Series 45

H Frame
Open Circuit
Axial Piston Pumps
Repair Manual
2 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
2005 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: F101348, F101 347, F101 345, P106 084
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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TABLES, ILLUSTRATIONS,
AND COMPLEMENTARY
INFORMATION
SPECIAL TEXT
FORMATTING
TABLE OF CONTENTS
Using this manual
3 BLN 10238 520L0612 August 2005
Series 45 H 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
Endcap ............................................................................................................................................................... 9
Cylinder kit ........................................................................................................................................................ 9
Bias piston, servo piston, and optional displacement limiter .......................................................10
Pressure compensator valve ....................................................................................................................10
Old style .....................................................................................................................................................10
New style ...................................................................................................................................................10
Input shaft, and swashplate ......................................................................................................................11
Swashplate, journal bearing and roller bearing ................................................................................11
Shaft seal .........................................................................................................................................................12
Control ..............................................................................................................................................................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
Input shaft ......................................................................................................................................................16
Swashplate ......................................................................................................................................................16
Journal bearings ...........................................................................................................................................16
Servo piston and displacement limiter ................................................................................................16
Bias piston .......................................................................................................................................................17
Valve plate .......................................................................................................................................................17
Endcap .............................................................................................................................................................18
Shaft bearing kits .........................................................................................................................................18
Housing ...........................................................................................................................................................18
PC valve ............................................................................................................................................................19
Control ..............................................................................................................................................................19
Auxiliary pad ..................................................................................................................................................20
INTRODUCTION
DISASSEMBLY
INSPECTION
4 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
Journal bearing ............................................................................................................................................21
Front bearing and swashplate ................................................................................................................21
Input shaft .......................................................................................................................................................21
Servo and bias pistons and displacement limiter ............................................................................22
Pressure compensator valve ....................................................................................................................22
New style ..............................................................................................................................................22
Old style ................................................................................................................................................23
Control ..............................................................................................................................................................23
Cylinder kit assembly ..................................................................................................................................24
Cylinder kit installation ..............................................................................................................................24
Valve plate .......................................................................................................................................................25
Endcap .............................................................................................................................................................25
Shaft seal .........................................................................................................................................................26
Auxiliary pad ..................................................................................................................................................27
ASSEMBLY
5 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
OVERVIEW This manual details the major repair procedures for Frame H 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 H Open Circuit Axial Piston Pumps Service Manual, 520L0611. 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 10238 520L0612 August 2005
Series 45 H 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 10238 520L0612 August 2005
Series 45 H 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.
8 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 287
h
9
/16 inch
I8 mm
Remove auxiliary A pad
AUXILIARY PAD
J080
J140
J110
J130
J100
dJ095
dJ120
dJ090
J020
E101 288
h inch
I8 mm
Remove auxiliary B pad
J090 d
J140
J080
J100
J120 d
J110
J095 d
J020
J130
E101 289
I8 mm
h inch
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 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
1. Remove the 4 endcap screws (J030)
using a 10 mm internal hex wrench.
2. Carefully remove the endcap (J020).
Prevent the valve plate (B090) from
falling off. Keep the timing pin (J050)
in the end cap.
3. Place the endcap and valve plate in
a clean area, protecting them from
contamination.
4. Remove the bearing kit (B01)
consisting of cup (B010), and bearing
cone (B020). Also remove and discard
housing O-ring (K060) and the 2
interface O-rings (K070).
ENDCAP
dK060
K070 d
B090 s
I10 mm
B010
B020
B01
J030
J050
J020
E101 301
Remove endcap and components
CYLINDER KIT 1. Tilt the housing on its side to allow
uid to drain.
2. Remove the cylinder block kit while
holding onto the front shaft.
3. Set cylinder block on a clean dry
surface.
sP010
E101 292
Remove cylinder block kit
10 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
BIAS PISTON, SERVO
PISTON, AND OPTIONAL
DISPLACEMENT LIMITER
E101 293
dK110
dK100
B083
dB082
B084
B081
h1-
3
/8 in
dL020A
L020
h1-
3
/8 in
L030
L040
L010
Remove servo and bias pistons 1. 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.
2. 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.
3. Note the orientation of the servo
piston. The end of the piston with
the hole should be facing upward.
dD016
dK080
dK090
D015
D014
D013
D019
D018
D016 d
K080 d
K090 d
A98-21
thru
A00-23
E101 328
New style
Old style
C120
C120A
O
Remove PC valve
PRESSURE
COMPENSATOR VALVE
Old style
1. Remove the PC plug (C120) from the
pump using a 3/16 inch hex wrench.
Discard the O-ring (C120A).
2. Remove the PC cartridge using an
11/16 inch hex wrench. Discard the
O-rings (D016, K080) and backup
ring (K090).
3. Further disassembly can be made by
loosening the locknuts (D015, D018)
on the set screw (D014).
New style
1. Remove the PC plug (C120) from the
pump using a 9/16 inch hex wrench.
Discard the O-ring (C120A)
2. The new style is a one-piece
cartridge. Remove the PC cartridge
with a 11/16 inch hex wrench.
Discard the O-rings (D016, K080) and
the backup ring (K090).
11 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
INPUT SHAFT 1. Rotate pump back to a position so
that the shaft is pointing down.
2. Pull the shaft (J010) from the shaft
seal.
E101 294
J010
Remove shaft
1. 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.
2. Remove the journal bearings (B030).
It is important to record the location
and orientation of the journal
bearings if they are to be reused.
3. Remove the roller bearing kit (B06)
consisting of cone (B070) and cup
(B060). You may need to remove the
shaft seal before removing the cup
(see following procedure for seal
removal).
SWASHPLATE, JOURNAL
BEARING AND ROLLER
BEARING
B030
B060
B070
E101 295
B06
B040
Remove swashplate and bearings
12 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
1. Orient the housing shaft side up.
Caution
The PC spool may fall out once the
endcap is removed and the housing is
tipped in this orientation. Be careful not
to damage the spool.
2. Remove the retaining-ring (K010)
using internal retaining ring pliers.
3. Remove the shaft seal if necessary.
Replace the shaft seal every time the
shaft is removed from the unit.
SHAFT SEAL
K020 P
K010
E101 335
b
Remove shaft seal
CONTROL Unscrew the plug (C030) using a 7/8 inch
hex wrench. Discard the O-ring (C040).
If the springs (C070, C060) remain in the
bore, remove them along with the spring
seat (C080) and the PC spool (C090) with
a magnet.
C110
C130
C020
C010
C030
C040
C050
C060
C070
C080
C090
E101 334
Remove the control
13 BLN 10238 520L0612 August 2005
Series 45 H 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) and
retaining ring (K048).
3. Remove the 3 pins (K046).
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
i
E101 354
l
R
K048
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.
Block spring removal
Most repairs do not require block spring removal. Perform this procedure only if you
suspect problems with the block spring.
4. Turn the block over. Using a press, apply pressure on the block spring washer
(K044) to compress the block 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
14 BLN 10238 520L0612 August 2005
Series 45 H 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.
H Frame
Slipperfoot thickness 3.23 mm
[0.128 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
15 BLN 10238 520L0612 August 2005
Series 45 H 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 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 ow.
K041
flat to 0.002 mm
[0.000079 in]
i
f
P101 067E
MB
MA
H Frame
Minimum cylinder block height (A)
(57 and 75 cc)
62.23 mm
[2.450 in]
Maximum block bore
diameter (B)
57 cc
19.80 mm
[0.779 in]
75 cc
21.57 mm
[0.849 in]
Inspect cylinder block
16 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
INPUT 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
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
L020A d
L020
iL010
E101 274
L030
L040
O
Inspect servo piston / displacement limiter
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.
17 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BIAS PISTON
K110 d
K100 d
B083
dB082
B081
B084
E101 273
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.
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
18 BLN 10238 520L0612 August 2005
Series 45 H 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.
RJ050
iB010
J020 i
iB020
E101 307
B01
Inspect end cap and components
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
P106 010
19 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
PC VALVE
CONTROL
Inspect the screen in the end of the valve
for contamination. It is important that
the valve is not plugged.
Check the spool for nicks and scratches.
Make sure the PC spool orice is not
contaminated or plugged.
New style
Old style
screen end
screen
E101 340E
C090 i
E101 341
i
Inspect the control spool and orice
Inspect the PC valve
20 BLN 10238 520L0612 August 2005
Series 45 H 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 287
h
9
/16 inch
I8 mm
21 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
E101 296
B070
B060
B06
K070 d
B030 l
B040 l
J010
JOURNAL BEARING
INPUT SHAFT
FRONT BEARING AND
SWASHPLATE
1. Coat the journal bearings (B030) with
hydraulic uid and install them into
the pump housing.
If journal bearings are reused, reinstall
them in their original orientation and
position.
2. Reinstall the front bearing kit (B06).
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
22 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
1. Lubricate all sides of the servo
piston (L010) and its respective bore
liberally with hydraulic oil. Reinstall
the servo piston with the hole end
up. Reinstall the displacement limiter
plug (L020) and tighten with a
1
3
/8 inch socket to 175-245 Nm
[130-180 lbfft].
2. Install the set screw (L040) and use
a 19 mm hex wrench to torque
the adjustment seal/nut (L030) at
78 to 95 Nm [58 to 70 lbfft].
3. Lubricate the bias piston (B084) and
its respective bore with a liberal
coating of hydraulic oil. Reinstall the
bias plug (B081) and spring (B083)
with new O-rings. Use a 1
3
/8 inch
socket to tighten to 175-245 Nm
[130-180 lbfft].
It is extremely important that the bias
piston plug (B081) be correctly torqued,
as it may back out at lower torques.
SERVO AND BIAS
PISTONS AND
DISPLACEMENT LIMITER
E101 297
dK110
dK100
B083
dB082
B084
B081
h1-
3
/8 in
dL020A
L020
h1-
3
/8 in
L030
L040
L010
l
Install servo and bias pistons
PRESSURE
COMPENSATOR VALVE
D016
K080
K090
E101 356
New style
C120
C120A d
h
9
/16 inch hex
t16 Nm
[12 lbfft]
Install PC valve New style
1a. Using a
9
/16 inch hex wrench, install
short hex plug (C120) with a new
O-ring (C120A). Torque this plug to
16 Nm [12 lbfft]. After installing the
plug, install the new PC cartridge.
Torque to 37 Nm [27 lbfft] with
an
11
/16 inch hex wrench. Reset your
pressure compensating setting
following the Series 45 Service
Manual, BLN-10129, as these do
not come preset. The gain for the PC
setting is 56.9 bar [825 psi]/turn.
23 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
PRESSURE
COMPENSATOR VALVE
D016
K080
K090
D015
D014
D013
D019
D018
A98-21
thru
A00-23
E101 355
Old style
C120
C120A d
I
3
/16 inch hex
t12.2 Nm
[9.0 lbfft]
Install PC valve Old style
1b. Install the remote PC plug with a
3
/16 inch internal hex wrench. Torque
this plug to 12.2 Nm [9.0 lbfft].
After installing the plug, instal the
PC cartridge and torque to 37 Nm
[27 lbfft] using an 11/16 inch
hex wrench. Reset your pressure
compensating setting following the
Series 45 Service Manual, BLN-10129,
as these do not come preset. The
new gain for the PC setting is 56.9
bar [825 psi]/turn.
CONTROL
C110
C130
C020
C010
C030
C040
C050
C060
C070
C080
C090
E101 334
Install the control Install the spool (C090) into the bore.
Place the springs (C070, C060) onto the
spring guide (C080) and install them
into the bore. Install the spring seat
(C050) onto the springs. Install the seal
nut (C020) and lock nut (C130) onto the
set screw until snug against the plug.
Reinstall the displacement limiter plug
(C030) and tighten with a 7/8 inch hex
wrench to 40.7-94.9 Nm [30-70 lbfft]. Be
sure to use a new O-ring (C040).
24 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
1. Coat all parts with hydraulic uid
prior to reassembly.
2. 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
3. Turn the block over and install the
retaining ring (K048) and hold-
down pins (K046) squarely in their
respective grooves. Install the ball
guide (K047) to the cylinder block.
4. 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
block bores. Lubricate the pistons,
slippers, retainer, and ball guide
before assembly. Set the cylinder kit
aside on a clean surface until needed.
K045
K044
K043
K042
K041
P010
K047 l
K049 l
K050 l
K046
E101 357
K048
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 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 298
25 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
ENDCAP 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 10 mm internal hex wrench, install
and torque endcap screws at 84.0 to
108.5 Nm [67 to 82 lbfft], using the criss
cross pattern. Retorque the rst screw to
ensure proper torque retention.
J030
J020
K070 d
B020
dK060
E101 308
I10 mm
t84 - 108.5 Nm
[62 - 80 lbfft]
Install endcap
VALVE PLATE
MJ050
B010 i
J020 i
E101 299
B090 g
e
e
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
26 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
SHAFT SEAL 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 snap ring (K010).
Install shaft seal and retaining ring
K020 P
K010
E101 336
b
27 BLN 10238 520L0612 August 2005
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
AUXILIARY PAD
Torque-to-turn shaft
10.1 to 18.1 Nm [90 to 160 lbfin]
1. 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.
2. 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 on 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]
3. 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.
4. Reinstall any other external components, including the auxiliary pump (if present),
that were removed.
Install the auxiliary pad (pad A shown)
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 287
h
9
/16 inch
I8 mm
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BLN 10238 520L0612 August 2005
Huess 0805