45 Series H Frame Repair Manual (520L0612 19Sep2005 REV a)

Series 45H Frame Open CircuitAxial Piston Pumps

Repair Manual

2 BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair 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 aren’t in conflict with agreed specifications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group.

Front cover illustrations: F101348, F101 347, F101 345, P106 084

ORGANIZATION AND HEADINGS

To help you quickly find information in this manual, the material is divided into sections, topics, subtopics, and details, with descriptive headings set in red type. Section titles appear at the top of every page in large red type. Topic headings appear in the 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) files, these references represent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identified by titles set in 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 files, these references represent clickable hyperlinks that jump to the corresponding document pages.

Defined terms and acronyms are set in bold black type in the text that defines or introduces them. Thereafter, the terms and acronyms receive no special formatting.

Black italic type is used in the text to emphasize important information, or to set-off words and terms used in an unconventional manner or alternative context. Red and blue italics represent hyperlinked text in the PDF version of this document (see above).

An indented Table of Contents (TOC) appears on the next page. Tables and illustrations in the TOC set in blue type. In the PDF version of this document, the TOC entries are hyperlinked to the pages where they appear.

TABLES, ILLUSTRATIONS, AND COMPLEMENTARY INFORMATION

SPECIAL TEXT FORMATTING

TABLE OF CONTENTS

Using this manual

3BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualContents

Overview ........................................................................................................................................................... 5General instructions ...................................................................................................................................... 5Safety precautions ......................................................................................................................................... 6

Unintended machine movement ....................................................................................................... 6Flammable cleaning solvents ............................................................................................................... 6Fluid under pressure ................................................................................................................................ 6Personal safety ........................................................................................................................................... 6

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

Auxiliary pad .................................................................................................................................................... 8Endcap ............................................................................................................................................................... 9Cylinder kit ........................................................................................................................................................ 9Bias piston, servo piston, and optional displacement limiter .......................................................10Pressure compensator valve ....................................................................................................................10

Old style .....................................................................................................................................................10New style ...................................................................................................................................................10

Input shaft, and swashplate ......................................................................................................................11Swashplate, journal bearing and roller bearing ................................................................................11Shaft seal .........................................................................................................................................................12Control ..............................................................................................................................................................12Cylinder kit ......................................................................................................................................................13

Disassemble the cylinder block kit ...................................................................................................13Block spring removal .............................................................................................................................13

Overview .........................................................................................................................................................14Pistons and slippers .....................................................................................................................................14Ball guide, slipper retainer, and hold-down pins ...............................................................................14Block spring, and washers .........................................................................................................................15Cylinder block ...............................................................................................................................................15Input shaft ......................................................................................................................................................16Swashplate ......................................................................................................................................................16Journal bearings ...........................................................................................................................................16Servo piston and displacement limiter ................................................................................................16Bias piston .......................................................................................................................................................17Valve plate .......................................................................................................................................................17Endcap .............................................................................................................................................................18Shaft bearing kits .........................................................................................................................................18Housing ...........................................................................................................................................................18PC valve ............................................................................................................................................................19Control ..............................................................................................................................................................19Auxiliary pad ..................................................................................................................................................20

INTRODUCTION

DISASSEMBLY

INSPECTION

4 BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualContents

Journal bearing ............................................................................................................................................21Front bearing and swashplate ................................................................................................................21Input shaft .......................................................................................................................................................21Servo and bias pistons and displacement limiter ............................................................................22Pressure compensator valve ....................................................................................................................22

New style ..............................................................................................................................................22Old style ................................................................................................................................................23

Control ..............................................................................................................................................................23Cylinder kit assembly ..................................................................................................................................24Cylinder kit installation ..............................................................................................................................24Valve plate .......................................................................................................................................................25Endcap .............................................................................................................................................................25Shaft seal .........................................................................................................................................................26Auxiliary pad ..................................................................................................................................................27

ASSEMBLY

5BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualIntroduction

OVERVIEW This manual details the major repair procedures for Frame H open circuit axial piston pumps. These include the complete disassembly, inspection, and reassembly of the unit. Where rework of worn or damaged components is possible, specifications 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 certified on a regular basis.

W WarningUse of components that do not comply with rework specifications may result in loss of performance, which may constitute a safety hazard. Do not reuse components that don’t comply to given specifications: replace with genuine Sauer-Danfoss service parts.

Minor repair procedures, adjustments, and troubleshooting information are given in the Frame H Open Circuit Axial Piston Pumps Service Manual, 520L0611. Minor repairs include service operations that can be performed without removing the unit’s endcap. Removal of the endcap voids your warranty.

Follow these general procedures when repairing Series 45 variable displacement open circuit pumps.

w Remove the unitPrior to performing major repairs, remove the unit from the vehicle/machine. Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid may be under high pressure and / or hot. Inspect the outside of the pump and fittings for damage. Cap hoses after removal to prevent contamination.

e Keep it cleanCleanliness is a primary means of assuring satisfactory pump life, on either new or repaired units. Clean the outside of the pump thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

As with any precision equipment, all parts must be kept free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. If left unattended, cover the pump with a protective layer of plastic.

l Lubricate moving partsDuring assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up.

d Replace all O-rings and gasketsIt is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

t Secure the unitFor major repair, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the pump while removing and torquing the endcap bolts.

GENERAL INSTRUCTIONS

6 BLN 10238 • 520L0612 • August 2005


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 movementW WarningUnintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable / disconnect the mechanism while servicing.

Flammable cleaning solventsW WarningSome cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

Fluid under pressureW WarningEscaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic fluid.

Personal safetyW WarningProtect yourself from injury. Use proper safety equipment, including safety glasses, at all times.

7BLN 10238 • 520L0612 • August 2005


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 specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage

Note correct orientation

Mark orientation for reinstallation

Torque specification

Press in – press fit

Pull out with tool – press fit

Cover splines with installation sleeve

Pressure measurement / gauge location or specification

SYMBOLS USED IN SAUER-DANFOSS LITERATURE

The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.

8 BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualDisassembly

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 287

h9/16 inch

I8 mm

Remove auxiliary A pad

AUXILIARY PAD

J080

J140

J110

J130

J100

dJ095

dJ120

dJ090

J020

E101 288

h ¾ inch

I8 mm

Remove auxiliary B pad

J090 d

J140

J080

J100J120 d

J110

J095 d

J020

J130

E101 289

I8 mm

h¾ inch

Remove auxiliary C pad

If a second pump is used, you must remove the second pump. You must remove auxiliary C pad to remove the endcap. You don’t need to remove auxiliary pads A or B to remove the end cap.

1. Remove the plate cover screws (J130) and remove the plate cover (J110).

2. Remove the coupling (J140) and the pad seal (J120). If you have an auxiliary B or C pad, discard the O-ring (J120). The seal (J120) may be re-used for auxiliary A pads if it is undamaged

3. Remove the auxiliary pad screws (J100) with an 8 mm internal hex wrench and remove the adapter (J080).

4. Remove and discard the O-rings (J090, J095).

9BLN 10238 • 520L0612 • August 2005


1. Remove the 4 endcap screws (J030) using a 10 mm internal hex wrench.

2. Carefully remove the endcap (J020). Prevent the valve plate (B090) from falling off. Keep the timing pin (J050) in the end cap.

3. Place the endcap and valve plate in a clean area, protecting them from contamination.

4. Remove the bearing kit (B01) consisting of cup (B010), and bearing cone (B020). Also remove and discard housing O-ring (K060) and the 2 interface O-rings (K070).

ENDCAP

dK060

K070 d

B090 s

I10 mm

B010

B020B01

J030

J050

J020

E101 301

Remove endcap and components

CYLINDER KIT 1. Tilt the housing on its side to allow fluid to drain.

2. Remove the cylinder block kit while holding onto the front shaft.

3. Set cylinder block on a clean dry surface.

sP010

E101 292

Remove cylinder block kit

10 BLN 10238 • 520L0612 • August 2005


BIAS PISTON, SERVO PISTON, AND OPTIONAL DISPLACEMENT LIMITER

E101 293

dK110

dK100

B083

dB082

B084

B081

h1-3/8 in

dL020A

L020

h1-3/8 in

L030

L040

L010

Remove servo and bias pistons1. Remove the bias guide plug (B081) using a 1-3/8 inch hex wrench. Also, remove the bias spring (B083), and piston (B084). Discard the O-rings (B082, K100) and backup ring (K110).

It may be necessary to remove the piston and spring by reaching through the inside of the unit and pushing them out through the bore.

2. Remove the servo piston plug (L020) and servo piston (L010) using a 1-3/8 inch hex wrench. Discard the O-ring (L020A).

It may be necessary to remove the piston by reaching through the inside of the housing.

3. Note the orientation of the servo piston. The end of the piston with the hole should be facing upward.

dD016

dK080

dK090

D015

D014

D013

D019

D018

D016 d

K080 d

K090 d

A98-21thru

A00-23

E101 328

New style

Old style

C120

C120A

O

Remove PC valvePRESSURE COMPENSATOR VALVE

Old style1. Remove the PC plug (C120) from the

pump using a 3/16 inch hex wrench. Discard the O-ring (C120A).

2. Remove the PC cartridge using an 11/16 inch hex wrench. Discard the O-rings (D016, K080) and backup ring (K090).

3. Further disassembly can be made by loosening the locknuts (D015, D018) on the set screw (D014).

New style1. Remove the PC plug (C120) from the

pump using a 9/16 inch hex wrench. Discard the O-ring (C120A)

2. The new style is a one-piece cartridge. Remove the PC cartridge with a 11/16 inch hex wrench. Discard the O-rings (D016, K080) and the backup ring (K090).

11BLN 10238 • 520L0612 • August 2005


INPUT SHAFT 1. Rotate pump back to a position so that the shaft is pointing down.

2. Pull the shaft (J010) from the shaft seal.

E101 294

J010

Remove shaft

1. Lift the swashplate (B040) up at an angle and remove it from the housing. Note the orientation for reinstallation. Reinstall the swashplate in its original orientation to reduce start-up wear.

2. Remove the journal bearings (B030). It is important to record the location and orientation of the journal bearings if they are to be reused.

3. Remove the roller bearing kit (B06) consisting of cone (B070) and cup (B060). You may need to remove the shaft seal before removing the cup (see following procedure for seal removal).

SWASHPLATE, JOURNAL BEARING AND ROLLER BEARING

B030

B060

B070

E101 295

B06

B040

Remove swashplate and bearings

12 BLN 10238 • 520L0612 • August 2005


1. Orient the housing shaft side up. C

CCautionThe PC spool may fall out once the endcap is removed and the housing is tipped in this orientation. Be careful not to damage the spool.

2. Remove the retaining-ring (K010) using internal retaining ring pliers.

3. Remove the shaft seal if necessary.

Replace the shaft seal every time the shaft is removed from the unit.

SHAFT SEAL

K020 P

K010

E101 335

b

Remove shaft seal

CONTROL Unscrew the plug (C030) using a 7/8 inch hex wrench. Discard the O-ring (C040). If the springs (C070, C060) remain in the bore, remove them along with the spring seat (C080) and the PC spool (C090) with a magnet.

C110C130

C020C010

C030

C040C050C060

C070C080

C090

E101 334

Remove the control

13BLN 10238 • 520L0612 • August 2005


CYLINDER KITDisassemble the cylinder block kit1. Pull to remove the slipper retainer

(K049) with the pistons (K050) from the cylinder kit.

The pistons are not selectively fitted, however units with high hour usage may develop wear patterns. Number the pistons and bores for reassembly if they are to be reused.

2. Remove the ball guide (K047) and retaining ring (K048).

3. Remove the 3 pins (K046).

K050

K049

K047

K046

K041

K042

K043

K044

K045

P010

i

E101 354

l

R

K048

Disassemble the cylinder block kit

W WarningRisk of personal injury:

Compressing the block spring requires about 350

to 400 N [80 to 90 lbf ]. Use a press sufficient to maintain this force

with reasonable effort. Ensure the spring is

secure before attempting to remove the spiral

retaining ring. Release the pressure slowly after the

retaining ring is removed.

Block spring removal

Most repairs do not require block spring removal. Perform this procedure only if you suspect problems with the block spring.

4. Turn the block over. Using a press, apply pressure on the block spring washer (K044) to compress the block spring (K043). Compress the spring enough to safely remove the spiral retaining ring (K045). While maintaining pressure, unwind the spiral retaining ring. Carefully release the pressure and remove the outer block spring washer, block spring, and inner block spring washer (K042) from the cylinder block. W

14 BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualInspection

BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN PINS

OVERVIEW

PISTONS AND SLIPPERS

After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow to air dry. Blow out oil passages in the housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any rework or resurfacing.

i

Slipperretainer

Ball guide

Hold down pins

P101 471

The ball guide should be free of nicks and scratches, and should not be excessively scored. Examine for discoloration that may indicate excessive heat or lack of lubrication. The slipper retainer should be flat, and slippers should fit in the retainer with minimal side play. Place the hold-down pins on a flat surface and roll them to make sure they are straight. Discard and replace any damaged parts.

H Frame

Slipperfoot thickness 3.23 mm

[0.128 in]

Piston/slipper end play 0.05 mm

[0.002 in]

Inspect guide, retainer, and pins

Inspect the pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.

Inspect the running surface of the slippers. Replace any piston assemblies with scored or excessively rounded slipper edges. Measure the slipper foot thickness. Replace any piston assemblies with excessively worn slippers. Check the slipper axial end-play. Replace any piston assemblies with excessive end-play.

Minimum slipper foot thickness and maximum axial end-play are given in the table to the right.

K050

Slipper

Maximum end play

Minimumslipper footthickness

P104 109E

Inspect pistons

15BLN 10238 • 520L0612 • August 2005


BLOCK SPRING, AND WASHERS

CYLINDER BLOCK

iWasher

Cylinder block spring

Spring retainer

Retaining ring

P101 472

If cylinder kit was fully disassembled, visual inspection of the cylinder block, spring, and washers should indicate minimal wear. Replace if cracks or other damage is present.

Inspect block spring and washers

Examine the running face of the cylinder block. The surface should be smooth and free of nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce output flow.

K041

flat to 0.002 mm

[0.000079 in]

i

fP101 067E

MB

MA

H Frame

Minimum cylinder block height (A)

(57 and 75 cc)

62.23 mm

[2.450 in]

Maximum block bore

diameter (B)

57 cc19.80 mm

[0.779 in]

75 cc21.57 mm

[0.849 in]

Inspect cylinder block

16 BLN 10238 • 520L0612 • August 2005


INPUT SHAFT Check to see that the shaft (J010) and its splines are straight and free of damage or heavy wear. Inspect the shaft surface where it meets the shaft seal. Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic fluid out of the unit. Clean the sealing area with a nonabrasive material if necessary. Lubricate the shaft with a light coat of hydraulic fluid.

Inspect shaft

J010

i

l

P104 423

SWASHPLATE Carefully inspect each surface of the swashplate for wear. All swashplate surfaces should be smooth. Inspect the swashplate’s slipper running surface for flatness and brass transfer. Excessive brass transfer from slippers may indicate that the slippers should be replaced. Finally, check the swashplate bearing journal for scratches. Replace swashplate if necessary.

Inspect swashplate

Check the servo piston (L010) for any obvious wear or damage. Replace piston if necessary. Discard and replace the servo plug O-ring (L020A).

JOURNAL BEARINGS

i

P104 335

B030

Inspect journal bearingsInspect the journal bearings for damage or excessive wear. Replace journal bearings if scratched, warped, or excessively worn. The polymer wear layer must be smooth and intact.

SERVO PISTON AND DISPLACEMENT LIMITER

L020A d

L020

iL010

E101 274

L030

L040

O

Inspect servo piston / displacement limiter

B040

i

P104 353

Swashplate is not reworkable. Servo pads extend above surface of running face, making lapping impossible. Positioning of servo pads is extremely important. Do not remove and repress servo pads.

17BLN 10238 • 520L0612 • August 2005


BIAS PISTON

K110 d

K100 dB083

dB082

B081

B084

E101 273

Inspect bias pistonInspect the bias piston (B084), guide (B081), and spring (B083) for abnormal wear. Replace if necessary. Discard and replace the 2 O-rings (B082, K100) and the backup ring (K110).

On reassembly, the bias piston guide backup ring (K110) must be the ring located closest to the center of the pump.

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 fingernail or pencil tip across the diameter of the sealing land surface (see illustration). No deep or outstanding grooves should be felt, as these may decrease pump flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the endcap and valve plate for any possible contamination; even a few thousandths of an inch may affect pump operation.

VALVE PLATE

Inspect valve plate

Measure the thickness of the valve plate. Ensure that valve plate parallelism is equal to or less than 0.025 mm [0.001 in]. Appearance should be flat and smooth on both the running face and the bottom surface. The valve plate should be flat to 0.0038 mm [0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks. The valve plate must be replaced if any cracks exist.

B090

4.95 mm [0.195 in] min.

0.025 mm

[0.001 in]

0.0038 mm

[0.00015 in]convex max

i

a

f

P104 354E

18 BLN 10238 • 520L0612 • August 2005


ENDCAP Inspect the endcap (J020). Check and record orientation of the timing pin (J050). Carefully check the bearing cup (B010) for wear.

RJ050

iB010

J020 i

iB020

E101 307

B01

Inspect end cap and components

SHAFT BEARING KITS The tapered roller bearing kit consists of a cup and cone. Make sure the cup and cone are free of excessive wear or contamination. Rotate the bearings to check for smoothness. If a contaminated bearing is suspected, clean with a solvent and lubricate with hydraulic fluid.

Replace the bearing if the problem is not remedied by cleaning,

Inspect for uneven wear. If abnormal wear is found, replace the bearing kit.

il

e

E101 182

Inspect shaft bearings

HOUSING Inspect the housing to ensure that it is clean and free of foreign material. Inspect the swashplate bearing surfaces, and endcap mating surfaces. Also inspect the servo and bias piston bores for galling and excessive wear.

Inspect housing

i

P106 010

19BLN 10238 • 520L0612 • August 2005


PC VALVE

CONTROL

Inspect the screen in the end of the valve for contamination. It is important that the valve is not plugged.

Check the spool for nicks and scratches. Make sure the PC spool orifice is not contaminated or plugged.

New style

Old style

screen end

screen

E101 340E

C090 i

E101 341

i

Inspect the control spool and orifice

Inspect the PC valve

20 BLN 10238 • 520L0612 • August 2005


AUXILIARY PAD Inspect sealing surfaces on the endcap and auxiliary pad, and make sure that they are clean and free of contaminants. Inspect the coupling (J140) for any signs of excessive or abnormal wear. Replace all O-rings. Replace excessively worn parts if necessary.

Inspect auxiliary pad components

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 287

h9/16 inch

I8 mm

21BLN 10238 • 520L0612 • August 2005

Series 45 H Frame Open Circuit Axial Piston PumpRepair ManualAssembly

E101 296

B070

B060

B06

K070 d

B030 l

B040 l

J010

JOURNAL BEARING

INPUT SHAFT

FRONT BEARING AND SWASHPLATE

1. Coat the journal bearings (B030) with hydraulic fluid and install them into the pump housing.

If journal bearings are reused, reinstall them in their original orientation and position.

2. Reinstall the front bearing kit (B06). The cup (B060) should be a slip fit with the housing.

3. Coat the curved surface of the swashplate (B040) with hydraulic fluid. Reinstall the swashplate in its original orientation. Lubricate the flat face with hydraulic oil to prevent premature wear during start-up. To insert the swashplate, tilt the ‘ear’ located opposite the control face so that it is raised. Insert the opposite side towards the servo piston.

4. Insert the input shaft (J010) through the bearing into the housing.

Install housing components

22 BLN 10238 • 520L0612 • August 2005


1. Lubricate all sides of the servo piston (L010) and its respective bore liberally with hydraulic oil. Reinstall the servo piston with the ‘hole end’ up. Reinstall the displacement limiter plug (L020) and tighten with a 1 3/8 inch socket to 175-245 N•m

[130-180 lbf•ft].

2. Install the set screw (L040) and use a 19 mm hex wrench to torque the adjustment seal/nut (L030) at 78 to 95 N•m [58 to 70 lbf•ft].

3. Lubricate the bias piston (B084) and its respective bore with a liberal coating of hydraulic oil. Reinstall the bias plug (B081) and spring (B083) with new O-rings. Use a 1 3/8 inch socket to tighten to 175-245 N•m [130-180 lbf•ft].

It is extremely important that the bias piston plug (B081) be correctly torqued, as it may back out at lower torques.

SERVO AND BIAS PISTONS AND DISPLACEMENT LIMITER

E101 297

dK110

dK100

B083

dB082

B084

B081

h1-3/8 in

dL020A

L020

h1-3/8 in

L030

L040

L010

l

Install servo and bias pistons

PRESSURE COMPENSATOR VALVE

D016

K080

K090

E101 356

New style

C120

C120A d

h9/16 inch hex

t16 N•m [12 lbf•ft]

Install PC valveNew style1a. Using a 9/16 inch hex wrench, install

short hex plug (C120) with a new O-ring (C120A). Torque this plug to 16 N•m [12 lbf•ft]. After installing the plug, install the new PC cartridge. Torque to 37 N•m [27 lbf•ft] with an 11/16 inch hex wrench. Reset your pressure compensating setting following the Series 45 Service Manual, BLN-10129, as these do not come preset. The gain for the PC setting is 56.9 bar [825 psi]/turn.

23BLN 10238 • 520L0612 • August 2005


PRESSURE COMPENSATOR VALVE

D016

K080K090

D015

D014

D013

D019

D018

A98-21thru

A00-23

E101 355

Old style

C120

C120A d

I3/16 inch hex

t12.2 N•m [9.0 lbf•ft]

Install PC valveOld style1b. Install the remote PC plug with a

3/16 inch internal hex wrench. Torque this plug to 12.2 N•m [9.0 lbf•ft]. After installing the plug, instal the PC cartridge and torque to 37 N•m [27 lbf•ft] using an 11/16 inch hex wrench. Reset your pressure compensating setting following the Series 45 Service Manual, BLN-10129, as these do not come preset. The new gain for the PC setting is 56.9 bar [825 psi]/turn.

CONTROL

C110C130

C020C010

C030

C040C050C060

C070C080

C090

E101 334

Install the controlInstall the spool (C090) into the bore. Place the springs (C070, C060) onto the spring guide (C080) and install them into the bore. Install the spring seat (C050) onto the springs. Install the seal nut (C020) and lock nut (C130) onto the set screw until snug against the plug. Reinstall the displacement limiter plug (C030) and tighten with a 7/8 inch hex wrench to 40.7-94.9 N•m [30-70 lbf•ft]. Be sure to use a new O-ring (C040).

24 BLN 10238 • 520L0612 • August 2005


1. Coat all parts with hydraulic fluid prior to reassembly.

2. Install the inner block spring washer (K042), block spring (K043), and outer washer (K044) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove. Wind the spiral retaining ring (K045) into the groove in the cylinder block. W

3. Turn the block over and install the retaining ring (K048) and hold-down pins (K046) squarely in their respective grooves. Install the ball guide (K047) to the cylinder block.

4. Install the pistons (K050) to the slipper retainer (K049). Install the piston/retainer assembly into the cylinder block. Ensure the concave surface of the retainer seats on the ball guide. If you’re reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean surface until needed.

K045

K044

K043

K042

K041 P010

K047 l

K049 l

K050 l

K046

E101 357

K048

Assemble cylinder kitCYLINDER KIT ASSEMBLY

W WarningRisk of personal injury:

Compressing the block spring requires about 350

to 400 N [80 to 90 lbf ]. Use a press sufficient to maintain this force with

reasonable effort. Ensure the spring is secure before

attempting to install the spiral retaining ring.

Release the pressure slowly after the retaining ring is

installed.

Be sure to install the slipper retainer so it mates correctly with the ball guide (concave side of the slipper retainer against the convex side of the ball guide).

CYLINDER KIT INSTALLATION

Install cylinder kitSet 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 flange facing downward.

When the pump housing is in its original upright position, the bottom of the cylinder kit should be relatively flush with the shoulder of the shaft.

P010 s

K030

Prevent shaft from rotating

Slightly rotatecylinder block

E101 298

25BLN 10238 • 520L0612 • August 2005


ENDCAP Install the bearing cone (B020) onto the shaft end. Using assembly grease to hold seals (K060, K070), install the endcap to the housing. Ensure that the seals remain properly seated and are not pinched during assembly. With a 10 mm internal hex wrench, install and torque endcap screws at 84.0 to 108.5 N•m [67 to 82 lbf•ft], using the criss cross pattern. Retorque the first screw to ensure proper torque retention.

J030

J020

K070 d

B020dK060

E101 308

I10 mm

t84 - 108.5 N•m [62 - 80 lbf•ft]

Install endcap

VALVE PLATE

MJ050B010 i

J020 i

E101 299

B090 g

e

e

Clean the valve plate (B090) and endcap. Install the timing pin (J050) in the endcap and verify that it is properly oriented. The timing pin should be 4.6 ± 0.25 mm [0.181 ± 0.001 in] above the mounting surface. Apply a liberal amount of assembly grease to the backside of the valve plate surface to hold it in position. Install the valve plate over the timing pin and bearing cup.

To insure proper pump operation, it is extremely important to ensure that there is no contamination between the endcap and valve plate.

Install endcap components

26 BLN 10238 • 520L0612 • August 2005


SHAFT SEAL Cover shaft splines with an installation sleeve. Install a new shaft seal (K020) with the cup side facing the pump. Press seal into housing until it is just below the retaining ring groove. Press evenly to avoid binding and damaging the seal. Install snap ring (K010).

Install shaft seal and retaining ring

K020 P

K010

E101 336

b

27BLN 10238 • 520L0612 • August 2005


AUXILIARY PAD

Torque-to-turn shaft

10.1 to 18.1 N•m [90 to 160 lbf•in]

1. Install the adapter (J080) with new O-rings (J090, J095). Tighten the screws (J100) at 47.5 to 61 N•m [35 to 45 lbf•ft] with a 8 mm internal hex wrench.

2. Test the Torque-to-Turn with the unit assembled (excluding auxiliary pumps). Rotate the input shaft using a torque wrench.

Test the torque to turn on the shaft (after break-away) with swashplate at full angle and the assembly well oiled. Readings outside the table values may indicate internal problems. If necessary, disassemble pump and check.

A pad J130 screws B and C pad J130 screws

37 to 50 N•m

[27 to 37 lbf•ft]

91 to 111 N•m

[67 to 82 lbf•ft]

3. Reinstall the coupling (J140). Reinstall the auxiliary pad seal (J120) and auxiliary pump or cover plate (J110), if present, then torque the screws (J130) to the values in the table. For A pads, use a 9/16 inch hex wrench. For B and C pads, use a ¾ inch hex wrench.

4. Reinstall any other external components, including the auxiliary pump (if present), that were removed.

Install the auxiliary pad (pad ‘A’ shown)

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 287

h9/16 inch

I8 mm

Sauer-Danfoss Mobile Power and Control Systems– Market Leaders Worldwide

Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market.

Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others.

We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them.

Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company2800 East 13th StreetAmes, IA 50010, USAPhone: +1 515 239-6000, Fax: +1 515 239 6618

Sauer-Danfoss GmbH & Co. OHGPostfach 2460, D-24531 NeumünsterKrokamp 35, D-24539 Neumünster, GermanyPhone: +49 4321 871-0, Fax: +49 4321 871 122

Sauer-Danfoss ApSDK-6430 Nordborg, DenmarkPhone: +45 7488 4444, Fax: +45 7488 4400

www.sauer-danfoss.com

OUR PRODUCTS

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BLN 10238 • 520L0612 • August 2005

Huess 0805

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45 Series H Frame Repair Manual (520L0612 19Sep2005 REV a)

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