Series 45

G Frame
Open Circuit
Axial Piston Pumps
Repair Manual
2 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
2004 Sauer-Danfoss. All rights reserved. Printed in U.S.A.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations arent in conict with agreed specications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Front cover illustrations: F101 522, F101 523, F101 521, P104 467
ORGANIZATION AND
HEADINGS
To help you quickly nd information in this manual, the material is divided into sections,
topics, subtopics, and details, with descriptive headings set in red type. Section titles
appear at the top of every page in large red type. Topic headings appear in the left
hand column in BOLD RED CAPITAL LETTERS. Subtopic headings appear in the body
text in bold red type and detail headings in italic red type.
References (example: See Topic xyz, page XX) to sections, headings, or other publications are
also formatted in red italic type. In Portable Document Format (PDF) les, these references
represent clickable hyperlinks that jump to the corresponding document pages.
Tables, illustrations, and graphics in this manual are identied by titles set in blue italic
type above each item. Complementary information such as notes, captions, and drawing
annotations are also set in blue type.
References (example: See Illustration abc, page YY) to tables, illustrations, and graphics
are also formatted in blue italic type. In PDF les, these references represent clickable
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Dened terms and acronyms are set in bold black type in the text that denes or
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in the TOC set in blue type. In the PDF version of this document, the TOC entries are
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TABLES, ILLUSTRATIONS,
AND COMPLEMENTARY
INFORMATION
SPECIAL TEXT
FORMATTING
TABLE OF CONTENTS
Using this manual
3 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
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 ................................................................................................................................................. 9
Endcap ............................................................................................................................................................... 9
Cylinder kit ......................................................................................................................................................10
Bias piston, servo piston, and optional displacement limiter .......................................................10
Input shaft, and swashplate ......................................................................................................................11
Journal bearing and roller bearing ........................................................................................................11
Shaft seal .........................................................................................................................................................12
Control disassembly ....................................................................................................................................13
PC only ........................................................................................................................................................13
PC / LS .........................................................................................................................................................13
Cylinder kit ......................................................................................................................................................14
Disassemble the cylinder block kit ...................................................................................................14
Block spring removal .............................................................................................................................14
Overview .........................................................................................................................................................15
Pistons and slippers .....................................................................................................................................15
Ball guide, slipper .........................................................................................................................................15
Retainer, and hold-down pins ..................................................................................................................15
Block spring, and washers .........................................................................................................................16
Cylinder block ...............................................................................................................................................16
Control ..............................................................................................................................................................17
Shaft .................................................................................................................................................................17
Swashplate ......................................................................................................................................................18
Journal bearings ...........................................................................................................................................18
Servo piston and displacement limiter ................................................................................................18
Bias piston .......................................................................................................................................................18
Valve plate .......................................................................................................................................................19
Endcap .............................................................................................................................................................19
Shaft bearing kits .........................................................................................................................................20
Housing ...........................................................................................................................................................20
Auxiliary pad ..................................................................................................................................................21
DISASSEMBLY
INSPECTION
INTRODUCTION
4 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
Journal bearing ............................................................................................................................................22
Front bearing and swashplate ................................................................................................................22
Input shaft .......................................................................................................................................................22
Servo and bias pistons and displacement limiter ............................................................................23
Cylinder kit assembly ..................................................................................................................................24
Cylinder kit installation ..............................................................................................................................24
Valve plate .......................................................................................................................................................25
Endcap .............................................................................................................................................................25
Shaft seal .........................................................................................................................................................26
PC control ........................................................................................................................................................27
LS control (optional) ....................................................................................................................................27
Auxiliary pad ..................................................................................................................................................28
Reattach the control ....................................................................................................................................29
ASSEMBLY
5 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
OVERVIEW This manual details the major repair procedures for Series 45 Frame G open circuit axial
piston pumps. These include the complete disassembly, inspection, and reassembly of
the unit. Where rework of worn or damaged components is possible, specications are
given to ensure these parts meet factory tolerances. Only Sauer-Danfoss Authorized
Service Centers (ASCs) are authorized to perform major repairs. Sauer-Danfoss ASCs
are trained by the factory to perform major repairs and their facilities are certied on a
regular basis.
A Warning
Use of components that do not comply with rework specications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that dont
comply to given specications: replace with genuine Sauer-Danfoss service parts.
Minor repair procedures, adjustments, and troubleshooting information are given in
the Frame G Variable Motors Service Manual, 520L0605. Minor repairs include service
operations that can be performed 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 uid may be under high pressure and / or hot. Inspect the outside of the pump
and ttings 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, all parts must be kept 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 lm of clean hydraulic oil. This assures that
these parts will be lubricated during start-up.
_ Replace all O-rings and gaskets
It is recommended that all O-rings be replaced. 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
will be necessary to secure the pump while removing and torquing the endcap bolts.
GENERAL INSTRUCTIONS
6 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
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 ammable. To avoid possible re, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure
A Warning
Escaping hydraulic uid under pressure can have sufcient force to penetrate your skin
causing serious injury and/or infection. This uid may also be hot enough to cause burns.
Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the
system before removing hoses, ttings, 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 uid.
Personal safety
A Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
7 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
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 specication
_ Parallelism specication
_ External hex head
_ Internal hex head
_ Torx head
_ O-ring boss port
_ Tip, helpful suggestion
_ Lubricate with hydraulic uid
_ 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 specication
_ Press in press t
_ Pull out with tool press t
_ Cover splines with installation
sleeve
_ Pressure measurement / gauge
location or specication
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 denes each symbol and explains its purpose.
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Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 265
h
9
/16 inch
I8 mm
Remove auxiliary A pad
AUXILIARY PAD
J080
J140
J110
J130
J100
dJ095
dJ120
dJ090
J020
E101 266
h inch
I8 mm
Remove auxiliary B pad
J090 d
J140
J080
J100
J120 d
J110
J095 d
J020
J130
I8 mm
h inch
E101 267
Remove auxiliary C pad
If a second pump is used, you must remove the second pump. You must remove auxiliary
C pad to remove the endcap. You dont need to remove auxiliary pads A or B to remove
the end cap.
1. Remove the plate cover screws (J130) and remove the plate cover (J110).
2. Remove the coupling (J140) and the pad seal (J120). If you have an auxiliary B or C
pad, discard the O-ring (J120). The seal (J120) may be re-used for auxiliary A pads if it
is undamaged
3. Remove the auxiliary pad screws (J100) with an 8 mm internal hex wrench and
remove the adapter (J080).
4. Remove and discard the O-rings (J090, J095).
9 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
DETACH CONTROL 5. Remove the control from the
housing by removing the 4 control
bolts (C300), using a 4 mm internal
hex wrench.
6. Remove and discard the 4 O-rings
(C200).
7. Remove the 4 endcap screws (J030)
using a 12 mm internal hex wrench.
8. Carefully remove the endcap (J020).
Prevent the valve plate (B090) from
falling off. Also, the timing pin (J050)
should remain in the end cap.
9. Place the endcap and valve plate in
a clean area, protecting them from
contamination.
10. Remove the bearing kit (B015)
consisting of cup (B010), and bearing
cone (B020). Also remove and discard
housing O-ring (K060) and the 2
interface O-rings (K070).
ENDCAP
C300
C200 d
I4 mm
E101 263
dK060
J030
J050
J020
K070 d
B090 s
E101 264
I12 mm
B010
B020
B015
Remove endcap and components
Remove control
10 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CYLINDER KIT 11. Tilt the housing on its side to allow
uid to drain.
12. Remove the cylinder block kit while
holding onto the front shaft.
13. Set cylinder block on a clean, dry
surface.
sP010
E101 268
Remove cylinder block kit
BIAS PISTON, SERVO
PISTON, AND OPTIONAL
DISPLACEMENT LIMITER
dL020A
L020
dK110
dK100
B083
dB082
L010 B084
B081
h1-
3
/8 in
E101 269
h1-
3
/8 in
L030
L040
Remove servo and bias pistons 14. Remove the bias guide plug (B081)
using a 1-
3
/8 inch hex wrench. Also,
remove the bias spring (B083), and
piston (B084). Discard the O-rings
(B082, K100) and backup ring (K110).
It may be necessary to remove the piston
and spring by reaching through the
inside of the unit and pushing them out
through the bore.
15. Remove the servo piston plug (L020)
and servo piston (L010) using
a 1-
3
/8 inch hex wrench. Discard the
O-ring (L020A).
It may be necessary to remove the piston
by reaching through the inside of the
housing.
16. Take note of the orientation of the
servo piston. The end of the piston
with the hole should be facing
upward.
11 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
INPUT SHAFT, AND
SWASHPLATE
17. Rotate pump back to a position so
that the shaft is pointing down.
18. Pull the shaft (J010) from the shaft
seal.
19. Lift the swashplate (B040) up at
an angle and remove it from the
housing. Note the orientation
for reinstallation. Reinstall the
swashplate in its original orientation
to reduce start-up wear.
20. Remove the journal bearings (B030).
It is important to record the location
and orientation of the journal
bearings if they are to be reused.
21. Remove the roller bearing kit (B065)
consisting of bearing cone (B070)
and cup (B060). You may need
to remove the shaft seal before
removing the cup.
JOURNAL BEARING AND
ROLLER BEARING
B040 R
J010
E101 270
Remove shaft and swashplate
B030
B060
B070
E101 271
RB065
Remove bearings
12 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
22. Orient the housing shaft side up.
23. Remove the retaining-ring (K010)
using internal retaining ring pliers.
24. Remove the shaft seal (K020) if
necessary.
Replace the shaft seal every time the
shaft is removed from the unit.
SHAFT SEAL
K020 p
K010
E101 272
Remove shaft seal
13 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CONTROL DISASSEMBLY
Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
ipping or relocating the
housing as not to lose or
damage the spool.
PC only
1. With a
3
/16 inch internal hex wrench,
remove the plug (C103) and O-ring
(C103A). Discard the O-ring. Remove
the set screw (C102). Remove the
spool (C132). Note the orientation of
the spool for reinsertion. There may
be differences in reinserting into the
same bore. Remove the adjusting
screw (C138) and O-ring (C138A).
Discard the O-ring. Remove the
springs (C134, C135) along with the
spring guide (C133).
PC / LS
2. With a
3
/16 inch internal hex wrench,
remove the 4 plugs (C103, C104,
C105, and C106) and their O-rings.
Discard the O-rings. Remove the
2 set screws (C102). Remove the
spool (C112). Note the orientation
of the spools for reinsertion. There
may be differences in reinserting
into the same bore. Remove the
spool (C132).
3. Remove the adjusting screw (C138)
and the O-ring (C138A). Discard the
O-ring. Remove the springs (C134,
C135) and spring guide (C133).
4. Remove the adjusting screw (C118),
O-ring (C118A) and 2 backup
rings (C118B). Discard the O-ring
and backup rings. Remove the
springs (C114, C115) and spring
guide (C113).
C133
C135
C134
C138A d
C138
dC103A
C103
C132 R
C200 d
C102
C300
E101 209
Disassemble the PC control
C118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
C104
C103
C132 R
C133
C105
C106
C105A d
dC106A
C300
C135
C134
C138A d
C138
C102
C200 d
C103A d
dC104A
E101 210
Disassemble the PC / LS control
Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
ipping or relocating the
housing as not to lose or
damage the spool.
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Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CYLINDER KIT Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(K049) with the pistons (K050) from
the cylinder kit.
The pistons are not selectively tted,
however units with high hour usage
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
2. Remove the ball guide (K047).
3. Remove the 3 pins (K046).
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. Using a press,
apply pressure on the block spring
washer (K044) to compress the block
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
i
E101 012
l
R
Disassemble the cylinder block kit
A Warning
Risk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf ].
Use a press sufcient
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.
spring (K043). Compress the spring enough to safely remove the spiral retaining ring
(K045). While maintaining pressure, unwind the spiral retaining ring. Carefully release
the pressure and remove the outer block spring washer, block spring, and inner block
spring washer (K042) from the cylinder block. A
15 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
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.
i
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 at, and slippers
should t in the retainer with minimal
side play. Place the hold-down pins on a
at surface and roll them to make sure
they are straight. Discard and replace any
damaged parts.
G Frame
Slipperfoot thickness 4.41 mm
[0.174 in]
Piston/slipper end play 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.
K050
Slipper
Maximum end play
Minimum
slipper foot
thickness

P104 109E
Inspect pistons
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Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BLOCK SPRING, AND
WASHERS
CYLINDER BLOCK
i
Washer
Cylinder block spring
Spring retainer
Retaining ring
P101 472
If cylinder kit was fully dissembled, 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 ow.
K041
flat to 0.002 mm
[0.000079 in]
i
f
P101 067E
MB
MA
G Frame
Minimum cylinder block height (A)
(74 and 90 cc)
68.88 mm
[2.712 in]
Maximum block bore
diameter (B)
74 cc
21.57 mm
[0.849 in]
90 cc
22.74 mm
[0.895 in]
Inspect cylinder block
17 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
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
clean hydraulic oil.
C133
C135
C134
C138A d
eC138
dC103A
C103
C132 R
C200 d
C102
C300
E101 212
e
iC118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
C104
C103
C132 R
C133
C105
C106
C105A d
dC106A
C135
C134
C138A d
C138 i
C102
C200 d
C103A d
dC104A
E101 211
e
e
Inspect the PC control Inspect the PC/LS control
SHAFT Check to see that the shaft (J010) and its
splines are straight and free of damage
or heavy wear. Inspect the shaft surface
where it meets the shaft seal. Replace
the shaft if a groove exists at the sealing
land surface that may let dirt into or
hydraulic uid out of the unit. Clean the
sealing area with a nonabrasive material
if necessary. Lubricate the shaft with a
light coat of hydraulic uid.
Inspect shaft
J010
i
l
P104 423
18 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
SWASHPLATE Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect the
swashplates slipper running surface
for atness and brass transfer. Excessive
brass transfer from slippers may indicate
that the slippers should be replaced.
Finally, check the swashplate bearing
journal for scratches. Replace swashplate
if necessary.
Inspect swashplate
Check the servo piston (L010) for any
obvious wear or damage. Replace piston
if necessary. Discard and replace the
servo plug O-ring (L020A).
JOURNAL BEARINGS
i
P104 335
B030
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.
SERVO PISTON AND
DISPLACEMENT LIMITER
BIAS PISTON
K110 d
K100 d
B083
dB082
B081
B084
E101 273
L020A d
L020
iL010
E101 274
L030
L040
O
Inspect servo piston / displacement limiter
Inspect bias piston Inspect the bias piston (B084), guide
(B081), and spring (B083) for abnormal
wear. Replace if necessary. Discard and
replace the 2 O-rings (B082, K100) and
the backup ring (K110).
On reassembly, the bias piston guide
backup ring (K110) must be the ring
located closest to the center of the
pump.
B040
i
P104 353
Swashplate is not reworkable. Servo pads extend above surface of running face, making
lapping impossible. Positioning of servo pads is extremely important. Do not remove and
repress servo pads.
19 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
ENDCAP Inspect the endcap (J020). Check and
record orientation of the timing pin
(J050). Carefully check the bearing cup
(B010) for wear.
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 are observed, replace the valve plate.
Run a ngernail 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
ow. 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.
VALVE PLATE
Inspect valve plate
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 at and smooth on both
the running face and the bottom surface. The valve plate should be at to 0.0038 mm
[0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks.
The valve plate must be replaced if any cracks exist.
B090
4.95 mm [0.195 in] min.
0.025 mm
[0.001 in]
0.0038 mm
[0.00015 in]
convex max
i
a
f
P104 354E
RJ050
iB010
J020 i
iB020
E101 278
B015
Inspect end cap and components
20 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
SHAFT BEARING KITS 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 uid.
Replace the bearing if the problem is not
remedied by cleaning.
Inspect for uneven wear. If abnormal
wear is found, replace the bearing kit.
i
l
e
E101 182
Inspect shaft bearings
HOUSING Inspect the housing to ensure that it is
clean and free of foreign material. Inspect
the swashplate bearing surfaces, and
endcap mating surfaces. Also inspect the
servo and bias piston bores for galling
and excessive wear.
Inspect housing
i
P104 424
21 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
AUXILIARY PAD 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.
Inspect auxiliary pad components
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 265
h
9
/16 inch
I8 mm
22 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
B030 l
J010
B040 l
E101 275
B065
B070
B060
JOURNAL BEARING
INPUT SHAFT
FRONT BEARING AND
SWASHPLATE
1. Install the journal bearings (B030)
into the pump housing.
If journal bearings are reused, reinstall
them in their original orientation and
position.
2. Reinstall the front bearing kit (B065).
The cup (B060) should be a slip t
with the housing.
3. Coat the curved surface of the
swashplate (B040) with hydraulic
uid. Reinstall the swashplate in its
original orientation. Lubricate the
at face with hydraulic oil to prevent
premature wear during start-up. To
insert the swashplate, tilt the ear
located opposite the control face so
that it is raised. Insert the opposite
side towards the servo piston.
4. Insert the input shaft (J010) through
the bearing into the housing.
Install housing components
Coat all parts with new, clean hydraulic uid before reassembly
23 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
5. Lubricate all sides of the servo
piston (L010) and its respective bore
(closest to the control face) liberally
with hydraulic oil. Reinstall the servo
piston with the hole end up.
6. Install the displacement limiter screw
(L040) into the plug (L020) until ush
with the bottom of the plug. Install
the seal nut (L030) onto the set screw
until snug against the plug. Reinstall
the displacement limiter plug (L020)
and tighten with a 1
3
/8 inch socket to
175-245 Nm [130-180 lbfft]. Once
the desired displacement limit is set,
torque the seal nut (L030) using a
19 mm hex wrench at 78 to 95 Nm
[58 to 70 lbfft].
7. Lubricate the bias piston (B084) and
its respective bore (opposite the
control face) with a liberal coating of
hydraulic oil. Reinstall the bias plug
(B081) and spring (B083) with new O-
rings as shown in the gure at right.
Use a 1
3
/8 inch socket to tighten to
175-245 Nm [130-180 lbfft].
SERVO AND BIAS
PISTONS AND
DISPLACEMENT LIMITER
dL020A
L020
dK110
dK100
B083
dB082
lL010
B084
B081
h1-
3
/8 in
E101 279
h1-
3
/8 in
L030
L040
l
Install servo and bias pistons
It is extremely important that the bias piston plug (B081) be correctly torqued, as it may
back out at lower torques.
24 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
8. Coat all parts with hydraulic uid
prior to reassembly.
9. Install the inner block spring washer
(K042), block spring (K043), and
outer washer (K044) into the cylinder
block. Using a press, compress the
block spring enough to expose the
retaining ring groove. Wind the spiral
retaining ring (K045) into the groove
in the cylinder block. A
10. Turn the block over and install the
hold-down pins (K046) squarely in
their respective grooves. Install the
ball guide (K047) to the cylinder
block.
11. Install the pistons (K050) to the
slipper retainer (K049). 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
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
E101 012
l
Assemble cylinder kit CYLINDER KIT ASSEMBLY
A Warning
Risk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf ].
Use a press sufcient 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.
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).
CYLINDER KIT
INSTALLATION
Install cylinder kit 12. 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 the shaft
splines into the ball guide and align
it with the block splines. When the
cylinder block kit slides completely
over the shaft splines, reposition
the unit with the ange facing
downward.
When the pump housing is in its original
upright position, the bottom of the
cylinder kit should be relatively ush
with the shoulder of the shaft.
P010 s
K030
Prevent shaft from rotating
Slightly rotate
cylinder block
E101 276
block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly.
Set the cylinder kit aside on a clean surface until needed.
25 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
VALVE PLATE
MJ050
B010 i
J020 i
E101 280
B090 g
e
e
13. Clean the valve plate (B090) and
endcap. Install the timing pin
(J050) in the endcap and verify
that it is properly oriented. The
timing pin should be 4.6 0.25 mm
[0.181 0.001 in] above the
mounting surface. 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 cup.
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
ENDCAP 14. Install the bearing cone (B020) onto
the shaft end. Using assembly grease
to hold seals (K060, K070), install the
endcap to the housing. Ensure that
the seals remain properly seated and
are not pinched during assembly.
With a 12 mm internal hex wrench,
install and torque endcap screws
at 127 to 155 Nm [94 to 115 lbfft],
using the criss cross pattern.
Retorque the rst screw to ensure
proper torque retention.
dK060
J030
J020
K070 d
E101 281
I12 mm
t127 - 155 Nm
[94 - 115 lbfft]
B020
Install endcap
26 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
SHAFT SEAL 15. Cover shaft splines with an
installation sleeve. Install a new shaft
seal (K020) with the cup side facing
the pump. Press seal into housing
until it is just below the retaining
ring groove. Press evenly to avoid
binding and damaging the seal.
Install retaining ring (K010).
Install shaft seal and retaining ring
K020 P
K010
E101 277
b
27 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
Assemble PC (only) control 16. Clean all control parts and cover with
a light coating of hydraulic uid prior
to reassembly.
17. Install the spherical end of the PC
spool (C132) into the PC bore (refer
to illustration). Install the PC plug
(C103) using a new O-ring. Torque at
10.8 to 13.5 Nm [8 to 10 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 onto the PC plug (C138) and
install it so that it sits one turn below
the surface of the control housing.
Install and tighten set screw (C102)
at 7.5 to 10.8 Nm [5.5 to 8.0 lbfft] to
retain the adjusting plug.
PC CONTROL
C133
C135
C134
C138A d
eC138
dC103A
C103
C132 R
C200 d
C102
C300
E101 212
e
iC118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
tC104
C103
C132 R
C133
C105 t
tC106
C105A d
dC106A
C135
C134
C138A d
C138 i
C102
C200 d
C103A d
dC104A
E101 227
e
e
Assemble PC/LS control Install the PC portion as described in
PC control, above.
18. 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), torque at
10.8 to 13.5 Nm [8 to 10 lbfft]. Place
the 2 LS springs (C114, C115) onto
the LS spring guide (C113) and install
into the LS bore. Place a new O-ring
(C116) and back-up rings (C117)
onto the LS adjustment screw (C118).
Install the LS plug assembly so that it
sits one turn below the surface of the
control housing. Install and tighten
set screw (C102) at 7.5 to 10.8 Nm
[5.5 to 8.0 lbfft]. Also, install the
plugs (C105, C106) with new O-rings.
Torque the plugs at 10.8 to 13.5 Nm
[8 to 10 lbfft].
PC and LS spools need to be adjusted
to proper setting according to tag
nomenclature.
LS CONTROL (OPTIONAL)
28 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
AUXILIARY PAD
Torque-to-turn shaft
13.2 to 23.5 Nm [117 to 208 lbfin]
19. Install the adapter (J080) with new
O-rings (J090, J095). Tighten the
screws (J100) at 47.5 to 61 Nm
[35 to 45 lbfft] with a 8 mm internal
hex wrench.
20. Test the Torque-to-Turn with the
unit assembled (excluding auxiliary
pumps). Rotate the input shaft using
a torque wrench.
Test the torque 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 J130 screws B and C pad J130 screws
37 to 50 Nm
[27 to 37 lbfft]
91 to 111 Nm
[67 to 82 lbfft]
21. Reinstall the coupling (J140).
Reinstall the auxiliary pad seal (J120)
and auxiliary pump or cover plate
(J110), if present, then 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. Also, the B and C
pads use an O-ring (J120) instead
of a pad seal as shown. Replace this
O-ring upon re-installation.
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 265
h
9
/16 inch
I8 mm
22. Reinstall any other external components, including the auxiliary pump (if present),
that were removed before disassembly.
Install the auxiliary pad (pad A shown)
29 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
REATTACH THE CONTROL 23. Install 4 new seal rings (C200) in
the recesses on the control housing
using petroleum jelly to retain
them. Install the control assembly
onto the endcap using the 4 screws
(C300). Torque at 5.4 to 7.5 Nm
[4 to 5.5 lbfft] using a criss cross
pattern, and retorque the rst screw
to ensure proper torque retention.
Install the control
C300
C200 d
I4 mm
E101 282
t5.4 - 7.5 Nm
[4 - 5.5 lbfft]
30 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Notes
31 BLN 10228 520L0608 Dec 2004
Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Notes
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Phone: +1 515 239-6000, Fax: +1 515 239 6618
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Postfach 2460, D-24531 Neumnster
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Phone: +49 4321 871-0, Fax: +49 4321 871 122
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Phone: +45 7488 4444, Fax: +45 7488 4400
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BLN 10228 520L0608 Dec 2004