Series 45 Frame J

Open Circuit Axial

Piston Pumps
Repair Manual
2 BLN 10230 520L0610 May 2005
Series 45 Frame J 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 478, F101 480, F101 479, P101 854
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
introduces them. Thereafter, the terms and acronyms receive no special formatting.
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TABLES, ILLUSTRATIONS,
AND COMPLEMENTARY
INFORMATION
SPECIAL TEXT
FORMATTING
TABLE OF CONTENTS
Using this manual
3 BLN 10230 520L0610 May 2005
Series 45 Frame J 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
Detach control ................................................................................................................................................. 8
Endcap ............................................................................................................................................................... 8
Cylinder kit ........................................................................................................................................................ 9
Input shaft, swashplate, and bias spring ................................................................................................ 9
Roller bearing, cup, and journal bearings ............................................................................................10
Shaft seal .........................................................................................................................................................10
Control ..............................................................................................................................................................11
PC only ........................................................................................................................................................11
PC / LS .........................................................................................................................................................11
Cylinder block kit disassembly ................................................................................................................12
Disassemble the cylinder block kit ...................................................................................................12
Block spring removal .............................................................................................................................12
INSPECTION Overview .........................................................................................................................................................13
Pistons and slippers .....................................................................................................................................13
Ball guide, slipper, retainer, and hold-down pins ..............................................................................13
Block spring, and washers .........................................................................................................................14
Cylinder block ...............................................................................................................................................14
Control ..............................................................................................................................................................15
Input shaft .......................................................................................................................................................16
Swashplate ......................................................................................................................................................16
Journal bearings ...........................................................................................................................................16
Valve plate .......................................................................................................................................................17
Endcap .............................................................................................................................................................17
Servo piston ...................................................................................................................................................18
Housing ...........................................................................................................................................................18
Shaft bearing kits .........................................................................................................................................18
Auxiliary pad ..................................................................................................................................................19
ASSEMBLY Journal bearing .............................................................................................................................................20
Bearings, swashplate, and shaft ..............................................................................................................20
Cylinder kit assembly ..................................................................................................................................21
Cylinder kit installation ..............................................................................................................................21
Valve plate and endcap .............................................................................................................................22
Shaft seal .........................................................................................................................................................23
PC control ........................................................................................................................................................23
LS control (optional) ....................................................................................................................................24
Auxiliary pad ..................................................................................................................................................25
Install the control .........................................................................................................................................26
4 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Introduction
OVERVIEW This manual details the major repair procedures for Series 45 Frame J 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 J Open Circuit Axial Piston Pump Service Manual, 520L0607. 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 10230 520L0610 May 2005
Series 45 Frame J 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 10230 520L0610 May 2005
Series 45 Frame J 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 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
J100
J110
J130
J140
J080
J120
dJ095
dJ090
J020
E101 194
h
9
/16 inch
I8 mm
Remove auxiliary A pad
AUXILIARY PAD
J080
J140
J110
J130
J100
dJ095
dJ120
dJ090
J020
E101 195
h inch
I8 mm
Remove auxiliary B pad
J090 d
J140
J080
J100
J120 d
J110
J095 d
J020
J130
E101 196
I8 mm
h inch
Remove auxiliary C pad
If a second pump is used, you must remove the second pump. 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 or C
pad, discard the O-ring (J120).
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).
8 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
C200 d
C300
E101 174
I4 mm
DETACH CONTROL 5. Remove the control from the endcap
by removing the 4 control bolts
(C300), using a 4 mm internal hex
wrench.
6. Remove and discard the 4 O-rings
(C200).
Remove control
7. Remove the 4 endcap screws (J030)
using a 10 mm internal hex wrench.
8. Carefully remove the endcap (J020).
Prevent the valve (B090) plate from
falling off.
9. Place the endcap and valve plate in
a clean area, protecting them from
contamination.
10. Remove the bearing cup (B010),
bearing cone (B020) and housing
O-ring (K060). Discard the O-ring.
ENDCAP
J030
B090
K060
J020
E101 175
I10 mm
d
B020
B010
Remove endcap and components
9 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CYLINDER KIT
sK041
P101 368
Remove cylinder block kit 11. Tilt the housing on its side to allow
uid to drain.
12. Remove the cylinder block kit while
holding onto the front shaft.
13. Set cylinder block on a clean dry
surface.
14. Rotate pump back to a position so
that the shaft is pointing down.
15. Pull the shaft (J010) from the shaft
seal.
16. Compress the bias spring (B025) and
rotate the servo piston assembly
(P020) towards the swashplate
(B040).
17. Lift the swashplate/servo piston
assembly up at an angle and remove
it from the housing.
18. Remove the servo piston (P020)
and bias spring (B025) from the
swashplate by removing the clevis
pin (B043) and snap ring (B044).
Discard the snap ring.
INPUT SHAFT,
SWASHPLATE, AND BIAS
SPRING
K030
pJ010
E101 176
B040
B025
B044
B043
P020
Remove shaft, swashplate, and bias spring
10 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
19. Pull to remove the front tapered
roller bearing cup (B060) and cone
(B070).
20. Examine the cradle bearings
(B030) to determine if they need
replacement.
Removing the pins (B071) will likely
damage the cradle bearings, so make
sure you have replacement bearings
before you remove them.
21 If cradle bearings need replacing,
remove the 2 pins (B071) holding the
cradle bearings, and then remove the
cradle bearings. Note the location
and orientation of the bearings for
re-installation.
iB030
B071
pB070
pB060
E101 178
R
K020 p
K010
E101 191
ROLLER BEARING, CUP,
AND JOURNAL BEARINGS
SHAFT SEAL
Remove bearings
22. Orient the housing with the ange
facing up.
23. Using snap-ring pliers, remove the
snap ring (K010).
24. 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 shaft seal
11 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
ipping or relocating the
housing as not to lose or
damage the spool.
CONTROL PC only
Remove the plug (C103) and O-ring
(C103A). Discard the O-ring. Remove the
screw (C102). Remove the spool (C132).
Note the orientation of the spool for
reinsertion. There may be differences in
reinserting into the same bore. Remove
the adjusting screw (C138) and O-ring
(C138A). Discard the O-ring. Remove
the springs (C134, C135) along with the
spring guide (C133).
PC / LS
Remove the 4 plugs (C103, C104, C105,
C106) and their O-rings (C103A, C104A,
C105A, C106A). Discard the O-rings.
Remove the 2 set screws (C102). Remove
the spools (C112, C132). Note which bore
each spool came out of. Also note the
orientation of each spool for reinsertion.
There may be differences in reinserting
into the same bore.
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 (C116) and 2 backup rings (C117).
Discard the O-ring and backup rings.
Remove the springs (C114, C115) and
spring guide (C113).
dC103A
C132 R
C133
C135
C134
dC138A
C138
C102
E101 193
C103
Disassemble the PC control
C112 R
C104
C103
C105
C105A
C106
C102
C113
C115
C114
C117 d
C116 d
C117 d
C118
C133
C135
C134
C138
E101 180
dC138A
RC132
dC103A
d
C106A
d
C104A d
Disassemble the PC / LS control
12 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Disassembly
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 hourly usage
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
2. Remove the ball guide (K047).
3. Remove the 3 pins (K046).
Most repairs do not require block spring
removal. Perform this procedure only
if you suspect problems with the block
spring.
Block spring removal
4. Turn the block over. Using a press,
apply pressure on the block spring
washer (K044) to compress the block
CYLINDER BLOCK KIT
DISASSEMBLY
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
i
E101 012
l
R
Disassemble the cylinder block kit
A Warning
Risk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf ].
Use a press sufcient
to maintain this force
with reasonable effort.
Ensure the spring is
secure before attempting
to remove the spiral
retaining ring. Release the
pressure slowly after the
retaining ring is removed.
spring (K043). Compress the spring enough to safely remove the spiral retaining ring
(K045). While maintaining pressure, unwind the spiral retaining ring. Carefully release
the pressure and remove the outer block spring washer, block spring, and inner block
spring washer (K042) from the cylinder block. A
13 BLN 10230 520L0610 May 2005
Series 45 Frame J 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.
J Frame
Slipperfoot thickness 3.23 mm
[0.127 in]
Piston/slipper end play 0.05 mm
[0.002 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 10230 520L0610 May 2005
Series 45 Frame J 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.
K041
flat to 0.002 mm
[0.000079 in]
i
f
P104 340
MB
MA
J Frame 45-60 cc 65-75 cc
Minimum cylinder
block height (A)
62.25 mm
[2.45 in]
Maximum block
bore diameter (B)
19.8 mm
[0.785 in]
21.57 mm
[0.85 in]
Inspect block spring and washers
Inspect cylinder block
15 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Inspection
CONTROL Carefully examine the PC (and LS) plug(s) for signs of wear. Also check the small tip of the
plug(s) for heavy wear and replace if necessary. 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.
C103
C103A
iC132
C133
C135
C134
C138A
C102
C112 i
C104
C103
C103A
C105
C105A
C106
C102
C113
C115
C114
C117
C116
C117
C118 i
C133
C135
C134
iC138
C138A
E101 181
iC132
iC138
e
e
e
C104A
C106A
Inspect the PC control Inspect the PC/LS control
16 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Inspection
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.
INPUT SHAFT
SWASHPLATE
JOURNAL BEARINGS
J010
i
P104 334
l
Inspect shaft
B040
i
P104 336
i
P104 335
B030
Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect the
swashplates slipper running surface for
damage 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 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.
Inspect swashplate
17 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Inspection
3.88 mm [0.153 in] min.
0.025 mm
[0.001 in]
0.005 mm
[0.0002 in]
convex max
a
f
P101 069E
s
i
B090
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.
ENDCAP
i
E101 192
B091 i
B092 i
e
RJ050
Inspect the endcap. Remove the check
valve (B092) to expose the spring (B091).
Check and record orientation of the
timing pin (J050) The split in the timing
pin should be facing into or out of the
slot in the valve plate. Inspect the check
valve for wear on its sealing face and
replace if necessary. Make sure the spring
is undamaged. Replace any components
if excess wear is present.
Inspect endcap and components
18 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Inspection
SERVO PISTON Check the servo piston assembly (P020)
for any obvious wear or damage. Check
the corresponding endcap bore for
galling or excessive wear. Discard the
piston if damaged. Replace the servo
piston-rings.
HOUSING Inspect the housing to ensure that it is
clean and free of foreign material. Inspect
the swashplate bearing surfaces, and
endcap mating surfaces.
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.
SHAFT BEARING KITS
i
P104 337
Inspect housing
Inspect servo piston
P020
d
i
P104 338
i
l
e
E101 182
Inspect shaft bearings
19 BLN 10230 520L0610 May 2005
Series 45 Frame J 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
iJ140
J080
J120
dJ095
dJ090
J020
E101 199
i
20 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
lB040
B043
B044
B025
P020
J010
E101 183
B070
B060
lB030
B071 P
l
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
BEARINGS, SWASHPLATE,
AND SHAFT
2. Reinstall shaft bearing cup (B060)
and cone (B070). Before replacing
the bias spring (B025), coat the
curved surface of the swashplate
with hydraulic uid.
3. Reinstall the swashplate/servo
piston/bias spring assembly in
its original orientation in the
housing. Rotate the servo piston
perpendicular to the swashplate,
and at the same time compress the
bias spring to t into housing pocket.
Lubricate all sides of the servo piston
and its respective bore liberally with
hydraulic oil. Also, lubricate the at
face of the swashplate to prevent
premature wear during start-up.
4. Insert the input shaft (J010) through
the bearing into the housing. You
may need to push on the servo
piston to rotate the swashplate in
order to put the shaft in properly.
Install housing components
21 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
5. Coat all parts with hydraulic uid
prior to reassembly.
6. 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
7. Turn the block over and install the
hold-down pins (K046), and ball
guide (K047) to the cylinder block.
8. 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
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
Fix the shaft
on this end
Slightly rotate
cylinder block
E101 184
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
i
E101012
l
R
before assembly. Set the cylinder kit aside on a clean surface until needed.
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).
9. 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 over 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 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
10. Clean the valve plate (B090) and
endcap. 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 to 3.61 0.25 mm
[0.14 0.01 in] above the valve plate
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 (B092),
and bearing cup (B010).
To insure proper pump operation, it is
extremely important to ensure that there
is no contamination between the endcap
and valve plate.
VALVE PLATE AND
ENDCAP
eB090
J050
B091
B092
E101 185
B010
e
g
K060
J020
J030
10 mm
127 to 155 Nm
[94 to 114 lbfft]
I
t
E101 186
g
B020
Install endcap components
Install endcap 11. Install the bearing cone (B020) onto
the shaft. Using assembly grease
to hold the seal (K060), install the
endcap to the housing. Ensure that
seals remain properly seated and are
not pinched during assembly. With
a 10 mm internal hex wrench, install
and torque endcap screws at 127
to 155 Nm [94 to 114 lbfft], using
the criss cross pattern. Retorque the
rst screw to ensure proper torque
retention.
23 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
SHAFT SEAL
K020 P
K010

E101 187
Install shaft seal
Assemble PC (only) control 13. Clean all control parts and cover with
a light coating of hydraulic uid prior
to reassembly.
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
(C103A). 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 and install it so that it
sits one turn below the surface of the
control housing. Install and tighten
set screw (C102) at 7.5 to 10.8 Nm
[5.5 to 8.0 lbfft] to retain the
adjusting plug.
PC CONTROL
dC103A
C132 R
C133
C135
C134
dC136
C138
C102
E101 179
t7.5 to 10.8 Nm
[5.5 to 8.0 lbfft]
t10.8 to 13.5 Nm
[8.0 to 10.0 lbfft]
C103
12. Lubricate the lip of the new shaft
seal (K020) with clean hydraulic uid.
Place a protective sleeve over the
shaft end to prevent damage to the
seal during installation. Keeping the
seal perpendicular to the shaft, press
the new seal into the housing just far
enough to clear the retaining ring
groove. Install seal with the cupped
side toward the shaft bearing. Do not
damage the seal during installation.
Using the appropriate snap ring
pliers, install the seal retaining ring
(K010). Remove the installation
sleeve.
24 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
C112 R
C104 t
tC103
C105 t
C105A
tC106
tC102
C113
C115
C114
C117 d
C116 d
C117 d
C118
C133
C135
C134
C138
E101 189
dC136
RC132
dC103A
d
dC106A
C104A d
Assemble PC/LS control Install the PC portion as described in PC
control, page 23.
15. Hold the control in a horizontal
position. Install the spherical end of
the LS spool (C112) into the LS bore
(see illustration). Using a new O-ring,
install the LS plug (C104), torque at
10.8 to 13.5 Nm [8 to 10 lbfft]. Place
the 2 LS springs (C114, C115) onto
the LS spring guide (C113) and install
into the LS bore. Place a new O-ring
(C116) and back-up rings (C117)
onto the LS adjustment screw (C118).
Install the LS plug assembly so that it
sits one turn below the surface of the
control housing. Install and tighten
set screw (C102) at 7.5 to 10.8 Nm
[5.5 to 8.0 lbfft]. Also, install the
plugs (C105, C106) with new O-rings.
Torque the plugs at 10.8 to 13.5 Nm
[8 to 10 lbfft].
PC and LS spools need to be adjusted
to proper setting according to tag
nomenclature.
LS CONTROL (OPTIONAL)
25 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
AUXILIARY PAD 16. Install the adapter (J080) with new O-rings (J090, J095). Tighten the screws (J100) at
47.5 to 61 Nm [35 to 45 lbfft].
17. Install the coupling (J140) onto the shaft.
18. Install the plate cover (J130) and seal (J120). If you have auxiliary pad B or C,
install a new O-ring (J120). Tighten the plate cover screws (J130) at 91 to 111 Nm
[67 to 82 lbfft]. If you have an auxiliary A pad, install the J130 screws at 37 to 50 Nm
[27 to 37 lbfft].
J100
J110
J130
J140
J080
J095 d
J090 d
E101 259
h
9
/16 inch
I8 mm
t37 - 50 Nm
[27 - 37 lbfft]
t47.5 - 61 Nm
[35 - 45 lbfft]
J020
J120
Remove auxiliary A pad
J110
J130
dJ095
dJ120
dJ090
J020
E101 260
h inch
t91 - 111 Nm
[67 - 82 lbfft]
I8 mm
t47.5 - 61 Nm
[35 - 45 lbfft]
J100
J140
J080
Remove auxiliary B pad
dJ090
J140
J080
J100
dJ120
J110
dJ095
J020
J130
E101 261
h inch
t37 - 50 Nm
[27 - 37 lbfft]
I8 mm
t37 - 50 Nm
[27 - 37 lbfft]
Remove auxiliary C pad
26 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Assembly
19. Using petroleum jelly to retain them, install 4 new seal rings (C200) in the recesses
on the control housing. Install the control assembly onto the endcap using the 4
screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 lbfft] using a criss cross pattern
and retorque the rst screw to ensure proper torque retention.
Install the control
E101 190
C200 d
C300
t5.4 to 7.5 Nm
[4 to 5.5 lbfft]
I4 mm
INSTALL THE CONTROL
27 BLN 10230 520L0610 May 2005
Series 45 Frame J Open Circuit Axial Piston Pump
Repair Manual
Notes
Sauer-Danfoss Mobile Power and Control Systems
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We offer our customers optimum solutions for their needs and
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products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
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2800 East 13th Street
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Phone: +1 515 239-6000, Fax: +1 515 239 6618
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Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
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DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
www.sauer-danfoss.com
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BLN 10230 520L0610 May 2005
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