Series 45

K and L Frame
Open Circuit
Axial Piston Pumps
Repair Manual
2 BLN 10196 520L0632 May 2005
Series 45 K and L 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: F101 472, F101 473, F101 474, F101 475, P104 327
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
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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
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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 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
INTRODUCTION Overview ........................................................................................................................................................... 4
General instructions ...................................................................................................................................... 4
Safety precautions ......................................................................................................................................... 5
Unintended machine movement ....................................................................................................... 5
Flammable cleaning solvents ............................................................................................................... 5
Fluid under pressure ................................................................................................................................ 5
Personal safety ........................................................................................................................................... 5
Symbols used in Sauer-Danfoss literature ............................................................................................. 6
DISASSEMBLY Auxiliary pad .................................................................................................................................................... 7
Control .............................................................................................................................................................. 8
Endcap and roller bearing .......................................................................................................................... 8
Cylinder kit ....................................................................................................................................................... 9
Input shaft, swashplate, and bias spring ................................................................................................ 9
Roller bearing, cup, and journal bearings ............................................................................................10
Shaft seal ........................................................................................................................................................10
Control housing ............................................................................................................................................11
Cylinder kit disassembly ............................................................................................................................12
Block spring removal .............................................................................................................................12
INSPECTION Overview .........................................................................................................................................................13
Pistons and slippers .....................................................................................................................................13
Ball guide, slipper .........................................................................................................................................13
Retainer, and hold-down pins ..................................................................................................................13
Block spring, and washers .........................................................................................................................14
Cylinder block ...............................................................................................................................................14
Control ..............................................................................................................................................................15
Shaft .................................................................................................................................................................15
Swashplate ......................................................................................................................................................16
Journal bearing .............................................................................................................................................16
Valve plate .......................................................................................................................................................17
Endcap .............................................................................................................................................................17
Shaft bearing kits .........................................................................................................................................18
Servo piston and guide ..............................................................................................................................18
Housing ...........................................................................................................................................................19
Auxiliary pad ..................................................................................................................................................19
ASSEMBLY Journal bearing ............................................................................................................................................20
Bias spring, swashplate, and bearing ....................................................................................................20
Input shaft .......................................................................................................................................................20
Cylinder kit assembly ..................................................................................................................................21
Cylinder kit installation ..............................................................................................................................21
Valve plate and endcap .............................................................................................................................22
Shaft seal .........................................................................................................................................................23
Control ..............................................................................................................................................................24
Auxiliary pad ..................................................................................................................................................25
4 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
OVERVIEW This manual details the major repair procedures for Series 45 Frame K and L 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
Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual, 520L0532. 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
5 BLN 10196 520L0632 May 2005
Series 45 K and L 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.
6 BLN 10196 520L0632 May 2005
Series 45 K and L 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.
7 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
AUXILIARY PAD
J140
J095 d
J100
J090 d
J085
J120
J110
J130
J140
J095 d
J100
J090 d
J085
J120 d
J110
J130
h
9
/16 inch
h inch
h8 mm
h8 mm
E101 196
Remove auxiliary A pad Remove auxiliary B pad
If a second pump is used, you must remove it. You dont need to remove auxiliary pads to
remove the end cap.
1. Remove the 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
pad, discard the O-ring (J120). The pad seal for an auxiliary A pad is reusable if
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).
5. Remove the coupling (J140).
8 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
6. Using a 5 mm internal hex wrench,
remove the 4 control screws (C300)
that fasten the control assembly to
the endcap (J020).
7. Remove the control from endcap.
Discard interface O-rings. (C200).
CONTROL
ENDCAP AND ROLLER
BEARING
C200
C300
I5 mm
d
P104 328
B045
B070
B020
B046
J030
I8 mm
J020
e
d
d
s
P101 351
B010
L020
L080
26 mm
Remove control
8. Remove the 4 endcap screws (J030)
using an 8 mm internal hex wrench.
9. Remove the endcap. Remove the
servo piston (L020) and guide (L080).
Use care; valve plate (B070) may
adhere to inside surface. Discard
O-rings (B045, B046). Once the valve
plate is removed, the check valve can
be removed. Refer to Inspection, page
17, for more information.
To protect these parts from
contamination, place the endcap and
valve plate in a protected area.
10. Slide the rear tapered roller bearing
cone (B020) from the bottom end
of the shaft. The bearing cup (B010)
may remain within the endcap.
Remove bearing cup if replacement is
necessary. See Inspection, page 18.
Remove endcap and roller bearing
9 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CYLINDER KIT 11. Slide the cylinder block assembly
(P010) out of the pump housing
by pushing on the shaft from the
bottom of the pump. Push the
shaft only far enough so that the
cylinder kit may be removed by
hand. Keep track of the three small
hold-down pins (K046) located inside
the cylinder kit. Once removed, set
the cylinder kit in a protected area.
Contamination or scratches may lead
to poor performance or pump failure.
P010
i
s
K046
P104 339
Remove cylinder kit
INPUT SHAFT,
SWASHPLATE, AND BIAS
SPRING
pJ010
B040
B025
P101 353
12. Rotate the swashplate (B040) until
level with pump housing. Pull the
shaft (J010) from the shaft seal
and bearing kit. Slightly compress
the bias spring (B025) and lift the
swashplate out. Lift the bias spring
from the pump housing.
Remove shaft and swashplate
10 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
13. Pull to remove the front tapered
roller bearing (B050). Carefully pry to
remove the journal bearings (B030)
and retaining pins (B071) from the
pump housing. Record the location
and orientation of the journal
bearings if they are to be reused. If
necessary, remove the front bearing
cup (B060) from the pump housing.
SHAFT SEAL
ROLLER BEARING, CUP,
AND JOURNAL BEARINGS
P101 352
K020 p
K010
B071
B030
B050
pB060
m
p
P101 369
14. Orient the housing with the ange
facing up. Using snap-ring pliers,
remove the snap ring (K010).
Carefully pry out the shaft seal
(K020).
If you are unable to pull the shaft seal
out, try to push the seal out by going
through the inside of the housing.
Remove bearings
Remove shaft seal
11 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CONTROL HOUSING
C112 i
C106A d
iC132
C103
dC103A
C133
C113
C134
C115
C114
C135
C117 d
dC136
C116 d
C117 d
C118 i
iC138
E101 192
R
R
C102
C106
Disassemble control
Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
ipping or relocating the
housing as not to lose or
damage the spool.
15. With a
3
/16 inch internal hex wrench,
remove the plugs (C103, 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).
The PC and LS spools are not the same.
They must be identied as to which bore
they come out of.
16. Remove the adjusting screw (C138)
and the O-ring (C138A). Discard the
O-ring. Remove the springs (C134,
C135) and spring guide (C133).
17. Remove the adjusting screw (C118),
O-ring (C116) and 2 backup rings
(C117). Discard the O-ring and
backup rings. Remove the springs
(C114, C115) and spring guide (C113).
12 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
K045
K044
K043
K042
K041
P010
K047 l
K049 l
K050 l
P101 356
K046
K048 (L Frame only)
Disassemble cylinder kit CYLINDER KIT
DISASSEMBLY
18. Remove pistons (K050) and slipper
retainer (K049) from the cylinder
block.
The pistons are not selectively tted,
however units with high hourly usage
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
19. Remove the ball guide (K047), hold-
down pins (K046), and retaining
ring (K048) from the cylinder
block (K041).
Most repairs do not require block spring
removal. Perform this procedure only
if you suspect problems with the block
spring.
Block spring removal
20. 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
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.
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
13 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BALL GUIDE, SLIPPER
RETAINER, AND HOLD-
DOWN PINS
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.
K Frame
Slipperfoot thickness 4.03 mm
[0.159 in]
Piston/slipper end play 0.102 mm
[0.004 in]
L Frame
Slipperfoot thickness 2.67 mm
[0.105 in]
Piston/slipper end play 0.102 mm
[0.004 in]
Inspect guide, retainer, and pins
OVERVIEW 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.
PISTONS AND SLIPPERS 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
14 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BLOCK SPRING, AND
WASHERS
i
Washer
Cylinder block spring
Spring retainer
Retaining ring
P101 472
If cylinder kit was fully dissembled, visual
inspection of the cylinder block, spring,
and washers should indicate minimal
wear. Replace if cracks or other damage
is present.
CYLINDER BLOCK 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.
C100
A
flat to 0.002 mm
[flat to 0.000080 in]
M
i
f
P101 358
MB
K Frame 38 cc 45 cc
Minimum cylinder
block height (A)
56.48 mm
[2.224 in]
Maximum block bore
diameter (B)
16.44 mm
[0.65 in]
17.98 mm
[0.71 in]
L Frame 25 cc 30 cc
Minimum cylinder
block height (A)
50.8 mm
[2.00 in]
Maximum block bore
diameter (B)
13.88 mm
[0.546 in]
15.22 mm
[0.60 in]
Inspect block spring and washers
Inspect cylinder block
15 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
Inspect the shaft for any signs of damage.
Replace the shaft if a groove exists at
the sealing land surface that may let dirt
into or hydraulic uid out of the unit. If
necessary, clean the sealing area with
a non-abrasive material. Inspect the
input splines or keyway, block spines
and output splines. Replace the shaft if
damaged. Ensure that the shafts splines
are straight and lubricate the shaft with a
light coating of hydraulic uid.
SHAFT
J010
i
P101 360
l
Inspect shaft
CONTROL
C112 i
C106A d
iC132
C103
dC103A
C133
C113
C134
C115
C114
C135
C117 d
dC136
C116 d
C117 d
C118 i
iC138
E101 192
R
R
C102
C106
Carefully examine the LS plug for signs
of wear. Also check the small tip of the
LS plug for heavy wear and replace if
necessary. Inspect each spools springs
to make sure they are intact. Check
the inside and outside surfaces of the
springs for wear and replace if necessary.
Check the spools outside diameter for
scratches and / or burrs. Clean and coat
all spools, bores, and seals with a light
coating of hydraulic oil.
Inspect control components
16 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
SWASHPLATE
i
P101 362
B040
JOURNAL BEARING
B030
i
P101 363
Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect the
swashplates slipper running surface for
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
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.
17 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
ENDCAP
B095
B090
P101 484
i
J050
Inspect the endcap. Remove the check
valve (B095) to expose the spring (B090).
Check and record orientation of the
timing pin (J050). Inspect the check valve
for wear on its sealing face and replace
if necessary. Make sure the spring is
undamaged. Carefully check the bearing
cup for wear, and ensure that it ts
tightly.
Inspect endcap and components
Inspect the valve plate for scratches and grooves. Check the plate for evidence of
any cavitation along the running face of the valve plate. If pitting from cavitation
exists, replace the valve plate. Check for excess wear on the brass running face. If any
discoloration or burn marks 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 0.005 mm
[0.0002 in] convex. A magnetic particle inspection is recommended to detect cracks. The
valve plate must be replaced if any cracks exist.
B090
3.88 mm [0.153 in] min.
0.025 mm
[0.001 in]
0.005 mm
[0.00020 in]
convex max
i
a
f
P101 419
18 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
SHAFT BEARING KITS
i
l
e
P101 366
The tapered roller bearing kits consist of
a cup and cone. Both the cup and cone
should be free of excessive wear and
contamination. Rotate the bearings to
check for smoothness. If a contaminated
bearing is suspected, clean with a solvent
and lubricate with hydraulic uid. If the
problem is not remedied by cleaning,
replace the bearing. Also inspect for
uneven wear. If abnormal wear is found,
replace the bearing kit.
Inspect shaft bearings
Inspect the servo piston guide (L080)
for abnormal wear. Check the inside
diameter of the bore for galling or
excessive wear. Inspect the servo piston
(L020) for wear on its end and for
scratches along its cylindrical surface.
Replace both parts if any wear is
noticeable.
SERVO PISTON AND
GUIDE
L080
L020
i
P101 365
Inspect servo piston and guide
19 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
HOUSING
i
P101 489
Inspect the housing to ensure that it is
clean and free of foreign material. Inspect
the swashplate, bearing surfaces, and
endcap mating surfaces.
Inspect housing
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.
J140 i
J095 d
J100
J090 d
J085
J120
J110
J130
i
E101 197
Inspect auxiliary pad components
20 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
1. Coat the journal bearings (B030)
with hydraulic uid and install them
into the pump housing. Punch in
retaining pins (B071) a minimum of
0.5 mm [0.002 in] below the bearing
surface.
If journal bearings are reused, reinstall
them in their original orientation and
position.
JOURNAL BEARING
INPUT SHAFT
BIAS SPRING,
SWASHPLATE, AND
BEARING
B060
B050
lB040
J010
B030
B025
B071
l
l
P101 490
3. Insert the input shaft (J010) through
the bearing into the housing.
2. Reinstall shaft bearing cup (B060)
and cone (B050). Before replacing
the bias spring (B025), coat the
curved surface of the swashplate
(B040) with hydraulic uid. Tilt the
bias spring inward towards the
center of the pump housing. To
insert the swashplate, tilt the servo
arm downward and into the pump
housing. Make sure the cast knob
on the swashplate ts over the bias
spring and that it settles properly
unto the journal bearings.
Install housing components
21 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
4. Coat all parts with hydraulic uid
prior to reassembly.
5. 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
6. Turn the block over and install the
retaining ring (L Frame only; K048),
hold-down pins (K046), and ball
guide (K047) to the cylinder block.
7. 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
P101 356
K046
K048 (L Frame only)
Prevent shaft from rotating
P101 491E
Slightly rotate
cylinder block
Assemble cylinder kit
Install cylinder block
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.
CYLINDER KIT
INSTALLATION
Be sure to install the slipper retainer so it mates correctly with the ball guide (concave
side of the slipper retainer against the convex side of the ball guide).
8. 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.
22 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
9. Install the inlet check valve spring
(B090) and poppet (B095) into the
endcap (J020). A small amount
of grease will keep the poppet in
position. Clean the valve plate (B070)
and endcap (J020). Install the timing
pin (J050) in the endcap and verify
that it is properly oriented with the
split facing into or out of the slot
in the valve plate. The timing pin
should be installed 3.6 0.25 mm
[0.14 0.01 in] above the endcap
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, check valve, and
bearing cup. Install the piston (L020)
into the guide (L080), and torque the
guide to 61 - 75 Nm [45 - 55 lbfft].
VALVE PLATE AND
ENDCAP
eB070
J050 R
B020
eJ020
B090
B095 g
P101 492
g
B010
L080
L020
t61 - 75 Nm
[45 -55 lbfft]
B045 g
gB046
J030
8 mm
47.5 to 61 Nm
[35 to 45 lbfft]
J020
I
t
P101 493
Install endcap components
Install endcap 10. Using assembly grease to hold
seals, install the endcap to the
housing. Ensure that seals remain
properly seated and are not pinched
during assembly. Install and torque
endcap screws at 47.5 to 61 Nm
[35 to 45 lbfft], using the criss cross
pattern, and retorque the rst screw
to ensure proper torque retention.
23 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
SHAFT SEAL 11. 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 deep enough to allow
the retaining ring to be installed.
Press evenly to avoid binding and
damaging the seal. Install snap ring
(K010).
Install shaft seal
E101 191
K020 P
K010

24 BLN 10196 520L0632 May 2005

Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
12. Clean and lubricate all control parts
and cover with a light coating of
hydraulic uid prior to reassembly.
13. 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 (C106), torque at
10.8 to 13.5 Nm [8 to 10 lbfft]. Place
the two LS springs (C115, C114) 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 lbfft].
CONTROL
C112 i
C106A d
iC132
C103
dC103A
C133
C113
C134
C115
C114
C135
C117 d
dC136
C116 d
C117 d
C118 i
iC138
P101 370
R
R
C102
t7.5 to 10.8 Nm
[5.5 to 8.0 lbfft]
t10.8 to 13.5 Nm
[8 to 10 lbfft]
(C103 and C106)
C106
C200
C300
I5 mm
d
P101 367
t15 to 18 Nm
[11 to 13 lbfft]
15. Using petroleum jelly to retain them,
Install the 3 seal rings (C200) in the
recesses on the control housing.
Install the control assembly onto the
endcap using the 4 screws. Torque at
15 to 18 Nm [11 to 13 lbfft] using a
criss cross pattern and retorque the
rst screw to ensure proper torque
retention.
14. 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 lbfft]. to
retain the adjusting plug.
Assemble the control
Install the control
PC and LS spools need
to be adjusted to proper
setting according to tag
nomenclature
25 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
AUXILIARY PAD 16. Install the adapter (J085) with new O-rings (J090, J095). Tighten the screws (J100) at
67.5 to 82.5 Nm [49.8 to 60.8 lbfft].
17. Install the coupling (J140) onto the shaft.
18. Install the seal (J120) and plate cover (J130). If you have auxiliary pad B, install a new
O-ring (J120). Tighten the plate cover screws (J130) to the specications shown in
the drawings below.
J140 i
J095 d
J100
J090 d
J085
J120
J110
J130
E101 198
t36.6 to 50.1 Nm
[27.0 to 37.0 lbfft]
t67.5 to 82.5 Nm
[49.8 to 60.8 lbfft]
Install auxiliary A pad
J140
J095 d
J100
J090 d
J085
J120 d
J110
J130
t61 to 73 Nm
[45 to 54 lbfft]
t67.5 to 82.5 Nm
[49.8 to 60.8 lbfft]
E101 223
Install auxiliary B pad
26 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Notes
27 BLN 10196 520L0632 May 2005
Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Notes
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Postfach 2460, D-24531 Neumnster
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Phone: +45 7488 4444, Fax: +45 7488 4400
www.sauer-danfoss.com
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BLN 10196 520L0632 May 2005
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