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Series 42
rotation of the motor output. Series 42 pumps provide an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation. Series 42 pumps utilize a cradle swashplate design with a hydraulic servo control cylinder. Control is provided through a compact servo control system. A choice of servo controls are available. These include mechanicallyor electrically-actuated feedback controls, hydraulic or electric proportional controls, and a three-position electric control. These controls are designed for low hysteresis and responsive performance.
Series 42 - Advanced Technology Today 2 Sizes of Variable Displacement Pumps Complete Family of Control Systems Proven Reliability and Performance Optimum Product Configurations Compact Profile Quiet Operation Worldwide Sales and Service
Cover picture: Series 42 pump with electrohydraulic displ. control (EDC). Copyright 1994-1999 Sauer-Sundstrand GmbH & Co. All rights reserved. Contents subject to change. Printed in Germany F000 719
Series 42
Series 42
2 6 7 7 8
Series 42 Pumps .......................................................................................................................................... Series 42 Variable Pump Features ............................................................................................................. System Circuit Description ......................................................................................................................... Pump Circuit Schematic ............................................................................................................................. Technical Specifications .............................................................................................................................
General Specifications ....................................................................................................................................................... 8 Hardware Features ............................................................................................................................................................. 8 Fluids and Filtration ............................................................................................................................................................ 9 Technical Date .................................................................................................................................................................... 9
Series 42
Displacement Limiter Options - Dimensions All Frame Sizes ........................................................... 45 Speed Sensor Option* - Dimensions All Frame Sizes ........................................................................ 46 Auxiliary Mounting Pads - Dimensions All Frame Sizes ..................................................................... 47
SAE A Auxiliary Mounting Pad ...................................................................................................................................... 47 SAE B Auxiliary Mounting Pad ...................................................................................................................................... 47
Series 42
Swashplate
Piston
Input Shaft
Roller Bearing
P100 380E
Valve Plate
3
Charge Pump
P100 382E
M4
Piston Swashplate
Input Shaft
A
System Check Relief Valves
P100 381E
Series 42
Heat Exchanger
Output Shaft
Suction Flow Charge Pressure Servo Pressure High Pressure Case Flow
P100 384E
A Series 42 variable pump (left) is shown in a hydraulic circuit with a Series 40 - M35 fixed motor. A suction filtration configuration is shown. Pressure regulation
valves are included on the pump. Note the position of the reservoir and heat exchanger.
P100 385E
L1 S M4 M5
A Series 42 pump schematic is shown above. The system ports "A" and "B" connect to the high pressure work lines. The pump receives return fluid in its inlet port and discharges pressurized fluid through the outlet port. Flow direction is determined by swashplate position. System
port pressure can be gauged through ports M1 and M2. The pump has two case drains (L1 and L2) to ensure there is lubricating fluid in the system. This pump includes a manual displacement control. For other control schematics see the related control section.
Series 42
Most specifications for Series 42 pumps are listed on these two pages. For definitions of the various specifications, see the related pages in this publication. Not all hardware options are available for all configurations; consult the Series 42 Pump Model Code Supplement or Price Book for more information.
General Specifications
General Specifications Pump Type Direction of Input Rotation Recommended Installation Position Filtration Configuration Other System Requirements In-line, axial piston, positive variable displacement pumps including cradle swashplate and servo control Clockwise or Counterclockwise Pump installation recommended with control position on the top or side. Consult SAUER-SUNDSTRAND for non conformance guidelines. The housing must always be filled with hydraulic fluid. Suction or charge pressure filtration Independent braking system, suitable reservoir and heat exchanger
T002 001E
Hardware Features
Hardware Features Frame Size Pump Configuration Displacement cm /rev (in /rev) Weight kg (lb) Moment of Inertia kg m2 (lb ft2 ) Type of Mounting (SAE flange size per SAE J744) Port Connections Integral Charge Pump Options cm3/rev (in3/rev) Charge Relief Valve Settings (std) bar (psi)
3 3
28 Single Variable Pump 28 (1.71) 34.5 (76) .0018 (.043) SAE "B" SAE-Twin Ports, Radial 11 (0.67) 15 (0.92) 14 (205) 20 (294) 140-345 bar (2030-5000 psi) Option Splined, Tapered, or Straight Key SAE "A" (9T & 11T), SAE "B", SAE "B-B" MDC, EDC, FNR, NFPH, NFPE Suction or Remote Pressure Filtration Option
41
System Pressure Regulation Displacement Limiters Input Shaft Options Auxiliary Mounting Pad (SAE Pad per SAE J744) Control Options Filtration Configuration Loop Flushing
T002 002E
Series 42
Charge Pump Displacement Charge Pump Standard Internal Option External Option 15 cm3/rev. (.92 in3/rev) T002 012E
in Hg vacuum 6 24
T002 009E
Charge Pressure Relief Valve 28 Type Standard Setting Option 20 bar (294 psi) Shim adjustable
T002 013E
41
Speed limits 28 Minimum speed Rated speed at maximum displacement Maximum speed at maximum displacement
1
Adjustment
Check / High Pressure Relief Valve 140 / 175 / 190 / 210 / 230 / 250 / 280 / 300 / 345 bar (2030 / 2540 / 2755 / 3045 / 3335 3625 / 4060 / 4350 / 5000 psi) Relief valve / check Options No relief valve / check only No relief valve / no check
T002 014E
Settings
Viscosity
Minimum Recommended operating range Maximum mm2/s 7 12-60 1 600 [SUS] [49] [70-278] [7 500] intermittent, cold star t
T002 010E
intermittent
Required fluid cleanliness level Recommended x-ratio for suction filtration Recommended x-ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration
ISO 4406 Class 18/13 35-45=75 (102) 15-20=75 (1010) 100 m-125 m
T002 007E
Series 42
The model code is a modular description of a specific product and its options. To create a model code to include the specific options desired, see the Series 42 Model Code Supplement or the Series 42 Price Book.
saue
Ames, Iowa, U.S.A. Model Code Neumnster, Germany Typ
Model Code
Identification Number
Place of Manufacture
42
28 C E1A2
0 1
ANC 2 CNN 2 1
2 1 N N N NNN NNN
Series
Rotation
Shaft Type
Special Hardware
Housing Loop Flushing Filtration Charge/Implement Pump Relief Setting Special Drive Features Auxiliary Mounting Pad
10
Series 42
Inch-System:
Pump output flow Input Torque Input Power Q = PD PS v 231 PD p 2 mh PD PS p 396 000 mh gpm
Metric-System:
Pump output flow Input torque Input power Pe Qe Me = = Vg n v 1000 Vg p 20 mh l/min
PT
lbfin
Nm
hp
Me n = 9550
Qe p kW 600 mh
Description:
Inch-System: PD PS p v mh = = = = = Pump displacement per rev. Hydrostatic pump speed Differential hydraulic pressure Pump volumetric efficiency Pump mechanical - hydraulic (Torque) efficiency v mh pHD pND = = = = in
3
Metric-System: Vg n p = = = Pump displacement per rev. Hydrostatic pump speed pHD - pND (differential hydraulic pressure) Pump volumetric efficiency Pump mechanical - hydraulic (Torque) efficiency high pressure low pressure bar bar cm3 rpm bar rpm psi
System Requirements
Independent Braking System
WARNING The loss of hydrostatic drive line power in any mode of operation (e.g., forward, reverse, or neutral mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.
S000 001E
Reservoir
The reservoir should be designed to accommodate maximum volume changes during all system operating modes and to promote de-aeration of the fluid as it passes through the tank. A suggested minimum reservoir volume is 5/8 of the maximum charge pump flow per minute with a minimum fluid volume equal to 1/2 of the maximum charge pump flow per minute. This allows 30 seconds fluid dwell for removing entrained air at the maximum return flow. This is usually adequate to allow for a closed reservoir (no breather) in most applications. The reservoir outlet to the charge pump inlet should be above the bottom of the reservoir to take advantage of gravity separation and prevent large foreign particles from entering the charge inlet line. A 100 - 125 mm screen over the outlet port is recommended. The reservoir inlet (fluid return) should be positioned so that flow to the reservoir is discharged below the normal fluid level, and also directed into the interior of the reservoir for maximum dwell and efficient de-aeration. A baffle (or baffles) between the reservoir inlet and outlet ports will promote de-aeration and reduce surging of the fluid.
11
Series 42
psi 50 150
T002 003E
Speed Limits
Rated speed is the speed limit recommended at full power condition and is the highest value at which normal life can be expected. Maximum speed is the highest operating speed permitted and cannot be exceeded without reduction in the life of the product or risking immediate failure and loss of drive line power (which may create a safety hazard). Mobile applications must have an applied speed below the stated maximum speed. In addition, applications must have a braking system, redundant to the transmission, which will stop and hold the vehicle should hydrostatic drive line power be lost. Consult Bulletin BLN-9884 (Pressure and Speed Limits) when determining speed limits for a particular application.
Speed limits 28 Minimum speed Rated speed at maximum displacement Maximum speed at maximum displacement
1
Pressure Limits
System pressure is the dominant operating variable affecting hydraulic unit life. High pressure, which results from high load, reduces expected life in a manner similar to many mechanical assemblies such as engines and gear boxes. There are load-to-life relationships for the rotating group and for the shaft anti-friction bearings. Continuous pressure is the average, regularly occurring pressure. Maximum pressure is the highest intermittent pressure allowed, and is the relief valve setting. It is determined by the maximum machine load demand. For most systems, the load should move at this pressure. Maximum pressure is assumed to occur a small percentage of operating time, usually less than 2% of the total. Both the continuous and maximum pressure limits must be satisfied to achieve the expected life. All pressure limits are differential pressures (referenced to charge pressure) and assume normal charge pressure and no externally applied shaft loads.
Inlet Pressure
Charge pump inlet conditions must be controlled in order to achieve expected life and performance. A continuous inlet vacuum of not less than 0.8 abs bar (not more than 5 in Hg vac) is recommended. Normal vacuums less than 0.7 abs bar (greater than 10 in Hg vac) would indicate inadequate inlet design or a restricted filter. Vacuums less than 0.7 abs bar (greater than 10 in Hg vac) during cold start should be expected, but should improve quickly as the fluid warms. Inlet vacuum should never exceed the maximum inlet vacuum.
Inlet pressure (vaccum) Rated pressure Minimum (coldstart) bar (absolut) 0.8 0.2 in Hg vacuum 6 24
T002 009E
12
Series 42
Temperature Range1)
Minimum Rated Maximum
1)
Viscosity
Minimum Recommended operating range Maximum mm2/s 7 12-60 1 600 [SUS] [49] [70-278] [7 500] intermittent, cold star t
T002 010E
intermittent
For maximum unit efficiency and bearing life the fluid viscosity should remain in the continuous viscosity range. The minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation. The maximum viscosity should be encountered only at cold start.
13
Series 42
circuit systems, and closed circuits with cylinders being supplied from the same reservoir, a considerably higher filter efficiency is recommended. This also applies to systems with gears or clutches using a common reservoir. For these systems, a filter within the range of 15-20 = 75 (10 10) or better is typically required. Since each system is unique, the filtration requirement for that system will be unique and must be determined by test in each case. It is essential that monitoring of prototypes and evaluation of components and performance throughout the test program be the final criteria for judging the adequacy of the filtration system. See publication BLN-9887 or 697581 and ATI-E9201 for more information.
Cleanliness Level and x-Ratio
Required fluid cleanliness level Recommended x-ratio for suction filtration Recommended x-ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration ISO 4406 Class 18/13 35-45=75 (102) 15-20=75 (1010) 100 m-125 m
T002 007E
Filter x-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given diameter ("x" in m) upstream of the filter to the number of these particles downstream of the filter.
14
Series 42
Filter
Strainer Reservoir
To Pump Case
Suction filtration
Reservoir
Strainer
Filter To Low Pressure Side of Loop and Servo Control Charge Relief Valve Charge Pump To Pump Case
P001 604E
Reservoir
Strainer
Filter with Bypass To Low Pressure Side of Loop and Servo Control Charge Relief Valve Charge Pump To Pump Case
P001 605E
Series 42
Low Pressure
High Pressure
P100 389E
Many factors influence the charge flow requirements and the resulting charge pump size selection. These factors include system pressure, pump speed, pump swashplate angle, type of fluid, temperature, size of heat exchanger, length and size of hydraulic lines, control response characteristics, auxiliary flow requirements, hydraulic motor type, etc. The total charge flow requirement is the sum of the charge flow requirements of each of the components in the system. When initially sizing and selecting hydrostatic units for an application, it is frequently not possible to have all of the information necessary to accurately evaluate all aspects of charge pump size selection. The following procedure will assist the designer in arriving at an initial charge pump selection for a typical application. In most Series 42 applications a general guideline is that the charge pump displacement (CPD) should be equal to or greater than 10% of the total displacement (TD) of all units in the system (see example at right). This rule assumes that all units are of high speed, piston design. Both Series 42 pumps may be equipped with integral charge pumps. These charge pump sizes have been selected to meet the needs of a majority of Series 42 applications. Series 42 pumps are also available without charge pumps. When a pump is equipped without a charge pump, an external charge supply is required to ensure adequate charge pressure and cooling.
Charge Pump Displacement Charge Pump Standard Internal Option External Option 15 cm3/rev. (.92 in3/rev) T002 012E
Charge pump sizing example: A system consists of a single Series 42 - 28 Variable Pump driving two Series 40 -M35 Fixed Motors: TD = 28 + 35 + 35 = 98 cm3 CDP = 10 % x TD = 9.8 cm3 A charge pump displacement of 9.8 cm3 or more is required. The standard 11 cm3 charge pump should provide sufficient charge flow for this application.
16
Series 42
It is emphasized that particular application conditions may require a more detailed review of charge pump sizing. System features and conditions that may invalidate the 10% of displacement rule include (but are not limited to): operation at low input speeds (below 1500 RPM) shock loadings excessively long system lines auxiliary flow requirements use of high torque low speed motors
If a charge pump of sufficient displacement to meet the 10% of displacement rule is not available or if any of the above conditions exist which could invalidate the 10% rule, contact your Sauer-Sundstrand representative.
kW 3
hp 4
15 cm3 (0.92 in3) 11 cm3 (0.67 in3)
3 2 2 1 1
17
Series 42
Charge Pressure Relief Valve 28 Type Standard Setting Option Adjustment 20 bar (294 psi) Shim adjustable
T002 013E
41
To Case
Charge Relief Valve WARNING Incorrect charge pressure settings may result in the inability to build required system pressure and/ or inadequate loop flushing flows. Correct charge pressure must be maintained under all conditions of operation to maintain pump control performance.
S000 002E
18
Series 42
Charge check and high pressure relief valve WARNING High pressure relief valves are intended for transient overpressure protection and are not intended for continuous pressure control. Operation over relief valves for extended periods of time may result in severe heat build up. High flows over relief valves may result in pressure levels exceeding the nominal valve setting and potential damage to system components.
S000 031E
Check / High Pressure Relief Valve 140 / 175 / 190 / 210 / 230 / 250 / 280 / 300 / 345 bar (2030 / 2540 / 2755 / 3045 / 3335 3625 / 4060 / 4350 / 5000 psi) Relief valve / check Options No relief valve / check only No relief valve / no check
T002 014E
Settings
Bypass Valves
In some applications it is desirable to bypass fluid around the variable displacement pump when pump shaft rotation is either not possible or not desired. For example, a "down" vehicle may be moved to a service or repair location or winched on a trailer without operating the prime mover. This is accomplished with bypass valves. Series 42 pumps are available with a bypass function which, when open, connects both sides of the main hydraulic circuit. This allows fluid to circulate without rotating the pump and prime mover. The bypass valve is integral with the combination charge check and high pressure relief valve assembly. A plunger located in the plug of the valve assembly must be manually depressed to open the valve. The valve remains open until the prime mover is restarted and charge pressure automatically closes it. The plungers in both of the check/relief valve assemblies should be depressed for proper bypass operation.
Bypass Plunger
WARNING Bypass valves are intended for moving a machine or vehicle for very short distances at very slow speeds. They are NOT intended as tow valves.
S000 030E
19
Series 42
Displacement Limiter Specs 28 Approx Disp. per rev of Adjusting Screw (cm3/rev) (in3/rev) Maximum Displacement Limiter Range 3.6 (0.22) 41 5.0 (0.31)
Servo Control Cylinder Displacement Limiter (Set for Reduced Maximum Displacement)
P100 395E
20
Series 42
Required current Max. current Max. frequency Voltage high Voltage low Temperature range
4.5-15 VDC 12 mA at 5 VDC (no load) 20 mA at 5 VDC 15 kHz Supply voltage -0.5 V 0.5 VDC max. -40 to 110 C [-40 to 250 F]
T000 049E
1)
It is not acceptable to energize the 4.5-15 VDC speed sensor with 12 VDC batter y voltage; it must be energized by a regulated power supply. If it is desirable to energize the sensor with batter y voltage, contact your Sauer-Danfoss representative for an optional speed sensor.
P001 492
Mating Connector straight right angle No.: K14956 No.: K14957 Id.-No.: 500724 Id.-No.: 500725
3 P001 755E
Packard Weather-Pack 4 pin (Supplied Connector) Mating Connector No.: K03379 Id.-No.: 505341
A B C D P001 758E
21
Series 42
P100 397E
0 (psi)
200
300
WARNING Incorrect charge pressure settings may result in the inability to build required system pressure and/ or inadequate loop flushing flows. Correct charge pressure must be maintained under all conditions of operation to maintain pump control performance.
S000 002E
(at 26 mm /sec)
30
P100 398E
22
Series 42
spline tooth wear, and assume the mating spline has a minimum hardness of Rc 55 and full spline depth with good lubrication. Maximum torque ratings are based on shaft torsional strength and assume a maximum of 200 000 load reversals.
Shaft Availability and Torque Rating1 28 140 226 192 362 362 (3200) (1240) (2000) (1700) (3200) 140 226 192 362 340 734 362 41 (1240) (2000) (1700) (3200) (3000) (6500) (3200)2
Nm (in lbf) Spline 13 tooth, 16/32 pitch Spline 15 tooth, 16/32 pitch Spline 19 tooth, 16/32 pitch Tapered 25.4 mm (1 in) Dia 1/8 (1.5 in/ft) taper Straight Keyed 25.4 mm (1 in) Dia Tapered 31.75 mm (1-1/4 in) Dia 1/8 (1.5 in/ft) taper Straight Keyed 31.75 mm (1-1/4 in) Dia
1
Max
362
(3200)
362
(3200)2
Max
734
(6500)
Max
734
(6500)
T002 017E
The limitations of these input shafts constrain the allowable auxiliary coupling torque. 2 Not recommended for all options.
NOTE: Recommended mating splines for splined output shafts should be in accordance with ANSI B92.1 Class 5. Sauer-DANFOSS external splines are modified Class 5 Fillet Root Side Fit. The
external spline Major Diameter and Circular Tooth Thickness dimensions are reduced in order to assure a clearance fit with the mating spline.
S000 029E
23
Series 42
The combination of auxiliary pad shaft torque, plus the main pump torque should not exceed the maximum pump input shaft rating shown in the Shaft Availability and Torque Ratings table on the previous page. All torque values assume a 58 Rc shaft spline hardness on mating pump shaft. Continuous (Cont) torque ratings for splines are based on spline tooth wear. Maximum torque is based on maximum torsional strength and 200 000 load reversals. Applications subject to severe vibratory or high "G" loading may require an additional structural support. This is necessary to prevent leaks and possible mounting flange damage. Refer to the "Mounting Flange Loads" section for additional information.
Auxiliary Pad 1 Pad Size Spline minimum spline length mm SAE A SAE A special SAE B SAE B-B
1
9 tooth 16/32 pitch 11 tooth 16/32 pitch 13 tooth 16/32 pitch 15 tooth 16/32 pitch
F min.
SAE A SAE B
44 [1.73] 46 [1.81]
With Undercut Without Undercut 2.3 (.09) Cutter clearance Coupling B max. C max. R 0.8 (.03) max.
P001 614E
24
0 P -0.05
Pad Size
(+.000) (-.002)
Series 42
CG Pump 2
L1
L2
P100 400E
Estimated maximum and continuous acceleration factors for some typical applications are shown in the table below.
G-factors for Sample Applications Continuous (Vibratory) Acceleration GR Skid Steer Loader Trencher (Rubber Tires) Asphalt Paver Windrower Areal Lift Turf Care Vehicle Vibratory Roller 4 3 2 2 1.5 1.5 6 Maximum (Shock) Acceleration GS 10 8
1
Estimating overhung load moment M R = G R (W1L1 + W2L2 + ... +WnLn) M S = G S (W1L1 + W2L2 + ... +WnLn) MR = MS = GR = GS = W = L = Rated load moment [Nm] Shock load moment [Nm] Rated (vibratory) acceleration (gs)1 [m/s2] Max shock acceleration (gs)1 [m/s2] Weight of pump [kg] Distance from mounting flange to center of gravity [m] (see outline drawings)
6 5 4 4 10
T002 023E
Calculations will be carried out by multiplying the gravity (g= 9,81 m/s2) with a given factor. This factor depends on the application.
Allowable overhung load moment values are shown in the table below. Exceeding these values will require additional pump support.
Allowable Overhung Load Moments Frame Size 28 41 Rated Load Moment (MR) Nm 1441 1441 (in lbf) (12 750) (12 750) Shock Load Moment (MS) Nm 3413 3413 (in lbf) (30 200) (30 200)
T002 022E
25
Series 42
FB L
0 Re
90 Re
Re = Me / L
Thrust loads in either direction should be avoided. If continuously applied external radial loads are 25% of the maximum allowable or more, or thrust loads are known to occur, contact your Sauer-Sundstrand representative for an evaluation of unit bearing life. Tapered output shafts or clamp-type couplings are recommended for applications where radial shaft side loads are present. L Me Re Tout = = = =
Distance from mounting flange to point of load Maximum external moment Maximum radial side load Thrust load
26
Series 42
Note that all pressure limits are differential pressures (referenced to charge pressure) and assume normal charge pressure. The pumps will meet satisfactory life expectancy if applied within the parameters specified in this bulletin. For more detailed information on hydraulic unit life see BLN-9884, "Pressure and Speed Limits".
27
Series 42
95
Efficiency %
90
85
etric Efficiency 5000 psi (345 bar) Volum Overall Efficien cy 25 0 0 p si ( 170 ba r) Overall Efficiency 5000 psi (345 bar)
The performance map provides typical pump overall efficiencies at various operating parameters. These efficiencies also apply for all Series 42 pumps at maximum displacement.
87%
88%
System Pressure
210 140 70 0
1000 0 0
85 %
80 %
100
P100 402E
28
Series 42
All controls are designed to provide smooth, stepless, and positive control of the transmission in either direction. Optional servo supply and drain orifices are available for special response needs.
MDC
EDC
FNR
NFPH
NFPE
29
Series 42
Feedback Linkage
MDC Handle
Charge Pressure
P100 403E
The MDC is a high gain control. With a small movement of the control handle (input signal), the servo valve moves to the full open position porting maximum flow to the swashplate servo control cylinder. The MDC provides a fast response with low input force. The full over-travel spool design allows rapid changes in input signal without damaging the control mechanism. Precision parts provide repeatable and accurate displacement settings with a given input signal. Mechanical feedback mechanism maintains pump displacement for a given input signal. Swashplate vibration is not transmitted to the operator's hands. The swashplate and double-acting servo control cylinder are coupled to a spring centering mechanism. The servo control valve is spring centered so that with no input signal the servo cylinder is cross ported.
M4 M5
P100 404E
MDC Schematic
30
Series 42
if the prime mover is shut down; if the external control linkage fails at the control handle; if there is a loss of charge pressure.
33 Maximum b
-a
Non-Linear Manual Displacement Control The Non-Linear Manual Displacement Control provides very small changes in pump output flow relative to input handle rotation when operating near the neutral (zero flow) position, and larger changes as the handle nears its maximum flow position. This non-linear relationship between the control input and pump output flow enhances vehicle control and inching capabilities. Control Input Signal Torque required to move control handle to maximum displacement is 1.36 0.23 Nm (12 2 inlbf). In order to prevent damage to the control, stops must be provided in the control linkage to limit the maximum linkage travel and maximum torque on the control handle. Maximum allowable input torque at the control handle is 17 Nm (150 inlbf).
Handle Angle Required for Swashplate Position Swashplate Position (ref above graphs) Swashplate Movement Begins (point "a") 5.3 4.0 5.3 Full Displacement Reached (point "b") 28 24 28
T002 025E
CW
Lever Rotation
"0"
Displacement
CCW a
-b -33 Maximum
100 %
P100 405E
33 Maximum b
CW a
-b -33 Maximum
100 %
P100 406E
Response Time The time required for the pump output flow to change from zero to maximum can be tailored by orifice selection. Optional orifices are available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be conducted to verify the proper orifice selection. Neutral to maximum swashplate response is approximately 60% of the response for maximum to maximum swashplate travel. For response times other than those shown please contact your Sauer-Sundstrand representative. 31
MDC Response Time Response (sec) Frame Size 28 41 Fast 0.5 0.6 Medium 1.3 1.6 Slow (Std) 2.5 2.5
T002 026E 14 bar (200 psi) charge pressure, maximum to maximum displacement.
Series 42
Pump Flow Direction with MDC Control Input Shaft Rotation CW Handle Rotation Port A Flow Port B Flow High Pressure Servo Gauge Port CW Out In M4 CCW In Out M5 CCW CW In Out M4 CCW Out In M5
T002 027E Refer to pump outline drawings for port locations
Clevis Style
P100 407E
Electric Override to Neutral Specs Solenoid at Override Activatation Voltage Max Current De-energized 12 or 24 VDC 2A
T002 028E
32
Series 42
NSS Specs Switch Neutral Position Voltage Current Rating Neutral Play Closed 12 or 24 VDC 5A 2 Backup Alarm Switch Option Switch Neutral Position Voltage Current Rating Alarm Direction Switch Closes at Open 12 or 24 VDC 2.5 A Either CW or CCW 2.6 ~ 3.75
T002 030E
M4 M5
C D
{ | z
X7
Neutral Start Switch w/ Backup Alarm Electric Solenoid Override to Neutral w/ Brake Release Neutral Start Switch Contacts (A and B) (Closed in Neutral) Backup Alarm Switch Contacts (C and D) (Closed in Reverse)
P100 408E
33
Series 42
Feedback Linkage
EDC Assembly
PCP Valve
P100 409E
34
Series 42
if the prime mover is shut down; if the external electrical input signal is lost; if there is a loss of charge pressure.
X1 PCP X2
P100 410E
Pump Flow Direction with EDC Control Input Shaft Rotation CW Voltage to Pin: Port A Flow Port B Flow Hi Servo Gauge Port EDC Pilot Gauge Port CCW
Response Time The time required for the pump output flow to change from zero to maximum can be tailored by orifice selection. Optional orifices are available to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be conducted to verify the proper orifice selection. Neutral to maximum swashplate response is approximately 60% of the response for maximum to maximum swashplate travel. For response times other than those shown please contact your Sauer-Sundstrand representative.
EDC Response Time Response (sec) Frame Size 28 41 Fast 0.5 0.6 Medium 1.3 1.6 Slow (Std) 2.5 2.5
T002 031E 14 bar (200 psi) charge pressure, maximum to maximum displacement.
35
Series 42
The required input signal to provide a given swashplate position is shown in the chart and table at right. The point of initial swashplate movement is defined as a system differential pressure of 3.5 bar (50 psi).
-b -a
Displacement
Current mA "0" a b
100 %
P001 015E
Coil Options There are two types of coils available: the standard "normal" coil and a low current coil option. The optional low input current control (5-18 mA) allows an EDC to be used in conjunction with a microprocessor without the need for an amplifier board.
EDC Signal Required for Swashplate Position Swashplate Postion Movement Begins (point "a")
mA at VDC
Pin Connection
EDC Input Specs Normal Current Coil Resistance ( at 24C [75F]) ( at 104C [220F]) Max Input Current mA at VDC Coil A/B: 20 Coil C/D: 16 350 at 6 Low Current 650 850 46 at 30
T002 033E
14 3 5 0.5 7 1.5 14 3
85 10 18 1 42.5 5 85 10
Single Coil (Low Current) Dual Coil in Series Dual Coil in Parallel
36
Series 42
M4 M5
X1 X2
P100 413
Pump Flow Direction with NFPH Control Input Shaft Rotation CW Higher Pressure into Control Port: Port A Flow Port B Flow High Servo Gauge Port X1 Out In M4 X2 In Out M5 CCW
p
100 %
NFPH control
45 bar bar
In Out M4
Out In
"0"
Displacement
6 bar 15 bar 22 bar Signal Pressure
=3 45 bar
M5
T002 035E
=0
bar
100 %
X1
X2
=0
=3
37
Series 42
A
B
P100 NFPE Control on Series 42 Pump415
Electric control. Eliminates mechanical linkage for flexibility of control design. Power limiting characteristic reduces machine power requirements. Smooth operation.
A
M4 M5
Input Signal Requirements The NFPE control requires a pulse-width-modulated (PWM) input current to optimize performance. The recommended PWM frequency is 200 Hz. The minimum PWM frequency is 80 Hz. Coil resistance is 5.6 W at 22C. The NFPE control utilizes AMP Junior Power Timer connectors. The solenoids are compatible with SauerSundstrand microprocessors, electric circuit boards and handles.
P100 416E
NFPE control
=0 =3 p 45 bar bar
CW Solenoid energized Port A Flow Port B Flow High Servo Gauge Port A Out In M4 B In Out M5 A
CCW B Out In M5
T002 036E
=0
Displacement
710
1000 1300
In Out M4
P100 417E
38
Series 42
2
P100 418
Input Signal Requirements The solenoids are available in versions for 12 or 24 VDC. Maximum power consumption is 30 Watts. They are available with terminals for a DIN 43650 connector or with a Packard Weather-Pack 2-way sealed connector. An AMP Jr Power Timer connector is also available.*
M4 M5
#1
#2
P100 419E
100 %
Displacement
100 %
Connectors
P001 635E
39
Series 42
mm [in]
0.3 [0.01] R
9.7 [0.38]
"Y"
System Pressure Gauge Port M2 9/1618* System Pressure Port "B" 1-1/1612* 31 [1.22] Servo Pressure Gauge Port M5 9/1618*
93.2 [3.67]
114.4 [4.50]
"X"
31 [1.22] System Pressure Port "A" 1-1/1612* System Pressure Gauge Port M1 9/1618* 57.7 108 [4.25] [2.27] 152.7 To C.G. [6.01] 31 [1.20] 14.0 [0.55] 75.1 [2.96]
"V"
"W"
199.5 [7.85]
73.0 [2.875]
73.0 [2.875]
Charge Pressure Relief Valve VIEW "W" (BOTTOM VIEW) BASE UNIT W/ MDC AND SUCTION FILTRATION
P100 421E
40
Series 42
mm [in]
25.38 [.999] dia 70 [2.76] Coupling Must Not Protrude Beyond This Point
9 [.32]
Charge Pressure Gauge Port M3 (Charge Pressure Supply for No Charge Pump Option) 3/4 - 16* Charge Check/ System Pressure Relief Valve Port "B" Charge Pump Inlet Port S 1-1/16 - 12*
"T" "U" "W" Pitch Dia "Z" Teeth, 16/32 Pitch 30 Pressure Angle Fillet Root Side Fit Compatible With Ansi B92.1-1970 Class 5 Also Mates With Flat Root Side Fit "V" Coupling Must Not Protrude Beyond This Point
60.5 [2.38]
30 [1.18] Case Drain Port L1 1-1/1612* 49.7 [1.96] 147.7 [5.81] "S" Charge Check / System Pressure Relief Valve Port "A" 9 [.32]
VIEW "V" (RIGHT SIDE VIEW) BASE UNIT W/ MDC AND SUCTION FILTRATION
43.4 [1.71] Coupling Must Not Protrude Beyond 33.5 [1.32] Max 6.3 X 22.2 Dia Woodruff Key [.248 X .875]
Splined Input Shaft Options Max. Coupling Engagement S 32.6 [1.29] 38 [1.50] Max. Shaft Diameter T 19 [0.75] 22 [0.87] Full Spline Length U 16.7 [0.66] 23.5 [0.92] Major Diameter V 22.16 [0.872] 25.34 [0.998] Pitch Diameter W 20.638 [0.8125] 23.813 [0.9375] Number Of Teeth Z 13 15
T002 040E
.750-16UNF-2A Thd
12.7 27 [1.06] Hex [.50] 22.2 [.87] Gage 9.5 [.37] Gage Dim 125 Taper Per Meter [1.50 Per Foot] Compatible With Sae Standard J501 25.4 [1.00] Nominal Shaft Dia TAPERED SHAFT CONFIGURATION
P100 422E
*All SAE straight thread O-ring ports per SAE J1926, unless otherwise specified Shaft rotation is determined by viewing pump from input shaft end. Contact your Sauer-Sundstrand representative for specific installation drawings.
41
Series 42
mm [in]
X7
VIEW "Y" (TOP VIEW) BASE UNIT W/ MDC MDC Control Handle
L4
29.23 [1.15] 103.45 [4.07]
"Y"
Servo Pressure Gauge Port M5 0.5625-18* Displacement Limiter Side 2 Option 'A' or '1' 178.91 34 [1.34]
91.3 [3.59]
Neutral Adjust (Optional) System Pressure Gauge Port M2 0.5625-18* System Pressure Port B 1.0625-12* 26.5 [1.04] Lifting Bracket
M5 L2
M2
38.5 [1.52] 38.5 [1.52] 26.5 [1.04] System Pressure Port A 1.0625-12* (Optional) System Pressure Gauge Port M2 0.5625-18*
"X"
N
81.1 [3.19] Case Drain Port L2 1.3125-12*
"V"
14.3 dia [0.563] 2 Places
M1
"W"
165.7 [6.52]
69 [2.72]
132.2 [5.2]
73 [2.87] 96.7 [3.81] System Pressure Ports (A & B) 105.1 max [4.14]
73 [2.87]
VIEW "X" (FRONT VIEW) BASE UNIT W/ MDC 85 [3.35] Case Drain Port L2
M41
Charge Pressure Relief Valve VIEW "W" (BOTTOM VIEW) BASE UNIT W/ MDC AND SUCTION FILTRATION
P100 423E
42
Series 42
mm [in]
19 T002 041E
"S" "U" "W" Pitch dia "Z" Teeth, 16/32 Pitch 30 Pressure Angle Fillet Root Side Fit ANSI B92.1-1970 Class 5 Also Mates with Flat Root Side Fit
"V"
141 [5.55] Servo Pressure Gauge Port M4 0.5625-18* Displacement Limiter - Side 1 Option 'A' or '1'
M4
Charge Pressure Gauge Port (Charge Pressure Supply for Filtration Option 'N') 0.750-16* Lifting Bracket System Pressure Check Relief Valve Port B
Coupling Must Not Protrude Beyond This Point SPLINED SHAFT CONFIGURATION (SEE TABLE) 70.4 [2.77] 43.4 [1.71]
55 [2.17]
37 [1.46]
A
Charge Inlet Port S 1.3125-12* System Pressure Check Relief Valve Port A
22.2 [0.87]
Taper 1:8 Per SAE J 501 Nominal 25.4mm Coupling Must Not Protrude Beyond This Point TAPERED SHAFT: OPTION K
219.17 [8.63] VIEW "V" (RIGHT SIDE VIEW) BASE UNIT W/ MDC AND SUCTION FILTRATION) 8 [0.32]
78 [3.07] 70 [2.75] 6.35 [0.250] Sq. Key x 43.9 [1.73] Lg 25.38 [0.999] Coupling Must Not Protrude Beyond This Point
P100 424E
*All SAE straight thread O-ring ports per SAE J1926, unless otherwise specified Shaft rotation is determined by viewing pump from input shaft end. Contact your Sauer-Sundstrand representative for specific installation drawings.
43
Series 42
mm [in]
"J" "G" To Filter Port D 7/814*
53.5 [2.11]
"Z"
16 [0.63]
From Filter Port E 7/814* Charge Pressure Gauge Port M3 Partial Filter Flow (Charge Relief Valve Before Filter) 9/1618*
"H" (2 Places) VIEW "Z" (FRONT VIEW) VARIABLE PUMP W/ PRESSURE FILTRATION
"F"
53.5 [2.11]
"Z"
16 [0.63]
"H" (2 Places) VIEW "Z" (FRONT VIEW) VARIABLE PUMP W/ PRESSURE FILTRATION
"F"
P100 425E
Dimensions
Frame Size 28 cm3 41 cm3 101.5 [4.00] 116 [4.57] 117.9 [4.64] 128.8 [5.07] T002 042E
F G H J
44
Series 42
mm [in]
"E"
"U"
Displacement Limiter #2 Displacement Limiter #1
"E"
"B" VIEW "U" (LEFT SIDE VIEW) VARIABLE PUMP W/ DISPLACEMENT LIMITER VIEW "V" (RIGHT SIDE VIEW) VARIABLE PUMP W/ DISPLACEMENT LIMITER
"V"
TOP VIEW VARIABLE PUMP W/ DISPLACEMENT LIMITERS
Dimension
Optional Adjustable Displacement Limiters Shaft Rotation Displacement Limiter# Limits Flow Out Port 1 B CW 2 A 1 A CCW 2 B
A B C D E
69 [2.72]
120.1 max 127.8 max [4.73] [5.03] 107.1 max 105.1 max [4.22] [4.14] 144.5 max 159.6 max [5.69] [6.28] 30.6 [1.20] 33.6 [1.32] T002 043E
"D"
T000 075E
TOP VIEW VARIABLE PUMP W/ NFPH OR NFPE CONTROL AND DISPLACEMENT LIMITERS
P100 426E
*All SAE straight thread O-ring ports per SAE J1926, unless otherwise specified Shaft rotation is determined by viewing pump from input shaft end. Contact your Sauer-Sundstrand representative for specific installation drawings.
45
Series 42
mm [in]
A B C D
Sauer-Sundstrand Mating Parts Kit Part No. K03379 (Male Terminals)
"SH"
Sauer-Sundstrand Mating Parts Kit Part No. K14956 or Ident. No. 500724 (straight) Part No. K14957 or Ident. No. 500725 (right angle)
41 cm3
T002 044E
"SM"
P100 427E
46
Series 42
"P" Pitch dia 30 Pressure Angle "N" Teeth, 16/32 Pitch Fillet Root Side Fit per ANSI B92.1-1970 Class 5 (See Table)
mm [in]
106.4 [4.19]
O-Ring Seal Required Ref: 82.27 [3.239] I.D. x 1.78 [0.070] Cross Section 10.97 [0.43] min Coupling Clearance 38.0 [1.50] min Shaft Clearance
REAR VIEW
"A"
P100 428E
73.03 [2.875]
"P" Pitch dia 30 Pressure Angle "N" Teeth, 16/32 Pitch Fillet Root Side Fit per ANSI B92.1-1970 Class 5 (See Table)
73.03 [2.875] 146 [5.75] 101.69 dia [4.004] 107.82 dia [4.245] 87.03 [3.426] (3) Places
146 [5.75]
O-Ring Seal Required Ref: 101.32 [3.989] I.D. x 1.78 [0.070] Cross Section 18.87 [0.743] min Coupling Clearance 46.0 [1.81] min Shaft Clearance
REAR VIEW
"A"
P100 429E
*All SAE straight thread O-ring ports per SAE J1926, unless otherwise specified Shaft rotation is determined by viewing pump from input shaft end. Contact your Sauer-Sundstrand representative for specific installation drawings.
47
Series 42
mm [in]
Sauer-Sundstrand Mating Parts Kit Part No. K09129 Ident. No. 514117
"MC"
M4
"V"
"MS" See View "S" Option A-H Electric Neutral Override and Brake Release Option 1,2 Option 3-6 Neutral Start Switch Neutral Start Switch And Backup Alarm 165 Ref [6.5] Wire Length "MN" Mounting Flange
85.4 [3.36] Spot Face 50.8 Depth [2.00] 832 Machine Screws
"T" "U"
TOP VIEW VARIABLE PUMP W/ DISPLACEMENT LIMITERS
Neutral Start Switch With No Connector (Screw Terminals) Sauer-Sundstrand Mating Parts Kit Part No. K03377 (Male Terminals)
A B
Manual Displacement Control Frame Size 28 cm3 41 cm3 MB 177.4 (6.98) 187.4 (7.38) MC 127.2 (5.01) 144.2 (5.68) MH 169.4 (6.67) 186.4 (7.34) MN 175.4 (6.91) 185.4 (7.30) MS 192.7 (7.58) 202.7 (7.98) MX 94.3 (3.71) 104.3 (4.11) MY 152.8 (6.02) 162.8 (6.41)
T002 046E
A B C D
Packard Weather-Pack 4-Way Tower Connector (Female Terminals) VIEW "T" NEUTRAL START SWITCH CONNECTORS
26.4 rad [1.04] Max Travel Max Displacement 15 Nm max [11 ftlbf] max
33 28
CCW
Neutral
28 33
CW
Max Displacement Max Travel 8.26 dia [0.325] Option 2: Clevis Handle
CW
Max Displacement Max Travel
41 cm3
Pump C L
P100 431E
48
Series 42
mm [in]
Sauer-Sundstrand Mating Parts Kit Part No. K03383 (Female Terminals)
"EJ"
"EC"
Packard Weather-Pack 4-Way Conector (Male Terminal) Sauer-Sundstrand Mating Parts Kit No. K08106 Ident. No. 615061
99.7 [3.93]
D C
A B
"EL"
"S"
"V"
TOP VIEW VARIABLE PUMP W/ EDC MS CONNECTOR
P100 432E
"NF"
Frame Size 28 cm
3
"V"
TOP VIEW VARIABLE PUMP W/ NFPH CONTROL
*All SAE straight thread O-ring ports per SAE J1926, unless otherwise specified Shaft rotation is determined by viewing pump from input shaft end. Contact your Sauer-Sundstrand representative for specific installation drawings.
49
Series 42
mm [in]
"S"
"TH" A B Sauer-Sundstrand Mating Parts Kit Part No. K09129 Ident. No. 514117
52 [2.05]
108.75 [4.28]
A B
"U"
TOP VIEW VARIABLE PUMP W/ FNR CONTROL
Sauer-Sundstrand Mating Parts Kit No. K19815 Ident. No. 508388 (Female Terminal)
3-Position (FNR) Control Frame Size 28 cm3 41 cm3 "TP" 130.5 [5.14] 138.2 [5.44] "TH" 162 [6.38] 179.6 [7.07] "TJ" 135.3 [5.33] 152.9 [6.02] T002 049E
AMP Junior Power Timer* 2 Pin Connector (Male Terminal) VIEW "S" FNR CONNECTORS * Special temperature requirements, see your SauerSundstrand representative when considering this option
P100 434E
A Sauer-Sundstrand Mating Parts Kit No. K19815 Ident. No. 508388 (Female Terminal)
101.5 [4.00]
"PH"
AMP Junior Power Timer 2 Pin Connector (Male Terminal) VIEW "S" NFPE CONNECTOR
101.5 [4.00]
"S"
"U"
VIEW "U" (LEFT SIDE VIEW)
P100 435E
Manifold Height Frame Size 28 cm3 41 cm3 "PH" 162.3 [6.39] 179.3 [7.06] T002 050E
50
Series 42
Remote Pressure Filtration Remote Pressure Filtration (Partial Flow) (Full Flow) E M3 D E M3 D
M3
PCP
M8
L1 No Relief Valve
M4 M5
P100 436E
NFPH
X2 X1
M3
L1 No Relief Valve
M4 M5
P100 437E
51