes low ow.
Use pump with appropriate
rotational conguration.
Item Description Action
Check for air in system. Air in system causes erratic
operation.
Activate PC allowing system
to bleed air. Check inlet line for
leaks and eliminate source of air
ingression.
Check control spools. Sticking control spools cause
erratic operation.
Inspect spools for free movement
in bore. Clean or replace.
PHASED OUT PRODUCT

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