H1 45/53 Closed

Circuit Axial Piston

Pumps

Service Manual
 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Revisions

History of Revisions Table of Revisions

Date Page Changed Rev.

Jun 2007 - First edition AA

© 2007 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 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: F101545, F101546, F101547, F101548, F101549, P106 215E

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Contents

Introduction Overview............................................................................................................................................................ 5
Warranty............................................................................................................................................................. 5
General instructions....................................................................................................................................... 5
Safety precautions.......................................................................................................................................... 6
Unintended machine movement........................................................................................................ 6
Flammable cleaning solvents................................................................................................................ 6
Fluid under pressure................................................................................................................................. 6
Personal safety............................................................................................................................................ 6
Symbols used in Sauer-Danfoss literature.............................................................................................. 7
Design................................................................................................................................................................. 8
The system circuit........................................................................................................................................... 9
The basic closed circuit............................................................................................................................ 9
Case drain and heat exchanger............................................................................................................ 9
The system schematic.................................................................................................................................10

Operation Pressure limiter valves.................................................................................................................................11

High pressure relief valve (HPRV) and charge check........................................................................12
Bypass function..............................................................................................................................................13
Charge pressure relief valve......................................................................................................................13
Electrical displacement control (EDC)....................................................................................................14
EDC principle.............................................................................................................................................14
EDC operation . ........................................................................................................................................14
Manual overRide (MOR)..............................................................................................................................15

Operating Overview..........................................................................................................................................................16
parameters Input speed.....................................................................................................................................................16
System pressure.............................................................................................................................................16
Charge pressure.............................................................................................................................................17
Charge inlet pressure...................................................................................................................................17
Case pressure..................................................................................................................................................17
Temperature and viscosity.........................................................................................................................18
Temperature..............................................................................................................................................18
Viscosity......................................................................................................................................................18

Technical Overview..........................................................................................................................................................19
specifications General specifications.................................................................................................................................19
Physical properties.......................................................................................................................................19
Operating parameters ................................................................................................................................20
Fluid specifications.......................................................................................................................................20

Fluid and filter Fluid and filter recommendations...........................................................................................................21

maintenance Hazardous material.................................................................................................................................21

Pressure Port locations and gauge installation....................................................................................................22

measurements

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Contents

Initial startup General . ...........................................................................................................................................................23

procedures Start-up procedure.......................................................................................................................................23

Troubleshooting Overview..........................................................................................................................................................25
Safety precautions........................................................................................................................................25
Electrical troubleshooting..........................................................................................................................25
System operating hot..................................................................................................................................26
Transmission operates normally in one direction only...................................................................26
System Does not operate in either direction......................................................................................27
System noise or vibration...........................................................................................................................27
Neutral difficult or impossible to find....................................................................................................28
Sluggish system response..........................................................................................................................28

Inspections and Pump adjustment.........................................................................................................................................29

adjustments Standard procedures...................................................................................................................................29
Charge pressure relief valve adjustment..............................................................................................30
Pressure limiter adjustment......................................................................................................................31
Engaging the bypass function.................................................................................................................33
Checking for proper HPRV valve operation...................................................................................33
Displacement limiter adjustment............................................................................................................34
Control Neutral Adjustment......................................................................................................................35
Mechanical neutral adjustment...............................................................................................................37
Servo adjustment....................................................................................................................................37

Minor repair Standard procedures, removing the pump.........................................................................................39

Electric control module...............................................................................................................................40
Control solenoids..........................................................................................................................................41
Shaft seal, roller bearing and shaft replacement...............................................................................42
Charge pump..................................................................................................................................................44
Charge check / HPRV....................................................................................................................................46
Charge pressure relief valve......................................................................................................................47
Pressure limiter valve replacement.........................................................................................................48

Torque chart Fastener size and torque chart.................................................................................................................49

Plug size and torque chart.........................................................................................................................49
Fasteners and plugs......................................................................................................................................50

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Introduction

Overview This manual includes information for the installation, maintenance, and minor repair of
H1 tandem pumps. It includes a description of the unit and its individual components,
troubleshooting information, and minor repair procedures.

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 Global Service Partners is available for major

repairs. Sauer-Danfoss trains and certifies Global Service Partners on a regular basis.
You can locate your nearest Global Service Partner using the distributor locator at
www.sauer-danfoss.com.

Warranty Performing adjustments and minor repairs according to the procedures in this manual
will not affect your warranty. Major repairs requiring the removal of a unit’s center
section, servo sleeves, or front flange voids the warranty unless a Sauer-Danfoss
Authorized Service Center performs them.

General instructions Follow these general procedures when repairing H1 tandem variable displacement
closed circuit pumps.

w Remove the unit

Prior to performing repairs, remove the unit from the vehicle/machine. Chock the wheels
on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid
may be under high pressure and/or hot. Inspect the outside of the pump and fittings for
damage. Cap hoses after removal to prevent contamination.

e Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
and air drying is usually adequate.

As with any precision equipment, you must keep all parts free of foreign material and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the pump with a protective layer of plastic.

d Replace all O-rings and gaskets

We recommend you replace all O-rings and seals during service. Lightly lubricate O-rings
with clean petroleum jelly prior to assembly.

t Secure the unit

For repair, place the unit in a stable position with the shaft pointing downward. It will be
necessary to secure the pump while removing and torquing fasteners and components.

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Introduction

Safety precautions Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing a
hydraulic system.

Unintended machine movement

W 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

W 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

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

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Introduction

Symbols used in  WARNING may result in injury  Tip, helpful suggestion

Sauer-Danfoss
literature  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

The symbols above appear in the illustrations and text of this manual. They are intended
to communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend
above defines each symbol and explains its purpose.

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Introduction

Design Sauer-Danfoss H1 tandem closed circuit piston pumps convert input torque to hydraulic
power. The tandem design powers two independent drive trains for dual-path propel
applications. The two-piece input shaft transmits rotational force to the cylinder block. A
splined coupling connects the front and rear shafts. Bearings at the front, rear, and center
of the pump support the shaft. Splines connect each shaft to a 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 block spring, ball guide, and slipper retainer hold the
slippers to the swashplate. The reciprocating movement of the pistons occurs as the slippers
slide against the inclined swashplates during rotation. Via the valve plates, one half of each
cylinder block is connected to port A or C and the other half to port B or D. Front and rear
sections have independent porting in the center section. As each piston cycles in and out of
its bore, fluid is drawn from one port and displaced to the other thereby imparting hydraulic
power into the system. A small amount of fluid is allowed to flow from the cylinder block/
valve plate and slipper/swashplate interfaces for lubrication and cooling. Case drain ports
return this fluid to the reservoir. An external charge pump (not shown) provides clean, cool
fluid to makeup this lubricating flow and to maintain minimum loop pressure.

The angle of each swashplate controls the volume and direction of fluid displaced into
the system. The servo pistons control the angle of the swashplates. Each pump control, by
varying the pressure at the servo pistons, controls each piston’s position. An electric signal
to the control coils transmits the command from the operator to the pump. Mechanical
feedback of the swashplate position to the control through the feedback pins allows for
very precise displacement control and increases overall system stability. Non-feedback
control options do not use the mechanical feedback link.

Cross section view

Electric displacement control Servo piston

Swashplate feedback pin

Valve plate

Rear bearing
Piston Charge Pump

Slipper

Shaft seal

Shaft

Front bearing

Swashplate bearing

Swashplate Cylinder block P106 337E

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Introduction

The system circuit The basic closed circuit

Hydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid
flows in either direction from the pump to the motor and back. Either of the hydraulic
lines can be under high pressure. In pumping mode the position of the pump swashplate
determines which line is high pressure as well as the direction of fluid flow.

Case drain and heat exchanger

The pump and motor require case drain lines to remove hot fluid from the system. The
pump and motor drain from the topmost port to ensure the cases remain full of fluid. The
motor case drain can connect to the lower drain port on the pump housing or it can tee
into the case drain line upstream of the heat exchanger. A heat exchanger with bypass
valve cools the case drain fluid before it returns to the reservoir.

System circuit diagram

Heat Exchanger
Bypass Valve System Pressure
Reservoir
Displacement Control Servo Pressure

Charge/Low Loop Pressure

Heat Exchanger
Suction/Case Drain/
Charge Pump System Return

Bent Axis Variable

Servo Control Displacement Motor
Cylinder
Charge Filter

Motor Swashplate
Charge Check/
Variable High Pressure Relief Valve
Displacement Output
Pump Shaft
Loop
Flushing
Valve
Charge
Pressure
Pressure
Relief
Limiter
Valve
Valve

To Pump
Case

Input To
Shaft Motor Synchronizing
Case Shaft
Pump Swashplate
Charge Check/High Pressure Relief Valve P104 464E

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Introduction

The system schematic System schematic

C2 C1

E D M3
M5
T
M4 A

flow out A

L2 CW

T T

B
L1 S
P106 338E

Above schematic shows the function an H1 45/53 axial piston variable displacement
pump with electric displacement control (EDC).

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Operation

Pressure Limiter Pressure limiter valves provide system pressure protection by compensating the pump
Valves swashplate position when the set pressure of the valve is reached. A pressure limiter is a
non-dissipative (non heat generating) pressure regulating system.

Each side of the transmission loop (and each section of the tandem pump) has a
dedicated pressure limiter valve that is set independently. Each system port may have a
different pressure limiter setting.

The pressure limiter setting is the maximum differential pressure between the high and
low loops. When the pressure limiter setting is reached, the valve ports oil to the low-
pressure side of the servo piston. The change in pressure across the servo rapidly reduces
pump displacement. Fluid flow from the valve continues until the resulting drop in pump
displacement causes system pressure to fall below the pressure limiter setting.

An active pressure limiter destrokes the pump to near neutral when the load is in a
stalled condition. The pump swashplate moves in either direction necessary to regulate
the system pressure, including increasing stroke when overrunning or over-center.

The pressure limiter is optional on H1 pumps.

Pressure limiter valve

To Servo

High Pressure P003 481E

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Operation

High pressure relief All H1 pumps have a combination high pressure relief and charge check valve. The high-
valve (HPRV) pressure relief function is a dissipative (heat generating) pressure control valve for the
and charge check purpose of limiting excessive system pressures. The charge check function replenishes
the low-pressure side of the working loop with charge oil. Each side of the transmission
loop has a dedicated non-adjustable, factory-set HPRV valve. When system pressure
exceeds the factory setting, oil is passed from the high pressure system loop into the
charge gallery, and into the low pressure system loop via the charge check.

The pump may have different pressure settings at each system port. When an HPRV valve
is used in conjunction with a pressure limiter, the HPRV valve is always factory set above
the setting of the pressure limiter. The system pressure shown in the order code for
pumps with only HPRV is the HPRV setting. The system pressure shown in the order code
for pumps with pressure limiter and HPRV, is the pressure limiter setting.

HPRVs are set at low flow condition. Any application or operating condition which leads
to elevated HPRV flow will cause a pressure rise with flow above the valve setting.

High Pressure Relief and Charge Check Pressures marked on HPRV valve
Valve with Bypass Valve in charging mode Mark Pressure bar [psi]
20 200 [2900]
25 250 [3626]
30 300 [4351]
35 350 [5076]
37 370 [5366]
40 400 [5801]
42 420 [6092]
P003 269
45 450 [6527]
48 480 [6962]
High Pressure Relief and Charge Check 51 510 [7397]
Valve with Bypass Valve in relief mode

P003 268

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Operation

Bypass function The HPRV valve also provides a loop bypass function when each of the two HPRV
hex plugs are mechanically backed out 3 full turns. Engaging the bypass function
hydraulically connects both A & B sides of the working loop to the common charge
gallery. The bypass function allows you to move a machine or load without rotating the
pump shaft or prime mover.

CCaution
The HPRV valves are not tow valves. Damage to the pump and motor can occur when
operating without charge flow. Limit vehicle/machine movement to no more than 20%
of maximum speed and no longer that three minutes. Reseat the HPRV valves after
vehicle/machine movement.

Charge Pressure The charge pressure relief valve maintains charge pressure at a designated level above
Relief Valve case pressure. The charge pressure relief valve is a direct acting poppet valve that opens
and discharges fluid to the pump case when pressure exceeds a designated level. This
level is nominally set with the pump running at 1800 min-1 (rpm). For external charge
flow, the CPRV is set with a flow of 30 l/min [8 US gal/min]. In forward or reverse, charge
pressure will be slightly lower than in neutral position. The model code of the pump
specifies the charge relief setting.

Typically charge pressure increases from 1.2-1.5 bar per 10 l/min [17.4-21.8 psi per
2.64 US gal/min].

Charge pressure relief valve

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Operation

Electrical EDC Principle

displacement The Electrical Displacement Control (EDC) consists of proportional solenoids on each
control (EDC) side of a three-position, four-way porting spool. The proportional solenoid applies
a force to the spool, which ports hydraulic fluid to either side of the servo piston.
Differential pressure across the servo piston rotates the swashplate, changing the
pump‘s displacement from full displacement in one direction to full displacement in the
opposite direction.

EDC Operation
H1 EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal.
Pulse width modulation allows more precise control of current to the solenoids. The
PWM signal causes the solenoid pin to push against the porting spool, which pressurizes
one end of the servo piston, while draining the other. Pressure differential across the
servo piston moves the swashplate. A swashplate feedback link, opposing control
links, and a linear spring provide swashplate position force feedback to the solenoid.
The control system reaches equilibrium when the position of the swashplate spring
feedback force exactly balances the input command solenoid force from the operator.
As hydraulic pressures in the operating loop change with load, the control assembly and
servo/swashplate system work constantly to maintain the commanded position of the
swashplate.

The EDC incorporates a positive neutral dead-band as a result of the control spool
porting, spring preload from the servo piston assembly, and the linear control spring.
Once the neutral threshold current is reached, the swashplate position becomes
directly proportional to the control current. To minimize the effect of the control neutral
deadband, we recommended the transmission controller or operator input device
incorporate a jump up current.

The neutral position of the control spool does provide a positive preload pressure to
each end of the servo piston assembly.

When the control input signal is either lost or removed, or if there is a loss of charge
pressure, the spring-loaded servo piston automatically returns the pump to neutral
position.

The EDC is a displacement (flow) control. Pump swashplate position is proportional

to the input command and therefore vehicle or load speed (excluding influence of
efficiency), is dependent only on the prime mover speed or motor displacement.

EDC-Schematic Diagram

C2 C1

M4 M5
Feedback
T P
from
swashplate P106 256E

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Operation

Manual OverRide All controls are available with a Manual OverRide (MOR) for temporary actuation of the
(MOR) control to aid in diagnosis. FNR controls always include MOR functionality.

W Warning
Depressing the plunger causes the pump to go into stroke which will move the machine
or mechanism. Ensure the vehicle or machine is in a safe condition (wheels off the
ground or mechanism disconnected) before attempting to use the MOR feature.

An O-ring seals the MOR plunger. Initial actuation of the function requires additional
force to overcome the O-ring resistance. A threshold force of 45 N is typically required at
first actuation. Additional actuations typically require a threshold force of 12 N to move
the MOR plunger. Force required to keep the pump at full stroke is typically 51 N. Do not
expect proportional control of the pump using the MOR.

Refer to control flow table for the relationship of solenoid to direction of flow.

Control solenoid

P003 204

EDC schematic diagram showing MOR

M14

C2 C1

F00B F00A T P
Feedback from
Swash plate P003 205E

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Operating parameters

Overview This section defines input speed and pressure operating parameters and limitations
for H1 pumps. For actual parameters, refer to the technical specifications for each
displacement.

Input Speed Minimum speed is the lowest input speed recommended during engine idle condition.
Operating below minimum speed limits the pump’s ability to maintain adequate flow for
lubrication and power transmission.

Rated speed is the highest input speed recommended at full power. Operating at or
below this speed generally yields satisfactory product life.

Maximum speed is the highest operating speed permitted. Exceeding maximum speed
reduces product life and can cause loss of hydrostatic power and braking capacity. Never
exceed the maximum speed limit under any operating conditions.

When determining speed limits for a particular application see Sauer-Danfoss

publication BLN-9884 Pressure and speed limits.

WWarning
Unintended vehicle or machine movement hazard
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking
capacity. You must provide a braking system, redundant to the hydrostatic transmission,
sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss.

System pressure is the differential pressure between system ports A & B. It is the
System Pressure dominant operating variable affecting hydraulic unit life. High system pressure, which
results from high load, reduces expected life. Hydraulic unit life depends on speed and
normal operating—or weighted average—pressure that you can only determine from a
duty cycle analysis.

Applied pressure is the chosen application pressure in the order code for the pump.
This is the pressure at which the drive line generates maximum pull or torque in the
application.

Rated pressure is the design pressure for the pump. Applications with applied pressures
at or below this pressure should yield satisfactory unit life given proper component
selection.

Maximum pressure (Peak) is the highest intermittent pressure allowed under any
circumstances. Applications with applied pressures between rated and maximum require
factory approval with complete application, duty cycle, and life expectancy analysis.

All pressure limits are differential pressures referenced to low loop (charge) pressure.
Subtract low loop pressure from gauge readings to compute the differential.

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Operating parameters

Charge Pressure An internal charge relief valve regulates charge pressure. The internal charge pump
supplies the control with pressure to operate the swashplate and to maintain a minimum
pressure in the low side of the transmission loop.

Minimum charge pressure is the lowest pressure safe working conditions allow in the
system loop. Minimum control pressure requirements are a function of speed, pressure,
and swashplate angle, and may be higher than the minimum charge pressure shown in
the technical specifications.

Maximum charge pressure is the highest charge pressure the charge relief adjustment
allows, and which provides normal component life. You can use elevated charge pressure
as a secondary means to reduce the swashplate response time.

The charge pressure setting listed in the order code is the set pressure of the charge
relief valve with the pump in neutral, operating at 1800 min-1 (rpm), and with a fluid
viscosity of 32 mm2/sec [150 SUS]. The charge pressure setting is referenced to case
pressure (the differential pressure above case pressure).

Charge Inlet Pressure At normal operating temperature charge inlet pressure must not fall below rated charge
inlet pressure.

Minimum charge inlet pressure is only allowed at cold start conditions. In some
applications it is recommended to warm up the fluid (for example in the tank) before
starting the engine and then run the engine at limited speed until the system fluid
temperature is raised to an acceptable level.

Case Pressure Under normal operating conditions, the rated case pressure must not be exceeded.
During cold start, case pressure must be kept below maximum intermittent case
pressure. Size drain plumbing accordingly.

CCaution
Possible component damage or leakage
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or
housings, causing external leakage. Performance may also be affected since charge and
system pressure are additive to case pressure.

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Operating parameters

Temperature and Temperature

viscosity High temperature limits apply at the hottest point in the transmission loop, which is
normally the motor case drain. Ensure the system generally runs at or below the rated
temperature. The maximum intermittent temperature is based on material properties:
Never exceed it.

Cold oil will generally not affect the durability of the transmission components, but it
may affect the ability of oil to flow and transmit power: therefore ensure temperatures
remain 16 °C [30 °F] above the pour point of the hydraulic fluid. Minimum temperature
relates to the physical properties of component materials.

Size heat exchangers to keep the fluid within these limits. Sauer-Danfoss recommends
testing to verify that these temperature limits are not exceeded.

Viscosity
For maximum efficiency and bearing life, ensure the fluid viscosity remains in the
recommended range. Minimum viscosity should be encountered only during brief
occasions of maximum ambient temperature and severe duty cycle operation. Maximum
viscosity should be encountered only at cold start.

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Technical specifications

Overview Specifications and operating parameters for pumps are given here for reference.

General Design Axial piston pump of cradle swashplate design with variable displacement
specifications Direction of Rotation Clockwise, counterclockwise
Pipe connections Main pressure ports: SAE straight thread O-ring boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation Pump installation recommended with control position on the top or side.
position Consult Sauer-Danfoss for non conformance to these guidelines.
The housing must always be filled with hydraulic fluid.
Rear case drain recommended
Auxiliary cavity pressure Will be equal to pump case pressure of rear housing.
Please verify mating pump shaft seal capability.

Physical properties Frame size

Feature Unit
45 53
Displacement cm3 [in3] 45 [2.75]* 53.8 [3.28]*
Oil volume liter [US gal] 2.3 [0.61]*
SAE flange, size B (SAE J 744) compatible
Mounting flange mounting pad.
Special bolt diameter. See installation drawings.
Auxiliary mounting SAE A, SAE B, SAE B-B (with metric fasteners)
Shafts Splined: 14-teeth 12/24, 15-teeth 16/32
External charge inlet port 0.8750-14 [7/8-14]
Main port configuration 1.3175-12UNF-2B [1 5/16-12UNF-2B]
Case drain ports L1, L2, L3, (SAE )-ring boss).
1.0625-12UNF-2B [1 1/16-12UNF-2B]
Use L3 as case drain for cooling purposes
Other ports SAE O-ring boss. See installation drawings.
Customer interface threads Metric fastener

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Technical specifications

Operating Frame size

Feature Unit
parameters 45 53
Minimum 500
Input speed Rated min-1 (rpm) 3400
Maximum 3500
Rated 400 [5800] 350 [5075]
System pressure Maximum bar [psi] 420 [6090] 400 [5800]
Minimum low loop 20 [150]
Minimum 30 [290]
Charge pressure bar [psi]
Maximum 35 [508]
Minimum (at corner power) 21.5 [312]
Control pressure bar [psi]
Maximum 40 [580]
Rated 2.0 [29]
Case pressure bar [psi]
Maximum 5.0 [75]

Fluid specifications Frame size

Feature Unit
45 53
Ratings and data are based Minimum 7 [49]
mm2/sec
on operation with premium Viscosity Recommended Range
[SUS]
12-80 [66-370]
petroleum-based hydraulic Maximum 1600 [7500]
fluids containing oxidation, Minimum -40 [-40]
rust, and foam inhibitors. Temperature Range Rated O
C [OF] 104 [220]
Maximum intermittent 115 [240]
Cleanliness per ISO 4460 22/18/13
Filtration Efficiency (charge pressure filtration b15-20 = 75 (b10≥10)
(recommended b-ratio
minimum Efficiency (suction and return line flitration) b35-45 = 75 (b10≥2)
Recomended inlet screen mesh size mm 100 - 125

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Fluid and filter maintenance

Fluid and filter To ensure optimum life, perform regular maintenance of the fluid and filter.
recommendations 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. Fluid contaminated by water may appear cloudy or milky or free water may settle
in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to
excessive heat. Change the fluid and correct the problem immediately if these conditions
occur.

Inspect vehicle for leaks daily. Change the Fluid and filter change interval
fluid and filter per the vehicle/machine Reservoir type Max oil change interval
manufacturer’s recommendations Sealed 2000 hours
or at intervals shown in the table. We Breather 500 hours
recommend first fluid change at 500 hours.

High temperatures and pressures will result in accelerated fluid aging. More frequent
fluid changes may be required.

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 with the fluid or when the filter indicator shows it’s necessary. Replace all
fluid lost during filter change.

For detailed filtration information, see Sauer-Danfoss publication 520L0463 Fluids

and Filtration. For information on biodegradable fluids see Sauer-Danfoss publication
520L0465 Biodegradable Hydraulic Fluids.

Hazardous material
W Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to state and federal environmental regulations.

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Pressure measurements

Port locations and The following table and drawing show the port locations and gauge sizes needed. When
gauge installation testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use
snubbers to protect gauges.

Port information
Port identifier Port size Wrench size Pressure obtained Gauge size, bar [psi]
L1, L2 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 bar [100 psi]
MA, MB, 9/16-18 UNF 1/4 internal hex System pressure 600 bar [10,000 psi]
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure 50 bar [1000 psi]
M4, M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 bar [1000 psi]

Port locations D065 O-ring plug

7/16-20 UNF-2B Gauge port MB
Remote filtration port D System pressure
use for air bleed when filling pump
7/8-14 UNF-2B 9/16-18 UNF-2B

Gage port M4
servo pressure Case drain Port L1
7/16-20 UNF 2B use highest port
as outlet
1 1/16-12 UNF 2B
Port B
split flange boss
1 5/16 code 62
per ISO 6162
thread: M12
18 Min. full
thread depth

Gauge port M3
Charge pressure
after filter Remote filtration port E
9/16-18 UNF-2B 7/8-14 UNF-2B
Charge pump inlet S
1 5/16-12 UNF 2B
Gauge port M5 Servo pressure
Gauge port MA Port A
7/16-20 UNF-2B
System pressure split flange boss 1 5/16 code 62
9/16-18 UNF-2B per ISO 6162 thread: M12 Charge constr port
18 Min. full thread depth 9/16-18 UNF-2B

Case drain port L2

1 1/16-12 UNF-2B

P106 232E

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Initial startup procedures

General Follow this procedure when starting-up a new pump installation or when restarting an
installation in which the pump has been removed and re-installed on a machine. Ensure
pump has been thoroughly tested on a test stand before installing on a machine.

WWarning
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 that may have occurred during shipping.

Start-up procedure 1. Ensure that the machine hydraulic oil and system components (reservoir, hoses,
valves, fittings, and heat exchanger) are clean and free of any foreign material.

2. Install new system filter element(s) if necessary. Check that inlet line fittings are
properly tightened and there are no air leaks.

3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M3.

4. Fill the housing by adding filtered oil in the upper case drain port. If the control is
installed on top, open the construction plug in the top of the control to assist in air
bleed.

5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a
10-micron filler filter. Fill inlet line from reservoir to pump. Ensure construction plug
in control is closed after filling.

6. Disconnect the pump from all control input signals.

7. Close construction plug removed in step 4.

CCaution
After start-up the fluid level in the reservoir may drop due to system components filling.
Damage to hydraulic components may occur if the fluid supply runs out. Ensure reservoir
remains full of fluid during start-up.

Air entrapment in oil under high pressure may damage hydraulic components. Check
carefully for inlet line leaks.

Do not run at maximum pressure until system is free of air and fluid has been thoroughly
filtered.

8. Use a common method to disable the engine to prevent it from starting.

Crank the starter for several seconds. Do not to exceed the engine manufacturer’s
recommendation. Wait 30 seconds and then crank the engine a second time as stated
above. This operation helps remove air from the system lines. Refill the reservoir to
recommended full oil level.

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Initial startup procedures

Startup procedure 9. When the gauge begins to register charge pressure, enable and start engine. Let the
(continued) engine run for a minimum of 30 seconds at low idle to allow the air to work itself out
of the system. Check for leaks at all line connections and listen for cavitation. Check
for proper fluid level in reservoir.

10. When adequate charge pressure is established (as shown in model code), increase
engine speed to normal operating rpm to further purge residual air from the system.

11. Shut off engine. Connect pump control signal. Start engine, checking to be certain
pump remains in neutral. Run engine at normal operating speed and carefully check
for forward and reverse control operation.

12. Continue to cycle between forward and reverse for at least five minutes to bleed all
air and flush system contaminants out of loop.

Normal charge pressure fluctuation may occur during forward and reverse operation.

13. Check that the reservoir is full. Remove charge pressure gauge. The pump is now
ready for operation.

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Troubleshooting

Overview This section provides general steps to follow if you observe undesirable system
conditions. Follow the steps listed until you solve the problem. Some of the items are
system specific. We reference the section in this manual of more information is available.
Always observe the safety precautions listed in the Introduction section and precautions
related to your specific equipment.

Safety precautions C Caution

High inlet vacuum causes cavitation which can damage internal pump components.

W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. Relieve pressure in the system before removing
hoses, fittings, gauges, or components. Seek immediate medical attention if you are cut
or burned by hydraulic fluid.

W 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.

C Caution
Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and reinstalling system
components and lines.

W Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to state, and federal environmental regulations.

Electrical troubleshooting

Item Description Action

Control operates pump in Control coil failure Measure resistance at coil pins. Resistance should be
one direction only. 14.20 Ω (24V) or 3.66 Ω (12V) at 20°C [70°F]. Replace coil.

No pump function No power to controller Restore power to controller.

Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, reconnect wires.
Filter bypass indicator Filter switch may be bad. Check/replace filter switch. Add gauge to filter bypass
switch port to verify proper fluid flow and verify switch
operation by measuring resistance.
open resistance=>510 Ω, closed resistance<=122 Ω

If available, use a manual override to check proper pump operation and verify electrical problem.

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Troubleshooting

System operating hot

Item Description Action

Oil level in reservoir. Insufficient hydraulic fluid does not meet Fill reservoir to proper level.
cooling demands of system.
Heat exchanger. Heat exchanger is not sufficiently cooling Check air flow and input air temperature
the system. for heat exchanger. Clean, repair or
replace heat exchanger.
Charge pressure. Low charge pressure overworks system. Measure charge pressure. Inspect and
adjust or replace charge relief valve. Inspect charge
pump. Repair or replace charge pump.
Charge pump inlet vacuum. High inlet vacuum overworks system. A dirty filter Check charge inlet vacuum. If high,
increases the inlet vacuum. Inadequate line size will inspect inlet filter and replace as necessary.
restrict flow. Check for adequate line size, length
or other restrictions
System relief pressure If the system relief valves are worn, contaminated, Verify settings of pressure limiters and
settings or valve settings are too low, the relief valves get high pressure relief valves and adjust or
overworked. replace as necessary.
System pressure. Frequent or long term operation over system relief Measure system pressure. If pressure
setting creates heat in system. is too high, reduce loads.

Transmission operates normally in one direction only

Item Description Action

Open bypass valves. Open bypass causes one or both directions to be Close/repair bypass function.
inoperative.
Input to pump control. Input to control module is operating improperly. Check control input and repair or replace as necessary.
Control orifices Control orifice(s) are blocked. Clean control orifices.
Control screens Control screen(s) are blocked. Clean or replace control screens.
Pressure limiters Malfunctioning pressure limiter can affect one direction Exchange pressure limiters. If the problem changes
while the other functions normally. direction, replace the valve that does not operate
correctly. Remember to return the PLs to their original
position afterward. Settings may be different for forward/
reverse.
High pressure relief valves Malfunctioning HPRV can affect one direction while the Exchange HPRVs. If the problem changes direction,
(HPRV) other functions normally. replace the valve that does not operate correctly.
Remember to return HPRVs to their original position
afterward. Settings may be different for forward/reverse.
Servo pressure Servo pressure low or decaying. Check for torn/missing servo seals. Replace and retest.
Refer to 520L0957 H1 45/53 Repair instructions for seal
locations. Only a Sauer-Danfoss Global Service
Partner may remove the servo piston without voiding the
warranty.

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Troubleshooting

System Does not operate in either direction

Item Description Action

Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level.
Pump control orifices Control orifices are blocked. Clean control orifices.
Pump control screens Control screens are blocked. Clean control screens. Refer to 520L0957 H1 45/53
Repair instructions for screen locations. If pump is being
repaired for warranty evaluation, repair must be done by
a Sauer-Danfoss Global Service Partner.
Open bypass valve If bypass valves are open, the system loop becomes Close bypass valves. Replace high pressure relief valve if
depressurized. defective.
Charge pressure with pump Low charge pressure insufficient to recharge system loop Measure charge pressure with the pump in neutral. If
in neutral pressure is low, go to next step.
Pump charge relief valve A pump charge relief valve that is leaky, or contaminated, Adjust or replace pump charge relief valve as necessary.
or set too low depressurizes the system.
Charge pressure with pump Low charge pressure, resulting from elevated loop Isolate pump from motor. With pump in partial stroke
in stroke leakage, is insufficient control pressure to hold pump in and engaged for only a few seconds, check pump charge
stroke. pressure. Low charge pressure indicates a malfunctioning
pump. Good charge pressure indicates a malfunctioning
motor or other system component. Check motor charge
relief operation (if present).
Charge pump inlet filter A clogged filter under supplies system loop. Inspect filter and replace if necessary.
Charge pump A malfunctioning charge pump provides insufficient Repair or replace the charge pump.
charge flow.

System pressure Low system pressure does not provide enough power to Measure system pressure. Continue to next step.
move load.
System relief valves Defective high pressure relief or pressure limiter valves Repair or replace high pressure relief or pressure limiter
cause slow system pressure. valves.
Input to control Input is operating improperly. Repair/replace control.

System noise or vibration

Item Description Action

Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump Air in system decreases efficiency of units and controls. Find location where air is entering into the system and
inlet vacuum Air in system is indicated by excessive noise in pump, repair. Check that inlet line is not restricted and is proper
foaming in oil, and hot oil. size.

Cold oil If oil is cold, it may be too viscous for proper function and Allow the oil to warm up to its normal operating
pump cavitates temperature with engine at idle speed.
Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is proper size.
Check filter and bypass switch.
Shaft couplings A loose shaft coupling causes excessive noise. Replace loose shaft coupling.
Shaft alignment Misaligned pump and prime mover shafts create noise. Align shafts.
Charge/system relief valves Unusual noise may indicate sticking valves. Possible Clean/replace valves and test pump.
contamination.

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Troubleshooting

Neutral difficult or impossible

Item Description Action

Input to pump control Input to control module is operating improperly. Disconnect input and check to see if pump comes back
to neutral. If Yes, input fault, replace/repair external
controller. If No, go to next step.
Pump control neutral Neutral set improperly. Shunt servo gauge ports M4 and M5 together with
external hose and see if pump comes back to neutral. If
Yes: control neutral improperly set (see page 35). If no:
balance swashplate (see Mechanical neutral adjustment,
page 37). If you still cannot set neutral, replace control.

Sluggish system response

Item Description Action

Oil level in reservoir Low oil level causes sluggish response. Fill reservoir.
High pressure relief valves/ Incorrect pressure settings affects system reaction time. Adjust or replace high pressure relief valves.
pressure limiter settings
Low prime mover speed Low engine speed reduces system performance Adjust engine speed.
Charge pressure Incorrect pressure affects system performance Measure and adjust charge pressure relief or replace
charge pump.
Air in system Air in system produces sluggish system response Fill tank to proper level. Cycle system slowly for several
minutes to remove air from system.
Contaminated control Control orifices are plugged. Clean control orifices.
orifices
Contaminated control Control screens are plugged. Clean or replace control screens.
screens
Pump inlet vacuum Inlet vacuum is too high resulting in reduced system Measure charge inlet vacuum. Inspect line for proper
pressure. sizing. Replace filter. Confirm proper bypass operation.

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Adjustments

Pump adjustment This section offers instruction on inspection and adjustment of pump components.
Read through the entire topic before beginning a service activity. Refer to Pressure
measurements, page 22, for location of gauge ports and suggested gauge size.

Standard procedures C Caution

Contamination can damage internal components and void your warranty. Take
precautions to ensure system cleanliness when removing and reinstalling system lines

1. With the prime mover off, thoroughly clean the outside of the pump.

2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines,
cap them and plug each open port to prevent contamination.

3. Ensure the surrounding area is clean and free of contaminants like dirt and grime.

4. Inspect the system for contamination.

5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil,
sludge, or metal particles.

6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain
the hydraulic system. Flush the lines and refill the reservoir with the correct filtered
hydraulic fluid.

7. Before re-installing the pump, test for leaks.

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Adjustments

Charge pressure This procedure explains how to check and adjust the charge pressure relief valve.
relief valve
adjustment 1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install
a 10 bar [100 psi] gauge at case pressure port L1, L2, or L3. Operate the system with
the pump in neutral (zero displacement) when measuring charge pressure.
Ensure charge pressure
is properly set before 2. The table shows the acceptable pump charge pressure range for some nominal
checking pressure limiter. charge relief valve settings (refer to model code located on serial number plate).
These pressures assume 1800 min-1 (rpm) pump speed and a reservoir temperature
of 50°C [120°F], and are referenced to case pressure.

Other charge pressure Charge pressure adjustment

relief valves are available.
D065 Optional construction port
See page 49 for torques
and wrench sizes on other 0 - 10 bar [0 - 100 psi]
3/16 in
charge pressure relief 11-14 N•m [8-10 lbf•ft] Charge pressure gauge port M3
valves. 0 - 50 bar [0 - 1000 psi]
1/4 in
43 N•m [32 lbf•ft]

Locknut
13 mm
12 N•m
Case drain port L2 [9 lbf•ft]
0 - 10 bar [0 - 100 psi]
9/16 in
Adjusting screw
49 N•m [36 lbf•ft]
4 mm P106 339E

Listed pressures assume a pump speed Charge pressure ranges

of 1800 min-1 (rpm) and charge flow of Model code Actual charge pressure*
26.5 l/min [7 US gal/min]. At higher pump 20 20 bar [290 psi ] ± 1.5 bar [21.8 psi]
speeds or higher charge flows the charge 24 24 bar [348 psi] ± 1.5 bar [21.8 psi]
pressure will rise over the rated setting. 26 26 bar [377 psi] ± 1.5 bar [21.8 psi]
30 30 bar [435 psi] ± 1.5 bar [21.8 psi]
3. Rotate the adjusting screw clockwise
* This is the actual charge pressure port gauge
to increase the setting; counter reading minus the case pressure port gauge
clockwise to decrease it. Subtract the reading. Factory set at 1800 min-1 (rpm) with a
case pressure reading to compute reservoir temperature of 50° C [120° F].
the actual charge pressure.

Pressure change per turn is dependant on charge flow entering pump.

4. While holding the adjusting screw, torque locknut to 17 N•m [13 lbf•ft].

5. When you achieve the desired charge pressure setting, remove the gauges and plug
the ports.

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Adjustments

Pressure limiter Lock motor output shaft to adjust the pressure limiter setting. Lock the vehicle’s brakes
adjustment or rigidly fix the work function so it cannot rotate.

1. Install 600 bar [10,000 psi] pressure gauges in the high pressure gauge ports (MA
Ensure charge pressure and MB). Install a 50 bar [1000 psi] pressure gauge in the charge pressure gauge port
is properly set before (M3).
checking pressure limiter.
Pressure limiter adjustment
Pressure limiter
adjusting screw
8 mm
System pressure gauge port MB
Pressure limiter
0 - 600 bar [0 - 10,000 psi]
locking nut
1/4 in
14 mm
If you change pressure 12 N•m [9 lbf.ft]
43 N•m [32 lbf•ft]
limiter settings, you must
also change the HPRV
valve to maintain proper Charge pressure gauge port M3 System pressure gauge port MA
PL function. Refer to 0 - 50 bar [0 - 1000 psi] (on bottom)
table on next page for 1/4 in 0 - 600 bar [0 - 10,000 psi]
corresponding settings. 43 N•m [32 lbf•ft] 1/4 in
43 N•m [32 lbf•ft]
HPRV valve P106 340E

Pressure limiter valve adjustment

Clockwise rotation Counterclockwise rotation
Pressure limiter valves Pressure limiter valves
Controls Controls Controls Controls
Port A Port B Port B Port A

Port B Port B
System System
pressure pressure

* *

Port A Port A
System System
* Clockwise rotation as seen from * Counterclockwise rotation as seen
pressure pressure
shaft end of pump from shaft end of pump P106 342E

Endcaps are different for clockwise and counter clockwise rotation.

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Adjustments

Pressure limiter 2. Start the prime mover and operate at normal speed.
adjustment
(continued) 3. Use a 17mm wrench to loosen the locking nut (L024).

4. Activate the control input until pressure in the high side of the system loop stops
The model code on the rising. This pressure is the PL setting.
serial plate gives the factory
setting of the PL (Pressure 5. Return the pump to neutral and adjust the PL setting using an internal hex wrench.
Limiter). The PL setting Wrench size is in the diagram on the previous page. Turn the adjusting screw
is referenced to charge clockwise to increase the PL setting, counter clockwise to decrease it. The adjustment
pressure. Subtract charge is very sensitive. Change per turn is approximately 150 bar [2176 psi].

Change per turn is 150 bar/rev [2176 psi/rev].

6. Repeat steps four and five until you reach the desired PL setting. After adjustment,
torque the locknut (L024) to 12 N•m [9 lbf•ft]. Do not over torque.

7. Shut down the prime mover. Remove gauges and replace plugs.

Pressure limiter settings

Pressure limiter setting HPRV setting Pressure limiter setting HPRV setting
150 200 400
180 230 410 450
200 250 420
230 280 430
250 300 440 480
280 330 450
300 350 460
330 380 470 510
350 400 480
380 420

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Adjustments

Engaging the bypass Use this procedure to bypass the pump to allow moving the vehicle/machine short
function distances when you cannot start the prime mover.

C Caution
It is possible to damage the drive motor(s) by operating in bypass mode without charge
pressure. Move the vehicle/machine at a speed not more than 20% of maximum for a
duration not exceeding 3 minutes.

1. To open the HPRVs (L150), rotate Engaging the bypass function

three revolutions counter clockwise
using a 22mm hex wrench. Do
not rotate more than 3 revolutions,
internal leakage will result.

2. To close the HPRVs, rotate them HPRV

clockwise until seated. Torque to 22 mm
70 N•m [52 lbf•lb]. 70 N•m
[52 lbf•ft]
P106 651E
3. If machine is towable with HPRVs
opened three turns and if wheels
are locked (not towable) with HPRV
valves closed, bypass function is
working correctly.

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Adjustments

Displacement limiter If your pump has displacement limiters, you will find them on either servo cover. You can
adjustment limit forward and reverse displacement independently.

Displacement limiters are not pre-set by the factory. We install them as far as possible
without contacting the servo piston. Limiting displacement requires clockwise
adjustment of the limiting screw.

1. Loosen the lockingnut. Displacement limiter adjustment

C Caution
Before adjusting the 2. Rotate the adjusting screw to
displacement limiter, achieve the desired maximum
mark the position of the displacement. Set the adjusting Adjusting screw
servo cylinder. Be sure screw against the servo piston by 4 mm
the servo cylinder does feel before counting turns. Refer
not turn when setting to the table below for change per
the displacement limiter turn. Clockwise rotation decreases
locknut. displacement, counter clockwise
rotation increases it. Adjustment is
possible from zero to maximum.

3. After establishing the desired Locknut

maximum displacement setting, hold
13 mm
the adjusting screw while torquing
23 N•m [17 lbf•ft]
the locknut to the value in the table
below. E101 427E

4. Test operation of the vehicle/

machine to verify proper maximum
speed of vehicle/work function.

Displacement limiter adjustment data

Displacement Locknut wrench size and Adjusting screw Approximate displacement change
torque size per revolution of adjusting screw
45 13 mm  23 N•m [17 lbf•ft] 4 mm internal hex 5.1 cm3 [0.31 in3]
53 13 mm  23 N•m [17 lbf•ft] 4 mm internal hex 6.0 cm3 [0.37 in3]

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Adjustments

Control Neutral All functions of the Electric Displacement Control (EDC), except neutral adjustment, are
Adjustment preset at the factory. Adjust the pump to neutral with the pump running on a test stand
or on the vehicle/machine with the prime mover operating. If adjustment fails to give
satisfactory results, you may need to replace the control or coils. See Minor repair page 41
for details.

W 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.

Adjustment of the EDC 1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5).
is very sensitive. Be sure Disconnect the external control input (electrical connections) from the control. Start
to hold the hex wrench the prime mover and operate at normal speed.
steady while loosening the
locknut. Total adjustment is 2. Use a 4mm internal hex wrench to hold the neutral adjusting screw (D015)
less than 120 degrees. stationary while loosening the locknut (D060) with a 13mm wrench.

3. Observe pressure gauges. If necessary, turn adjusting screw (D015) to reduce any
pressure differential.

Control adjustment
Adjusting screw Locknut
4 mm 13 mm
12 N•m [9 lbf•ft]
Servo pressure gauge port M4
Servo pressure gauge port M5 0 - 50 bar [0 - 1000 psi]
3/16 in
0 - 50 bar [0 - 1000 psi]
19 N•m [14 lbf•ft]
3/16 in
19 N•m [14 lbf•ft]

P106 343E

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Adjustments

Control Neutral 4. Rotate the neutral adjusting screw Neutral adjustment (EDC) (bottom view)
adjustment (D015) clockwise until the pressure
Solenoid shaft
(continued) increases on the gauge. Note the
Control spool
angular position of the wrench. Then
rotate the neutral adjusting screw
counter clockwise until the pressure
increases by an equal amount on the
other gauge. Again note the angular
position of the wrench.

5. Rotate the neutral adjusting screw

clockwise half the distance between
the wrench positions noted above.
The gauges should read the same
pressure, indicating that the control Adjusting
screw
is in its neutral position. (cam)
Feedback pin

6. Hold the neutral adjusting screw Maximum

stationary and tighten the lock nut adjustment
(D060). Torque to 10 N•m [7 lbf•ft]. Do less than 120°

not over torque the nut.

P106 046E

7. When the neutral position is set, stop

Illustration shows how cam on adjusting pin
the prime mover, remove the gauges, rotates to adjust for neutral position after pump
and install the gauge port plugs. is re-installed.
Reconnect the external control input.

A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is
usually not possible.

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Adjustments

Mechanical neutral Servo adjustment

adjustment 1. Run prime mover at 1800 min¯¹(rpm).

2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges.
Ensure the differential between M4 and M5 is less than 1.5 bar [22 psi].

3. Using a 3/4 in hex deep socket, unthread both servo cylinders 2-3 turns. This step
ensures the servo cylinders have no contact with the servo piston.

4. Stroke the pump by turning the control eccentric screw (or supplying current to
solenoid C1) until the servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than
at port M5 and the system pressure gauges indicate displacement. Pressure should
be greater at port MA for clockwise rotation, or MB for counter clockwise rotation.
This also indicates the servo piston is in contact with the servo cylinder on side M5.

5. Slowly thread the servo cylinder on the M5 side in until the system pressure
differential starts to decrease. Maintain servo pressure differential between 1-2
bar [14-29 psi] during this step. Continue turning the servo cylinder in until the
system pressure differential (between ports MA/MB) is less than 1.5 bar [22 psi]. This
procedure sets the servo and swashplate to mechanical neutral on the M5 side.

6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite
direction by turning the eccentric screw in the opposite direction, or by supplying
current to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA) from those
stated above since the pump is now stroking the other direction.

7. Remove all gauges and replace gauge port plugs. You can find wrench sizes and plug
torques in the Plug size and torque chart, page 49.

Servo adjustment

E300 E350
Servo can Servo can
locking plate locking bolt

P106 490E

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Adjustments

Mechanical neutral Servo Adjustment Side M4

adjustment
(continued) 1. Run prime mover at 1800 rpm.

2. If using a PWM signal to set mechanical neutral, start with the electronic control
testing tool off (no current to either solenoid). Check to be sure the servo pressure
differential is less than 1.5 bar [22 psi]. Reference Sauer-Danfoss testing specifications
TS-392 or control neutral adjustment page 35.

3. Turn neutral adjust excenter screw (or supply current to solenoid C2) until the servo
pressure at port M5 is 1 - 2 bar [14– 29 psi] greater than at port M4.

4. The system pressure differential must be greater than zero and the pressure at
port A (B for clockwise rotation) must be greater than the pressure at port B (A for
clockwise rotation). This step ensures the servo is in contact with the servo cylinder
on side M4.

5. Slowly turn in the servo cylinder on the M4 side until the system pressure differential
starts to decrease. The servo pressure differential must be maintained between
1-2 bar [14-29 psi] during this step. Continue turning in the servo cylinder until the
system pressure differential is less than 1.5 bar [22 psi]. This procedure sets the servo
and swashplate to mechanical neutral.

Verify neutral setting

1. If using a PWM signal to set mechanical neutral, check that servo pressure differential
is less than 1.5 bar [22 psi]. Refer to TS-392 or Control neutral adjustment page 35.

2. To verify mechanical neutral, provide current to solenoid C1, or turn neutral adjust
excenter screw, until the servo pressure differential is 3 bar [43 psi]. The system
pressure differential must be below 1.5 bar [22 psi]. Repeat test on solenoid C2 side.

3. The current required to set the servo pressure differential to 3 bar [43 psi] should be
the same for each solenoid. Refer to TS-392.

4. If using neutral adjust excenter screw to set mechanical neutral, reset control neutral
(see page 35).

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Standard Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary
procedures, pump attached, remove both pumps as a single unit. Tag and cap all hydraulic lines as
removing the pump they are disconnected, and plug all open ports to ensure that dirt and contamination do
not get into the system.

C Caution
Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and installing system lines.

Disassembly
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the
pump.

2. Tag, disconnect, and cap each hydraulic line connected to the pump. As hydraulic
lines are disconnected, plug each open port, to ensure that dirt and contamination
do not get into the pump.

3. Remove the pump and its auxiliary pump (if applicable) as a single unit.

Be careful, do not damage solenoids and electrical connections when using straps or
chains to support the pump.

Inspection
4. Ensure the work surface and surrounding area are clean and free of contaminants
such as dirt and grime.

5. Inspect the system for contamination.

6. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam
in the oil, sludge, or metal particles.

Reassembly
7. Before replacing the pump, replace all filters and drain the hydraulic system. Flush
the system lines and fill the reservoir with the correct, filtered hydraulic fluid.

8. Fill the pump with clean, filtered hydraulic fluid.

9. Attach the pump to the prime mover. Torque mounting screws according to the
manufacturers recommendation.

10. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid.

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Electric control Removal

module Refer to exploded diagram, next page.

1. Using a 5 mm internal hex wrench, remove the six cap screws (D250).

2. Remove the control module and gasket (D150). Discard the gasket.

3. If necessary, remove orifices (F100) using a 3 mm internal hex wrench. Tag and
number them for reinstallation.

Inspection
4. Inspect the machined surfaces on the control and top of the pump. If you find any
nicks or scratches, replace the component.
Remove plug on top of
control to ensure the Reassembly
swashplate feedback pin
is properly positioned in Ensure you install dowel pins (D300) in housing before installing control.
the center of the control
module when installing 5. Install a new gasket (D150).
control.
6. If you removed screen (D084), install a new one. Install with the mesh facing outward
(see drawing).

Proper screen orientation

D084
D084

Correct screen Incorrect screen

orientation orientation

P106 519E

7. If previously removed, install orifices (F100) using a 3 mm internal hex wrench.

Torque to 2.5 N•m [1.8 lbf•ft].

8. Install the control module and six cap screws (D250).

9. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.5 N•m [10 lbf•ft].

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Service Manual
Minor repair

Electric control Control module removal/installation

module
(continued)
D050 (3X)
4 mm
5 N•m [4 lbf•ft] D1

D025A D250
5 mm
13.5 N•m
[10 lbf•ft]
D025
D025A D050 (3X)
Torque sequence D084 4 mm

2 1 5 N•m
[4 lbf•ft]
D150

6 5

F100 (2X)
4 3 3 mm
2.5 N•m
[1.8 lbf•ft]
D300 (2X)

P106 052E

Control solenoids Removal

1. Disconnect electrical connection and remove the three cap screws (D050) using a
4 mm internal hex wrench.

2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.

3. If necessary, remove the coil using a 12 point 26 mm socket.

Inspection
4. Inspect the machined surface on the control. If you find any nicks or scratches,
replace the component.

Reassembly
5. Lubricate new O-ring (D025A) using petroleum jelly and install.

6. Install solenoid with three cap screws (D050) using a 4 mm internal hex wrench.
Torque screws to 5 N•m [4 lbf•ft].

7. Install coil using a 12 point 26 mm socket. Torque coil nut to 5 N•m [3.7 lbf•ft].

8. Reconnect electrical connections and test the pump for proper operation.

For repair part information, see Sauer-Danfoss publication H1 Parts Manual for your
model.
520L0958 • Rev AA • Jun 2007 41
 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Shaft seal, roller The shaft assembly is serviceable without disassembling the pump. Orient the pump on
bearing and shaft the work surface so the shaft is pointing to the side.
replacement
Removal
1. Unwind the spiral ring (J300) from the housing to release the shaft/seal/bearing
subassembly.

2. Pry on the lip of the seal carrier (J275) to dislodge it from the pump. Remove the seal
C Caution carrier. Remove and discard O-ring (J260). Press the seal (J250) out of the carrier and
Do not damage the discard.
housing bore, shaft or
bearing when removing 3. Pull the shaft (J100) with bearing (J150) out of the pump. If necessary, tap lightly on
the shaft and shaft seal. the shaft to dislodge it from the cylinder block. C

4. Remove the retaining ring (J200) using retaining ring pliers. Press the bearing off the
shaft.

Shaft assembly

Protective
sleeve
J100

J150
J200
J250

J260
J150
J275
J300

P106 150E

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Shaft seal, roller Inspection

bearing and shaft 5 Inspect the shaft journals for wear, scratching, and pits. Check the splines for fretting;
replacement replace if damaged. Rotate the bearing, if it does not rotate smoothly, replace it.
(continued)
Reassembly
6. Press the bearing (J150) onto the shaft (J100) and replace the retaining ring (J200).
Ensure the retaining ring diameter is less than 38.84 mm [1.53 in] when installed on
the shaft.

7. Install the shaft/bearing assembly into the pump.

8. Lubricate and install a new O-ring Positioning seal in seal carrier

(J260) onto seal carrier (J275). Press flush to this surface
Press a new seal (J250) into the +0.12 mm [ 0.005 in] / -0.72 mm [ 0.028 in]
seal carrier. Press the seal until it is
flush within +0.12mm [0.005 in] or Seal
-0.72 mm [0.0028 in] of the inside lip
of the carrier: see illustration. P106 498E

9. Cover the shaft with a protective sleeve while installing the seal carrier. Hand press
the seal carrier into the housing. Ensure the seal carrier clears the spiral ring groove
in the housing. Remove the protective sleeve.

10. Wind the spiral ring into the housing. Ensure the inside diameter of the spiral ring is
greater than 68 mm [2.677 in] after installation.

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Charge pump If the pump has an auxiliary pump attached, remove the auxiliary pump and connecting
shaft before removing the auxiliary pad.
Charge pump removal/installation

Ensure proper torque on Removal K400

aux pad screws (K450). 1. Position pump so end cover or 8 mm
If necessary, replace screws. auxiliary pad is on top.

2. If necessary, remove auxiliary pump

(not shown), or shipping cover (K300) K100
and pad seal (K250) as shown on
following page.
G450
3. Remove end cover/auxiliary pad G450
screws (K400) using a 10 mm internal K150
hex wrench.

Alignment pins (G450) are in end cover. K500

They may dislodge during disassembly.
S300
4. Remove and discard gasket (K150).

5. Remove thrust washer (K500). Note S200

thrust washer orientation.

6. Use a small hook to remove pressure K200

balance plate (S200) and seal (S300).
Note plate orientation. Discard seal.
S100
7. Remove coupling (K200). Use a small
hook if necessary.

8 Remove the charge pump outer ring S250

(S150), and gearset (S100).
S300
9. Remove valve plate (S250) with seal
(S300). Discard seal.

Cover Screw K350

Cover Pad Wrench size and torque
A 17 mm  48 N•m [35 lbf•ft]
B, C 19 mm  77 N•m [58 lbf•ft]

E101 406E

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Service Manual
Minor repair

Charge pump Inspection

(continued) 10. Inspect the components for wear, scratches or pitting. Carefully inspect the valve and
pressure-balance plates. Scratches on these components will cause a loss of charge
pressure. If any component shows signs of wear, scratching or pitting, replace it.

Reassemby
11. Install new seals (S300) in the valve (S250) and pressure-balance (S200) plates.

12. Install valve plate (S250) in the same orientation as removed.

13. Lubricate and install charge pump (S100) and outer ring (S150).

14. Install charge pump coupling (K200).

15. Install pressure balance plate (S200) in the same orientation as removed.

16. Install the thrust washer (K500). Coated side goes toward charge pump coupling
(K200).

17. Install a new cover gasket. (K150). If removed, install guide pins (K450).

18 . Install the auxiliary pad or charge pump cover and cap screws. Using a 10mm
internal hex wrench, torque the cap screws (K400) to 92 N•m [68 lbf•ft]. Torque in
sequence below.

19. Reinstall auxiliary pump or pad seal (K250) and shipping cover ((K300).

If necessary, you must replace charge pump components (gearset, outer ring, valve and
pressure-balance plates) as a kit.

Torque sequence Auxilliary pads

K350
(see table)
K300
1 4

K250

K400
8 mm

3 2

P106 346E

SAE B E101 533E SAE A

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Charge check / HPRV Removal

1. Using a hex wrench shown in the table below, remove the HPRVs (L150). Remove and
discard the O-rings (L060) and backup rings (L068).

Inspection
2. Inspect the sealing surfaces in the pump for nicks or scratches. Check the valves for
damage. Replace any damaged components.

Reassemby
3. Lubricate and install new backup rings (L068) and O-rings (L060).

4. Install HPRVs. Torque to the value in the table below.

5. Operate the vehicle/machine through full range of controls to ensure proper

operation. Check for leaks.

High pressure relief valves

L060

L068

E101 426E L100 / L200

22 mm
110 N•m
[81 lbf•ft]

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Minor repair

Charge pressure Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to
relief valve repair the internal components of the valve. Torque to 52 N•m [38 lbf•ft]
See Charge pressure relief valve adjustment, page 30, for adjustment instructions.

Removal
1. Using a 22 mm wrench, remove the charge pressure relief valve (V010). Discard seal
(V024).

Inspection
2. Inspect the sealing surfaces of the pump for nicks or scratches.

Reassemby
3. Lubricate and install new seal (V024).

4. Install the charge pressure relief valve. Torque to 52 N•m [38 lbf•ft].

5. Operate vehicle/machine through full range of controls to ensure proper operation.

Charge pressure relief valve

V024

V10
22 mm E101 424E
52 N•m
[38 lbf•ft]

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Minor repair

Pressure limiter Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual
valve replacement components. See Pressure limiter adjustment, page 31, for adjustment instructions.

Removal
1. Using a 14 mm wrench, remove the pressure limiter valve (L100). Discard O-ring.

Inspection
2. Inspect the sealing surfaces of the pump for nicks or scratches.

Reassemby
3. Install new O-ring. Lubricate 0-ring with petroleum jelly.

4. Replace pressure limiter valve. Torque to 30 N•m [22 lbf•ft].

5. Operate pump at full range of controls to ensure proper machine operation.

Pressure limiter is available as complete unit only. O-ring is available separately.

Pressure limiter
L300
14 mm
30 N•m [22 lbf•ft]

L400
14 mm O
30 N•m [22 lbf•ft]

L022

E101 425E

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 H1 45/53 Closed Circuit Axial Piston Pump
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Torque chart

Fastener size and Item Fastener Wrench size Torque

torque chart D015 Neutral adjust screw 4 mm internal hex NA
D050 Coil mounting bolt 4 mm internal hex 8 N•m [9 lbf•ft]
D060 Neutral adjust locking nut 13 mm 10 N•m [7 lbf•ft]
D250 Electric control mounting bolt 5 mm internal hex 13 N•m [10 lbf•ft]
E350 Servo cylinder locking bolt 11 mm 14.5 N•m [11 lbf•ft]
K350 Apad Shipping cover mounting bolt 17 mm 48 N•m [35 lbf•ft]
K350 B/Cpad Shipping cover mounting bolt 19 mm 77 N•m [58 lbf•ft]
K400 Rear cover/aux pad mounting bolt 10 mm internal hex 92 N•m [68 lbf•ft]
L010 Pressure limiter adjust screw 8 mm NA
L300/L400 Pressure limiter cartridge 14 mm 30 Nm [22 lbf•ft]
L024 Pressure limiter locking nut 14 mm 20 N•m [15 lbf•ft]
L100/L200 High pressure relief valve 22 mm 70 N•m [52 lbf•ft]
V10 Charge pressure cartridge 22 mm 52 N•m [38 lbf•ft]
V020 Charge pressure adjusting screw 4 mm internal hex NA

Plug size and torque Item O-ring plug Wrench size Torque
chart B015 7/16 - 20 3/16 in internal hex 19 N•m [14 lbf•ft]
B020 1-1/16 - 12 9/16 in internal hex 49 N•m [36 lbf•ft]
D065 7/16 - 20 3/16 in internal hex 19 N•m [14 lbf•ft]
G250 9/16 - 18 7 mm internal hex 22-26 N•m [16-20 lbf•ft]
G300/G302 9/16-18 UNF 1/4 in internal hex 42 N•m [30 lbf•ft]

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 H1 45/53 Closed Circuit Axial Piston Pump
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Torque chart

Fasteners and plugs

L200
High pressure
relief valve

V020
Charge pressure
adjusting screw

V022
Charge pressure
locking nut

V10
Charge pressure
cartridge
K400
L100 Rear cover / auxiliary pad
High pressure mounting bolt
relief valve K350
Rear cover mounting bolt

P106 348E

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 H1 45/53 Closed Circuit Axial Piston Pump
Service Manual
Notes

Fasteners and plugs

(continued)

B020 O-ring plug, 1-1/16 - 12 G251 O-ring plug, 9/16 - 18

D250
Electric control
mounting bolt

G300 O-ring plug, 9/16 - 18

D065 O-ring plug, 7/16 - 20

D015 Neutral adjusting screw B015 O-ring plug, 7/16 - 20

D060 Neutral adjust locking nut L010 Pressure limiter adjusting screw
L024 Pressure limiter locking nut

D050 Coil mounting bolt L300/L400 Pressure limiter cartridge

E350 G302 O-ring plug, 9/16 - 18

Servo cylinder locking bolt

B020 O-ring plug, 1-1/16 - 12

P106 349E

520L0958 • Rev AA • Jun 2007 51

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems
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520L0958 • Rev AA • Jun 2007