45 series g frame repair manual (520l0608) (15mar2006)
TRANSCRIPT
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Series 45
G Frame
Open Circuit
Axial Piston Pumps
Repair Manual
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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 conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Front cover illustrations: F101 522, F101 523, F101 5 21, P104 467
ORGANIZATION AND
HEADINGS
To help you quickly find 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 lefthand column in BOLD RED CAPITALLETTERS. 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) files, these references
represent clickable hyperlinks that jump to the corresponding document pages.
Tables, illustrations, and graphics in this manual are identified by titles set in blueitalic
type above each item. Complementary information such as notes, captions, and drawing
annotations are also set in blue type.
References (example: SeeIllustration abc, page YY) to tables, illustrations, and graphics
are also formatted in blue italic type. In PDF files, these references represent clickable
hyperlinks that jump to the corresponding document pages.
Defined terms and acronyms are set in bold blacktype in the text that defines or
introduces them. Thereafter, the terms and acronyms receive no special formatting.
Black italictype is used in the text to emphasize important information, or to set-off
words and terms used in an unconventional manner or alternative context. Redand blue
italics represent hyperlinked text in the PDF version of this document (see above).
An indented Table ofContents (TOC) appears on the next page. Tables and illustrations
in the TOC set in blue type. In the PDF version of this document, the TOC entries are
hyperlinked to the pages where they appear.
TABLES, ILLUSTRATIONS,
AND COMPLEMENTARY
INFORMATION
SPECIAL TEXT
FORMATTING
TABLE OF CONTENTS
Using this manual
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Repair Manual
Contents
Overview ...........................................................................................................................................................5
General instructions ...................................................................................................................................... 5
Safety precautions .........................................................................................................................................6Unintended 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 .......................................................10Input 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 .............................................................................................................................................................19Shaft bearing kits .........................................................................................................................................20
Housing ...........................................................................................................................................................20
Auxiliary pad ..................................................................................................................................................21
DISASSEMBLY
INSPECTION
INTRODUCTION
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Contents
Journal bearing ............................................................................................................................................22
Front bearing and swashplate ................................................................................................................22
Input shaft .......................................................................................................................................................22Servo 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
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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, specifications aregiven 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 certified on a
regular basis.
W WarningUse of components that do not comply with rework specifications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that dont
comply to given specifications: 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 serviceoperations 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.
w Remove the unitPrior 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 fluid may be under high pressure and / or hot. Inspect the outside of the pump
and fittings for damage. Cap hoses after removal to prevent contamination.
e Keep it cleanCleanliness 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.
l Lubricate moving partsDuring assembly, coat all moving parts with a film of clean hydraulic oil. This assures thatthese parts will be lubricated during start-up.
d Replace all O-rings and gasketsIt is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean
petroleum jelly prior to assembly.
t Secure the unitFor 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
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Introduction
SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.
Unintended machine movement
W WarningUnintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable
/ disconnect the mechanism while servicing.
Flammable cleaning solvents
W WarningSome cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure
W WarningEscaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.
Personal safety
W WarningProtect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
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Introduction
WARNING may result in injury
CAUTION may result in damage toproduct 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 specification
Parallelism specification
External hex head
Internal hex head
Torx head
O-ring boss port
Tip, helpful suggestion
Lubricate with hydraulic fluid
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 specification
Press in press fit
Pull out with tool press fit
Cover splines with installationsleeve
Pressure measurement / gaugelocation or specification
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 defines each symbol and explains its purpose.
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Disassembly
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 265
h9/16inch
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
J090d
J140
J080
J100
J120d
J110
J095d
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).
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Disassembly
DETACH CONTROL 5. Remove the control from the
housing by removing the 4 control
bolts (C300), using a 4 mm internalhex 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
C200d
I4 mm
E101 263
dK060
J030
J050J020
K070d
B090s
E101 264
I12 mm
B010
B020B015
Remove endcap and components
Remove control
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Disassembly
CYLINDER KIT 11. Tilt the housing on its side to allow
fluid 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
L010B084
B081
h1-3/8 in
E101 269
h1-3/8 in
L030
L040
Remove servo and bias pistons14. 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.
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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
B040R
J010
E101 270
Remove shaft and swashplate
B030
B060
B070
E101 271
RB065
Remove bearings
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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
K020p
K010
E101 272
Remove shaft seal
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CONTROL DISASSEMBLY
C CautionIf removing the LS or PC
spool is not possible, be
extremely careful when
flipping 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).C
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).C
3. Remove the adjusting screw (C138)
and the O-ring (C138A). Discard the
O-ring. Remove the springs (C134,
C135) and spring guide (C133).C
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 springguide (C113).C
C133
C135
C134C138Ad
C138
dC103A C103
C132R
C200d
C102
C300
E101 209
Disassemble the PC control
C118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
C104
C103
C132R
C133
C105
C106
C105Ad
dC106A
C300
C135
C134
C138Ad
C138
C102
C200d
C103Ad
dC104A
E101 210
Disassemble the PC / LS control
C CautionIf removing the LS or PC
spool is not possible, be
extremely careful when
flipping or relocating the
housing as not to lose or
damage the spool.
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Disassembly
CYLINDER KIT Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(K049) with the pistons (K050) fromthe cylinder kit.
The pistons are not selectively fitted,
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
WWarningRisk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf].
Use a press sufficient
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.W
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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 fromcontamination. 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 flat, and slippers
should fit in the retainer with minimal
side play. Place the hold-down pins on a
flat 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 assemblieswith 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
Minimumslipper footthickness
P104 109E
Inspect pistons
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Inspection
BLOCK SPRING, AND
WASHERS
CYLINDER BLOCK
iWasher
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 minimalwear. 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 freeof nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce
output flow.
K041
flat to 0.002 mm
[0.000079 in]
i
fP101 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 cc21.57 mm
[0.849 in]
90 cc22.74 mm
[0.895 in]
Inspect cylinder block
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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 forscratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
clean hydraulic oil.
C133
C135
C134C138Ad
eC138
dC103AC103
C132R
C200
d
C102
C300
E101 212
e
iC118
dC118B
dC118Bd
C118A
C114
C115
C113
RC112
C104
C103
C132R
C133
C105
C106
C105Ad
dC106A
C135
C134
C138Ad
C138i
C102
C200d
C103Ad
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 fluid out of the unit. Clean thesealing area with a nonabrasive material
if necessary. Lubricate the shaft with a
light coat of hydraulic fluid.
Inspect shaft
J010
i
l
P104 423
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Inspection
SWASHPLATE Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect theswashplates slipper running surface
for flatness 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 bearingsInspect 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
K110d
K100dB083
dB082
B081
B084
E101 273
L020Ad
L020
iL010
E101 274
L030
L040
O
Inspect servo piston / displacement limiter
Inspect bias pistonInspect 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.
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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 anydiscoloration or burn marks are observed, replace the valve plate.
Run a fingernail 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
flow. 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 flat and smooth on both
the running face and the bottom surface. The valve plate should be flat 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
J020i
iB020
E101 278
B015
Inspect end cap and components
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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 orcontamination. Rotate the bearings to
check for smoothness. If a contaminated
bearing is suspected, clean with a solvent
and lubricate with hydraulic fluid.
Replace the bearing if the problem is not
remedied by cleaning.
Inspect for uneven wear. If abnormal
wear is found, replace the bearing kit.
il
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
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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
h9/16 inch
I8 mm
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Assembly
B030l
J010
B040l
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 fit
with the housing.
3. Coat the curved surface of the
swashplate (B040) with hydraulic
fluid. Reinstall the swashplate in its
original orientation. Lubricate the
flat 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 fluid before reassembly
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Assembly
5. Lubricate all sides of the servo
piston (L010) and its respective bore
(closest to the control face) liberallywith hydraulic oil. Reinstall the servo
piston with the hole end up.
6. Install the displacement limiter screw
(L040) into the plug (L020) until flush
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 figure 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
lL010B084
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.
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Assembly
8. Coat all parts with hydraulic fluid
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.W
10. Turn the block over and install the
hold-down pins (K046) squarely in
their respective grooves. Install theball 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 kitCYLINDER KIT ASSEMBLY
WWarningRisk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf].
Use a press sufficient to
maintain this force with
reasonable effort. Ensure
the spring is secure before
attempting to install
the spiral retaining ring.
Release the pressure slowlyafter 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 kit12. 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 alignit with the block splines. When the
cylinder block kit slides completely
over the shaft splines, reposition
the unit with the flange facing
downward.
When the pump housing is in its original
upright position, the bottom of the
cylinder kit should be relatively flush
with the shoulder of the shaft.
P010s
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.
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Assembly
VALVE PLATE
MJ050B010i
J020i
E101 280
B090g
e
e
13. Clean the valve plate (B090) and
endcap. Install the timing pin
(J050) in the endcap and verifythat 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 thereis 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 first screw to ensure
proper torque retention.
dK060
J030
J020
K070d
E101 281
I12 mm
t127 - 155 Nm[94 - 115 lbfft]
B020
Install endcap
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Assembly
SHAFT SEAL 15. Cover shaft splines with an
installation sleeve. Install a new shaft
seal (K020) with the cup side facingthe 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
K020P
K010
E101 277
b
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Assembly
Assemble PC (only) control16. Clean all control parts and cover with
a light coating of hydraulic fluid 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
C134C138Ad
eC138
dC103A C103
C132R
C200d
C102
C300
E101 212
e
iC118
dC118B
dC118B
dC118A
C114
C115
C113
RC112
tC104C103
C132R
C133
C105t
tC106
C105Ad
dC106A
C135
C134
C138A
dC138i
C102
C200d
C103Ad
dC104A
E101 227
e
e
Assemble PC/LS controlInstall 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)
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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 mayindicate 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
h9/16inch
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)
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Assembly
REATTACH THE CONTROL 23. Install 4 new seal rings (C200) in
the recesses on the control housing
using petroleum jelly to retainthem. 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 first screw
to ensure proper torque retention.
Install the control
C300
C200d
I4 mm
E101 282
t5.4 - 7.5 Nm[4 - 5.5 lbfft]
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Notes
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Notes
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Ames, IA 50010, USA
Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sauer-Danfoss (Neumnster) GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
Sauer-Danfoss (Nordborg) ApS
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