Series 45

Frame F
Open Circuit
Axial Piston Pumps
Repair Instructions
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
2006 Sauer-Danfoss. All rights reserved. Printed in U.S.A.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations arent in confict with agreed specifcations. 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: F101 464, F101 385, F101 186, P104 359
OrganizatiOn and
headings
To help you quickly fnd information in this manual, the material is divided into sections,
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taBLes, iLLustratiOns,
and COmPLementary
inFOrmatiOn
sPeCiaL text
FOrmatting
taBLe OF COntents
Using this manual
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Contents
intrOduCtiOn
disassemBLy
insPeCtiOn
Overview ........................................................................................................................................................... 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
Auxiliary pad .................................................................................................................................................... 8
Detach control ................................................................................................................................................. 8
Displacement limiter ..................................................................................................................................... 9
Endcap................................................................................................................................................................ 9
Cylinder kit .....................................................................................................................................................10
Input shaft, swashplate, and pistons......................................................................................................10
Journal bearings, and roller bearing ......................................................................................................11
Shaft seal ........................................................................................................................................................11
Control disassembly ....................................................................................................................................12
PC only ........................................................................................................................................................12
PC / LS .........................................................................................................................................................12
Cylinder kit ......................................................................................................................................................13
Disassemble the cylinder block kit ...................................................................................................13
Block spring removal .............................................................................................................................13
Overview .........................................................................................................................................................14
Pistons and slippers .....................................................................................................................................14
Ball guide, slipper retainer, and hold-down pins ...............................................................................14
Block spring, and washers .........................................................................................................................15
Cylinder block ...............................................................................................................................................15
Control ..............................................................................................................................................................16
Shaft .................................................................................................................................................................16
Swashplate ......................................................................................................................................................17
Journal bearings ...........................................................................................................................................17
Valve plate .......................................................................................................................................................18
Endcap..............................................................................................................................................................18
Shaft bearing kits .........................................................................................................................................19
Servo piston ...................................................................................................................................................19
Bias piston .......................................................................................................................................................19
Housing ...........................................................................................................................................................20
Auxiliary pad ..................................................................................................................................................20
Displacement limiter ...................................................................................................................................20
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Contents
assemBLy Journal bearing ............................................................................................................................................21
Front bearing and swashplate ................................................................................................................21
Input shaft .......................................................................................................................................................21
Cylinder kit assembly ..................................................................................................................................22
Cylinder kit installation ..............................................................................................................................22
Valve plate and endcap .............................................................................................................................23
Endcap..............................................................................................................................................................23
Shaft seal .........................................................................................................................................................24
PC control ........................................................................................................................................................24
LS control (optional) ....................................................................................................................................25
Auxiliary pad ..................................................................................................................................................26
Displacement limiter ...................................................................................................................................27
Attach the control ........................................................................................................................................27
Pump adjustment ........................................................................................................................................27
5 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Introduction
Overview This manual details the major repair procedures for Frame F pumps. These include the
complete disassembly, inspection, and reassembly of the unit. Where rework of worn
or damaged components is possible, this manual gives specifcations to ensure these
parts meet factory tolerances. Only Sauer-Danfoss Global Service Partners are authorized
to perform major repairs. The factory trains Sauer-Danfoss Global Service Partners to
perform major repairs and certifes their facilities on a regular basis.
A Warning
Use of components that do not comply with rework specifcations may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that dont
comply to given specifcations: replace with genuine Sauer-Danfoss service parts.
Series 45 Frame F Axial Piston Pump Service Manual 11005158 gives minor repair
procedures, adjustments, and troubleshooting information. Minor repairs include service
operations that you can perform without removing the units endcap. Removal of the
endcap voids your warranty.
Follow these general procedures when repairing Series 45 variable displacement open
circuit pumps.
@ Remove the unit
Prior to performing major 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 fuid may be under high pressure and/or hot. Inspect the outside of the pump
and fttings for damage. Cap hoses after removal to prevent contamination.
_ 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 materials 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.
_ Lubricate moving parts
During assembly, coat all moving parts with a flm of clean hydraulic oil. This assures that
these parts will be lubricated during start-up.
_ Replace all O-Rings and gaskets
We recommend you replace all O-rings, seals, and gaskets. Lightly lubricate all O-rings
with clean petroleum jelly prior to assembly.
_ Secure the unit
For major repair, place the unit in a stable position with the shaft pointing downward. It
is necessary to secure the pump while removing and torquing the endcap bolts.
generaL instruCtiOns
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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
A 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
A warning
Some cleaning solvents are fammable. To avoid possible fre, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure
A warning
Escaping hydraulic fuid under pressure can have suffcient force to penetrate your skin
causing serious injury and/or infection. This fuid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fuid under pressure. Relieve pressure in the
system before removing hoses, fttings, 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 fuid.
Personal safety
A warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Introduction
@ WARNING may result in injury
@ CAUTION may result in damage to
product or property
_ Reusable part
_ Non-reusable part, use a new part
_ Non-removable item
_ Option either part may exist
_ Superseded parts are not
interchangeable
_ Measurement required
_ Flatness specifcation
_ Parallelism specifcation
_ External hex head
_ Internal hex head
_ Torx head
_ O-ring boss port
_ Tip, helpful suggestion
_ Lubricate with hydraulic fuid
_ Apply grease / petroleum jelly
_ Apply locking compound
_ Inspect for wear or damage
_ Clean area or part
_ Be careful not to scratch or damage
_ Note correct orientation
_ Mark orientation for reinstallation
_ Torque specifcation
_ Press in press ft
_ Pull out with tool press ft
_ Cover splines with installation
sleeve
_ Pressure measurement / gauge
location or specifcation
symBOLs used in
sauer-danFOss
Literature
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 defnes each symbol and explains its purpose.
8 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
auxiLiary Pad If a second pump is used, you must
remove it. You dont need to remove
auxiliary pads to remove the end cap.
1. Remove the cover plate screws
(J130) and the cover plate (J110). If
you have auxiliary A pad, use a
9
/16
inch hex wrench; use a inch hex
wrench for auxiliary B or C pad.
2. Remove the coupling (J140) and the
pad seal (J120).
3. Remove the auxiliary pad screws
(J100) with a 10 mm internal
hex wrench, and remove the
adapter (J080).
4. Remove and discard the O-rings
(J090), and (J095).
J130
J110
J140
J080
J100
10 mm
J090
J120
E101 457E
J095
Remove auxiliary pad
detaCh COntrOL 1. Remove the control from the endcap
by removing the 4 control bolts
(C300), using a 4 mm internal hex
wrench.
2. Remove and discard the 4 interface
O-rings (C200).
Remove control
C300
4 mm
C200
E101 230
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
endCaP
disPLaCement Limiter
1. Remove the 4 endcap screws (J030)
using a 10 mm internal hex wrench.
2. Carefully remove the endcap (J020).
The valve plate (B090) may adhere to
the endcap. Ensure it does not fall off
and become scratched or damaged.
3. Place the endcap and valve plate in
a clean area, protecting them from
contamination.
4. Remove the housing O-ring (K060)
and discard.
5. Remove the shaft bearing cone
(B020) from the shaft. The cup (B010)
will likely remain in the end cap;
remove it using a bearing puller if
necessary.
J030
B090
10 mm
J020
K060
B010
B020
E101 232
Remove endcap and components
3. Remove the adjustment seal/nut
(L030A) with a
7
/8 inch wrench.
The L030 adjustment seal/nut serves as
a locking seal/nut, preventing the L040
screw from backing out.
4. Remove the adjustment screw (L040)
with a 1/4 in. internal hex wrench.
Remove plug (L010) with a 7/8 in.
wrench. Discard the O-ring (L010A).
L030A
L010
L010A
L040
E101 231
1/4 in
7/8 in
7/8 in
Remove displacement limiter
10 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
CyLinder kit
Caution
Take care that the top and
bottom of the kit do not
become contaminated or
scratched: this may lead
to poor performance or
pump failure.
P010
E101 233
Remove cylinder block kit 1. Set the pump on its side.
2. Remove the cylinder block kit (P010)
while holding onto the front of the
shaft.
3. Set cylinder block on a clean dry
surface.
Remove shaft, swashplate, and pistons
J010
P020
B080
B043
B043
B044
B025
B044
E101 234
B040
inPut shaFt,
swashPLate, and
PistOns
1. Rotate pump with the shaft pointing
down.
2. Pull the shaft (J010) from the shaft
seal.
3. Lift the swashplate/piston assembly
up and remove it from the
housing. Note the orientation for
reinstallation.
Reinstall swashplate in its original
orientation to reduce wear.
4. Remove the servo piston (P020), bias
spring (B025), and the bias piston
(B080) from the swashplate by
removing the clevis pins (B043) and
snap rings (B044).
11 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
shaFt seaL
JOurnaL Bearings,
and rOLLer Bearing
B070
B071
B060
E101 235
B030
Remove bearings 1. Remove the journal bearings (B030)
and, if necessary, remove the pins
(B071).
2. Remove the roller bearing cone
(B070) and cup (B060). You may
need to remove the shaft seal before
removing the cup.
1. Orient the housing shaft side up.
2. Remove the retaining-ring (K010)
using internal retaining ring pliers.
3. Remove the shaft seal (K020).
Replace the shaft seal every time the
shaft is removed from the unit.
Remove shaft seal
E101 236
K020
K010
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
COntrOL disassemBLy PC only
1. Remove the plug (C103) and O-ring
(C103A). Discard the O-ring. Remove
set screw (C102) with a 4 mm
internal hex wrench. Tilt control or
use a small magnet to remove the
spool (C132). Note the orientation of
the spool for reinsertion. There may
be differences in reinserting into the
same bore.
2. Remove the adjusting screw (C138)
with a 1/4 in. internal hex wrench.
Remove and discard O-ring (C138A).
Remove the springs (C134, C135)
along with the spring guide (C133).
PC / Ls
1. Using a
3
/16 inch internal hex wrench,
remove the 4 plugs (C103, C104,
C105, and C106) and their O-rings.
Discard the O-rings. Using a 4 mm
internal hex wrench, remove the 2
set screws (C102). Remove the spool
(C112). Note the orientation of the
spools for reassembly. There may be
differences in reinserting into the
same bore. Remove the spool (C132).
2. Using a 1/4 inch internal hex wrench,
remove the adjusting screw (C138)
and the O-ring (C138A). Discard the
O-ring. Remove the springs (C134,
C135) and spring guide (C133).
3. Using a 1/4 inch internal hex wrench,
remove the adjusting screw (C118),
O-ring (C118) and 2 backup rings
(C118B). Discard the O-ring and
backup rings. Remove the springs
(C114, C115) and spring guide (C113).
C200
C103
E101 237
C132
C138A
C138
C134
C135
C133
C102
C103A 3/16 in
1/4 in
4 mm
Disassemble the PC control
E101 458E
C112
C103A
C103
C132
C104A
C104
C106A
C106
C200
C105A C105
C102
C113
C115
C114
C118B
C118A
C133
C135
C134
C138A
C138
C118B
C118
3/16 in
1/4 in
1/4 in
4 mm
3/16 in
Disassemble the PC / LS control
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
CyLinder kit disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(P049) with the pistons (P050) from
the cylinder kit.
The pistons are not selectively ftted,
however units with high hourly usage
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
2. Remove the ball guide (P047).
3. Remove the 3 pins (P046).
Most repairs do not require block spring
removal. Perform this procedure only
if you suspect problems with the block
spring.
Block spring removal
4. Turn the block over with the running
sueface pointing up. Using a press,
apply pressure on the block spring
washer (P044) to compress the
block spring (P043). Compress the
spring A enough to safely remove
the spiral retaining ring (P045).
While maintaining pressure, unwind
the spiral retaining ring. Carefully
release the pressure and remove the
outer block spring washer (P044),
block spring, and inner block spring
washer (P042) from the cylinder
block.
E101 239
P050
P041
P049
P047
P046
P042
P043
P044
P045
Disassemble the cylinder block kit
A Warning
Risk of personal injury:
Compressing the block
spring requires a force
of about 350 to 400 N
[80 to 90 lbf ]. Use a press
suffcient to maintain this
force with reasonable
effort. Ensure the spring is
secure before attempting
to remove the spiral
retaining ring. Release the
pressure slowly after the
retaining ring is removed.
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
BaLL guide, sLiPPer
retainer, and hOLd-
dOwn Pins
Overview
PistOns and sLiPPers
After disassembly, wash all parts (including the end-cap and housing) thoroughly with
clean solvent and allow to air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.
Slipper
retainer
Ball guide
Hold down pins
P101 471
The ball guide should be free of
nicks and scratches, and should not
be excessively scored. Examine for
discoloration that may indicate excessive
heat or lack of lubrication. The slipper
retainer should be fat, and slippers
should ft in the retainer with minimal
side play. Place the hold-down pins on a
fat surface and roll them to make sure
they are straight. Discard and replace any
damaged parts.
F Frame
Slipperfoot thickness (min) 4.41 mm
[0.174 in]
Piston/slipper end play (max) 0.05 mm
[0.002 in]
Inspect guide, retainer, and pins
Inspect the pistons for damage and
discoloration. Discolored pistons may
indicate excessive heat; do not reuse.
Inspect the running surface of the
slippers. Replace any piston assemblies
with scored or excessively rounded
slipper edges. Measure the slipper foot
thickness. Replace any piston assemblies
with excessively worn slippers. Check the
slipper axial end-play. Replace any piston
assemblies with excessive end-play.
Minimum slipper foot thickness and
maximum axial end-play are given in the
table to the right.
C103
Slipper
Maximum end play
M inimum
slipper fo ot
thick ness
P104 109E
Inspect pistons
15 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
BLOCk sPring and
washers
CyLinder BLOCk
Washer
Cylinder block spring
Spring retainer
Retaining ring
P101 472
If cylinder kit was fully disassembled,
visual inspection of the cylinder block,
spring, and washers should indicate
minimal wear. Replace if cracks or other
damage is present.
Inspect block spring and washers
Examine the running face of the cylinder block. The surface should be smooth and free
of nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce
output fow. If necessary, you may resurface the cylinder block as long as the minimum
height and fatness specifcations can be maintained.
K041
A
flat to 0.002 mm
[0.000079 in]
P101 067E
B
check for burrs,
nicks, and scratches
Frame F
Minimum cylinder
block height (A)
68.88 mm
[2.712 in]
74cc Maximum block
bore diameter (B)
21.56 mm
[0.849 in]
90cc Maximum block
bore diameter (B)
22.74 mm
[0.895 in]
Inspect cylinder block
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
shaFt
COntrOL Carefully examine the PC (and LS) plug(s) for signs of wear. Also check the small tip of the
plug(s) for heavy wear and replace if necessary. Check the inside and outside surfaces
of the springs for wear and replace if necessary. Check the spools outside diameter for
scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
hydraulic oil.
C200
C103
E101 240
C138A
C138
C134
C135
C133
C102
C103A
C132
E101 241
C112
C103A
C103
C132
C104A
C104
C106A
C106
C200
C105A
C105
C102
C113
C115
C114
C118B
C118A
C133
C135
C134
C138A
C118B
C118
C138

Inspect the PC control Inspect the PC/LS control
Check to see that the shaft (J010) and its
splines are straight and free of damage
or heavy wear. Inspect the shaft seal
journal. Replace the shaft if a groove
exists at the sealing land surface that
may let dirt into or hydraulic fuid out
of the unit. Clean the sealing area with
a nonabrasive material if necessary.
Lubricate the shaft with a light coat of
hydraulic fuid.
J010
E101 242
Inspect shaft
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
swashPLate
JOurnaL Bearings
E101 243
Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect
the swashplates slipper running
surface for fatness and brass transfer.
Excessive brass transfer from slippers
may indicate that the slippers should be
replaced. Finally, check the swashplate
bearing journals for scratches. Replace
swashplate if necessary.
Inspect swashplate
P104 335
Inspect journal bearings Inspect the journal bearings for
damage or excessive wear. Replace
journal bearings if scratched, warped, or
excessively worn. The polymer wear layer
must be smooth and intact.
Frame F
Flatness 0.0025 mm
[0.001 in]
Parallelism 0.0635 mm
[0.0025 in]
18 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
endCaP
J050
B010
E101 244
J020
Inspect the endcap (J020). Check the
timing pin (J050). Carefully check the
bearing cup (B010) for wear, and ensure
that it fts tightly.
Inspect endcap and components
Inspect the valve plate for scratches and grooves. Check the plate for evidence of
any cavitation along the running face of the valve plate. If pitting from cavitation
exists, replace the valve plate. Check for excess wear on the brass running face. If any
discoloration or burn marks exist, replace the valve plate.
Run a fngernail or pencil tip across the diameter of the sealing land surface (see
illustration). No deep or outstanding grooves should be felt, as these may decrease pump
fow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the
endcap and valve plate for any possible contamination; even a few thousandths of an
inch may affect pump operation. Ensure the minimum thickness, fatness, and parallelism
specifcations are met after rework.
Measure the thickness of the valve plate. Ensure that valve plate parallelism is equal
to or less than 0.025 mm [0.001 in]. Appearance should be fat and smooth on both
the running face and the bottom surface. The valve plate should be fat to 0.0038 mm
[0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks.
Replace the valve plate if any cracks exist.
vaLve PLate
Inspect valve plate
B090
4.95 mm [0.195 in] min.
0.025 mm
[0.001 in]
0.0038 mm
[0.00015 in]
convex max
P104 363E
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
shaFt Bearing kits
Bias PistOn
The tapered roller bearing kit consists
of a cup and cone. Make sure the cup
and cone are free of excessive wear or
contamination. Rotate the bearings to
check for smoothness. If a contaminated
bearing is suspected, clean with a solvent
and lubricate with hydraulic fuid.
Replace the bearing if cleaning does not
remedy the problem.
Inspect for uneven wear. If abnormal
wear is found, replace the bearing kit.
E101 182
Inspect shaft bearings
P020
E101 245
E101 246
B080
Inspect servo piston
Inspect bias piston
servO PistOn Check the servo piston (P020) for any
obvious wear or damage. Check the
corresponding endcap bore for galling
or excessive wear. Discard the piston if
damaged. Replace the servo piston-rings.
Check the bias piston (B080) for any
obvious wear or damage. Check the
corresponding endcap bore for galling
or excessive wear. Discard the piston if
damaged. Replace the bias piston-rings.
0 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection
hOusing
auxiLiary Pad
disPLaCement Limiter Inspect the displacement limiter screw
threads. Ensure that the screw is not
bent. Also, inspect the seal/nut for
irregular wear. Replace if necessary.
Replace the O-ring.
L010A
E101 249
L030A
L010
L040
Inspect displacement limiter
E101 247
Inspect the housing to ensure that it is
clean and free of foreign material. Inspect
the swashplate bearing surfaces, and
endcap mating surfaces.
Inspect housing
Inspect sealing surfaces on the endcap
and auxiliary pad, and make sure that
they are clean and free of contaminants.
Inspect the coupling (J140) for any signs
of excessive or abnormal wear. Replace
all O-rings. Replace excessively worn
parts if necessary.
J130
J110
J140
J080
J100
J090
J120
E101 248
J095
Inspect auxiliary pad components
1 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
JOurnaL Bearing
inPut shaFt
FrOnt Bearing and
swashPLate
1. Coat the journal bearings (B030) with
hydraulic fuid and install them into
the pump housing.
2. Punch in retaining pins (B071) to a
minimum of 0.5 mm [0.02 in] below
the bearing surface.
If journal bearings are reused, reinstall
them in their original orientation and
position.
1. Reinstall the front bearing kit. The
cup (B060) should be a slip ft with
the housing.
2. Using a clevis pin (B043) and snap
ring (B044) install the servo piston
(P020) and bias spring (B025) to one
end of the swashplate. Install the bias
piston (B080) to the other end.
Swashplate is symmetrical. Servo and
bias pistons may be installed in either
end of swashplate.
3. Coat the surfaces of the swashplate
(B040) with hydraulic fuid. Reinstall
the swashplate in its original
orientation. Lubricate the fat
face with hydraulic oil to prevent
premature wear during start-up.
Insert the input shaft (J010) through the
bearing into the housing.
J010
P020
B080
B043
B043
B044
B025
B044
E101 250
B040
B050
B060
B030
B071
Install housing components
Caution
Ensure clevis pins (B043)
are seated properly in
swashplate counterbores.
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
1. Coat all parts with hydraulic fuid
prior to reassembly.
2. Install the inner block spring washer
(P042), block spring (P043), and
outer washer (P044) into the cylinder
block. Using a press, compress the
block spring enough to expose the
retaining ring groove. Wind the spiral
retaining ring (P045) into the groove
in the cylinder block. A
3. Turn the block over and install the
hold-down pins (P046) and ball
guide (P047) to the cylinder block.
4. Install the pistons (P050) to the
slipper retainer (P049). Install the
piston/retainer assembly into the
cylinder block. Ensure the concave
surface of the retainer seats on
the ball guide. If youre reusing the
pistons, install them to the original
block bores. Lubricate the pistons,
slippers, retainer, and ball guide
before assembly. Set the cylinder kit
aside on a clean surface until needed.
E101 251
P050
P041
P049
P047
P046
P042
P043
P044
P045
P010
K030
Prevent shaft from rotating
Slightly rotate
cylinder block
E101 252
Assemble cylinder kit
Install cylinder block
CyLinder kit assemBLy
A Warning
Risk of personal injury:
Compressing the block
spring requires a force
of about 350 to 400 N
[80 to 90 lbf ]. Use a press
suffcient to maintain this
force with reasonable
effort. Ensure the spring is
secure before attempting
to install the spiral
retaining ring. Release the
pressure slowly after the
retaining ring is installed.
CyLinder kit
instaLLatiOn
Be sure to install the slipper retainer so
it mates correctly with the ball guide
(concave side of the slipper retainer
against the convex side of the ball guide).
1. Set the pump on its side. Secure the
end of the shaft with one hand and
keep it horizontal. Insert the cylinder
kit onto the shaft. While holding the
shaft still, slightly rotate the cylinder
block kit to help start it onto the
shaft splines over the ball guide and
align it with the block splines.
2. When the cylinder block kit slides
completely over the shaft splines,
reposition the unit with the front
fange facing downward.
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
vaLve PLate and
endCaP
1. Clean the valve plate (B090) and
endcap. Install the timing pin (J050)
in the endcap. The timing pin should
be 3.6 mm [.01 in] [0.25 mm
[0.001 in.] above the valve plate
surface.
2. Apply a liberal amount of assembly
grease to the backside of the valve
plate surface to hold it in position.
Install the valve plate over the timing
pin and bearing kit.
To insure proper pump operation, it is
extremely important to ensure that there
is no contamination between the endcap
and valve plate.
Install endcap components
B090
J050
Bearing kit
E101 253E
endCaP
J030
10 mm
J020
K060
E101 436
203 Nm [150 lbfft]
Install endcap and components 1. Lubricate O-Ring (K060) with
hydraulic fuid and install into
housing.
2. Install endcap (J020) with valve
plate and bearing assembly. Ensure
the valve plate does not slip during
assembly. Lower the endcap carefully
onto the servo and bias pistons and
ensure the pistons seat into the
bores in the endcap. Install endcap
screws (J030) using a 10 mm internal
hex wrench. Torque to 203 Nm
[150 lbfft].
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
shaFt seaL
K020
K010
E101 254
1. Cover shaft splines with an
installation sleeve to protect the seal.
Install a new shaft seal (K020) with
the cup side facing the pump.
2. Press seal into housing until it is
just below retaining ring groove.
Press evenly to avoid binding and
damaging the seal. Install snap ring
(K010).
Install shaft seal and retaining ring
Assemble PC (only) control 1. Clean and lubricate all control
parts and cover with a light coating
of clean hydraulic fuid prior to
reassembly.
2. Install the spherical end of the PC
spool (C132) into the PC bore (refer
to illustration). With a 3/16 internal
hex wrench, install the PC plug
(C103) using a new O-ring (C103A).
Torque to 12 Nm [9 lbfft]. Place the
two PC springs (C134, C135) onto the
PC spring guide (C133) and install
into the PC bore. Place a new O-ring
(C138A) onto the PC plug (C138)
and install it with a 1/4 internal hex
wrench so that it sits one turn below
the surface of the control housing.
Using a 4 mm internal hex wrench,
install set screw (C102). Torque to
9 Nm [7 lbfft].
PC COntrOL
C200
C103
E101 255
C138A
C138
C134
C135
C133
C102
C103A
C132
3/16 in
1/4 in
4 mm
12 Nm [9 lbfft]
9 Nm [7 lbfft]
5 50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
E101 238
C112
C103A
C103
C132
C104A
C104
C106A
C106
C200
C105A C105
C102
C113
C115
C114
C118B
C118A
C133
C135
C134
C138A
C138
C118B
C118
3/16 in
1/4 in
3/16 in
1/4 in
4 mm
12 Nm [9 lbfft]
12 Nm
[9 lbfft]
12 Nm
[9 lbfft]
9 Nm
[7 lbfft]
3/16 in
Assemble PC/LS control Install the PC portion as described in
PC control, page 24.
1. Hold the control in a horizontal
position. Install the spherical end of
the LS spool (C112) into the LS bore
(see illustration). Using a new O-ring,
install the LS plug (C104) with a
3/16 internal hex wrench, torque to
12 Nm [9 lbfft].
2. Place the 2 LS springs (C114, C115)
onto the LS spring guide (C113) and
install into the LS bore. Place a new
O-ring (C118A) and back-up rings
(C118B) onto the LS adjustment
screw (C118). Using a 1/4 internal hex
wrench, install the LS plug assembly
so that it sits one turn below the
surface of the control housing.
3. Install and tighten set screw (C102)
to 9 Nm [7 lbfft]. Also, install the
plugs (C105, C106) with new O-rings,
using a 3/16 internal hex wrench.
Torque the plugs to 12 Nm [9 lbfft].
Ls COntrOL (OPtiOnaL)
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
auxiLiary Pad
torque-to-turn shaft
13.5 to 24.4 Nm [120 to 216 lbfin]
1. Install the adapter (J080) with new
O-rings (J090) and (J095). Tighten the
screws (J100) to 27 Nm [20 lbfft]
with a 10 mm internal hex wrench.
2. Test torque-to-turn with the unit
assembled (excluding auxiliary
pumps) by rotating the input shaft
using a torque wrench.
Test the torque required to turn the shaft
(after break-away) with swashplate at
full angle and the assembly well oiled.
Readings outside the table values may
indicate internal problems. If necessary,
disassemble pump and check.
a pad J10 screws B and C pad J10 screws
37 to 50 Nm
[27 to 37 lbfft]
91 to 111 Nm
[67 to 82 lbfft]
4. Reinstall any other external
components, including the auxiliary
pump (if present), that were removed
before disassembly.
3. Reinstall the coupling (J140). Install
the auxiliary pad O-ring (J120) and
auxiliary pump or cover plate (J110).
Torque the screws (J130) to the
values in the table. For a pads, use
a
9
/16 inch hex wrench. For B and C
pads, use a inch hex wrench.
J130
J110
J140
J080
J100
10 mm
J090
J120
E101 229
J095
27 Nm
[20 lbfft]
Install the auxiliary pad
50L081 Rev AA Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
1. Install displacement limiter screw
(L040) into plug (L010).
2. Install new O-ring (L010A) onto plug
(L010). Thread plug with limiter into
endcap. Torque to 77 Nm [57 lbfft].
3. Turn adjustment / seal nut (L030A)
onto displacement limiter.
4. Using a
7
/8-inch wrench, torque
the adjustment seal/nut (L030) to
54 Nm [40 lbfft].
Refer to Frame F Service Manual
11005158 for instructions on adjusting
displacement limiter.
disPLaCement Limiter
4 mm
6 Nm
[5 lbfft]
C300
C200
E101 257
attaCh the COntrOL 1. Using petroleum jelly to retain them,
install 4 new seal rings (C200) in the
recesses on the control housing.
2. Install the control assembly onto the
endcap using the 4 screws (C300)
with a 4 mm internal hex wrench.
Torque to 6 Nm [5 lbfft] using a
criss cross pattern, and retorque the
frst screw to ensure proper torque
retention.
Install the control
L030A
L010
L010A
L040
E101 256
1/4 in
7/8 in
54 Nm [40 lbfft]
7/8 in
77 Nm [57 lbfft]
Install the displacement limiter
PumP adJustment 1. Install the pump on a test stand.
2. Adjust the pump according to specifcations shown in Series 45 Frame F Open Circuit
Axial Piston Pumps Service Manual 11005158.
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Phone: +1 515 239-6000
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DK-6430 Nordborg, Denmark
Phone: +45 7488 4444
Fax: +45 7488 4400
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Sannomiya Grand Bldg. 8F
2-2-21 Isogami-dori, Chuo-ku
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Phone: +81 78 231 5001
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Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0
Fax: +49 4321 871 122
www.sauer-danfoss.com
50L081 Rev AA Nov. 2006