45 Series F Frame Repair Manual (520L0821 Rev AA Nov 2006)

7/27/2019 45 Series F Frame Repair Manual (520L0821 Rev AA Nov 2006)

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Series 45

Frame FOpen Circuit

Axial Piston Pumps

Repair Instructions


2/28

50L081 Rev AA Nov. 2006

Series 45 Frame F Open Circuit Axial Piston Pump

Repair Instructions

2006 Sauer-Danoss. All rights reserved. Printed in U.S.A.

Sauer-Danoss accepts no responsibility or possible errors in catalogs, brochures and other printed material.

Sauer-Danoss 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 specifcations. All trademarks in

this material are properties o their respective owners. Sauer-Danoss and the Sauer-Danoss logotype are

trademarks o the Sauer-Danoss Group.

Front cover illustrations: F101 464, F101 385, F101 1 86, P104 359

OrganizatiOn and

headings

To help you quickly fnd inormation 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 o every page in large red type. Topic headings appear in the lethand column in BOLd red CaPitaLLetters. Subtopic headings appear in the body

text in bol p and detail headings in italic red type.

Reerences (example: See Topic xyz, page XX) to sections, headings, or other publications are

also ormatted in red italic type. In Portable document Format (PdF) fles, these reerences

represent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identifed by titles set in blueitalic

type above each item. Complementary inormation such as notes, captions, and drawing

annotations are also set in blue type.

Reerences (example: SeeIllustration abc, page YY) to tables, illustrations, and graphics

are also ormatted in blue italic type. In PDF fles, these reerences represent clickable

hyperlinks that jump to the corresponding document pages.

Defned terms and acronyms are set in bol blcp in the text that defnes or

introduces them. Thereater, the terms and acronyms receive no special ormatting.

Black italictype is used in the text to emphasize important inormation, or to set-o

words and terms used in an unconventional manner or alternative context. Redand blue

italics represent hyperlinked text in the PDF version o this document (see above).

An indented table oContents (tOC) appears on the next page. Tables and illustrations

in the TOC set in blue type. In the PDF version o 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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50L081 Rev AA Nov. 2006


Repair Instructions

Contents

intrOduCtiOn

disassemBLy

insPeCtiOn

Overview ...........................................................................................................................................................5

General instructions ...................................................................................................................................... 5

Saety precautions .........................................................................................................................................6Unintended machine movement .......................................................................................................6

Flammable cleaning solvents ...............................................................................................................6

Fluid under pressure ................................................................................................................................6

Personal saety ...........................................................................................................................................6

Symbols used in Sauer-Danoss literature.............................................................................................7

Auxiliary pad ....................................................................................................................................................8

Detach control .................................................................................................................................................8

Displacement limiter ..................................................................................................................................... 9

Endcap................................................................................................................................................................9

Cylinder kit .....................................................................................................................................................10Input shat, swashplate, and pistons......................................................................................................10

Journal bearings, and roller bearing ......................................................................................................11

Shat seal ........................................................................................................................................................11

Control disassembly ....................................................................................................................................12

PC only ........................................................................................................................................................12

PC / LS .........................................................................................................................................................12

Cylinder kit ......................................................................................................................................................13

Disassemble the cylinder block kit ...................................................................................................13

Block spring removal .............................................................................................................................13

Overview .........................................................................................................................................................14

Pistons and slippers .....................................................................................................................................14

Ball guide, slipper retainer, and hold-down pins ...............................................................................14

Block spring, and washers .........................................................................................................................15

Cylinder block ...............................................................................................................................................15

Control..............................................................................................................................................................16

Shat .................................................................................................................................................................16

Swashplate ......................................................................................................................................................17

Journal bearings ...........................................................................................................................................17

Valve plate .......................................................................................................................................................18

Endcap..............................................................................................................................................................18

Shat bearing kits .........................................................................................................................................19

Servo piston ...................................................................................................................................................19

Bias piston .......................................................................................................................................................19Housing ...........................................................................................................................................................20

Auxiliary pad ..................................................................................................................................................20

Displacement limiter ...................................................................................................................................20


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Repair Instructions

Contents

assemBLy Journal bearing ............................................................................................................................................21

Front bearing and swashplate ................................................................................................................21

Input shat .......................................................................................................................................................21Cylinder kit assembly ..................................................................................................................................22

Cylinder kit installation ..............................................................................................................................22

Valve plate and endcap .............................................................................................................................23

Endcap..............................................................................................................................................................23

Shat seal .........................................................................................................................................................24

PC control ........................................................................................................................................................24

LS control (optional) ....................................................................................................................................25

Auxiliary pad ..................................................................................................................................................26

Displacement limiter ...................................................................................................................................27

Attach the control ........................................................................................................................................27

Pump adjustment ........................................................................................................................................27


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Repair Instructions

Introduction

Overview This manual details the major repair procedures or Frame F pumps. These include the

complete disassembly, inspection, and reassembly o the unit. Where rework o worn

or damaged components is possible, this manual gives specifcations to ensure theseparts meet actory tolerances. Only Sauer-Danoss Global Service Partners are authorized

to perorm major repairs. The actory trains Sauer-Danoss Global Service Partners to

perorm major repairs and certifes their acilities on a regular basis.

W WarningUse o components that do not comply with rework specifcations may result in loss o

perormance, which may constitute a saety hazard. Do not reuse components that dont

comply to given specifcations: replace with genuine Sauer-Danoss service parts.

Series 45 Frame F Axial Piston Pump Service Manual11005158 gives minor repair

procedures, adjustments, and troubleshooting inormation. Minor repairs include service

operations that you can perorm without removing the units endcap. Removal o theendcap voids your warranty.

Follow these general procedures when repairing Series 45 variable displacement open

circuit pumps.

w Remove the unitPrior to perorming major repairs, remove the unit rom 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 o the pump

and fttings or damage. Cap hoses ater removal to prevent contamination.

e Keep it cleanCleanliness is a primary means o assuring satisactory pump lie, on either new or

repaired units. Clean the outside o the pump thoroughly beore disassembly. Take care

to avoid contamination o the system ports. Cleaning parts by using a clean solvent wash

and air drying is usually adequate.

As with any precision equipment, you must keep all parts ree o oreign materials and

chemicals. Protect all exposed sealing suraces and open cavities rom damage and

oreign material. I let unattended, cover the pump with a protective layer o plastic.

l Lubricate moving partsDuring assembly, coat all moving parts with a flm o clean hydraulic oil. This assures that

these parts will be lubricated during start-up.

d Replace all O-Rings and gasketsWe recommend you replace all O-rings, seals, and gaskets. 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 shat pointing downward. It

is necessary to secure the pump while removing and torquing the endcap bolts.

generaL instruCtiOns


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Repair Instructions

Introduction

saFety PreCautiOns Always consider saety precautions beore beginning a service procedure. Protect

yoursel and others rom injury. Take the ollowing general precautions whenever servicing

a hydraulic system.

u c o

W wUnintended movement o 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.

Flbl cl ol

W wSome cleaning solvents are ammable. To avoid possible fre, do not use cleaning

solvents in an area where a source o ignition may be present.

Fl p

W wEscaping hydraulic uid under pressure can have sufcient orce to penetrate your skin

causing serious injury and/or inection. This uid may also be hot enough to cause burns.

Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the

system beore removing hoses, fttings, gauges, or components. Never use your hand

or any other body part to check or leaks in a pressurized line. Seek medical attention

immediately i you are cut by hydraulic uid.

Pol f

W wProtect yoursel rom injury. Use proper saety equipment, including saety glasses, at all

times.


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50L081 Rev AA Nov. 2006


Repair Instructions

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 specifcation

Parallelism specifcation

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpul suggestion

Lubricate with hydraulic uid

Apply grease / petroleum jelly

Apply locking compound

Inspect or wear or damage

Clean area or part

Be careul not to scratch or damage

Note correct orientation

Mark orientation or reinstallation

Torque specifcation

Press in press ft

Pull out with tool press ft

Cover splines with installationsleeve

Pressure measurement / gaugelocation or specifcation

symBOLs used in

sauer-danFOss

Literature

The symbols above appear in the illustrations and text o this manual. They are intended

to communicate helpul inormation at the point where it is most useul to the reader.

In most instances, the appearance o the symbol itsel denotes its meaning. The legend

above defnes each symbol and explains its purpose.


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8 50L081 Rev AA Nov. 2006


Repair Instructions

Disassembly

auxiLiary Pad I a second pump is used, you must

remove it. You dont need to remove

auxiliary pads to remove the end cap.

1. Remove the cover plate screws

(J130) and the cover plate (J110). I

you have auxiliary A pad, use a 9/16

inch hex wrench; use a inch hex

wrench or auxiliary B or C pad.

2. Remove the coupling (J140) and the

pad seal (J120).

3. Remove the auxiliary pad screws

(J100) with a 10 mm internalhex wrench, and remove the

adapter (J080).

4. Remove and discard the O-rings

(J090), and (J095).

J130

J110

J140

J080

J100

10 mm

J090

J120

E101 457E

J095

Remove auxiliary pad

detaCh COntrOL 1. Remove the control rom the endcap

by removing the 4 control bolts

(C300), using a 4 mm internal hex

wrench.

2. Remove and discard the 4 interace

O-rings (C200).

Remove control

C300

4 mm

C200

E101 230


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Repair Instructions

Disassembly

endCaP

disPLaCement Limiter

1. Remove the 4 endcap screws (J030)

using a 10 mm internal hex wrench.

2. Careully remove the endcap (J020).

The valve plate (B090) may adhere to

the endcap. Ensure it does not all o

and become scratched or damaged.

3. Place the endcap and valve plate in

a clean area, protecting them rom

contamination.

4. Remove the housing O-ring (K060)

and discard.

5. Remove the shat bearing cone

(B020) rom the shat. The cup (B010)

will likely remain in the end cap;remove it using a bearing puller i

necessary.

J030

B090

10 mm

J020

K060

B010

B020

E101 232

Remove endcap and components

3. Remove the adjustment seal/nut

(L030A) with a 7/8 inch wrench.

The L030 adjustment seal/nut serves as

a locking seal/nut, preventing the L040

screw rom backing out.

4. Remove the adjustment screw (L040)

with a 1/4 in. internal hex wrench.

Remove plug (L010) with a 7/8 in.

wrench. Discard the O-ring (L010A).

L030A

L010 L010A

L040

E101 231

1/4 in

7/8 in

7/8 in

Remove displacement limiter


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10 50L081 Rev AA Nov. 2006


Repair Instructions

Disassembly

CyLinder kit

C CautionTake care that the top and

bottom o the kit do not

become contaminated or

scratched: this may lead

to poor perormance or

pump ailure.

P010

E101 233

Remove cylinder block kit1. Set the pump on its side.

2. Remove the cylinder block kit (P010)while holding onto the ront o the

shat.

3. Set cylinder block on a clean dry

surace.C

Remove shaft, swashplate, and pistons

J010

P020

B080

B043

B043

B044

B025

B044

E101 234

B040

inPut shaFt,

swashPLate, and

PistOns

1. Rotate pump with the shat pointing

down.

2. Pull the shat (J010) rom the shat

seal.

3. Lit the swashplate/piston assembly

up and remove it rom the

housing. Note the orientation or

reinstallation.

Reinstall swashplate in its original

orientation to reduce wear.

4. Remove the servo piston (P020), bias

spring (B025), and the bias piston

(B080) rom the swashplate by

removing the clevis pins (B043) and

snap rings (B044).


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Repair Instructions

Disassembly

shaFt seaL

JOurnaL Bearings,

and rOLLer Bearing

B070

B071

B060

E101 235

B030

Remove bearings1. Remove the journal bearings (B030)

and, i necessary, remove the pins

(B071).

2. Remove the roller bearing cone

(B070) and cup (B060). You may

need to remove the shat seal beore

removing the cup.

1. Orient the housing shat side up.

2. Remove the retaining-ring (K010)

using internal retaining ring pliers.

3. Remove the shat seal (K020).

Replace the shat seal every time the

shat is removed rom the unit.

Remove shaft seal

E101 236

K020

K010


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1 50L081 Rev AA Nov. 2006


Repair Instructions

Disassembly

COntrOL disassemBLy PC ol

1. Remove the plug (C103) and O-ring

(C103A). Discard the O-ring. Removeset screw (C102) with a 4 mm

internal hex wrench. Tilt control or

use a small magnet to remove the

spool (C132). Note the orientation o

the spool or reinsertion. There may

be dierences in reinserting into the

same bore.

2. Remove the adjusting screw (C138)

with a 1/4 in. internal hex wrench.

Remove and discard O-ring (C138A).

Remove the springs (C134, C135)

along with the spring guide (C133).

PC / Ls

1. Using a 3/16 inch internal hex wrench,

remove the 4 plugs (C103, C104,

C105, and C106) and their O-rings.

Discard the O-rings. Using a 4 mm

internal hex wrench, remove the 2

set screws (C102). Remove the spool

(C112). Note the orientation o the

spools or reassembly. There may be

dierences in reinserting into the

same bore. Remove the spool (C132).


remove the adjusting screw (C138)

and the O-ring (C138A). Discard the

O-ring. Remove the springs (C134,

C135) and spring guide (C133).


remove the adjusting screw (C118),

O-ring (C118) and 2 backup rings

(C118B). Discard the O-ring and

backup rings. Remove the springs

(C114, C115) and spring guide (C113).

C200

C103

E101 237

C132

C138A

C138

C134

C135

C133

C102

C103A 3/16 in

1/4 in

4 mm

Disassemble the PC control

E101 458E

C112

C103A

C103

C132

C104A

C104

C106A

C106C200

C105AC105

C102C113

C115

C114

C118B

C118A

C133

C135

C134

C138AC138

C118B

C118

3/16 in

1/4 in

1/4 in

4 mm

3/16 in

Disassemble the PC / LS control


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Repair Instructions

Disassembly

CyLinder kit dbl cl bloc

1. Pull to remove the slipper retainer

(P049) with the pistons (P050) romthe cylinder kit.

The pistons are not selectively ftted,

however units with high hourly usage

may develop wear patterns. Number the

pistons and bores or reassembly i they

are to be reused.

2. Remove the ball guide (P047).

3. Remove the 3 pins (P046).

Most repairs do not require block spring

removal. Perorm this procedure only

i you suspect problems with the block

spring.

Bloc p ol

4. Turn the block over with the running

sueace pointing up. Using a press,

apply pressure on the block spring

washer (P044) to compress the

block spring (P043). Compress the

springWenough to saely removethe spiral retaining ring (P045).

While maintaining pressure, unwind

the spiral retaining ring. Careully

release the pressure and remove the

outer block spring washer (P044),

block spring, and inner block spring

washer (P042) rom the cylinder

block.

E101 239

P050

P041

P049

P047

P046

P042

P043

P044

P045

Disassemble the cylinder block kit

WWarningRisk o personal injury:

Compressing the block

spring requires a orce

o about 350 to 400 N

[80 to 90 lb]. Use a press

sufcient to maintain this

orce with reasonable

eort. Ensure the spring is

secure beore attempting

to remove the spiral

retaining ring. Release the

pressure slowly ater the

retaining ring is removed.


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1 50L081 Rev AA Nov. 2006


Repair Instructions

Inspection

BaLL guide, sLiPPer

retainer, and hOLd-

dOwn Pins

Overview

PistOns and sLiPPers

Ater 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 ree romcontamination. Clean and dry parts again ater any rework or resuracing.

Slipperretainer

Ball guide

Hold down pins

P101 471

The ball guide should be ree o

nicks and scratches, and should not

be excessively scored. Examine or

discoloration that may indicate excessive

heat or lack o lubrication. The slipper

retainer should be at, and slippers

should ft in the retainer with minimal

side play. Place the hold-down pins on a

at surace and roll them to make sure

they are straight. Discard and replace any

damaged parts.

F F

Slipperoot thickness (min) 4.41 mm

[0.174 in]

Piston/slipper end play (max) 0.05 mm

[0.002 in]

Inspect guide, retainer, and pins

Inspect the pistons or damage and

discoloration. Discolored pistons may

indicate excessive heat; do not reuse.

Inspect the running surace o the

slippers. Replace any piston assemblies

with scored or excessively rounded

slipper edges. Measure the slipper oot

thickness. Replace any piston assemblieswith excessively worn slippers. Check the

slipper axial end-play. Replace any piston

assemblies with excessive end-play.

Minimum slipper oot thickness and

maximum axial end-play are given in the

table to the right.

C103

Slipper

Maximum end play

M inimumslipper fo otthick ness

P104 109E

Inspect pistons


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1550L081 Rev AA Nov. 2006


Repair Instructions

Inspection

BLOCk sPring and

washers

CyLinder BLOCk

Washer

Cylinder block spring

Spring retainer

Retaining ring

P101 472

I cylinder kit was ully disassembled,

visual inspection o the cylinder block,

spring, and washers should indicateminimal wear. Replace i cracks or other

damage is present.

Inspect block spring and washers

Examine the running ace o the cylinder block. The surace should be smooth and reeo nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce

output ow. I necessary, you may resurace the cylinder block as long as the minimum

height and atness specifcations can be maintained.

K041

A

flat to 0.002 mm

[0.000079 in]

P101 067E

B

check for burrs,

nicks, and scratches

F F

Minimum cylinder

block height (A)

68.88 mm

[2.712 in]

74cc Maximum block

bore diameter (B)

21.56 mm

[0.849 in]

90cc Maximum block

bore diameter (B)

22.74 mm

[0.895 in]

Inspect cylinder block


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1 50L081 Rev AA Nov. 2006


Repair Instructions

Inspection

shaFt

COntrOL Careully examine the PC (and LS) plug(s) or signs o wear. Also check the small tip o the

plug(s) or heavy wear and replace i necessary. Check the inside and outside suraces

o the springs or wear and replace i necessary. Check the spools outside diameter orscratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating o

hydraulic oil.

C200

C103

E101 240

C138A

C138

C134

C135

C133

C102

C103A

C132

E101 241

C112

C103A

C103

C132

C104A

C104

C106A

C106

C200

C105A

C105

C102C113

C115

C114

C118B

C118A

C133

C135

C134

C138A

C118B

C118

C138

Inspect the PC control Inspect the PC/LS control

Check to see that the shat (J010) and its

splines are straight and ree o damage

or heavy wear. Inspect the shat seal

journal. Replace the shat i a grooveexists at the sealing land surace that

may let dirt into or hydraulic uid out

o the unit. Clean the sealing area with

a nonabrasive material i necessary.

Lubricate the shat with a light coat o

hydraulic uid.

J010

E101 242

Inspect shaft


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150L081 Rev AA Nov. 2006


Repair Instructions

Inspection

swashPLate

JOurnaL Bearings

E101 243

Careully inspect each surace o the

swashplate or wear. All swashplate

suraces should be smooth. Inspectthe swashplates slipper running

surace or atness and brass transer.

Excessive brass transer rom slippers

may indicate that the slippers should be

replaced. Finally, check the swashplate

bearing journals or scratches. Replace

swashplate i necessary.

Inspect swashplate

P104 335

Inspect journal bearingsInspect the journal bearings or

damage or excessive wear. Replace

journal bearings i scratched, warped, or

excessively worn. The polymer wear layer

must be smooth and intact.

F F

Flatness 0.0025 mm

[0.001 in]

Parallelism 0.0635 mm

[0.0025 in]


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18 50L081 Rev AA Nov. 2006


Repair Instructions

Inspection

endCaP

J050

B010

E101 244

J020

Inspect the endcap (J020). Check the

timing pin (J050). Careully check the

bearing cup (B010) or wear, and ensure

that it fts tightly.

Inspect endcap and components

Inspect the valve plate or scratches and grooves. Check the plate or evidence o

any cavitation along the running ace o the valve plate. I pitting rom cavitation

exists, replace the valve plate. Check or excess wear on the brass running ace. I anydiscoloration or burn marks exist, replace the valve plate.

Run a fngernail or pencil tip across the diameter o the sealing land surace (see

illustration). No deep or outstanding grooves should be elt, as these may decrease pump

ow. Lap or replace i grooves or nicks are present. Inspect the mating suraces o the

endcap and valve plate or any possible contamination; even a ew thousandths o an

inch may aect pump operation. Ensure the minimum thickness, atness, and parallelism

specifcations are met ater rework.

Measure the thickness o 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 ace and the bottom surace. The valve plate should be at to 0.0038 mm[0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks.

Replace the valve plate i any cracks exist.

vaLve PLate

Inspect valve plate

B090

4.95 mm [0.195 in] min.

0.025 mm

[0.001 in]

0.0038 mm

[0.00015 in]

convex max

P104 363E


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150L081 Rev AA Nov. 2006


Repair Instructions

Inspection

shaFt Bearing kits

Bias PistOn

The tapered roller bearing kit consists

o a cup and cone. Make sure the cup

and cone are ree o excessive wear orcontamination. Rotate the bearings to

check or smoothness. I a contaminated

bearing is suspected, clean with a solvent

and lubricate with hydraulic uid.

Replace the bearing i cleaning does not

remedy the problem.

Inspect or uneven wear. I abnormal

wear is ound, replace the bearing kit.

E101 182

Inspect shaft bearings

P020

E101 245

E101 246

B080

Inspect servo piston

Inspect bias piston

servO PistOn Check the servo piston (P020) or any

obvious wear or damage. Check the

corresponding endcap bore or galling

or excessive wear. Discard the piston i

damaged. Replace the servo piston-rings.

Check the bias piston (B080) or any

obvious wear or damage. Check the

corresponding endcap bore or galling

or excessive wear. Discard the piston i

damaged. Replace the bias piston-rings.


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0 50L081 Rev AA Nov. 2006


Repair Instructions

Inspection

hOusing

auxiLiary Pad

disPLaCement Limiter Inspect the displacement limiter screw

threads. Ensure that the screw is not

bent. Also, inspect the seal/nut or

irregular wear. Replace i necessary.

Replace the O-ring.

L010A

E101 249

L030A

L010

L040

Inspect displacement limiter

E101 247

Inspect the housing to ensure that it is

clean and ree o oreign material. Inspect

the swashplate bearing suraces, andendcap mating suraces.

Inspect housing

Inspect sealing suraces on the endcap

and auxiliary pad, and make sure that

they are clean and ree o contaminants.

Inspect the coupling (J140) or any signs

o excessive or abnormal wear. Replace

all O-rings. Replace excessively worn

parts i necessary.

J130

J110

J140

J080

J100

J090

J120

E101 248

J095

Inspect auxiliary pad components


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150L081 Rev AA Nov. 2006


Repair Instructions

Assembly

JOurnaL Bearing

inPut shaFt

FrOnt Bearing and

swashPLate

1. Coat the journal bearings (B030) with

hydraulic uid and install them into

the pump housing.

2. Punch in retaining pins (B071) to a

minimum o 0.5 mm [0.02 in] below

the bearing surace.

I journal bearings are reused, reinstall

them in their original orientation and

position.

1. Reinstall the ront bearing kit. The

cup (B060) should be a slip ft withthe housing.

2. Using a clevis pin (B043) and snap

ring (B044) install the servo piston

(P020) and bias spring (B025) to one

end o the swashplate. Install the bias

piston (B080) to the other end. C

Swashplate is symmetrical. Servo and

bias pistons may be installed in either

end o swashplate.

3. Coat the suraces o the swashplate

(B040) with hydraulic uid. Reinstall

the swashplate in its original

orientation. Lubricate the at

ace with hydraulic oil to prevent

premature wear during start-up.

Insert the input shat (J010) through the

bearing into the housing.

J010

P020

B080

B043

B043

B044

B025

B044

E101 250

B040

B050

B060

B030

B071

Install housing components

C CautionEnsure clevis pins (B043)

are seated properly in

swashplate counterbores.


22/28

50L081 Rev AA Nov. 2006


Repair Instructions

Assembly

1. Coat all parts with hydraulic uid

prior to reassembly.

2. Install the inner block spring washer

(P042), block spring (P043), and

outer washer (P044) into the cylinder

block. Using a press, compress the

block spring enough to expose the

retaining ring groove. Wind the spiral

retaining ring (P045) into the groove

in the cylinder block.W

3. Turn the block over and install the

hold-down pins (P046) and ball

guide (P047) to the cylinder block.

4. Install the pistons (P050) to the

slipper retainer (P049). Install the

piston/retainer assembly into the

cylinder block. Ensure the concave

surace o the retainer seats on

the ball guide. I youre reusing the

pistons, install them to the original

block bores. Lubricate the pistons,

slippers, retainer, and ball guide

beore assembly. Set the cylinder kit

aside on a clean surace until needed.E101 251

P050

P041

P049

P047

P046

P042

P043

P044

P045

P010

K030

Prevent shaft from rotating

Slightly rotatecylinder block

E101 252

Assemble cylinder kit

Install cylinder block

CyLinder kit assemBLy

WWarningRisk o personal injury:

Compressing the block

spring requires a orce

o about 350 to 400 N

[80 to 90 lb]. Use a press

sufcient to maintain this

orce with reasonable

eort. Ensure the spring is

secure beore attempting

to install the spiral

retaining ring. Release thepressure slowly ater the

retaining ring is installed.

CyLinder kit

instaLLatiOn

Be sure to install the slipper retainer so

it mates correctly with the ball guide

(concave side o the slipper retainer

against the convex side o the ball guide).

1. Set the pump on its side. Secure the

end o the shat with one hand and

keep it horizontal. Insert the cylinder

kit onto the shat. While holding the

shat still, slightly rotate the cylinder

block kit to help start it onto theshat splines over the ball guide and

align it with the block splines.

2. When the cylinder block kit slides

completely over the shat splines,

reposition the unit with the ront

ange acing downward.


23/28

50L081 Rev AA Nov. 2006


Repair Instructions

Assembly

vaLve PLate and

endCaP

1. Clean the valve plate (B090) and

endcap. Install the timing pin (J050)

in the endcap. The timing pin shouldbe 3.6 mm [.01 in] [0.25 mm

[0.001 in.] above the valve plate

surace.

2. Apply a liberal amount o assembly

grease to the backside o the valve

plate surace to hold it in position.

Install the valve plate over the timing

pin and bearing kit.

To insure proper pump operation, it is

extremely important to ensure that thereis no contamination between the endcap

and valve plate.

Install endcap components

B090

J050

Bearing kit

E101 253E

endCaP

J030

10 mm

J020

K060

E101 436

203 Nm [150 lbfft]

Install endcap and components1. Lubricate O-Ring (K060) with

hydraulic uid and install into

housing.

2. Install endcap (J020) with valve

plate and bearing assembly. Ensure

the valve plate does not slip during

assembly. Lower the endcap careully

onto the servo and bias pistons and

ensure the pistons seat into the

bores in the endcap. Install endcap

screws (J030) using a 10 mm internal

hex wrench. Torque to 203 Nm

[150 lbt].


24/28

50L081 Rev AA Nov. 2006


Repair Instructions

Assembly

shaFt seaL

K020

K010

E101 254

1. Cover shat splines with an

installation sleeve to protect the seal.

Install a new shat seal (K020) withthe cup side acing the pump.

2. Press seal into housing until it is

just below retaining ring groove.

Press evenly to avoid binding and

damaging the seal. Install snap ring

(K010).

Install shaft seal and retaining ring

Assemble PC (only) control1. Clean and lubricate all control

parts and cover with a light coating

o clean hydraulic uid prior to

reassembly.

2. Install the spherical end o the PC

spool (C132) into the PC bore (reer

to illustration). With a 3/16 internal

hex wrench, install the PC plug

(C103) using a new O-ring (C103A).

Torque to 12 Nm [9 lbt]. Place the

two PC springs (C134, C135) onto the

PC spring guide (C133) and install

into the PC bore. Place a new O-ring

(C138A) onto the PC plug (C138)

and install it with a 1/4 internal hexwrench so that it sits one turn below

the surace o the control housing.

Using a 4 mm internal hex wrench,

install set screw (C102). Torque to

9 Nm [7 lbt].

PC COntrOL

C200

C103

E101 255

C138A

C138

C134

C135

C133

C102

C103A

C132

3/16 in

1/4 in

4 mm

12 Nm [9 lbfft]

9 Nm [7 lbfft]


25/28

550L081 Rev AA Nov. 2006


Repair Instructions

Assembly

E101 238

C112

C103A

C103

C132

C104A

C104

C106A

C106C200

C105AC105

C102 C113

C115

C114

C118B

C118A

C133

C135

C134

C138AC138

C118B

C118

3/16 in

1/4 in

3/16 in

1/4 in

4 mm

12 Nm [9 lbfft]12 Nm

[9 lbfft]

12 Nm

[9 lbfft]

9 Nm

[7 lbfft]

3/16 in

Assemble PC/LS controlInstall the PC portion as described in

PC control, page 24.

1. Hold the control in a horizontal

position. Install the spherical end o

the LS spool (C112) into the LS bore

(see illustration). Using a new O-ring,

install the LS plug (C104) with a

3/16 internal hex wrench, torque to

12 Nm [9 lbt].

2. Place the 2 LS springs (C114, C115)

onto the LS spring guide (C113) and

install into the LS bore. Place a new

O-ring (C118A) and back-up rings(C118B) onto the LS adjustment

screw (C118). Using a 1/4 internal hex

wrench, install the LS plug assembly

so that it sits one turn below the

surace o the control housing.

3. Install and tighten set screw (C102)

to 9 Nm [7 lbt]. Also, install the

plugs (C105, C106) with new O-rings,

using a 3/16 internal hex wrench.

Torque the plugs to 12 Nm [9 lbt].

Ls COntrOL (OPtiOnaL)


26/28

50L081 Rev AA Nov. 2006


Repair Instructions

Assembly

auxiLiary Pad

toq-o- f

13.5 to 24.4 Nm [120 to 216 lbin]

1. Install the adapter (J080) with new

O-rings (J090) and (J095). Tighten the

screws (J100) to 27 Nm [20 lbt]with a 10 mm internal hex wrench.

2. Test torque-to-turn with the unit

assembled (excluding auxiliary

pumps) by rotating the input shat

using a torque wrench.

Test the torque required to turn the shat

(ater break-away) with pl

fll l and the assembly ll ol.

Readings outside the table values may

indicate internal problems. I necessary,disassemble pump and check.

a p J10 c B C p J10 c

37 to 50 Nm

[27 to 37 lbt]

91 to 111 Nm

[67 to 82 lbt]

4. Reinstall any other external

components, including the auxiliary

pump (i present), that were removed

beore disassembly.

3. Reinstall the coupling (J140). Install

the auxiliary pad O-ring (J120) and

auxiliary pump or cover plate (J110).

Torque the screws (J130) to the

values in the table. For a pads, use

a 9/16 inch hex wrench. For B and C

pads, use a inch hex wrench.

J130

J110

J140

J080

J100

10 mm

J090

J120

E101 229

J095

27 Nm

[20 lbfft]

Install the auxiliary pad


27/28

50L081 Rev AA Nov. 2006


Repair Instructions

Assembly

1. Install displacement limiter screw

(L040) into plug (L010).

2. Install new O-ring (L010A) onto plug

(L010). Thread plug with limiter into

endcap. Torque to 77 Nm [57 lbt].

3. Turn adjustment / seal nut (L030A)

onto displacement limiter.

4. Using a 7/8-inch wrench, torque

the adjustment seal/nut (L030) to

54 Nm [40 lbt].

Reer to Frame F Service Manual11005158 or instructions on adjusting

displacement limiter.

disPLaCement Limiter

4 mm

6 Nm

[5 lbfft]

C300

C200

E101 257

attaCh the COntrOL 1. Using petroleum jelly to retain them,

install 4 new seal rings (C200) in the

recesses on the control housing.

2. Install the control assembly onto the

endcap using the 4 screws (C300)

with a 4 mm internal hex wrench.

Torque to 6 Nm [5 lbt] using a

criss cross pattern, and retorque the

frst screw to ensure proper torque

retention.

Install the control

L030A

L010L010A

L040

E101 256

1/4 in

7/8 in54 Nm [40 lbfft]

7/8 in77 Nm [57 lbfft]

Install the displacement limiter

PumP adJustment 1. Install the pump on a test stand.

2. Adjust the pump according to specifcations shown in Series 45 Frame F Open Circuit

Axial Piston Pumps Service Manual11005158.


28/28

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Phone: +45 7488 4444

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Documents

45 Series F Frame Repair Manual (520L0821 Rev AA Nov 2006)