Series 45 Axial Piston Open Circuit Pumps. Technical Information

Transcription

1 Series 45 Axial Piston Open Circuit Pumps Technical Information

2 Revisions History of Revisions Table of Revisions Date Page Changed Rev. July 29 34, 28 remove T2 shaft option from L and K Frames FN May 29 various revise fitting depth warning to LS port X FM March 29 various add fitting depth warning to LS port X FL October 28 62, 65 add SAE-C two bolt housing FK September dimension changes for Frame J FJ June 28 78, 93, 94, 95 various minor edits, removed S5 shaft from Frame E FI May 28 32, 74, 75, 92 correction to schematics drawings FH April correction to S2 spline width (inch measurement only) FG April 28 52, 53 correction to schematics drawings FG April 28 27, 5, 72, 89 add Load sensing - RP and BP must be 2 bar FF April Correction to S2 shaft - Class 6 and mm length FF March 28 4 Correction to TOC FE February 28 Various Add LS setting to specifications for each frame FD December 27 Various Relocate F and E sections, add displacement limiter info. FC November 27 5 Change load sensing setting - bar increments FB September 27 Various Add Frame F, remove Frame G, and many edits FA November 26 51, 52, 53 Revised schematics information E August 25 - Removed Frame H, added Frame J D April 23 Added Frame E C May 21 - Added Frame H and Frame G B May First printing A 29 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 specifications. 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. 2 52L519 Rev FN July 29

3 Contents General information Overview... 6 Design... 6 Typical applications... 6 High performance... 6 Latest technology... 6 Reliability... 6 The Series 45 product family... 7 Basic units... 7 Load sensing open circuit system... 8 Pressure compensated controls... 9 Operation... 9 Pressure compensated system characteristics... 9 Typical applications for pressure compensated systems... 9 Remote pressure compensated controls...1 Remote pressure compensated system characteristics...1 Typical applications for remote pressure compensated systems...1 Load sensing controls...11 Operation...11 Load sensing system characteristics...11 Typical applications for load sensing systems...11 Electrical on/off pressure compensated controls...12 Operating parameters...13 Fluids...13 Viscosity...13 Temperature...13 Inlet pressure...13 Case pressure...13 Pressure ratings...14 Speed ratings...14 Duty cycle and pump life...14 Speed, flow, and inlet pressure...14 Design parameters...15 Installation...15 Filtration...15 Reservoir...15 Fluid velocity...16 Shaft loads...16 Bearing life...16 Mounting flange loads...17 Auxiliary mounting pads...18 Input shaft torque ratings...18 Understanding and minimizing system noise...19 Sizing equations...2 Frames L and K Design...21 Specifications...22 Performance L25C...23 Performance L3D...24 Performance K38C...25 Performance K45D...26 Order code L519 Rev FN July 29 3

4 Contents Frames L and K (continued) Controls...29 Pressure compensated control (PC)...29 Remote PC control (RP)...29 Load sensing control (LS)...3 Load sensing control with internal bleed orifice (LB)...3 Normally closed on/off electric PC control (ED)...31 Normally open on/off electric PC control (AA)...31 Electric proportional control (EJ) (Normally closed)...32 Input shafts...33 Auxiliary mounting pads...35 SAE-A auxiliary mounting pad...35 SAE-B auxiliary mounting pad...35 SAE-A Auxilliary Pad...36 Mounting pads at 9 degrees...36 Running cover...36 Special SAE-A 11 tooth...36 Displacement limiter...37 Installation drawings...38 Axial ported endcap...38 Radial ported endcap...4 Electric on/off control...42 Frame J Design...43 Specifications...44 Performance J45B...45 Performance J51B...46 Performance J6B...47 Performance J65C...48 Performance J75C...49 Order code...5 Controls...52 Pressure compensated control (PC, BC)...52 Remote PC control (RP, BP)...52 Load sensing control (LS, BS)...53 Load sensing control with internal bleed orifice (LB, BB)...53 Normally closed on/off electric PC control (AG)...54 Normally open on/off electric PC control (AF)...54 Input shafts...55 Auxiliary mounting pads...58 SAE-A auxiliary mounting pad (non-integral)...58 SAE-B auxiliary mounting pad...58 Displacement limiter...59 SAE-C auxiliary mounting pad...6 Running cover...6 Installation drawings...61 Axial ported endcap...61 Radial ported endcap...64 Electric on/off control/radial endcap L519 Rev FN July 29

5 Contents Frame F Design...68 Specifications...69 Performance F74B...7 Performance F9C...71 Order code...72 Controls...74 Pressure compensated control (PC)...74 Remote PC Control (RP)...74 Load sensing control with internal bleed orifice (LB)...75 Load sensing control (LS)...75 Input shafts...76 Auxiliary mounting pads...77 SAE-A auxiliary mounting pad...77 SAE-B auxiliary mounting pad...77 Displacement limiter...78 SAE-C auxiliary mounting pad...78 Adjustable displacement limiter and running cover...79 Axial ported endcap...8 Radial ported endcap...82 Frame E Design...84 Specifications...85 Performance E1B...86 Performance E13B...87 Performance E147C...88 Order code...89 Controls...91 Pressure compensated control (PC)...91 Remote PC control (RP)...91 Load sensing control (LS)...92 Load sensing control with internal bleed orifice (LB)...92 Input shafts...93 Auxiliary mounting pads...95 SAE-A auxiliary mounting pad...95 SAE-B auxiliary mounting pad...95 SAE-C auxiliary mounting pad...96 Running cover...96 Displacement limiters...97 Installation drawings...98 Axial ported endcap, clockwise rotation...98 Axial ported endcap, counterclockwise rotation... 1 Radial ported endcap, clockwise rotation Radial ported endcap, counterclockwise rotation L519 Rev FN July 29 5

6 General information Overview Series 45 is a complete family of variable displacement, axial piston pumps for open circuit applications. Each frame within the Series 45 family is uniquely designed to optimize performance, size, and cost, matching the work function requirements of the demanding mobile equipment marketplace. Design High performance Displacements from 25 cm³ cm³ [ in 3 /rev] Speeds up to 36 rpm Pressures up to 31 bar [4495 psi] continuous, and 4 bar [58 psi] peak Variety of control system options including load sensing and pressure compensated Through-drive capability for multi-circuit systems Range of mounting flanges, shafts, and porting options for ease of installation Latest technology Customer-driven using quality function deployment (QFD) and design for manufacturability (DFM) techniques Optimized valve plates for maximum efficiency and quiet operation Computer-modeled castings to optimize inlet conditions for maximum pump speed Compact package size minimizing installation space requirements Heavy-duty tapered roller bearings for long life Single piece rigid housing to reduce noise and leak paths Integrated controls for high speed response and system stability Reliability Designed to rigorous standards Proven in both laboratory and field Manufactured to rigid quality standards Long service life Significantly fewer parts No gasketed joints Robust input shaft bearings to handle large external shaft loads Integrated gauge ports for monitoring operating conditions Typical applications Cranes Telescopic handlers Forklift trucks Wheel loaders Sweepers Backhoe loaders Forestry and agricultural machinery Fan drives Other uses 6 52L519 Rev FN July 29

7 General information The Series 45 product family Basic units The series 45 family of open circuit, variable piston pumps, offers a range of displacements from 25 to 147 cm³/rev [1.53 to 8.97 in 3 /rev]. With maximum speeds up to 36 rpm and continuous operating pressures up to 31 bar [4495 psi], you can tailor product selection to the flow and pressure requirements of your individual application. K/L Frame J Frame F Frame E Frame General performance specifications for the series 45 pump family Speed Pressure Theoretical flow Pump Displacement Mounting Continuous Max. Min. Continuous Maximum (at rated speed) Model cm 3 in 3 min -1 (rpm) min -1 (rpm) min -1 (rpm) bar psi bar psi US gal/min l/min Flange Frame L See page 21 L25C SAE B - 2 bolt L3D SAE B - 2 bolt Frame K See page 21 K38C SAE B - 2 bolt K45D SAE B - 2 bolt J45B J51B J6B See page 43 SAE B 2-bolt SAE C 2 and 4-bolt SAE B 2-bolt SAE C 2 and 4-bolt SAE B 2-bolt SAE C 2 and 4-bolt J65C SAE B 2-bolt SAE C 2 and 4-bolt J75C SAE B 2-bolt SAE C 2 and 4-bolt Frame F See page 68 F74B SAE B 2-bolt SAE C 4-bolt F9C SAE B 2-bolt SAE C 4-bol Frame E See page 84 E1B SAE C 4-bolt E13B SAE C 4-bolt E147C SAE C 4-bolt 52L519 Rev FN July 29 7

8 General information Load sensing open circuit system The pump receives fluid directly from the reservoir through the inlet line. A screen in the inlet line protects the pump from large contaminants. The pump outlet feeds a PVG-32 multi-section, load sensing, directional control valve. The PVG valve directs pump flow to the cylinder and gear motor. A heat exchanger cools the fluid returning from the valve. A filter cleans the fluid before it returns to the reservoir. Flow in the circuit determines the speed of the actuators. The position of the PVG valve determines the flow demand. A hydraulic pressure signal (LS signal) communicates demand to the pump control. The pump control monitors the pressure differential between pump outlet and the LS signal, and regulates servo pressure to control the swashplate angle. Swashplate angle determines pump flow. Actuator load determines system pressure. The pump control monitors system pressure and will decrease the swashplate angle to reduce flow if system pressure reaches the PC setting. A system relief valve in the PVG valve acts as a back-up to control system pressure. Pictorial circuit diagram K/L Frame Series 45 open circuit axial piston pump with load sensing control PVG 32 mulit-section load sensing control valve Double-acting cylinder Bi-directional gear motor System pressure Reservoir Filter Heat exchanger Servo pressure Actuator pressure Load sense pressure Actuator return P11 658E Suction / case drain / system return 8 52L519 Rev FN July 29

9 General information Pressure compensated controls Operation The PC control maintains constant system pressure in the hydraulic circuit by varying the output flow of the pump. Used with a closed center control valve, the pump remains in high pressure standby mode at the PC setting with zero flow until the function is actuated. This condition is often called a dead head condition. Typical operating curve Q max Simple closed-center circuit Flow Pressure PC setting P11 166E Once the closed center valve is opened, P the PC control senses the immediate drop in system pressure and increases pump flow by increasing the swashplate angle. The pump continues to increase flow until system pressure reaches the PC setting. If system pressure exceeds the PC setting, the PC control reduces the swashplate angle to maintain system pressure by reducing flow. The PC control continues to monitor system pressure and changes swashplate angle to match the output flow with the work function pressure requirements. If the demand for flow exceeds the capacity of the pump, the PC control directs the pump to maximum displacement. In this condition, actual system pressure depends on the actuator load. For additional system protection, install a relief valve in the pump outlet line. Each section includes control schematic diagrams, setting ranges, and response / recovery times for each control available. Response is the time (in milliseconds) for the pump to reach zero displacement when commanded by the control. Recovery is the time (in milliseconds) for the pump to reach full displacement when commanded by the control. Actual times can vary depending on application conditions. Pressure compensated system characteristics Constant pressure and variable flow High pressure standby mode when flow is not needed System flow adjusts to meet system requirements Single pump can provide flow to multiple work functions Quick response to system flow and pressure requirements Typical applications for pressure compensated systems Constant force cylinders (bailers, compactors, refuse trucks) On/off fan drives 52L519 Rev FN July 29 9

10 General information Remote pressure compensated controls The remote PC control is a two-stage control that allows multiple PC settings. Remote PC controls are commonly used in applications requiring low and high pressure PC operation. Typical operating curve Q max Closed center circuit with remote PC Flow Remote PC setting Pressure PC setting P11 969E P The remote PC control uses a pilot line connected to an external hydraulic valve. The external valve changes pressure in the pilot line, causing the PC control to operate at a lower pressure. When the pilot line is vented to reservoir, the pump maintains a low standby pressure of 15 to 2 bar [215 to 3 psi]. When pilot flow is blocked, the pump maintains pressure at the PC setting. An on-off solenoid valve can be used in the pilot line to create a low-pressure standby mode. A proportional solenoid valve, coupled with a microprocessor control, can produce an infinite range of operating pressures. Each section includes control schematic diagrams, setting ranges, and response / recovery times for each control available. Response is the time (in milliseconds) for the pump to reach zero displacement when commanded by the control. Recovery is the time (in milliseconds) for the pump to reach full displacement when commanded by the control. Actual times can vary depending on application conditions. Size the external valve and plumbing for a pilot flow of 3.8 l/min [1 US gal/min]. For additional system protection, install a relief valve in the pump outlet line. Remote pressure compensated system characteristics Constant pressure and variable flow High or low pressure standby mode when flow is not needed System flow adjusts to meet system requirements Single pump can provide flow to multiple work functions Quick response to system flow and pressure requirements Typical applications for remote pressure compensated systems Modulating fan drives Anti-stall control with engine speed feedback Front wheel assist 1 52L519 Rev FN July 29

11 General information Load sensing controls Operation The LS control matches system requirements for both pressure and flow in the circuit regardless of the working pressure. Used with a closed center control valve, the pump remains in low-pressure standby mode with zero flow until the valve is opened. The LS setting determines standby pressure. Typical operating curve Load sensing circuit Q max Flow Pressure PC setting P11 968E P Most load sensing systems use parallel, closed center, control valves with special porting that allows the highest work function pressure (LS signal) to feed back to the LS control. Margin pressure is the difference between system pressure and the LS signal pressure. The LS control monitors margin pressure to read system demand. A drop in margin pressure means the system needs more flow. A rise in margin pressure tells the LS control to decrease flow. LS control with bleed orifice The load sense signal line requires a bleed orifice to prevent high-pressure lockup of the pump control. Most load-sensing control valves include this orifice. An optional internal bleed orifice is available, if needed. Integral PC function The LS control also performs as a PC control, decreasing pump flow when system pressure reaches the PC setting. The pressure compensating function has priority over the load sensing function. For additional system protection, install a relief valve in the pump outlet line. Each section includes control schematic diagrams, setting ranges, and response / recovery times for each control available. Response is the time (in milliseconds) for the pump to reach zero displacement when commanded by the control. Recovery is the time (in milliseconds) for the pump to reach full displacement when commanded by the control. Actual times can vary depending on application conditions. Load sensing system characteristics Variable pressure and flow Low pressure standby mode when flow is not needed System flow adjusted to meet system requirements Single pump can supply flow and regulate pressure for multiple circuits Quick response to system flow and pressure requirements Typical applications for load sensing systems Priority steering Load independent flow control for boom lift, tilt, and rotation 52L519 Rev FN July 29 11

12 General information Electrical on/ off pressure compensated controls The electrical on/off pressure compensated control allows the pump to operate as a PC type control under normal operating conditions. A solenoid valve overrides the PC control allowing the pump to operate in a low-pressure standby mode. This function provides reduced horsepower and torque loss in certain situations. It may be particularly useful to reduce loads on a system during engine start. ED schematic (normally closed) S When closed, the solenoid valve prevents L1 P16 44 flow across the LS spool gain orifice, defeating the LS spool. The pump then functions as a PC control pump. When open, the solenoid valve allows flow across the LS spool gain orifice to reservoir. This flow generates a pressure differential across the LS spool that shifts the spool and de-strokes the pump. The pump then operates in a low-pressure standby condition. The solenoid valve is available in a normally closed or normally open configuration. M2 L2 B X ED is the nomenclature for a normally closed on/off control for the L and K frame pumps. Other frame sizes and configurations have different order code designations. (ED) Electric control cross-section System pressure Servo pressure Pilot Pressure Drain Solenoid LS adjustment LS spool PC adjustment PC spool P16 183E 12 52L519 Rev FN July 29

13 General information Operating parameters Fluids Ratings and performance data for Series 45 products are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors. These include premium turbine oils, API CD engine oils per SAE J183, M2C33F or G automatic transmission fluids (ATF), Dexron II (ATF) meeting Allison C-3 or Caterpillar T 2 requirements, and certain specialty agricultural tractor fluids. For more information on hydraulic fluid selection, see Sauer-Danfoss publications 52L463 Hydraulic Fluids and Lubricants,, and 52L465 Experience with Biodegradable Hydraulic Fluids,. Viscosity Maintain fluid viscosity within the recommended range for maximum efficiency and bearing life. Minimum viscosity should only occur during brief occasions of maximum ambient temperature and severe duty cycle operation. Maximum viscosity should only occur at cold start: Limit speeds until the system warms up. Fluid viscosity limits Condition mm 2 /s (cst) SUS ν min. ν max. continuous 9 58 intermittent continuous 11 5 intermittent (cold start) 1 47 Temperature Maintain fluid temperature within the limits shown in the table. Minimum temperature relates to the physical properties of the component materials. Cold oil will not affect the durability of the pump components. However, Temperature limits Minimum (intermittent, cold start) - 4 C [- 4 F] Continuous 82 C [18 F] Maximum 14 C [22 F] it may affect the ability of the pump to provide flow and transmit power. Maximum temperature is based on material properties. Don t exceed it. Measure maximum temperature at the hottest point in the system. This is usually the case drain. Ensure fluid temperature and viscosity limits are concurrently satisfied. Inlet pressure Maintain inlet pressure within the limits shown in the table. Low inlet pressure (vacuum) may limit maximum pump speed and cause cavitation. Refer to Inlet pressure vs. speed charts for each displacement. Case pressure Maintain case pressure within the limits shown in the table. The housing must always be filled with hydraulic fluid. Inlet pressure limits Minimum (continuous) Minimum (cold start).8 bar absolute [6.7 in. Hg vac.] (at reduced maximum speed).5 bar absolute [15.1 in. Hg vac.] Case pressure limits Maximum.5 bar [7 psi] above inlet (continuous) Intermittent 2 bar [29 psi] above inlet (cold start) C Caution Operating outside of inlet and case pressure limits will damage the pump. To minimize this risk, use full size inlet and case drain plumbing, and limit line lengths. 52L519 Rev FN July 29 13

14 General information Operating parameters (continued) Pressure ratings The specification tables in each section give maximum and continuous pressure ratings for each displacement. Not all displacements within a given frame operate under the same pressure limits. Definitions of the operating pressure limits appear below. System pressure is the differential pressure between the outlet and inlet ports. It is the dominant operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life. System pressure must remain at or below rated pressure during normal operation to achieve expected life. Continuous working pressure is the average, regularly occurring operating pressure. Operating at or below this pressure should yield satisfactory product life. For all applications, the load should move below this pressure. Maximum (peak) working pressure is the highest intermittent pressure allowed. Maximum machine load should never exceed this pressure. Speed ratings The specification tables in each section give minimum, maximum, and rated speeds for each displacement. Not all displacements within a given frame operate under the same speed limits. Definitions of these speed limits appear below. Rated speed is the maximum recommended operating speed at full displacement and 1 bar abs. [ in Hg vac] inlet pressure. Operating at or below this speed should yield satisfactory product life. Maximum speed is the highest recommended operating speed at full power conditions. Operating at or beyond maximum speed requires positive inlet pressure and/or a reduction of pump outlet flow. Refer to Inlet pressure vs. speed charts for each displacement. Minimum speed is the lowest operating speed allowed. Operating below this speed will not yield satisfactory performance. Duty cycle and pump life Knowing the operating conditions of your application is the best way to ensure proper pump selection. With accurate duty cycle information, your Sauer-Danfoss representative can assist in calculating expected pump life. Speed, flow, and inlet pressure Inlet pressure vs. speed charts in each section show the relationship between speed, flow, and inlet pressure for each displacement. Use these charts to ensure your application operates within the prescribed range. The charts define the area of inlet pressures and speeds allowed for a given displacement. Operating at lower displacements allows greater speed or lower inlet pressure L519 Rev FN July 29 Sample inlet pressure vs. speed chart Inlet Pressure (bar abs) Max. speed Rated speed 1% 9% 8% Shaft Speed min (rpm) (psi gauge) (in Hg vac) P11 972E Operating limit at 8% displacement Operating limit at 9% displacement Operating limit at 1% displacement

15 General information Design parameters Installation Series 45 pumps may be installed in any position. To optimize inlet conditions, we recommend installing the pump at an elevation below the minimum reservoir fluid level. Design inlet plumbing to maintain inlet pressure within prescribed limits (see Inlet pressure limits, page 13) Fill the pump housing and inlet line with clean fluid during installation. Connect the case drain line to the uppermost drain port (L1 or L2) to keep the housing full during operation. To allow unrestricted flow to the reservoir, use a dedicated drain line. Connect it below the minimum reservoir fluid level and as far away from the reservoir outlet as possible. Use plumbing adequate to maintain case pressure within prescribed limits (see Case pressure limits, page 13). Filtration To prevent damage to the pump, including premature wear, fluid entering the pump inlet must be free of contaminants. Series 45 pumps require system filtration capable of maintaining fluid cleanliness at ISO class 22/18/13 or better. Sauer-Danfoss does not recommend suction line filtration. Suction line filtration can cause high inlet vacuum, which limits pump operating speed. Instead we recommend a 125 µm (15 mesh) screen in the reservoir covering the pump inlet. This protects the pump from coarse particle ingestion. Return line filtration is the preferred method for open circuit systems. Consider these factors when selecting a system filter: Cleanliness specifications Contaminant ingression rates Flow capacity Desired maintenance interval Typically, a filter with a beta ratio of β 1 = 1 is adequate. However, because each system is unique, only a thorough testing and evaluation program can fully validate the filtration system. For more information, see Sauer-Danfoss publication 52L467 Design Guidelines for Hydraulic Fluid Cleanliness. Reservoir The reservoir provides clean fluid, dissipates heat, and removes entrained air from the hydraulic fluid. It allows for fluid volume changes associated with fluid expansion and cylinder differential volumes. Minimum reservoir capacity depends on the volume needed to perform these functions. Typically, a capacity of one to three times the pump flow (per minute) is satisfactory. Locate the reservoir outlet (suction line) near the bottom, allowing clearance for settling foreign particles. Place the reservoir inlet (return lines) below the lowest expected fluid level, as far away from the outlet as possible. 52L519 Rev FN July 29 15

16 General information Design parameters (continued) Velocity equations Fluid velocity Choose piping sizes and configurations sufficient to maintain optimum fluid velocity, and minimize pressure drops. This reduces noise, pressure drops, and overheating. It maximizes system life and performance. SI units Q = flow (l/min) A = area (mm²) Recommended fluid velocities System lines 6 to 9 m/sec [2 to 3 ft/sec] Suction line Case drain 1 to 2 m/sec [4 to 6 ft/sec] 3 to 5 m/sec [1 to 15 ft/sec] Typical guidelines; obey all pressure ratings. US units Q = flow (US gal/min) A = area (in²) Velocity = Q A (m/sec) Velocity =.321 Q A (ft/sec) Shaft loads Series 45 pumps have tapered roller bearings capable of accepting external radial and thrust loads. The external radial shaft load limits are a function of the load position, orientation, and the operating conditions of the pump. The maximum allowable radial load (R e ) is based on the maximum external moment (M e ) and the distance (L) from the mounting flange to the load. Compute radial loads using the formula below. Tables in each section give maximum external moment (M e ) and thrust load (T in, T out ) limits for each pump frame size and displacement. Radial load formula M e = R e L Shaft load orientation Re L = Distance from mounting flange to point of load M e = Maximum external moment R e = Maximum radial side load 9 Re 27 Re T out T in Re Axis of swashplate rotation L Re 21 Mounting flange P11 8E 16 52L519 Rev FN July 29 Bearing life All shaft loads affect bearing life. In applications where external shaft loads can not be avoided, maximize bearing life by orientating the load between the 15 and 21 positions, as shown. We recommend tapered input shafts or clamp-type couplings for applications with radial shaft loads. Tables in each section give B 1 bearing life for each pump frame size and displacement.

17 General information Design parameters (continued) Mounting flange loads Adding auxiliary pumps and/or subjecting pumps to high shock loads may overload the pump mounting flange. Tables in each section give allowable continuous and shock load moments for each frame size. Applications with loads outside allowable limits require additional pump support. Shock load moment (M S ) is the result of an instantaneous jolt to the system. Continuous load moments (M c ) are generated by the typical vibratory movement of the application. Estimating overhung load moments Use the equations below to estimate the overhung load moments for multiple pump mounting. See installation drawings in each section to find the distance from the mounting flange to the center of gravity for each frame size. Refer to the technical specifications in each section to find pump weight. Overhung load example mounting flange Center of Gravity (CG) pump 1 Center of Gravity (CG) pump 2 L1 L2 P11 81E Shock load formula Continuous load formula M s = G s K (W 1 L 1 +W 2 L W n L n ) M c = G c K (W 1 L 1 +W 2 L W n L n ) SI units M s = Shock load moment (N m) M c = Continuous (vibratory) load moment (N m) G s = Acceleration due to external shock (G s) G c = Acceleration due to continuous vibration (G s) K = Conversion factor =.981 W n = Mass of n th pump (kg) L n = Distance from mounting flange to n th pump CG (mm) US units M s = Shock load moment (lbf in) M c = Continuous (vibratory) load moment (lbf in) G s = Acceleration due to external shock (G s) G c = Acceleration due to continuous vibration (G s) K = Conversion factor = 1 W n = Weight of n th pump (lb) L n = Distance from mounting flange to n th pump CG (in) 52L519 Rev FN July 29 17

18 General information Design parameters (continued) Auxiliary mounting pads Auxiliary mounting pads are available for all radial ported Series 45 pumps. Since the auxiliary pad operates under case pressure, use an O-ring to seal the auxiliary pump mounting flange to the pad. Oil from the main pump case lubricates the drive coupling. All mounting pads meet SAE J744 Specifications. The combination of auxiliary shaft torque and main pump torque must not exceed the maximum pump input shaft rating. Tables in each section give input shaft torque ratings for each frame size. Applications subject to severe vibratory or shock loading may require additional support to prevent mounting flange damage. Tables in each section give allowable continuous and shock load moments for each frame size. The drawing and table below give mating pump dimensions for each size mount. Refer to installation drawings in each section for auxiliary mounting pad dimensions. Mating pump specifications Mounting flange (ref) mm [in.] P11 79E Undercut spline Sled-runner spline B max. C max. D max. E max. Coupling F min. spline engagement for full torque rating P Ø [+ -.2] Recommended cutter clearance 2.3 [.9] R.8 [.3] max. Dimensions SAE A SAE B SAE C P B C D E F [3.25] 6.35 [.25] 12.7 [.5] 58.2 [2.29] 15. [.59] 13.5 [.53] 11.6 [4.] 9.65 [.38] 15.2 [.6] 53.1 [2.9] 17.5 [.69] 14.2 [.56] 127. [5.] 12.7 [.5] [.92] 55.6 [2.19] 3.5 [1.2] 18.3 [.72] Input shaft torque ratings Input shaft tables in each section give maximum torque ratings for available input shafts. Ensure that your application respects these limits. Maximum torque ratings are based on shaft strength. Do not exceed them. Coupling arrangements that are not oil-flooded provide a reduced torque rating. Contact your Sauer-Danfoss representative for proper torque ratings if your application involves non oil-flooded couplings. Sauer-Danfoss recommends mating splines adhere to ANSI B92.1-Class 5. Sauer-Danfoss external splines are modified class 5 fillet root side fit. The external major diameter and circular tooth thickness dimensions are reduced to ensure a good clearance fit with the mating spline. Tables in each section give full spline dimensions and data L519 Rev FN July 29

19 General information Design parameters (continued) Understanding and minimizing system noise Tables in each section give sound levels for each frame size and displacement. Sound level data are collected at various operating speeds and pressures in a semi-anechoic chamber. Many factors contribute to the overall noise level of any application. Here is some information to help understand the nature of noise in fluid power systems, and some suggestions to help minimize it. Noise is transmitted in fluid power systems in two ways: as fluid borne noise, and structure borne noise. Fluid-borne noise (pressure ripple or pulsation) is created as pumping elements discharge oil into the pump outlet. It is affected by the compressibility of the oil, and the pump s ability to transition pumping elements from high to low pressure. Pulsations travel through the hydraulic lines at the speed of sound (about 14 m/s [46 ft/sec] in oil) until there is a change (such as an elbow) in the line. Thus, amplitude varies with overall line length and position. Structure-borne noise is transmitted wherever the pump casing connects to the rest of the system. The way system components respond to excitation depends on their size, form, material, and mounting. System lines and pump mounting can amplify pump noise. Follow these suggestions to help minimize noise in your application: Use flexible hoses. Limit system line length. If possible, optimize system line position to minimize noise. If you must use steel plumbing, clamp the lines. If you add additional support, use rubber mounts. Test for resonants in the operating range, if possible avoid them. 52L519 Rev FN July 29 19

20 General information Sizing equations Use these equations to help choose the right pump size and displacement for your application: Based on SI units Based on US units Flow Output flow Q = V g n η v 1 (l/min) Output flow Q = V g n η v 231 (US gal/min) Torque Input torque M = V g p 2 π η m (N m) Input torque M = V g p 2 π η m (lbf in) Power M n π Q p Input power P = = (kw) 3 6 η t M n π Q p Input power P = = (hp) η t Variables SI units [US units] V g = Displacement per revolution cm 3 /rev [in 3 /rev] p O = Outlet pressure bar [psi] p i = Inlet pressure bar [psi] p = p O - p i (system pressure) bar [psi] n = Speed min -1 (rpm) η v = Volumetric efficiency η m = Mechanical efficiency η t = Overall efficiency (η v η m ) 2 52L519 Rev FN July 29

21 Frames L and K Design Series 45 Frame L and K pumps have a single servo piston design with a cradletype swashplate set in polymer-coated journal bearings. A bias spring and internal forces increase swashplate angle. The servo piston decreases swashplate angle. Nine reciprocating pistons displace fluid from the pump inlet to the pump outlet as the cylinder block rotates on the pump input shaft. The block spring holds the piston slippers to the swashplate via the slipper retainer. The cylinder block rides on a bimetal valve plate optimized for high volumetric efficiency and low noise. Tapered roller bearings support the input shaft and a viton lip-seal protects against shaft leaks. An adjustable one spool (PC only, not shown) or two spool (LS and remote PC) control senses system pressure and load pressure (LS controls). The control ports system pressure to the servo piston to control pump output flow. Frame K/L cross section LS adjustment screw LS control (attached to endcap) LS spool PC spool PC adjustment screw Endcap (axial ported) Swashplate Bias spring Servo piston Tapered roller bearing Valve plate Block spring Tapered roller bearing Cylinder block Input shaft Shaft seal Piston Slipper retainer Slipper P11 659E 52L519 Rev FN July 29 21

22 Frames L and K Specifications Features and options Model For general operating parameters, including fluid viscosity, temperature, and inlet and case pressures, see page 13. For system design parameters, including installation, filtration, reservoir, and line velocities, see page 15. Feature Unit L25C L3D K38C K45D Maximum Displacement cm³ [in³] 25 [1.53] 3 [1.83] 38 [2.32] 45 [2.75] Flow at rated speed (theoretical) Input torque at maximum displacement (theoretical) Mass moment of inertia of internal rotating components l/min [US gal/min] N m/bar [lbf in/1 psi] kg m² [slug ft²] 8 [21].398 [243].169 [.125] 96 [25.4].477 [291].161 [.119] 1.7 [26.6].65 [369].184 [.135] Weight Axial ports kg [lb] 19 [42] Radial ports 24 [53] Rotation Clockwise, Counterclockwise Mounting Auxiliary mounting (See page 35) System ports (type) System ports (location) Control types (See page 29) SAE-B SAE-A, SAE-B, SAE-BB SAE O-ring boss Axial, Radial [31.5].716 [438].23 [.15] EP, ED, AA, PC, Remote PC, LS, LS with internal bleed Shafts (See page 33) Splined 13 tooth, 15 tooth Displacement limiters (See page 37) Tapered Straight Ø 25.4 mm [1 in], 1:8 taper Ø mm [.875 in], 1:8 taper Ø mm [.875 in] (short) Optional, adjustable Ø mm [.875 in] (long) For definitions of pressure and speed ratings, see page 14. For more information on external shaft loads, see page 16; mounting flange loads, see page 17. Ratings Model Rating Units L25C L3D K38C K45D Input speed¹ minimum min -1 (rpm) continuous maximum Working pressure continuous bar [psi] 26 [377] 21 [345] 26 [377] 21 [345] External shaft loads maximum 35 [575] 3 [435] 35 [575] 3 [435] External moment (M e ) N m [lbf in] 61 [54] 61 [54] 76 [673] 76 [673] Thrust in (T in ), out (T out ) N [lbf ] 1 [225] 1 [225] 12 [27] 12 [27] Bearing life at 14 bar [23 psi] B 1 hours Mounting flange load moments at 21 bar [345 psi] at 26 bar [377 psi] Vibratory (continuous) N m [lbf in] 15 [8895] Shock (max) 355 [31 42] 1. Input speeds are valid at 1 bar absolute [ in Hg vac] inlet pressure. See Inlet pressure vs. speed charts. For more information on noise levels, see page 19. Sound levels² db(a) 21 bar [345 psi] 26 bar [377 psi] Pump model 18 min -1 (rpm) Rated speed 18 min -1 (rpm) Rated speed L25C L3D 66 7 K38C K45D Sound data was collected in a semi-anechoic chamber. Values have been adjusted (-3 db) to reflect anechoic levels L519 Rev FN July 29

23 Frames L and K Performance L25C Flow and power data valid at 49 C [12 F] and viscosity of 17.8 mm²/sec [88 SUS]. Flow vs. speed Flow (l/min) Flow (US gal/min) Speed min (rpm) P11 97E Input power vs. speed 5 Power (kw) bar [377 psi] 21 bar [345 psi] 14 bar [23 psi] Power (hp) Speed min (rpm) P11 971E The chart on the right shows allowable inlet pressure and speed at various displacements. Greater speeds and lower inlet pressures are possible at reduced displacement. Operating outside of acceptable limits reduces pump life. Inlet pressure vs. speed Inlet Pressure (bar abs) Shaft Speed min (rpm) 1% 9% 8% (psi gauge) (in Hg vac) P11 972E 52L519 Rev FN July 29 23

24 Frames L and K Performance L3D Flow and power data valid at 49 C [12 F] and viscosity of 17.8 mm²/sec [88 SUS]. Flow vs. speed Flow (l/min) Flow (US gal/min) Speed min (rpm) P11 973E Input power vs. speed 5 6 Power (kw) bar [345 psi] 14 bar [23 psi] Power (hp) Speed min (rpm) P11 974E The chart on the right shows allowable inlet pressure and speed at various displacements. Greater speeds and lower inlet pressures are possible at reduced displacement. Operating outside of acceptable limits reduces pump life. Inlet pressure vs. speed Inlet Pressure (bar abs) % 9% 8% Shaft Speed min (rpm) (psi gauge) (in Hg vac) P11 972E 24 52L519 Rev FN July 29

25 Frames L and K Performance K38C Flow and power data valid at 49 C [12 F] and viscosity of 17.8 mm²/sec [88 SUS]. Flow vs. speed Flow (l/min) Flow (US gal/min) Speed min (rpm) P11 975E Input power vs. speed 6 8 Power (kw) bar [377 psi] 14 bar [23 psi] Power (hp) Speed min (rpm) P11 976E The chart on the right shows allowable inlet pressure and speed at various displacements. Greater speeds and lower inlet pressures are possible at reduced displacement. Operating outside of acceptable limits reduces pump life. Inlet pressure vs. speed Inlet Pressure (bar abs) % 9% 8% Shaft Speed min (rpm) (psi gauge) (in Hg vac) P11 977E 52L519 Rev FN July 29 25

26 Frames L and K Performance K45D Flow and power data valid at 49 C [12 F] and viscosity of 17.8 mm²/sec [88 SUS]. Flow vs. speed Flow (l/min) Flow (US gal/min) Speed min (rpm) P11 978E Input power vs. speed 6 8 Power (kw) bar [345 psi] 14 bar [23 psi] Power (hp) Speed min (rpm) P11 979E The chart on the right shows allowable inlet pressure and speed at various displacements. Greater speeds and lower inlet pressures are possible at reduced displacement. Operating outside of acceptable limits reduces pump life. Inlet pressure vs. speed Inlet Pressure (bar abs) % 9% 8% Shaft Speed min (rpm) (psi gauge) (in Hg vac) P11 977E 26 52L519 Rev FN July 29

27 Frames L and K Order code J K R S P C D E F G H L M N R KR LR S L R Product K Frame, variable displacement open circuit pump L Frame, variable displacement open circuit pump Rotation Left hand (counterclockwise) Right hand (clockwise) P Displacement and pressure rating 25C 25 cm³/rev [1.53 in³/rev], 26 bar [377 psi] continuous working pressure 3D 38C 45D 3 cm³/rev [1.83 in³/rev], 21 bar [345 psi] continuous working pressure 38 cm³/rev [2.32 in³/rev], 26 bar [377 psi] continuous working pressure 45 cm³/rev [2.75 in³/rev], 21 bar [345 psi] continuous working pressure C Control type PC Pressure compensated control RP LS LB ED EP AA Remote pressure compensated control Load sensing / pressure compensating control Load sensing / pressure compensating control with internal bleed orifice Normally closed on/off electric PC control Normally closed electric proportional control (fan drive applications) Normally open on/off electric PC control D PC setting (2 digit code, 1 bar increments) Example 1 = to 26 bar [145 to 377 psi] (25C and 38C) to 21 bar [145 to 345 psi] (3D and 45D) E Load sensing setting (2 digit code, 1 bar increments) Example 2 = 2 bar to 4 bar [174 to 58 psi] NN RP Not applicable (use with PC and RP controls) Must be 2 bar F Not used NN Not applicable G N H Pilot orifice None (standard) Gain orifice 52L519 Rev FN July 29 27

28 Frames L and K Order code (continued) J K R S P C D E F G H L M N 3 Standard orifice J1 Input shaft C2 13 tooth, 16/32 pitch (ANSI A Class 5) C3 15 tooth, 16/32 pitch (ANSI A Class 5) T1 K1 K2 Ø 25.4 mm [1 in], 1:8 taper Ø mm [.875 in] (short) Ø mm [.875 in] (long) J2 N R A T G B V Auxiliary mounting flange None Running cover SAE-A, 9-tooth output spline SAE-A, 11-tooth output spline SAE-A, 11 tooth rotated 9 degrees SAE-B, 13-tooth output spline SAE-BB, 15-tooth output spline J3 System port size and location Code Location Port type Inlet size Outlet size K Radial 4 bolt split flange 38.1 mm [1.5 in] 25.4 mm [1 in] M Axial 4 bolt split flange 31.8 mm [1.25 in] 25.4 mm [1 in] F Axial O-ring boss 1 7 /8 in. 1 5 /16 in. G Radial O-ring boss 1 7 /8 in. 1 5 /16 in. K1 Shaft seal A Single lip seal, viton K2 Mounting flange and housing port style 6 SAE-B 2-bolt, SAE O-ring boss housing ports K3 Not used N Not applicable L Displacement limiter KNB None PLB AAA M Special hardware NNN None N Special features NNN None Endcap machined and plugged Adjustable, factory set at max angle 28 52L519 Rev FN July 29

29 Frames L and K Controls Pressure compensated control (PC) Specifications Schematic diagram PC control setting range Model bar psi L25C L3D K38C K45D PC schematic M2 B Response/recovery times* (ms) Response Recovery L25C 3 9 L3D 3 1 K38C 3 15 K45D 3 11 * For definitions, see page 9 Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port L2 S L1 P11 98 Specifications Remote PC control (RP) PC control setting range Model bar psi L25C L3D K38C K45D Response/recovery times* (ms) Response Recovery L25C 3 9 L3D 3 1 K38C 3 15 K45D 3 11 * For definitions, see page 1. Schematic diagram Remote PC schematic X LS setting Model bar psi All 2 29 M2 B Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = Remote PC port L2 S L1 P L519 Rev FN July 29 29

30 Frames L and K Controls (continued) Specifications Load sensing control (LS) PC setting range Model bar psi L25C L3D K38C K45D Response/recovery times* (ms) Response Recovery L25C 3 7 L3D 3 7 K38C 3 8 K45D 3 8 Schematic diagram LS Schematic X * For definitions, see page 11. LS setting range Model bar psi All M2 L2 B Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = LS signal port X L1 P Load sensing control with internal bleed orifice (LB) Specifications PC setting range Model bar psi L25C L3D K38C K45D Response/recovery times* (ms) Response Recovery L25C 3 7 L3D 3 7 K38C 3 8 K45D 3 8 Schematic diagram LB Schematic X * For definitions, see page 11. LS setting range Model bar psi All M2 L2 B Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = LS signal port S L1 P L519 Rev FN July 29

31 Frames L and K Controls (continued) Specifications Normally closed on/off electric PC control (ED) PC control setting range Model bar psi L25C, K38C L3D, K45D 1-24 bar [ psi] 1-21 bar [ psi] Response/recovery times* (ms) Response Recovery L25C 3 9 L3D 3 1 K38C 3 15 K45D 3 11 * For definitions, see page 11. Schematic diagram ED schematic X LS setting range Model bar psi All M2 B Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = Remote PC port L2 S L1 P16 44 Normally open on/off electric PC control (AA) Specifications PC control setting range Model bar psi L25C, K38C, L3D, K45D 1-21 bar [ psi] Response/recovery times* (ms) Response Recovery L25C 3 9 L3D 3 1 K38C 3 15 K45D 3 11 * For definitions, see page 11. Schematic diagram AA schematic X LS setting range Model bar psi All M2 L2 B Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = Remote PC port S L1 P16 49 Evaluate the system to decide if normally open on/off (failsafe) control is necessary. 52L519 Rev FN July 29 31

32 Frames L and K Controls (continued) Specifications Electric proportional control (EJ) (Normally closed) PC control setting range Model bar psi L25C, K38C L3D, K45D 1-26 bar bar LS setting range Model bar psi All Schematic diagram EJ schematic X Legend B = Outlet S = Inlet L1, L2 = Case drain M2 = System pressure gauge port X = Remote PC port B M2 L2 S L1 P16 687E 32 52L519 Rev FN July 29

33 Frames L and K Input shafts Code C2 Description 13 tooth spline 16/32 pitch (ANSI A Class 5) Maximum torque rating¹ N m [lbf in] 288 [2546] Drawing Ø18.82 [.74] MAX Ø21.72 ±.9 [.855 ±.4] 13 TOOTH 16/32 PITCH 3 PRESSURE ANGLE [.813] PITCH DIA FILLET ROOT SIDE FIT COMPATIBLE WITH ANSI B CLASS 5 ALSO MATES WITH FLAT ROOT SIDE FIT 8 ±.475 [.31 ±.2] 15.2 ±.5 [.6 ±.2] COUPLING MUST NOT PROTRUDE BEYOND THIS POINT 33 [1.3] P11 993E C3 15 tooth spline 16/32 pitch (ANSI A Class 5) 44 [3575] 15 TOOTH 16/32 PITCH 3 PRESSURE ANGLE [.938] PITCH DIA FILLET ROOT SIDE FIT CLASS 5 ALSO MATES WITH FLAT ROOT SIDE FIT Ø21.92 MAX [.863] Ø25.27 ±.12 [.995 ±.5] 8±.475 [.31 ±.2] COUPLING MUST NOT PROTRUDE BEYOND THIS POINT ±.5 [.92 ±.2] 38 [1.5] P11 994E T1 Ø 25.4 mm [1 in] 1:8 taper (SAE J51) 362 [32] [1 ] REF [2.75] [1.6] [ ] [ ] WOODRUFF KE Y Ø22.22 GA UGE [.87] 3/4-16UNF-2A THD 8 ±.8 [.31 ±.3] 34.92±.63 [1.375 ±.25] 125 TAPER PER METER COMPATIBLE WITH SAE J [1] NOMINAL SHAFT DIAMETER 9.42 ±.3 [.37 ±.1] GA UGE C OUPLING MUST NO T PR OT RUDE BEY OND THIS POINT P11 996E 1. See Input shaft torque ratings, page 18 for an explanation of maximum torque. 52L519 Rev FN July 29 33

34 Frames L and K input shafts (continued) Code K1 Description Ø mm [.875 in] 33 mm [1.3 in] Maximum torque rating¹ N m [lbf in] 35 [27] Drawing 6.35 [.25] x 12.7 [.5] LONG SQUARE KEY [ ] Ø22.2 ±.25 [.874 ±.1] 8±.8 [.31 ±.3] K2 Ø mm [.875 in] 63 mm [2.48 in] long 35 [27] COUPLING MUST NOT PROTRUDE BEYOND THIS POINT 33 [1.3] P11 997E 6.35 [.25] x 38.1 [1.5] L ONG SQU ARE KE Y [ ] Ø22.2 ±.25 [.874 ±.1] 8 ±.3 [.315 ±.35] CO UPLING MUST NO T PR OT RUDE BEY OND THIS POINT 63 [2.48] P11 998E 1. See Input shaft torque ratings, page 18 for an explanation of maximum torque L519 Rev FN July 29