Series 45 Frame G

Open Circuit Axial

Piston Pumps

Service Manual
 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Using this manual

ORGANIZATION AND To help you quickly find information in this manual, the material is divided into sections,
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TABLE OF CONTENTS An indented Table of Contents (TOC) appears on the next page. Tables and illustrations
in the TOC set in blue type. In the PDF version of this document, the TOC entries are
hyperlinked to the pages where they appear.

© 2005 Sauer-Danfoss. All rights reserved. Printed in U.S.A.

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 aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.

Front cover illustrations: F101 437, F101 343, F101 169, P104 356

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 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual

INTRODUCTION 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

TECHNICAL General specifications .................................................................................................................................. 9

SPECIFICATIONS Type of mounting ..................................................................................................................................... 9
Auxiliary mounting pad options ......................................................................................................... 9
Control options.......................................................................................................................................... 9
Port options ................................................................................................................................................ 9
Direction of rotation ................................................................................................................................ 9
Installation position ................................................................................................................................. 9
Technical specifications .......................................................................................................................... 9
General specifications (continued) ........................................................................................................10
Hydraulic parameters..................................................................................................................................10
Inlet pressure ............................................................................................................................................10
Pressure compensator valve setting ................................................................................................10
Case pressure ...........................................................................................................................................10
Hydraulic fluid .........................................................................................................................................10
Hydraulic parameters (continued) .........................................................................................................11
Temperature range.................................................................................................................................11
Fluid viscosity ...........................................................................................................................................11
Filtration ....................................................................................................................................................11

FEATURES Displacement limiter ...................................................................................................................................12

Auxiliary mounting pads ...........................................................................................................................12
Input shafts .....................................................................................................................................................12
Control options .............................................................................................................................................13
Operation...................................................................................................................................................13
Control options .............................................................................................................................................14

PRESSURE Required tools ...............................................................................................................................................15

MEASUREMENT Port locations and gauge installation ...................................................................................................15

INITIAL START-UP General .............................................................................................................................................................16

PROCEDURES Start-up procedure ......................................................................................................................................16

FLUID AND FILTER Recommendations.......................................................................................................................................17

MAINTENANCE

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TROUBLESHOOTING Excessive noise and / or vibration ..........................................................................................................18

Actuator response is sluggish ..................................................................................................................18
System operating hot .................................................................................................................................19
Low pump output flow ..............................................................................................................................19
Pressure or flow instability ........................................................................................................................19
Pressure or flow instability (continued) ...............................................................................................20
System pressure not reaching PC setting ............................................................................................20
High inlet vacuum ........................................................................................................................................20

ADJUSTMENTS PC control ........................................................................................................................................................21

LS control ........................................................................................................................................................22

MINOR REPAIR 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 fitting sizes and torques ..........................................................................................................27

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Introduction

OVERVIEW 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
filter 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
certified on a regular basis. You can locate your nearest ASC using the distributor locator
at www.sauer-danfoss.com

SAFETY PRECAUTIONS 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 flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.

Fluid under pressure

 Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, 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 fluid.

Personal safety
 Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

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Introduction

SYMBOLS USED IN These symbols are in the illustrations and text of this manual. They communicate helpful
SAUER-DANFOSS information at the point where it is most useful to the reader.
LITERATURE
In most instances, the appearance of the symbol itself denotes its meaning. The legend
below defines the symbol and explains its purpose.

 WARNING may result in injury  Tip, helpful suggestion

 CAUTION may result in damage to  Lubricate with hydraulic fluid

product or property
 Apply grease / petroleum jelly
 Reusable part
 Apply locking compound
 Non-reusable part, use a new part
 Inspect for wear or damage
 Non-removable item
 Clean area or part
 Option – either part may exist
 Be careful not to scratch or damage
 Superseded – parts are not
interchangeable  Note correct orientation

 Measurement required  Mark orientation for reinstallation

 Flatness specification  Torque specification

 Parallelism specification  Press in – press fit

 External hex head  Pull out with tool – press fit

 Internal hex head  Cover splines with installation

sleeve
 Torx head
 Pressure measurement / gauge
 O-ring boss port location or specification

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Introduction

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, fluid
is drawn from the inlet and displaced to the outlet thereby imparting power into the
system circuit. A small amount of fluid 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 fluid to the reservoir.

The volume of fluid 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 fluid 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

LS control
(attached to endcap)

LS spool LS adjustment

PC spool PC adjustment

Displacement piston
Swashplate

Cylinder Slipper retainer

block

Tapered roller
bearing

Valve Shaft seal

plate

Cylinder
block
spring

Tapered
roller Input shaft
bearing

Slipper
Piston

Bias piston
Bias spring
Bias piston guide
P104 002E

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Introduction

SYSTEM CIRCUIT The pump receives fluid 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
fluid to the actuators in the system. Fluid returning from the system is cooled by a heat
exchanger and cleaned by a filter before returning to the reservoir.

The speed of the actuators in the system depends on the volume of fluid being 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 flow 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 flow to the system as it demands1 while limiting the maximum pressure.
Therefore flow and pressure in the system are compensated to meet requirements.

Pictorial circuit diagram

Double-acting cylinder
G Frame Series 45
open circuit axial
piston pump with
load sensing control
PVG 32
mulit-section
load
sensing
control
valve

Bi-directional
gear motor

System pressure

Servo pressure
Heat exchanger
Filter Actuator pressure
Reservoir
Load sense pressure

Actuator return

Suction / case drain /

P106 067E
system return

1
Full available flow is a function of pump displacement, operating speed, and efficiency. Refer to Series 45 Axial
Piston Open Circuit Pumps Technical Information, 520L0519 for details.

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Technical specifications

GENERAL Type of mounting

SPECIFICATIONS SAE-C mounting flange.

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 flanged ports, code 61 Inlet Code 62 outlet.
Axial (end) ports or radial (side) ports.

All other ports: SAE straight thread O-ring boss.

Direction of 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 fluid
in the reservoir. The housing must always be filled with hydraulic fluid.

Technical 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 177.6 198
[US gal/min] [46.9] [52.3]
Input torque at maximum displacement N•m/bar 1.178 1.432
(theoretical) [lbf•in/1000 psi] [719] [874]
Mass moment of inertia of internal kg•m² 0.00630 0.00650
rotating components [slug•ft²] [0.00465] [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 flange
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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Technical specifications

GENERAL Ratings Model

SPECIFICATIONS Rating Units G74B G90C
(continued) Input speed1 minimum 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 External moment (Me) N•m [lbf•in] 300 [2655]
loads 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 flange Vibratory (continuous) N•m [lbf•in] 1580 [14 000]
load moments 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.

HYDRAULIC Inlet pressure

PARAMETERS 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

PC control setting range

Model bar psi
G74B 100–310 1450–4495
G90C 100–260 1450–3770

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 fluids refer to Biodegradable Hydraulic Fluids,
520L0465. See Fluid and filter maintenance, page 17 for recommended fluid and filter
change intervals.

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Technical specifications

HYDRAULIC Temperature range

PARAMETERS (continued)
Temperature limits
Minimum
- 40° C [- 40° F]
(intermittent, cold start)
Continuous¹ 82° C [180° F]
Maximum2 104° C [220° F]

Fluid viscosity

Fluid viscosity limits

Condition mm2/s (cSt) SUS
continuous 9 58
ν min.
intermittent 6.4 47
continuous 110 500
ν max. intermittent
1000 4700
(cold start)

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 fluid and filter change intervals.

1
Hydraulic fluid 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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Features

DISPLACEMENT LIMITER Frame G Series 45 pumps are available Displacement limiter

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. P104 026

Auxiliary pad options

AUXILIARY MOUNTING Auxiliary mounting pads are available for
PADS 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 flange
to the pad. Oil from the main pump case
lubricates the drive coupling. For details
P106 023
refer to Series 45 Axial Piston Open Circuit
Pumps Technical Information 520L0519.

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.

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Features

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.

Operation Cross-section pump

General
3
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 flow. The pump
control, depending on conditions in the
system circuit, sets swashplate angle
by metering system pressure to the
servo piston. 2 P106 068E
1
Bias spring and servo piston set swashplate
position

PC control Cross-section PC control

The PC control design maintains a
constant pressure in the hydraulic circuit 4
as flow varies. The PC control modulates
pump flow accordingly to maintain
system pressure at the PC setting as
the PC adjusting plug (4) and spring (5) 6 5
defines. P104 049

PC spool shifts to port system pressure to

When system pressure, acting on the servo piston
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.

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Features

CONTROL OPTIONS LS control Typical load-sensing control valve

(continued) The LS control design matches pump Load
2 pressure
Return
flow with system demand. The LS control pressure
senses the flow demand of the system Tank
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 Load sense System
pressure 2 pressure P101 665E
or decreases pump flow to the system
Pressure drop across external control valve
until the pressure delta becomes equal defines system demand
to the LS setting as defined by the LS
adjusting plug (7) and spring (8). The LS control consists of two spool
valves that connect the servo piston
Cross-section LS control either to pump case or system pressure.
The PC spool (6) controls the pressure-
Spring Spring
guide 8 LS spring compensating function of the control
9Spool 7LS adjusting as previously described. The LS spool (9)
Plug plug controls the load-sensing function. The
PC adjusting PC spool has priority over the LS spool.
Plug plug

6Spool Spring Through internal porting, system

Spring (PC heavy)
guide pressure (upstream of ECV) is applied
P104 051
to the non-spring end of the LS spool,
LS spool shifts to port system pressure to servo
piston 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 flow to the hydraulic system. When the flow 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
flow until the delta across the ECV becomes equal to the LS setting. When flow 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 flow 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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Pressure measurement

REQUIRED TOOLS 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.

PORT LOCATIONS AND The illustration below shows gauge port locations. Recommended pressure gauges and
GAUGE INSTALLATION fittings are in the table.

Gauge and port information

Port Purpose Range of gauge Fitting
M2 System pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring fitting
M4 Servo pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring fitting
L1, L2 Case pressure 0-10 bar [0-100 psi] 7/8 - 14 O-ring fitting
7/16 - 20 O-ring fitting
X1 LS signal 0-300 bar [0-5000 psi]
(tee into LS signal line)

Gauge port locations

X
X
X

S B

M2
L1 L2 Legend
M4
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
P106 072E

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 Series 45 G Frame Open Circuit Axial Piston Pumps
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Initial start-up procedures

GENERAL 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, fittings, heat exchanger, etc.) are clean
prior to filling with fluid.

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. 
 CAUTION
Incorrect shaft alignment 2. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10
may result in damage micron filter pouring into the reservoir. Never reuse hydraulic fluid.
to drive shaft, bearings,
or seal which can cause 3. Fill the main pump housing with clean hydraulic fluid. Pour filtered oil directly into
external oil leakage. 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 fittings. Be certain it is free of restrictions and air leaks.

5. To ensure the pump stays filled 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 fifteen 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 fluid level in the reservoir; add clean filtered fluid if necessary.

The pump is now ready for operation.

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Fluid and filter maintenance

RECOMMENDATIONS To ensure optimum life of Series 45 products, perform regular maintenance of the fluid
and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid
cleanliness when servicing.

Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid
odor. Water in the fluid may be noted by a cloudy or milky appearance or free water
in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to
excessive heat. Change the fluid immediately if these conditions occur. Correct the
problem immediately.

Change the fluid and filter per the Fluid and filter change interval
vehicle / machine manufacturer’s Reservoir type Maximum change interval
recommendations or at these intervals: Sealed 2000 hours
Breather 500 hours
Change the fluid more frequently if it
becomes contaminated with foreign
matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater
than the recommended maximum.

Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.

Change filters whenever the fluid is changed or when the filter indicator shows that it is
necessary to change the filter. Replace all fluid lost during filter change.

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 Series 45 G Frame Open Circuit Axial Piston Pumps
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Troubleshooting

EXCESSIVE NOISE AND / Item Description Action

OR VIBRATION Insufficient hydraulic fluid causes
Check fluid level in reservoir. Fill the reservoir to proper level.
cavitation.
Air in system causes noisy, erratic Purge air and tighten fittings.
Check for air in system.
control. Check inlet for leaks.
Improper inlet conditions cause Correct pump inlet pressure /
Check pump inlet pressure /
erratic behavior and low output vacuum conditions. Refer to
vacuum.
flow. Hydraulic parameters, page 10.
A loose or incorrect shaft coupling Repair or replace coupling and
Inspect shaft couplings. causes excessive noise and / or ensure that correct coupling is
vibration. used.
Misaligned shafts create excessive
Check shaft alignment. Correct shaft misalignment.
noise and / or vibration.
Allow system to warm up before
Hydraulic fluid viscosity above operating, or use fluid with the
acceptable limits or low fluid appropriate viscosity grade for
Hydraulic fluid viscosity above
temperature will not allow the expected operating temperatures.
acceptable limits.
pump to fill or control to operate See Hydraulic Fluids, Series 45
properly. Technical Information Manual,
520L0519.

ACTUATOR RESPONSE IS Item Description Action

SLUGGISH Adjust external relief valve
setting following manufacturer’s
Check external system relief valve Low external relief valve setting
recommendations. External relief
setting. slows down system.
setting must be above PC setting
to operate properly.
Low PC setting prevents the pump
Adjust PC and LS setting. Refer to
Check PC and LS control setting. from achieving full stroke. Low LS
Adjustments, page 20.
setting limits output flow.
Incorrect LS signal will not allow Inspect system to ensure that
Check LS control signal pressures.
pump to operate correctly. proper LS signal transmit to pump.
Worn internal parts don’t allow the Refer to Authorized Service Center
Internal system leaks.
pump to operate properly. for required repair.
Allow system to warm up before
Hydraulic fluid viscosity above operation or sue fluid with the
acceptable limits or low fluid appropriate viscosity grade for
Hydraulic fluid viscosity above
temperature will not allow the expected operating temperatures.
acceptable limits.
pump to fill or control to operate See Hydraulic Fluids, Series 45
properly. Technical Information Manual,
520L0519.
Malfunctioning valving may not Repair or replace system valving as
Check external system valving.
allow system to respond properly. required.
High case pressure causes the
Check pump case pressure. Correct case drain line restrictions.
system to be sluggish.
Check pump inlet pressure / High inlet vacuum causes low
Correct inlet pressure conditions.
vacuum. output flow.

18 BLN-10225 • 520L0605 • May 2005

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting

SYSTEM OPERATING HOT Item Description Action

Insufficient volume of hydraulic
Fill reservoir to proper level. Verify
Check fluid level in reservoir. fluid will not meet cooling
proper size of reservoir.
demands of system.
Insufficient air flow, high input air
Inspect heat exchanger. Check air Clean, repair, or replace heat
temperature, or undersized heat
flow and input air temperature for exchanger as required. Verify
exchangers will not meet cooling
the heat exchanger. proper size of heat exchanger.
demands of the system.
Adjust external system relief valve
setting following manufacturer’s
Check external system relief valve Fluid passing through relief valve
recommendations. External relief
setting. adds heat to system.
valve setting must be above PC
setting for proper operation.
Check pump inlet pressure / High inlet vacuum adds heat to Correct inlet pressure / vacuum
vacuum. system. conditions.

LOW PUMP OUTPUT Item Description Action

FLOW Insufficient hydraulic fluid will limit
Check fluid level in reservoir. output flow and cause internal Fill the reservoir to proper level.
damage to pump.
Allow system to warm up before
operating, or use fluid with the
Fluid viscosity above acceptable
appropriate viscosity grade for
Hydraulic fluid viscosity above limits or low fluid temperature
expected operating temperatures.
acceptable limits. will not allow the pump to fill or
See Hydraulic fluids, Series 45
control to operate properly.
Technical Information Manual,
520L0519.
Adjust external relief valve
following manufacturer’s
Check external system relief valve Eternal relief valve set below PC
recommendation. External relief
setting. setting causes low output flow.
valve setting must be above PC
setting to operate properly.
Low PC setting prevents the pump Adjust PC and LS setting. Refer to
Check PC and LS control setting.
from achieving full stroke. Adjustment, page 21.
Check pump inlet pressure / High inlet vacuum causes low
Correct inlet pressure conditions.
vacuum. output flow.
Check input speed. Low input speeds decrease flow. Adjust input speed.
Incorrect rotational configuration Use pump with appropriate
Check pump rotation.
causes low flow. rotational configuration.

PRESSURE OR FLOW Item Description Action

INSTABILITY Activate PC allowing system
Air in system causes erratic to bleed air. Check inlet line for
Check for air in system.
operation. leaks and eliminate source of air
ingression.
Sticking control spools cause Inspect spools for free movement
Check control spools.
erratic operation. in bore. Clean or replace.

BLN-10225 • 520L0605 • May 2005 19

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting

PRESSURE OR FLOW Item Description Action

INSTABILITY (continued) Low LS setting may cause Adjust LS setting to proper level.
Check LS setting.
instability. See Adjustments, page 21.
Blocked LS signal line interferes
Check LS signal line. Remove blockage.
with proper LS operation.
Adjust external relief valve or PC
Insufficient pressure differential control settings to appropriate
Check external relief valve and PC
between PC setting and external level. Relief valve setting must
setting.
relief valve. be above PC setting to operate
properly.
Chattering external relief valve
Check external relief valve. may cause unstable feedback to Adjust or replace relief valve.
pump control.

SYSTEM PRESSURE NOT Item Description Action

REACHING PC SETTING System pressure will not rise above Adjust PC to appropriate setting.
Check PC control setting.
PC setting. Refer to Adjustments, page 21.
Adjust external relief valve
External relief valve setting below according to manufacturer’s
Check external relief valve. PC setting prevents pressure recommendations. External relief
compensation. valve must be set above PC setting
to operate properly.
Broken, damaged, or missing
Inspect PC control spring. Replace the spring as required.
spring will cause erratic operation.
Wear of PC spool causes internal
Inspect PC spool for wear. Replace the spool as required.
leakage in the control.
Inspect PC spool for proper Improper orientation results in
Correct orientation of spool.
orientation. poor operation.
Clean PC control components, take
Check PC control for Contamination may interfere with
appropriate action to eliminate
contamination. movement of the PC spool.
contamination.

HIGH INLET VACUUM Item Description Action

Low temperature increases
Allow system to warm up before
 Caution Check fluid temperature. viscosity. High fluid viscosity
operating.
High inlet vacuum causes causes high inlet vacuum.
cavitation which can Blocked or restricted inlet screen
Inspect inlet screen. Clean screen / remove blockage.
damage internal pump causes high inlet vacuum.
components. Too many fittings, bends, or long Eliminate fittings to make path
Check inlet piping.
piping causes high inlet vacuum. more direct.
Select fluid with appropriate
viscosity for expected operating
Hydraulic fluid viscosity above High fluid viscosity causes high
temperature. See Hydraulic fluids,
acceptable limits. inlet vacuum.
Series 45 Technical Information
Manual, 520L0519.

20 BLN-10225 • 520L0605 • May 2005

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Adjustments

PC CONTROL PC 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 Before performing adjustments, read page 14, Pressure measurement.

Escaping hydraulic fluid
under pressure can
have sufficient force 1. Install a pressure gauge in port M1 PC control adjustment
to penetrate your skin or M2 to measure system pressure. Case drain port L1
causing serious injury Install a pressure gauge in case G 0 - 10 bar [0 - 145 psi]
and/or infection. Relieve drain port L1 or L2 to measure case I 3/8 in LS adjusting plug
pressure in the system pressure. C B 7/8-14 I6 mm
before removing hoses, t 54 - 136 N•m
fittings, gauges, or 2. Start the prime mover and allow [40 - 100 lbf•ft]
LS set screw
components. fluid to reach normal operating
I 4 mm
temperature. Operate a hydraulic
t 7.5 - 10.8 N•m
Unintended movement of function to its full extension, loading
[5.5 - 8 lbf•ft]
the machine or mechanism the pump at maximum pressure and
may cause injury to the zero flow.
technician or bystanders. X Port
To protect against 3. Loosen the PC set screw and turn the G 0-300 bar
unintended movement, PC adjusting plug until the desired [0-5000 psi]
secure the machine or setting is indicated on the pressure I 3/16 in
disable / disconnect gauge at port M1 or M2 . Clockwise B 7/16-20
the mechanism while rotation increases pressure, t 13-27 N•m
servicing. counterclockwise rotation decreases; [10-20 lbf•ft]
approximate gain 42 bar [610 psi]
P106 069E
per turn.

If the pressure does not increase, an Gauge port M2

external system relief valve may require G 0 - 300 bar [0 - 4351 psi]
Caution adjustment. External system relief valve I 3/16 in
Contamination can must be set above the PC setting for B 7/16-20
damage internal proper operation. t 34-68 N•m
components and void the [25-50 lbf•ft]
manufacturer’s warranty. 4. While holding the position of the PC
Take precautions to ensure adjusting plug, torque the PC set screw to 7.5 - 10.8 N•m [5.5 - 8 lbf•ft].
system cleanliness when
removing and reinstalling 5. Stop the prime mover, remove the pressure gauges, and return the system to its
system lines. normal operating configuration.

1
P C setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual
setting.

BLN-10225 • 520L0605 • May 2005 21

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Adjustments

LS CONTROL 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 fluid Before performing adjustments, read page 15, Pressure measurement.
under pressure can
have sufficient force 1. Install a pressure gauge in port M1
to penetrate your skin or M2 to measure system pressure. LS control adjustment
causing serious injury Install a pressure gauge in drain port Case drain port L1
and/or infection. Relieve L1 or L2 to measure case pressure. G 0 - 10 bar [0 - 145 psi]
pressure in the system Tee-in a gauge to the LS / remote PC I 3/8 in LS adjusting plug
before removing hoses, signal line (port X). C B 7/8-14 I6 mm
fittings, gauges, or t 54 - 136 N•m
components. 2. Start the prime mover and allow fluid [40 - 100 lbf•ft]
LS set screw
to reach normal operating temperature.
I 4 mm
Unintended movement of Slowly operate a hydraulic function
t 7.5 - 10.8 N•m
the machine or mechanism that will demand approximately half
[5.5 - 8 lbf•ft]
may cause injury to the flow from the pump, but keep system
technician or bystanders. pressure below the PC set point.
To protect against X Port
unintended movement, 3. Loosen the LS set screw. While G 0-300 bar
secure the machine or watching the pressure gauges, [0-5000 psi]
disable / disconnect turn the LS adjusting plug until I 3/16 in
the mechanism while the desired pressure differential B 7/16-20
servicing. between port M1 or M2 and t 13-27 N•m
port X is achieved1. Clockwise [10-20 lbf•ft]
Caution rotation increases the setting,
P106 069E
Contamination can counterclockwise rotation
damage internal will decrease it; approximate
components and void the gain = 17 bar [250 psi] per turn. Gauge port M2
manufacturer’s warranty. G 0 - 300 bar [0 - 4351 psi]
Take precautions to ensure 4. While holding the position of the I 3/16 in
system cleanliness when LS adjusting plug, torque the LS set B 7/16-20
removing and reinstalling screw to 7.5 - 10.8 N•m [5.5-8 lbf•ft]. t 34-68 N•m
system lines. [25-50 lbf•ft]
5. Operate a hydraulic function to its
full extension loading the pump at
Adjusting plug, set screw, and gauge
maximum pressure and zero flow.
locations shown

If the pressure does not 6. Loosen the PC set screw and turn the
increase, an external PC adjusting plug until the desired setting is indicated on the pressure gauge at port
system relief valve may M1 or M22. Clockwise rotation increases pressure, counterclockwise rotation decreases
require adjustment. it; approximate gain = 42 bar [610 psi] per turn.
External system relief
valve must be set above 7. While holding the position of the PC adjusting plug, torque the PC set screw to
the PC setting for proper 7.5 - 10.8 N•m [5.5-8 lbf•ft].
operation.
8. Stop the prime mover, remove the pressure gauges, and return the system to its
normal operating configuration.
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.

22 BLN-10225 • 520L0605 • May 2005

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair

SHAFT SEAL The Series 45 open circuit variable pumps use a lip-type shaft seal. You can replace this
REPLACEMENT 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 Shaft seal and retaining ring
pliers, remove the retaining ring
(K010) from the housing. K010

lpd
C Caution 2. Remove the shaft seal (K020) from
Don’t damage the pump the bore in the pump housing and K020
b
housing or shaft. 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.
P106 024

5. Lubricate the lip of the new shaft seal with clean hydraulic fluid. Place a protective
sleeve over the shaft end to prevent damage to the seal during installation.

 Caution 6. Keeping the seal perpendicular to the shaft, press the new seal into the housing just
Premature bearing failure far enough to clear the retaining ring groove.  Install seal with the cupped side
can result if the shaft seal toward the shaft bearing. Do not damage the seal during installation.
contacts the shaft bearing.
Press the seal into the 7. Using the appropriate snap ring pliers, install the seal retaining ring.
housing only far enough
to clear the retaining ring 8. Remove the installation sleeve.
groove.

BLN-10225 • 520L0605 • May 2005 23

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair

AUXILIARY PADS You 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 8. Install the screws (J130) and torque to 94 - 115 N•m [67 - 82 lbf•ft]. If you have an
during shipment and 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

J090 dg
J095
J140
J080
J120 J095
J080
J100
I10 mm J140
J090 dg
t47.5 - 61 N•m
J110 J095
[35 - 45 lbf•ft]
J120
J130 J110 J080
h3/4 inch
t91 - 111 N•m J100 J140
[67 - 82 lbf•ft] J120

P106 029E
J120

J110
J130
h3/4 inch
t91 - 111 N•m
[67 - 82 lbf•ft]

24 BLN-10225 • 520L0605 • May 2005

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair

CONTROL Disassembly Control assembly

1. Remove the 4 screws (C300) holding
C103
the control housing onto the I3/16 inch
end cap. t10.8 - 13.5 N•m
C104 [8 - 10 lbf•ft]
I /16 inch
3
2. Remove the control and discard the C103A d
t10.8 - 13.5 N•m
4 interface O-rings (C200). [8 - 10 lbf•ft] C132 R
e
3. Remove the PC set screw (C102), dC104A
C105
PC adjusting plug (C138), O-ring RC112 I3/16 inch
(C138A), springs (C134, C135), and e t10.8 - 13.5 N•m
seat (C133). Discard the O-ring. C300 [8 - 10 lbf•ft]
I4 mm dC105A
4. Remove the plug (C103), O-ring C102
t5.4 - 7.5 N•m
I6 mm
(C103A), and PC spool (C132) from [4 - 5.5 lbf•ft]
t7.5 - 10.8 N•m
the control housing. Discard the [5.5 - 8 lbf•ft]
O-ring. Note orientation of the spool C200 d
for reassembly. dC106A
C106 C133

For PC only controls, skip steps 5 I3/16 inch C135

through 7 t10.8 - 13.5 N•m
[8 - 10 lbf•ft] C134

5. Remove the plug (C105) and O-ring C113 C138A d

(C105A), or the plug (C106) and C115 C138 i
O-ring (C106A). Discard the O-ring C114
(C105A or C106A). dC118B E101 226

dC118A
6. Remove the LS set screw (C102), dC118B
LS adjusting plug (C118), O-ring iC118
(C118A), back-up rings (C118B),
springs (C114, C115), and seat (C113). LS control shown; parts C104 through C106 and
Discard the C118A O-ring. 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 fluid.

BLN-10225 • 520L0605 • May 2005 25

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair

CONTROL (continued) Reassembly Control assembly

13. Install the PC spool (C132), spherical
C103
end first, into the PC bore. Using a
I3/16 inch
new O-ring (C103A), install the plug
t10.8 - 13.5 N•m
(C103). Torque the plug (C103) to C104 [8 - 10 lbf•ft]
10.8 - 13.5 N•m [8 - 10 lbf•ft]. I3/16 inch
C103A d
t10.8 - 13.5 N•m
14. Place the two PC springs (C134, [8 - 10 lbf•ft] C132 R
C135) onto the spring guide (C133) e
and install into the PC bore. Place dC104A
C105
a new O-ring (C138A) onto the RC112 I3/16 inch
PC adjusting screw and thread it e t10.8 - 13.5 N•m
into the PC bore until flush, then [8 - 10 lbf•ft]
C300
make another full turn. Install and dC105A
I4 mm
torque the PC set screw (C102) to C102
t5.4 - 7.5 N•m
7.5 - 10.8 N•m [5.5-8 lbf•ft]. [4 - 5.5 lbf•ft]
I6 mm
t7.5 - 10.8 N•m
For PC only controls, skip steps 15 [5.5 - 8 lbf•ft]
through 17. C200 d
dC106A
15. Install the LS spool (C112), spherical C106 C133
end first, into the LS bore. Using I3/16 inch C135
a new O-ring (C105A or C106A), t10.8 - 13.5 N•m
install the plug (C105 or C106). [8 - 10 lbf•ft] C134
Torque the plug (C105 or C106) to
C113 C138A d
10.8 - 13.5 N•m [8 - 10 lbf•ft].
C115 C138 i
16. Using a new O-ring (C104A), install C114
the plug (C104). Torque the plug to dC118B E101 226

10.8 - 13.5 N•m [8 - 10 lbf•ft]. dC118A

dC118B
17. Place the two LS springs (C134, C135)
onto the spring guide (C113) and iC118
LS control shown; parts C104 through C106 and
install into the LS bore. Place a new
C112 through C118 are not used on PC control
O-ring (C118A) and back-up rings
(C118B) onto the LS adjusting screw
and thread it into the LS bore until flush, 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 re-
torque the first screw to ensure proper torque retention.

20. Check and adjust the control setting. See Adjustments, page 21.

26 BLN-10225 • 520L0605 • May 2005

 Series 45 G Frame Open Circuit Axial Piston Pumps
Service Manual
Minor repair

PLUG AND FITTING SIZES If any plugs or fittings are removed from the unit during service, install and torque as
AND TORQUES indicated here. This drawing is a composite. Your configuration may differ but here is the
appropriate wrench size and torque:

Plug locations, sizes, and torques

K130
K120 B 7/8 inch
B 7/16 inch I 3/8 inch
I 3/16 inch t 93 N•m
t 10.8-13.5 N•m [70 lbf•ft]
[8-10 lbf•ft]

J020
J040
B 7/16 inch
I 3/16 inch
t 10.8-13.6 N•m
[8-10 lbf•ft]

L020
B 1-3/16 inch
h 1-3/8 inch
t 176-244 N•m
[130-180 lbf•ft]

P106 071E

J040
B 7/16 inch
K120
I 3/16 inch
B 7/16 inch
t 10.8-13.6 N•m
I 3/16 inch
[8-10 lbf•ft]
t 10.8-13.5 N•m
K130 [8-10 lbf•ft]
B 7/8 inch
I 3/8 inch
t 93 N•m
[70 lbf•ft]

BLN-10225 • 520L0605 • May 2005 27

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
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Sauer-Danfoss is a comprehensive supplier providing complete
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building, material handling, municipal, forestry, turf care, and many
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Gear pumps and motors We offer our customers optimum solutions for their needs and
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Centers strategically located in all parts of the world.
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Postfach 2460, D-24531 Neumünster
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Phone: +49 4321 871-0, Fax: +49 4321 871 122

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Phone: +45 7488 4444, Fax: +45 7488 4400
BLN-10225 • 520L0605 • March 2005
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