d series gear pump kit program (bln-2-41714 rev a)

D Series Hydraulic Gear Pump Kit Program

Assembly and Test Procedures with Part Numbers

2D Series Hydraulic Gear Pump Kit ProgramAssembly and Test Procedures with Part numbers

BLN-2-41714 Rev A April 2005

2002, 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 arent in conict with agreed specications. 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: E100 459, E100 460, E100 461, E100 462, E100 463 and E100 464



Contents

Overview .................................................................................................................................................. 4Tool requirements ................................................................................................................................. 4Test Equipment ...................................................................................................................................... 4

Codes ......................................................................................................................................................... 5-10

Seal kits ..................................................................................................................................................... 10Service kits ............................................................................................................................................... 10Body kits ................................................................................................................................................... 10Cover kits .................................................................................................................................................. 11Bearing plate kits ................................................................................................................................... 11Shaft kits ................................................................................................................................................... 12Shaft torque limitations ...................................................................................................................... 12Gear plate kits ......................................................................................................................................... 12Single pump screw kits ....................................................................................................................... 13Dual pump screw bolt kits ................................................................................................................. 13Seal installation tool kit ....................................................................................................................... 13

Illustration ................................................................................................................................................ 14Kit requirement ...................................................................................................................................... 14Assembly .................................................................................................................................................. 14-16

Illustration ................................................................................................................................................ 17Kit requirement ...................................................................................................................................... 17Assembly .................................................................................................................................................. 18-21

Pump identication code ................................................................................................................... 22

Pumps without ow divider .............................................................................................................. 22Cause for rejection ................................................................................................................................ 22Air pressure test ..................................................................................................................................... 23Pumps without ow divider schematic ......................................................................................... 23Pressure and ow data ........................................................................................................................ 23

GENERAL INFORMATION

ORDER CODE ANALYSIS

KITS

SINGLE PUMP ASSEMBLY PROCEDURE

DUAL PUMP ASSEMBLY PROCEDURE

PUMP IDENTIFICATION

TEST PROCEDURE



General information

GENERAL INFORMATION OverviewThe Sauer-Danfoss D series kit program is being offered to those distributors that have the in-house capabilities to build, test and service the Sauer-Danfoss D series pumps.

Tool requirements, test stand recommendations, component part identication, assem-bly procedures and product identication codes are covered in the text of this document.

Should you have any questions on qualifying for this program, feel free to contact your Sauer-Danfoss representative.

Tool requirementsThe following tools are required to assemble a D series pump:A. Vise with soft jaw inserts (4 jaw opening) or holding xture.B. Rubber or polyurethane malletC. Socket wrench and 5/16 internal hex socketD. Torque wrench capable of reading lbfft [Nm]E. One set of 1/8 metal stamps (letters and numbers)F. Shaft seal bullet and installation (driving) toolG. Hand press or equivalent device to press in shaft seal

The assembly bench and surrounding area must be clean and free of dirt, grease, and other foreign matter.

Test equipmentThe test must be capable of running any pump displacement at rated ow at factory test pressure. Depending on displacement, horsepower requirements at 1800 rpm range from 10 hp to 50 hp. The test stand must include devices to check output ow, speed, inlet pressure and outlet pressure of the pump. Provisions should also be made to regu-late temperature. Filtration is necessary on any test stand; 10 micron is recommended. Use a quality grade hydraulic uid the viscosity range of 160 SSU at 110 F (based on Sauer-Danfoss production testing). Periodic maintenance of the oil and lters is recom-mended, along with calibration of the measuring devices. The gure below illustrates suggested circuitry and options.

A. Inlet pressure gage/vacuum gage

B. Electric motor - 1800 rpm

C. D series test pump

D. Relief valve (optional)

E. Outlet pressure gage

F. Temperature gage

G. Load valve

H. Oil cooler

I. Filter - 25 micron (optional)

J. Filter - 10 micron

K. Reservoir (ooded inlet - overhead type preferred)

L. Flow measuring device (meter)

E F

G

L

H

I

J

K

A

DBC

P100 559



Order code analysis

SINGLE SECTION PUMPS

DUAL SECTION PUMPS

9 9 9 D E 1 L 0 7 S H B B N 1 0 4 N N N 0 0 0 A F A N N N N 2 1 0 2 0 5

X Distributor code A General characteristics B Displacement 1(1) / input drive C Mounting D Rear cover control/port options E Control settings F Relief valve pressure H Screws J Nameplate information K Special features Z Date code

X Distributor code A General characteristics B Displacement 1(1) / input drive C Mounting R Porting prior to rear displacement of dual pumps S Rear displacement of dual pumps(1)

D Rear cover control/port options E Control settings F Relief valve pressure H Screws J Nameplate information K Special features Z Date code

D E 2 L 3 2 S F A A999X A B C

N 1 0 1D E F H J K Z

N N N 0 0 0 A X A N N N N1 0 4 R S

1 9 2 1 0 2 0 5

Notes: 1. This number denotes cubic centimeter displacement per revolution. For example, 32 = 31.8 cubic

centimeters per revolution. Theoretical pump delivery (gpm) is determined by multiplying actual cubic inch displacement by pump rpm and dividing by 231.

ZX A B C D E F H J K



Distributor code Code Decription Use your assigned distributor code

General characteristics Code Decription DE1L D-series, revision E, single pump, counterclockwise (left hand) rotation

DE1R D-series, revision E, single pump, clockwise (right hand) rotation

DE2L D-series, revision E, dual pump, counterclockwise (left hand) rotation

DE2R D-series, revision E, dual pump, clockwise (right hand) rotation

Displacement 1 (B1) Displacement Gear width Code cm3/rev in3/rev mm in. 07 7.0 0.43 7.1 0.280

10 9.5 0.58 9.5 0.375

13 12.6 0.77 12.7 0.500

14 14.3 0.87 14.4 0.565

17 17.0 1.04 17.0 0.670

19 19.0 1.16 19.0 0.750

21 20.5 1.25 20.6 0.810

23 22.5 1.37 22.4 0.883

25 25.4 1.55 25.4 1.000

29 29.0 1.77 29.0 1.141

32 31.8 1.94 31.7 1.250

38 38.0 2.32 38.0 1.496

41 41.0 2.50 40.9 1.610

Input drive (B2) Code Diameter (in.) Extension (in.) Type Description

PB 0.875 1.62 Straight key SAE B - 1/4 keyway

PD 0.750 2.00 Straight key 3/16 keyway

SE 0.625 1.25 Spline SAE A 9 tooth, 0.75 effective spline

SF 0.750 1.25 Spline 11 tooth, 0.79 effective spline

SH 0.875 1.62 Spline 13 tooth SAE B, 1.18 effective spline

Mounting Code Decription AA SAE A ange, 2-bolt

BB SAE B ange, 2-bolt

Porting prior to rear displacement (use with dual pumps only) Code Inlet port Outlet port 101 1 1/16 - 12 SAE, side 7/8 - 14 SAE, side

104 1 5/16 - 12 SAE, side 1 1/16 - 12 SAE, side

113 None 7/8 - 14 SAE, side

125 1 5/8 - 12 SAE, side 1 1/16 - 12 SAE, side

126 None 1 1/16 - 12 SAE, side

Order code analysis

CODES X

B

D E 1 LA

0 7 S FB

0 7 S F

B BC

1 0 4R



Rear displacement (use with dual pumps only) Displacement Gear width Code cm3/rev in3/rev mm in. 07 7.0 0.43 7.1 0.280

10 9.5 0.58 9.5 0.375

13 12.6 0.77 12.7 0.500

14 14.3 0.87 14.4 0.565

17 17.0 1.04 17.0 0.670

19 19.0 1.16 19.0 0.750

21 20.5 1.25 20.6 0.810

23 22.5 1.37 22.4 0.883

25 25.4 1.55 25.4 1.000

29 29.0 1.77 29.0 1.141

32 31.8 1.94 31.7 1.250

38 38.0 2.32 38.0 1.496

41 41.0 2.50 40.9 1.610

Rear cover control/port optionsNote: Codes N113 and N126 are for use with dual pumps only

Code Inlet port Outlet port N101 1 1/16 - 12 SAE, side 7/8 - 14 SAE, side

N104 1 5/16 - 12 SAE, side 1 1/16 - 12 SAE, side

N504 1 5/16 - 12 SAE, end 1 1/16 - 12 SAE, end

N113 None 7/8 - 14 SAE, side

N125 1 5/8 - 12 SAE, side 1 1/16 - 12 SAE, side

N126 None 1 1/16 - 12 SAE, side

Control settings Code Description NNN No control setting

Relief valve pressure Code Description 000 No relief valve

Order code analysis

CODES

S

1 9

N 1 0 1D

N N N

0 0 0

A F

E

F

H Single pump screws Displacement Rear cover control/port option D Code B1 N101, N104, and N504 N125 07 AF AJ

10 AG AJ

13 AG AJ

14 AG AK

17 AH AK

19 AH AK

21 AH AL

23 AJ AL

25 AJ AL

29 AK AM

32 AK AM

38 AL AN

41 AM AP



This table only used for the following codes: D = N101, N104, N504, N113, or N126 and R = 101, 104, 113, or 126 Do not use this table if D = N125 or R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code) 07 10 13 14 17 19 21 23 25 29 32 38 41 07 AS AS AS AT AT AT AU AU AU AV AV AW AX 10 AS AS AT AT AU AU AU AU AV AV AW AX AX 13 AS AT AT AU AU AU AV AV AV AW AW AX AY 14 AT AT AU AU AU AV AV AV AW AW AX AY AY 17 AT AU AU AU AV AV AV AW AW AX AX AY AY 19 AT AU AU AV AV AV AW AW AW AX AX AY AZ 21 AU AU AV AV AV AW AW AW AX AX AY AZ AZ 23 AU AU AV AV AW AW AW AW AX AX AY AZ AZ 25 AU AV AV AW AW AW AX AX AX AY AY AZ BA 29 AV AV AW AW AX AX AX AX AY AY AZ BA BA 32 AV AW AW AX AX AX AY AY AY AZ AZ BA BB 38 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC 41 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC

Dual pump screws

The following tables are to be used to determine the correct code for a dual pump.

1) Select the appropriate table (4 options) corresponding to the desired port codes.

2) Select the row corresponding to the displacement of the front pump.

3) Select the column corresponding to the displacement of the rear pump.

4) Select the 2 digit code where the two displacements meet.

Example: D code = N104, R code = 113, front displacement (B) = 21, and rear displacement (S) = 19

indicates the correct screw code H = AW.

Order code analysis

CODES

3 2 S F

A XH

This table only used for the following codes: D = N101, N104, N504, N113, or N126 and R = 125 Do not use this table if D = N125 or R = 101, 104, 113, or 126 Displacement 1 Rear displacement of dual pump code B (refer to S position code) 07 10 13 14 17 19 21 23 25 29 32 38 41 07 AT AT AU AU AV AV AV AV AW AW AX AY AY 10 AT AU AU AV AV AV AV AW AW AX AX AY AZ 13 AU AU AV AV AV AW AW AW AX AX AY AZ AZ 14 AU AV AV AV AW AW AW AX AX AY AY AZ AZ 17 AV AV AV AW AW AW AX AX AX AY AY AZ BA 19 AV AV AW AW AW AX AX AX AY AY AZ BA BA 21 AV AV AW AW AX AX AX AY AY AZ AZ BA BA 23 AV AW AW AX AX AX AY AY AY AZ AZ BA BB 25 AW AW AX AX AX AY AY AY AZ AZ BA BB BB 29 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC 32 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC 38 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD 41 AY AZ AZ AZ BA BA BA BB BB BC BC BD BE

3 2 S F



This table only used for the following codes: D = N125 and R = 101, 104, 113, or 126 Do not use this table if D = N101, N104, N504, N113 or R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code) 07 10 13 14 17 19 21 23 25 29 32 38 41 07 AU AU AV AV AW AW AW AW AX AX AY AZ AZ 10 AU AV AV AV AW AW AW AX AX AY AY AZ BA 13 AV AV AW AW AW AX AX AX AY AY AZ BA BA 14 AV AV AW AW AX AX AX AY AY AZ AZ BA BA 17 AW AW AW AX AX AX AY AY AY AZ AZ BA BB 19 AW AW AX AX AX AY AY AY AZ AZ BA BB BB 21 AW AW AX AX AY AY AY AY AZ BA BA BB BB 23 AW AX AX AY AY AY AY AZ AZ BA BA BB BC 25 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC 29 AX AY AY AZ AZ AZ BA BA BA BB BB BC BD 32 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD 38 AZ AZ BA BA BA BB BB BB BC BC BD BE BE 41 AZ BA BA BA BB BB BB BC BC BD BD BE BF

Dual pump screws continued

Order code analysis

CODES

3 2 S F

This table only used for the following codes: D = N125 and R = 125 Displacement 1 Rear displacement of dual pump code B (refer to S position code) 07 10 13 14 17 19 21 23 25 29 32 38 41 07 AV AW AW AW AX AX AX AY AY AZ AZ BA BB 10 AW AW AX AX AX AY AY AY AZ AZ BA BB BB 13 AW AX AX AX AY AY AY AZ AZ BA BA BB BC 14 AW AX AX AY AY AY AZ AZ AZ BA BA BB BC 17 AX AX AY AY AY AZ AZ AZ BA BA BB BC BC 19 AX AY AY AY AZ AZ AZ BA BA BB BB BC BD 21 AX AY AY AZ AZ AZ BA BA BA BB BB BC BD 23 AY AY AZ AZ AZ BA BA BA BB BB BC BD BD 25 AY AZ AZ AZ BA BA BA BB BB BC BC BD BE 29 AZ AZ BA BA BA BB BB BB BC BC BD BE BE 32 AZ BA BA BA BB BB BB BC BC BD BD BE BF 38 BA BB BB BB BC BC BC BD BD BE BE BF BG 41 BB BB BC BC BC BD BD BD BE BE BF BG BG

3 2 S F

Nameplate information Code Description AN Standard nameplate

BN Standard label (use with rear cover code N504)

Special features Code Description NNN No special features, standard black paint

A N

N N N

J

K

A XH

10

D Series Hydraulic Gear Pump Kit ProgramAssembly and Test Procedures with Part numbers


Date code Code Decription DDMMYY The date code must be stamped as indicated on every pump built. The

date code structure is as follows:

DD = day of month

MM = month of assembly

YY = year of assembly

Order code analysis and kits

CODES2 1 0 2 0 5

Z

E100 472

E100 473

SEAL KITS

SERVICE KITS

Item ID Description 163D9118 Shaft lip seal kit (lip seal only)

163D9119 Seal kit - D pump, single

163D9120 Seal kit - D pump, dual

Item ID Description 163D9277 Service kit - D pump, single, 14 & below

163D9278 Service kit - D pump, single, 17 & above

163D9279 Service kit - D pump, dual, 14 & below

163D9280 Service kit - D pump, dual, 17 & above

Item ID Description 163D9200 Body kit - right hand rotation pump - SAE A mount (C code AA)

163D9201 Body kit - left hand rotation pump - SAE A mount (C code AA)

163D9202 Body kit - right hand rotation pump - SAE B mount (C code BB)

163D9203 Body kit - left hand rotation pump - SAE B mount (C code BB)

BODY KITS

E100 444

11



COVER KITS

Item ID Description 163D9204 Cover kit - 1 5/16 - 12 side inlet, 1 1/16 - 12 side outlet (D code N104)

163D9205 Cover kit - 1 1/16 - 12 side inlet, 7/8 - 14 side outlet (D code N101)

163D9206 Cover kit - 1 5/16 - 12 end inlet, 1 1/16 - 12 end outlet (D code N504)

163D9207 Cover kit - no inlet, 7/8 - 14 side outlet (D code N113) for single inlet dual pumps only

163D9307 Cover kit - 1 5/8 - 12 side inlet, 1 1/16 - 12 side outlet (D code N125)

163D9283 Cover kit - no inlet, 1 1/16 - 12 side outlet (D code N126) for single inlet dual pumps only

Item ID Description 163D9208 Bearing plate kit - 1 5/16 - 12 side inlet, 1 1/16 - 12 side outlet (R code 104)

163D9281 Bearing plate kit - 1 5/8 - 12 side inlet, 1 1/16 - 12 side outlet (R code 125)

163D9282 Bearing plate kit - no inlet, 1 1/16 - 12 side outlet (R code 126) for single inlet dual pumps only

BEARING PLATE KITS (DUAL PUMPS)

Kits

E100 445

E100 446

12



Kits

SHAFT KITS

Code PB Code PD Code SE Code SF Code SH Pump 0.875 0.750 0.625 0.750 0.875 Dual pump Size keyed keyed 9 tooth 11 tooth 13 tooth idler drive shaft 07 163D9291 163D9218 163D9238 163D9228 163D9290 163D9253

10 163D9292 163D9219 163D9239 163D9229 163D9287 163D9254

13 163D9289 163D9220 163D9240 163D9230 163D9284 163D9255

14 163D9293 163D9294 163D9295 163D9296 163D9286 163D9288

17 163D9209 163D9221 163D9241 163D9231 163D9244 163D9256

19 163D9210 163D9222 163D9242 163D9232 163D9245 163D9257

21 163D9211 163D9223 163D9243 163D9233 163D9246 163D9258

23 163D9212 163D9224 163D9297 163D9234 163D9247 163D9259

25 163D9213 163D9225 163D9298 163D9235 163D9248 163D9260

29 163D9214 163D9226 163D9299 163D9236 163D9249 163D9261

32 163D9215 163D9227 163D9300 163D9237 163D9250 163D9262

38 163D9216 163D9303 163D9301 163D9305 163D9251 163D9263

41 163D9217 163D9304 163D9302 163D9306 163D9252 163D9264

Max. continuous Shaft code torque rating PB 183 lbfft

PD 117 lbfft

SE 88 lbfft

SF 130 lbfft

SH 183 lbfft

SHAFT TORQUELIMITATION

The chart to the right indicates the maximum shaft

torque rating for the various drive shaft options.

Pump size Gear plate kits 07 163D9265

10 163D9266

13 163D9267

14 163D9285

17 163D9268

19 163D9269

21 163D9270

23 163D9271

25 163D9272

29 163D9273

32 163D9274

38 163D9275

41 163D9276

GEAR PLATE KITS

E100 450

E100 465E

Keyed

E100 447E

Splined

E100 448E

Idler driveshaft

13



Kits

SINGLE PUMP SCREW KITS

E100 451

Code Screw kits AF 163D9077

AG 163D9078

AH 163D9082

AJ 163D9084

AK 163D9086

AL 163D9087

AM 163D9088

AN 163D9090

AP 163D9091

refer to page 7 to determine appropriate code

DUAL PUMP SCREW KITS

SEAL INSTALLATION TOOL KIT

Item ID Description 163D9117 Seal installation tool - Seal bullet and driving tool

E100 451

Code Screw kits AS 163D9093

AT 163D9094

AU 163D9095

AV 163D9096

AW 163D9097

AX 163D9098

AY 163D9099

AZ 163D9100

BA 163D9101

BB 163D9102

BC 163D9103

BD 163D9104

BE 163D9105

BF 163D9106

BG 163D9107

refer to page 8-9 to determine appropriate code

14



Single pump assembly procedure

ILLUSTRATION

One body kitOne cover kitOne drive shaft kitOne gear plate kitOne screw kit

KIT REQUIREMENT

ASSEMBLY 1. Place body assembly, with E-ring seal grooves facing up, into vise with soft jaws or in holding xture. Extreme caution must be used when using a vise to avoid distorting any parts or damaging mounting pilot.

2. Place the rubber seal ring in body groove.

3. Remove the two wear plates, pre-load seal (black rubber E-ring), and load seal (yellow k-lon E-ring) from the gear plate kit.

4. Place the pre-load seal in the bottom of the body E-ring groove.

E100 444

E100 450

Screw

Cover assembly

Seal ring

Seal ring

Wear plate

Wear plate

Dowel pinGear plate

Load ring

Pre-load ring

Body assembly

Shaft seal

Drive shaft

Idler shaft

Wear plate

E100 453E

Plastic plug

Plastic plug

15



5. Place the load seal directly on top of the pre-load seal.

6. Find the wear plate with the .250 diameter pressure hole and NO oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pres-sure hole located on the e-ring side of the body.

Pressure hole

E100 455E

ASSEMBLY(CONTINUED)

Pressure holeE100 456E


7. Lubricate key or spline end of drive shaft with Aerolube grease or equivalent and carefully insert in correct bearing bore.

8. Insert idler gear in the other bearing bore.

9. Lubricate gearset completely, using clean oil that is compatible with test stand oil.

10. Place cover assembly on assembly bench with machined surface facing up.

11. Place the rubber seal ring in cover seal ring groove.

13. Place the gear plate onto the cover.

14. Insert the two dowel pins through the gear plate and into the cover.

15. Place cover/gear plate assembly over shaft journals making certain that the pressure holes in the body and cover wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged.

16. Place appropriate screws in the cover holes and turn until thread engages. Use care so that cross threading does not occur.

17. Turn screws evenly with socket wrench to approximately 20 lbfft. Using a torque wrench, torque screws to 47 lbfft in a crossing pattern begining with one of the four center screws.

18. Remove assembly from vise or holding xture and return with drive shaft facing upwards.

19. Place seal bullet over drive shaft, sliding it downward until it bottoms out.

12. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the cover with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in cover.

16




ASSEMBLY(CONTINUED)

20. Apply Aerolube grease or equivalent to sealing lips of shaft seal.

21. Place the shaft seal over seal bullet with spring loaded side facing inward and slide it down. If shaft extension allows, remove bullet when sealing lips of seal are clear of keyway or spline.

22. Place driving tool over bullet and/or shaft and press seal into housing with a smooth uniform pressure. Be certain seal is not cocked when applying pressure.

23. Remove tool and bullet. NOTE: Bullets and driving tools should be inspected frequently for cracks or other imperfections that may cause seal damage.

24. Rotate drive shaft to make sure it turns smoothly.

.25Install seal withspring loaded sidefacing inward

SAE 'A' Body.25

Install seal withspring loaded sidefacing inward

SAE 'B' Body

E100 457E

17



Dual pump assembly procedure

ILLUSTRATION

One body kitOne cover kitOne drive shaft kitOne idler drive shaft kitTwo gear plate kitsOne bearing plate kitOne screw kit

KIT REQUIREMENTS

Gear plateDrive shaft

Idler shaft

Screw

Cover assembly

Seal ring

Wear plate

Bearing plate assembly

Dowel pin

Gear plate

Idler drive shaft

Idler shaft

Dowel pin

Seal ring

Seal ring

Seal ring

Wear plateLoad seal

Pre-load seal

Coupling

Wear plate

Wear platePre-load seal

Load seal

Shaft seal

Body assembly

E100 454E

Plastic plug

Plastic plug

Plastic plug

Plastic plug

18



ASSEMBLY 1. Place body assembly, with E-ring seal grooves facing up, into vise with soft jaws or in holding xture. Extreme caution must be used when using a vise to avoid distorting any parts or damaging mounting pilot.

2. Place the rubber seal ring in body groove.

3. Remove the two wear plates, pre-load seal (black rubber E-ring), and load seal (yellow k-lon E-ring) from the gear plate kit.

4. Place the pre-load seal in the bottom of the body E-ring groove.


6. Find the wear plate with the .250 diameter pressure hole and no oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pres-sure hole located on the E-ring side of the body.

7. Lubricate key or spline end of drive shaft with Aerolube grease or equiv-alent and carefully insert in correct bearing bore.

8. Insert idler gear in the other bearing bore.

9. Lubricate gear set completely, using clean oil that is compatible with test stand oil.

10. Place bearing plate assembly on assembly bench with E-ring grooved surface facing down.

11. Place the rubber seal ring in bearing plate seal ring groove.

Pressure hole

E100 455E


E100 446

E100 444

E100 450

19



12. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the bearing plate with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in bearing plate.

17. Remove the two wear plates, pre-load seal (black rubber E-ring), and load seal (blue k-lon E-ring) from the gear plate kit.

18. Place the pre-load seal in the bottom of the bearing plate E-ring groove.


20. Find the wear plate with the .250 diameter pressure hole and no oblong holes on the inlet side. Place this wear plate on top of the load ring with the bronze side facing up towards the gears and the .250 pressure hole located on the E-ring side of the bearing plate.

21. Insert coupling into spline bore of drive shaft.

22. Place idler drive shaft into the coupling spline bore. The internal spline of the idler drive shaft must engage with the coupling in the drive shaft.

Pressure hole

E100 455E



ASSEMBLY(CONTINUED)

13. Place the gear plate onto the bearing plate.

14. Insert the two dowel pins through the gear plate and into the bearing plate.

15. Place this bearing plate/gear plate assembly over shaft journals making certain that the pressure holes in the body and bearing plate wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged.

16. Place the rubber seal ring in bearing plate seal ring groove.

23. Lubricate gear set completely, using clean oil that is compatible with test stand oil.

E100 450

E100 448E

20



24. Place cover assembly on assembly bench with machined surface facing up.

25. Place the rubber seal ring in cover seal ring groove.

26. Find the wear plate with the .625 diameter pressure hole and two oblong holes on the inlet side. Place the wear plate in the cover with the bronze side facing up towards the gears and the .625 pressure hole located over the circular hole in cover.

27. Place the gear plate onto the cover.



ASSEMBLY(CONTINUED)

E100 445

28. Insert the two dowel pins through the gear plate and into the cover.

29. Place cover/gear plate assembly over shaft journals making certain that the pressure holes in the bearing plate and cover wear plates are on the same side. If necessary, tap lightly on the back of the cover until dowel pins are completely engaged.

30. Place appropriate screws in the cover holes and turn until thread engages. Use care so that cross threading does not occur.

31. Turn screws evenly with socket wrench to approximately 20 lbfft. Using a torque

wrench, torque screws to 47 lbfft in a crossing pattern begining with one of the four center screws.

32. Remove assembly from vise or holding xture and return with drive shaft facing upwards.

33. Place seal bullet over drive shaft, sliding it downward until it bottoms out.

34. Apply Aerolube grease or equivalent to sealing lips of shaft seal.

21



35. Place the shaft seal over seal bullet with spring loaded side facing inward and slide it down. If shaft extension allows, remove bullet when sealing lips of seal are clear of keyway or spline.

36. Place driving tool over bullet and/or shaft and press seal into housing with a smooth uniform pressure. Be certain seal is not cocked when applying pressure.

37. Remove tool and bullet. NOTE: Bullets and driving tools should be inspected frequently for cracks or other imperfections that may cause seal damage.

38. Rotate drive shaft to make sure it turns smoothly.


ASSEMBLY(CONTINUED)

.25Install seal withspring loaded sidefacing inward

SAE 'A' Body.25

Install seal withspring loaded sidefacing inward

SAE 'B' Body

E100 457E

22



Pump identication and test procedure

PUMPS WITHOUT FLOW DIVIDER

1. Mount pump to test stand with recommended features.

2. Connect all required lines to pump as shown in gure I on page 23.

3. Maintain oil temperature at 110 F 5 F throughout test.

4. Jog pump to assure priming.

5. Run pump at 1800 rpm in proper rotation at minimum back pressure for one minute.

6. Increase pressure in 500 psi increments up to specied test pressure, running for one minute at each increment.

7. Check for rated ow at specied test pressure as indicated in chart on page 23.

8. Repeat steps 5 and 6 for each section of dual pumps. Connect sections not being tested to tank.

PUMP IDENTIFICATION CODE

Proper identication of the unit is an important part of the total assembly, for you and your customer. Three items must be stamped on every unit:

1. Your assigned distributor code*

2. Complete order code

3. Date code

These items are to be stamped across the pilot of the body. For description and order code breakdown, see Order Code Analysis

* A three digit distributor code will be assigned to each participating distributor. This code identies you as the builder and suppliers of the unit. If Sauer-Danfoss is contacted about a unit, it allows us to make proper referrals for service or additional units, and will aid us if any problems should arise.

CAUSE FOR REJECTION 1. Failure to meet rated ow.

2. Air in discharge line.

3. External leakage at shaft seal, between sections, or at ports.

If pump is rejected, repeat applicable steps from assembly procedure.

999-

13S

H-B

B-10

1-21

-N101-NNN-000-AV-AN

-NN

N-210505

Pump identification code

P100 562E

23



Test procedure

AIR PRESSURE TEST 1. Plug pressure port(s).

2. Insert plug with air tting into tank port. Plug other tank port(s) if applicable.

3. Gradually apply air pressure from 0 to 35 psi in 15 to 20 seconds, and then hold for one minute while submerged in a petroleum based solvent.

4. Check for external air leakage.

5. Insert port protectors (cap plugs).

6. Clean exterior of pump

7. Apply rust preventative to all exposed bare metal parts.

If pump is rejected, repeat applicable steps from assembly procedure.

PUMPS WITHOUT FLOW DIVIDER SCHEMATIC

P100 561E

Figure I

PRESSURE AND FLOW DATA

Pump Test Minimum ow Size pressure (psi) required (GPM) 07 3500 2.8

10 3500 3.8

13 3500 5.1

14 3500 5.8

17 3500 6.9

19 3500 7.7

21 3500 8.5

23 3500 9.3

25 3500 10.5

29 3500 12.0

32 3500 13.2

38 3500 15.7

41 3000 16.9

Sauer-Danfoss Hydraulic Power Systems Market Leaders Worldwide

Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market.

Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others.

We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them.

Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company2800 East 13th StreetAmes, IA 50010, USAPhone: +1 515 239-6000, Fax: +1 515 239 6618

Sauer-Danfoss GmbH & Co. OHGPostfach 2460, D-24531 NeumnsterKrokamp 35, D-24539 Neumnster, GermanyPhone +49 4321 871-0, Fax: +49 4321 871 122

Sauer-Danfoss A/SDK-6430 Nordborg, DenmarkPhone: +45 7488 4444, Fax: +45 7488 4400

www.sauer-danfoss.com

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