© Blue Graphics Concept Sauer-Danfoss START-UP PROCEDURE PROPEL PUMP Instruction Sauer-Danfoss Belgium – T. Van Mossevelde

Know-How in Motion™ / Sauer-Danfoss 2 Example of propel setup EXAMPLE: H1-pump + H1-variable motor Reservoir screen 10 µm Charge pressure filter

Know-How in Motion™ / Sauer-Danfoss 3 Start-up procedure WARNING Unintended movement of machine or mechanism may cause injury to technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.  Prior to installing the units, check for shipping damage  Ensure that the hydraulic fluid and system components (reservoir, hoses, valves and valve blocks, fittings, heat exchanger,... ) are clean and free of contamination.  Install the different components  Add a measuring point (minimess) or bar gauge on the charge pressure port. (monitor charge pressure)  Check if line fittings are tightened properly  Do not connect input signal to servo control of pump A) Preparation and installation

Know-How in Motion™ / Sauer-Danfoss 4 Start-up procedure  Mount connection for external filling pump on: Integral charge pressure filtration: on point before filter (see schematic) No charge pressure filtration: on measuring point M3 (pressure charge pump)  Hydraulic filling group (flow 1 to 20 l/min) must have a relief valve that is set to bar. This group must have a fine pressure filtration ! The charge pressure relief valve in the pump is set between 20 and 30 bar. Filling of pumpcase will be ensured because oil will be directed to case when the pressure of filling pump exceeds the charge pressure setting.  Start filling hydraulic circuit with clean and filtered oil untill oil is visible through level glass in hydraulic tank. When high pressure system is filled, pressure from external pump will rise to level set at charge pressure relief valve in propel pump. The pump case will be filled, followed by the drain line to cooler to tank...  If present, repeat this step for other propel circuits untill oil level in tank is starting to rise. B) Filling of hydraulic system with external pump (preferred method !!)

Know-How in Motion™ / Sauer-Danfoss 5 Start-up procedure B) Filling with external pump – charge pressure filter mounted Charge pressure relief valve – filling oil to case and to tank when high pressure system is filled

Know-How in Motion™ / Sauer-Danfoss 6 Start-up procedure  Fill housings of pumps and motors by adding filtered oil in the upper case drain ports.  Open the case plug on top of pump (or plug on highest position of pump) to assist with air bleed.  continue filling untill oil is present  Fill hydraulic reservoir completely with clean oil of recommended type and viscosity.  After some time, the oil level will lower due to gravity  Loosen suction line of charge pump to check if oil present.  if not, fill suction line completely or make sure that oil is coming to avoid cavitation at inlet port of charge pump ! C) Filling of hydraulic system via hydraulic tank

Know-How in Motion™ / Sauer-Danfoss 7 Start-up procedure  Use a common method to disable the engine to prevent the engine from starting.  Preferably: disconnect electrical connector (if present) from controller of diesel engine. In some cases, it is possible to actuate the diesel engine start motor without starting the diesel engine. The pumps are rotated by start motor movement.  Crank the starter for several seconds (do not exceed recommendation of engine manufacturer)  Wait for a minute (cool down start motor) and crank the engine a second time  this operation helps remove air from system lines  Keep an eye on reservoir level  refill untill recommended level D) Starting diesel engine with start motor

Know-How in Motion™ / Sauer-Danfoss 8 Start-up procedure  Continue previous steps untill charge pressure on pump (or all propel pumps if present) reaches 3,5 bar.  Start diesel engine and let it run at idle speed for at least 30 seconds  work air out of system  When required charge pressure is reached at all pumps (20-30 bar), increase engine speed to normal operation rpm.  residual air out of system  Shut off the engine and connect control signal E) Starting diesel engine

Know-How in Motion™ / Sauer-Danfoss 9 Start-up procedure  Start engine and check to be sure that the pumps remain in neutral position  Increase engine speed to normal rpm and carefully check forward and reverse control  Continue to cycle between forward and reverse for at least 5 minutes  purge air from system  Check if reservoir level is at required level  The system is now ready for operation F) Initial movement of machine

Know-How in Motion™ / Sauer-Danfoss 10 Start-up procedure  Air entrapment in fluid under high pressure may damage hydraulic components  cavitation  Do not run at maximum pressure until system is completely free of air and fluid has been filtered thorougly  Always ensure recommended fluid supply, as this may damage hydraulic components when insufficient.  In case of contamination, immediatly stop working and build off all affected components to check internal damage. Flushing of complete system is necessary, oil samples need to be checked when same oil is used after flushing the system. Warnings

© Blue Graphics Concept Sauer-Danfoss START-UP PROCEDURE OPEN CIRCUIT PUMP Instruction LS/PC pumps Series 45 Sauer-Danfoss Belgium – T. Van Mossevelde

Know-How in Motion™ / Sauer-Danfoss 12 Start-up procedure Series 45-pump WARNING Unintended movement of machine or mechanism may cause injury to technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.  Prior to installing the units, check for shipping damage  Ensure that the hydraulic fluid and system components (reservoir, hoses, valves and valve blocks, fittings, heat exchanger,... ) are clean and free of contamination.  Install the components  Add a measuring point (minimess) in suction line (as close as possible to pump inlet) and on case of pump (see schematic)  Check if line fittings are tightened properly A) Preparation and installation

Know-How in Motion™ / Sauer-Danfoss 13 Start-up procedure Series 45-pump B) Schematic example S45 LS pump + PVG32 valve Reservoir screen 125 µm Return line filter + cooler Reservoir: Minimum oil level should be higher than the suction inlet port of the open circuit pump Drain line of pump case directly to tank, mounted on top of reservoir submerged under oil level

Know-How in Motion™ / Sauer-Danfoss 14 Start-up procedure Series 45-pump  Pump installation position recommended under minimum oil level  maintain low inlet pressure at all times  Suction line: short distance without corners if possible. Check fluid line speed for dimensioning diameter of suction line  Filtration  Suction filtration: 125 µm (150 mesh) screen Do not use a suction filter element !  high pump inlet pressure  Return line of open circuit must be filtered: β 10 = 10  See manual with id 520L0467 for more info about filtration  Oil fluid cleanliness: ISO class 22/18/13 or better  Case drain line of pump case must be connected directly to tank, whitout a filter, under the minimum oil level. Position must be as far away as possible from pump suction line ! Use highest case drain connection (L1 or L2) of pump  Oil capacity of reservoir for open circuit: 1x to 3x pump volume C) Installation guidelines

Know-How in Motion™ / Sauer-Danfoss 15 Start-up procedure Series 45-pump  Inlet pressure  Minimum continuous working: 0,8 bar absolute / - 0,2 bar  Minimum at cold start: 0,5 bar absolute / - 0,5 bar  Case pressure  Maximum continuous working: 0,5 bar above inlet  Intermittent (cold start): 2 bar above inlet D) Operation parameters  Difference between case pressure and suction pressure must be within specification at all times  Damage of pump when this condition is not fulfilled !  See catalogue: TI Series 45

Know-How in Motion™ / Sauer-Danfoss 16 Start-up procedure Series 45-pump  Fill pump housing with clean oil at highest case drain port  Fill suction line completely with oil  Fill oil tank to suffient level  Check if suction line is bleeding to make sure that the oil is present at the inlet port when loosening the inlet connection.  Loosen plug at highest point to purge air from system  Use a common method to disable the engine to prevent the engine from starting.  Keep an eye on reservoir level  refill untill recommended level  The oil level will lower due to the filling of the open circuit functions (valve blocks,...) E) Start-up guidelines

Know-How in Motion™ / Sauer-Danfoss 17 Start-up procedure Series 45-pump  Start diesel engine and let the diesel engine run at idle speed for a couple of minutes whitout actuating open circuit functions  purge air from system  Check difference between pump case pressure and suction pressure (See section D)  In case of LS-system: purge air from LS-signal line by actuating one work function that is not building up pressure untill LS-signal line is filled completely with oil.  If pressures are correct at cold start, increase engine speed to normal rpm and carefully check all open circuit functions:  Check for abnormal noise when high flow is delivered (avoid cavitation,...)  Check case pressure and suction pressure  Suction pressure will drop when higher flow is requested !  specification  When these tests are ok, the pump is ready for operation E) Start-up guidelines