Series 45

H Frame
Open Circuit
Axial Piston Pumps

Repair Manual
 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Using this manual

ORGANIZATION AND To help you quickly find information in this manual, the material is divided into sections,
HEADINGS 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
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TABLES, ILLUSTRATIONS, Tables, illustrations, and graphics in this manual are identified by titles set in blue italic
AND COMPLEMENTARY type above each item. Complementary information such as notes, captions, and drawing
INFORMATION 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
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SPECIAL TEXT Defined terms and acronyms are set in bold black type in the text that defines or
FORMATTING 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
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italics represent hyperlinked text in the PDF version of this document (see above).

TABLE OF CONTENTS 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.

© 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

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Contents

INTRODUCTION Overview ........................................................................................................................................................... 5

General instructions ...................................................................................................................................... 5
Safety precautions ......................................................................................................................................... 6
Unintended machine movement ....................................................................................................... 6
Flammable cleaning solvents ............................................................................................................... 6
Fluid under pressure ................................................................................................................................ 6
Personal safety ........................................................................................................................................... 6
Symbols used in Sauer-Danfoss literature............................................................................................. 7

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

Endcap ............................................................................................................................................................... 9
Cylinder kit ........................................................................................................................................................ 9
Bias piston, servo piston, and optional displacement limiter .......................................................10
Pressure compensator valve ....................................................................................................................10
Old style .....................................................................................................................................................10
New style ...................................................................................................................................................10
Input shaft, and swashplate ......................................................................................................................11
Swashplate, journal bearing and roller bearing ................................................................................11
Shaft seal .........................................................................................................................................................12
Control..............................................................................................................................................................12
Cylinder kit ......................................................................................................................................................13
Disassemble the cylinder block kit ...................................................................................................13
Block spring removal .............................................................................................................................13

INSPECTION Overview .........................................................................................................................................................14

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

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Contents

ASSEMBLY Journal bearing ............................................................................................................................................21

Front bearing and swashplate ................................................................................................................21
Input shaft .......................................................................................................................................................21
Servo and bias pistons and displacement limiter ............................................................................22
Pressure compensator valve ....................................................................................................................22
New style ..............................................................................................................................................22
Old style ................................................................................................................................................23
Control..............................................................................................................................................................23
Cylinder kit assembly ..................................................................................................................................24
Cylinder kit installation ..............................................................................................................................24
Valve plate.......................................................................................................................................................25
Endcap .............................................................................................................................................................25
Shaft seal .........................................................................................................................................................26
Auxiliary pad ..................................................................................................................................................27

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

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

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

w 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 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 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.

l Lubricate moving parts

During 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 gaskets

It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean
petroleum jelly prior to assembly.

t 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.

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.

Unintended machine movement

W 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

W Warning
Some 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 pressure

W Warning
Escaping 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 safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

SYMBOLS USED IN  WARNING may result in injury  Tip, helpful suggestion

SAUER-DANFOSS
LITERATURE  CAUTION may result in damage to  Lubricate with hydraulic fluid
product or property
 Apply grease / petroleum jelly
 Reusable part
 Apply locking compound
 Non-reusable part, use a new part
 Inspect for wear or damage
 Non-removable item
 Clean area or part
 Option – either part may exist
 Be careful not to scratch or damage
 Superseded – parts are not
interchangeable  Note correct orientation

 Measurement required  Mark orientation for reinstallation

 Flatness specification  Torque specification

 Parallelism specification  Press in – press fit

 External hex head  Pull out with tool – press fit

 Internal hex head  Cover splines with installation

sleeve
 Torx head
 Pressure measurement / gauge
 O-ring boss port location or specification

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.

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

AUXILIARY 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).

Remove auxiliary A pad Remove auxiliary B pad Remove auxiliary C pad

J130 J130 J130
h9/16 inch h ¾ inch h¾ inch

J110
J110
J110

J120
dJ120

J100 J140
J140 I8 mm J140 J100
J120 d
I8 mm
J100
I8 mm
J080
J080

dJ090 J080

dJ090 J090 d

dJ095
dJ095
J095 d
J020

J020

J020

E101 287
E101 288

E101 289

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

ENDCAP 1. Remove the 4 endcap screws (J030) Remove endcap and components
using a 10 mm internal hex wrench.
J030
2. Carefully remove the endcap (J020). I10 mm
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 J020

a clean area, protecting them from
contamination. J050
B090 s

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 dK060
interface O-rings (K070). B010

B01 B020

K070 d

E101 301

CYLINDER KIT 1. Tilt the housing on its side to allow Remove cylinder block kit
fluid to drain.

2. Remove the cylinder block kit while

holding onto the front shaft.

3. Set cylinder block on a clean dry

sP010
surface.

E101 292

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

BIAS PISTON, SERVO 1. Remove the bias guide plug (B081) Remove servo and bias pistons
PISTON, AND OPTIONAL using a 1-3/8 inch hex wrench. Also,
DISPLACEMENT LIMITER remove the bias spring (B083), and B081
piston (B084). Discard the O-rings h1-3/8 in
(B082, K100) and backup ring (K110).
dB082
It may be necessary to remove the piston L030
and spring by reaching through the dK100 L040
inside of the unit and pushing them out dK110
L020
through the bore. h1-3/8 in
B083
2. Remove the servo piston plug (L020)
dL020A
and servo piston (L010) using B084
a 1-3/8 inch hex wrench. Discard the L010
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.
E101 293

PRESSURE Old style

COMPENSATOR VALVE 1. Remove the PC plug (C120) from the Remove PC valve
pump using a 3/16 inch hex wrench.
Discard the O-ring (C120A). D019
D018 D015
2. Remove the PC cartridge using an D014
Old style
11/16 inch hex wrench. Discard the
D013
O-rings (D016, K080) and backup
A98-21
ring (K090). thru
A00-23 New style
3. Further disassembly can be made by dD016
loosening the locknuts (D015, D018)
dK090
on the set screw (D014). D016 d
dK080 K090 d
New style K080 d
1. Remove the PC plug (C120) from the
pump using a 9/16 inch hex wrench.
Discard the O-ring (C120A)

2. The new style is a one-piece

cartridge. Remove the PC cartridge C120A
with a 11/16 inch hex wrench.
O

Discard the O-rings (D016, K080) and

the backup ring (K090). C120
E101 328

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

INPUT SHAFT 1. Rotate pump back to a position so Remove shaft

that the shaft is pointing down.

2. Pull the shaft (J010) from the shaft

seal.
J010

E101 294

SWASHPLATE, JOURNAL 1. Lift the swashplate (B040) up at Remove swashplate and bearings
BEARING AND ROLLER an angle and remove it from the
BEARING housing. Note the orientation B040
for reinstallation. Reinstall the
swashplate in its original orientation
to reduce start-up wear.
B070
2. Remove the journal bearings (B030).
It is important to record the location B06 B060
and orientation of the journal
bearings if they are to be reused. B030

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).

E101 295

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

SHAFT SEAL 1. Orient the housing shaft side up. C Remove shaft seal

CCaution K010
The PC spool may fall out once the
endcap is removed and the housing is
K020 P
tipped in this orientation. Be careful not
to damage the spool. b

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.

E101 335

CONTROL Unscrew the plug (C030) using a 7/8 inch Remove the control
hex wrench. Discard the O-ring (C040).
If the springs (C070, C060) remain in the C130
C110
bore, remove them along with the spring C020
seat (C080) and the PC spool (C090) with C010
a magnet. C030

C040
C050
C060
C070
C080
C090

E101 334

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

CYLINDER KIT Disassemble the cylinder block kit

Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
R K050
(K049) with the pistons (K050) from
the cylinder kit.
K049
The pistons are not selectively fitted,
however units with high hour usage K047
may develop wear patterns. Number the
pistons and bores for reassembly if they K048
are to be reused.
K046

2. Remove the ball guide (K047) and P010

retaining ring (K048). l
K041

3. Remove the 3 pins (K046).

i K042

K043

K044
K045

E101 354

Block spring removal

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

W Warning 4. Turn the block over. Using a press, apply pressure on the block spring washer
Risk of personal injury: (K044) to compress the block spring (K043). Compress the spring enough to safely
Compressing the block remove the spiral retaining ring (K045). While maintaining pressure, unwind the
spring requires about 350 spiral retaining ring. Carefully release the pressure and remove the outer block
to 400 N [80 to 90 lbf ]. spring washer, block spring, and inner block spring washer (K042) from the cylinder
Use a press sufficient block. W
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.

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

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 H Frame
discoloration. Discolored pistons may Slipperfoot thickness 3.23 mm
indicate excessive heat; do not reuse. [0.128 in]
Piston/slipper end play 0.05 mm
Inspect the running surface of the [0.002 in]
slippers. Replace any piston assemblies
with scored or excessively rounded Inspect pistons
slipper edges. Measure the slipper foot
Maximum end play
thickness. Replace any piston assemblies
 
with excessively worn slippers. Check the
slipper axial end-play. Replace any piston Minimum Slipper
slipper foot
assemblies with excessive end-play. thickness
K050
Minimum slipper foot thickness and 
maximum axial end-play are given in the
table to the right. P104 109E

BALL GUIDE, SLIPPER The ball guide should be free of Inspect guide, retainer, and pins
RETAINER, AND HOLD- nicks and scratches, and should not
DOWN PINS be excessively scored. Examine for Slipper
discoloration that may indicate excessive retainer
heat or lack of lubrication. The slipper i
retainer should be flat, and slippers
should fit in the retainer with minimal Ball guide
side play. Place the hold-down pins on a
flat surface and roll them to make sure
Hold down pins
they are straight. Discard and replace any
damaged parts.
P101 471

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

BLOCK SPRING, AND If cylinder kit was fully disassembled, Inspect block spring and washers
WASHERS visual inspection of the cylinder block,
spring, and washers should indicate Washer
minimal wear. Replace if cracks or other i
damage is present.
Cylinder block spring

Spring retainer

Retaining ring

P101 472

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 flow.

H Frame Inspect cylinder block

Minimum cylinder block height (A) 62.23 mm
(57 and 75 cc) [2.450 in] MB
19.80 mm K041
57 cc
Maximum block bore [0.779 in] i
diameter (B) 21.57 mm
75 cc
[0.849 in] MA

flat to 0.002 mm
f [0.000079 in]
P101 067E

BLN 10238 • 520L0612 • August 2005 15

 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

INPUT SHAFT Check to see that the shaft (J010) and its Inspect shaft
splines are straight and free of damage
J010
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 i
hydraulic fluid out of the unit. Clean the l
sealing area with a nonabrasive material
if necessary. Lubricate the shaft with a P104 423

light coat of hydraulic fluid.

SWASHPLATE Carefully inspect each surface of the Inspect swashplate

swashplate for wear. All swashplate
surfaces should be smooth. Inspect the B040
swashplate’s slipper running surface
for flatness and brass transfer. Excessive
brass transfer from slippers may indicate
i
that the slippers should be replaced.
P104 353
Finally, check the swashplate bearing
journal for scratches. Replace swashplate
if necessary.

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.

JOURNAL BEARINGS Inspect the journal bearings for Inspect journal bearings
damage or excessive wear. Replace
i
journal bearings if scratched, warped, or
excessively worn. The polymer wear layer
must be smooth and intact.
B030

P104 335

SERVO PISTON AND Check the servo piston (L010) for any Inspect servo piston / displacement limiter
DISPLACEMENT LIMITER obvious wear or damage. Replace piston
if necessary. Discard and replace the iL010
servo plug O-ring (L020A).
L020
L040
L030 L020A d
O
E101 274

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

BIAS PISTON Inspect the bias piston (B084), guide Inspect bias piston
(B081), and spring (B083) for abnormal
wear. Replace if necessary. Discard and K110 d
B081
replace the 2 O-rings (B082, K100) and
the backup ring (K110).
B084
B083
On reassembly, the bias piston guide dB082 K100 d
backup ring (K110) must be the ring E101 273

located closest to the center of the

pump.

VALVE PLATE 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.

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.

Inspect valve plate

4.95 mm [0.195 in] min.

a 0.025 mm
[0.001 in]

i f 0.0038 mm
[0.00015 in]
convex max

B090

P104 354E

BLN 10238 • 520L0612 • August 2005 17

 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

ENDCAP Inspect the endcap (J020). Check and Inspect end cap and components
record orientation of the timing pin
(J050). Carefully check the bearing cup iB020
(B010) for wear.
B01
iB010

RJ050
J020 i

E101 307

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

Replace the bearing if the problem is not

remedied by cleaning,
E101 182

Inspect for uneven wear. If abnormal

wear is found, replace the bearing kit.

HOUSING Inspect the housing to ensure that it is Inspect housing

clean and free of foreign material. Inspect
the swashplate bearing surfaces, and i
endcap mating surfaces. Also inspect the
servo and bias piston bores for galling
and excessive wear.

P106 010

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

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

New style

screen

screen end
E101 340E

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

C090 i

E101 341

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

AUXILIARY PAD Inspect sealing surfaces on the endcap Inspect auxiliary pad components
and auxiliary pad, and make sure that
J130
they are clean and free of contaminants.
Inspect the coupling (J140) for any signs h9/16 inch
of excessive or abnormal wear. Replace
all O-rings. Replace excessively worn
parts if necessary. J110

J120

J100
J140 I8 mm

J080

dJ090

dJ095

J020

E101 287

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

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

If journal bearings are reused, reinstall

them in their original orientation and
J010
position.

FRONT BEARING AND 2. Reinstall the front bearing kit (B06). B040 l
SWASHPLATE The cup (B060) should be a slip fit
with the housing.
B030 l

3. Coat the curved surface of the

swashplate (B040) with hydraulic
fluid. Reinstall the swashplate in its
original orientation. Lubricate the
B070
flat face with hydraulic oil to prevent B06
premature wear during start-up. To
B060
insert the swashplate, tilt the ‘ear’
located opposite the control face so K070 d
that it is raised. Insert the opposite
side towards the servo piston.

INPUT SHAFT 4. Insert the input shaft (J010) through

the bearing into the housing.

E101 296

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 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

SERVO AND BIAS 1. Lubricate all sides of the servo Install servo and bias pistons
PISTONS AND piston (L010) and its respective bore
DISPLACEMENT LIMITER liberally with hydraulic oil. Reinstall B081
the servo piston with the ‘hole end’ h1-3/8 in
up. Reinstall the displacement limiter L030
plug (L020) and tighten with a dB082 L040
1 3/8 inch socket to 175-245 N•m
dK100 L020
[130-180 lbf•ft].
h1-3/8 in
dK110
2. Install the set screw (L040) and use
a 19 mm hex wrench to torque B083 dL020A
the adjustment seal/nut (L030) at
78 to 95 N•m [58 to 70 lbf•ft]. l
B084
L010
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

E101 297
piston plug (B081) be correctly torqued,
as it may back out at lower torques.

PRESSURE New style Install PC valve

COMPENSATOR VALVE 1a. Using a 9/16 inch hex wrench, install
short hex plug (C120) with a new New style
O-ring (C120A). Torque this plug to
16 N•m [12 lbf•ft]. After installing the
plug, install the new PC cartridge. D016
Torque to 37 N•m [27 lbf•ft] with K090
an 11/16 inch hex wrench. Reset your K080
pressure compensating setting
following the Series 45 Service
Manual, BLN-10129, as these do
not come preset. The gain for the PC C120A d
setting is 56.9 bar [825 psi]/turn.
C120
h9/16 inch hex
t16 N•m
[12 lbf•ft]
E101 356

22 BLN 10238 • 520L0612 • August 2005

 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

PRESSURE Old style Install PC valve

COMPENSATOR VALVE 1b. Install the remote PC plug with a
3/16 inch internal hex wrench. Torque D019
this plug to 12.2 N•m [9.0 lbf•ft]. D018 D015
After installing the plug, instal the Old style D014
PC cartridge and torque to 37 N•m
D013
[27 lbf•ft] using an 11/16 inch
A98-21
hex wrench. Reset your pressure thru
compensating setting following the A00-23

Series 45 Service Manual, BLN-10129, D016

as these do not come preset. The
K090
new gain for the PC setting is 56.9 K080
bar [825 psi]/turn.

C120A d
C120
I3/16 inch hex
t12.2 N•m
[9.0 lbf•ft]
E101 355

CONTROL Install the spool (C090) into the bore. Install the control
Place the springs (C070, C060) onto the
spring guide (C080) and install them C130
C110
into the bore. Install the spring seat C020
(C050) onto the springs. Install the seal C010
nut (C020) and lock nut (C130) onto the C030
set screw until snug against the plug.
C040
Reinstall the displacement limiter plug C050
(C030) and tighten with a 7/8 inch hex C060
wrench to 40.7-94.9 N•m [30-70 lbf•ft]. Be C070
sure to use a new O-ring (C040). C080
C090

E101 334

BLN 10238 • 520L0612 • August 2005 23


CYLINDER KIT ASSEMBLY
W Warning
Risk 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.
CYLINDER KIT
INSTALLATION
24
Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
1. Coat all parts with hydraulic fluid Assemble cylinder kit
prior to reassembly.
K050 l
2. Install the inner block spring washer
(K042), block spring (K043), and
outer washer (K044) into the cylinder
block. Using a press, compress the K049 l
block spring enough to expose the
retaining ring groove. Wind the spiral
retaining ring (K045) into the groove K047 l
in the cylinder block. W
K048
3. Turn the block over and install the
retaining ring (K048) and hold- K046
down pins (K046) squarely in their P010
K041
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 K042
cylinder block. Ensure the concave
surface of the retainer seats on K043
the ball guide. If you’re reusing the
pistons, install them to the original K044
block bores. Lubricate the pistons,
K045
slippers, retainer, and ball guide
before assembly. Set the cylinder kit E101 357
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).
Set the pump on its side. Secure the end Install cylinder kit
of the shaft with one hand and keep it
Prevent shaft from rotating
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 Slightly rotate
cylinder block
the shaft splines, reposition the unit with
the flange facing downward.
K030
When the pump housing is in its original
P010 s
upright position, the bottom of the
E101 298
cylinder kit should be relatively flush
with the shoulder of the shaft.
BLN 10238 • 520L0612 • August 2005
 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

VALVE PLATE Clean the valve plate (B090) and endcap. Install endcap components
Install the timing pin (J050) in the
endcap and verify that it is properly
B090 g
oriented. The timing pin should be 4.6
± 0.25 mm [0.181 ± 0.001 in] above the e
mounting surface. Apply a liberal amount
of assembly grease to the backside of the B010 i
MJ050
valve plate surface to hold it in position.
Install the valve plate over the timing pin
J020 i
and bearing cup. e

To insure proper pump operation, it is

extremely important to ensure that there
is no contamination between the endcap
and valve plate.
E101 299

ENDCAP Install the bearing cone (B020) onto Install endcap

the shaft end. Using assembly grease
to hold seals (K060, K070), install the J030
endcap to the housing. Ensure that
I10 mm
the seals remain properly seated and
t84 - 108.5 N•m
are not pinched during assembly. With [62 - 80 lbf•ft]
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 J020
ensure proper torque retention.

dK060
B020

K070 d

E101 308

BLN 10238 • 520L0612 • August 2005 25

 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

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

E101 336

26 BLN 10238 • 520L0612 • August 2005

 Series 45 H Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

AUXILIARY PAD 1. Install the adapter (J080) with new Install the auxiliary pad (pad ‘A’ shown)
O-rings (J090, J095). Tighten the
J130
screws (J100) at 47.5 to 61 N•m
[35 to 45 lbf•ft] with a 8 mm internal h9/16 inch
hex wrench.

2. Test the Torque-to-Turn with the J110

unit assembled (excluding auxiliary
pumps). Rotate the input shaft using J120
a torque wrench.

Test the torque to turn on the shaft J100

(after break-away) with swashplate at J140 I8 mm
full angle and the assembly well oiled.
Readings outside the table values may
indicate internal problems. If necessary,
disassemble pump and check.
J080

Torque-to-turn shaft
10.1 to 18.1 N•m [90 to 160 lbf•in]
dJ090

3. Reinstall the coupling (J140).

Reinstall the auxiliary pad seal (J120)
dJ095
and auxiliary pump or cover plate
(J110), if present, then torque the
J020
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.

A pad J130 screws B and C pad J130 screws

37 to 50 N•m 91 to 111 N•m E101 287
[27 to 37 lbf•ft] [67 to 82 lbf•ft]

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

BLN 10238 • 520L0612 • August 2005 27

OUR PRODUCTS
Hydrostatic transmissions
Hydraulic power steering
Electric power steering
Electrohydraulic power steering
Closed and open circuit axial piston
pumps and motors
Gear pumps and motors
Bent axis motors
Orbital motors
Transit mixer drives
Planetary compact gears
Proportional valves
Directional spool valves
Cartridge valves
Hydraulic integrated circuits
Hydrostatic transaxles
Integrated systems
Fan drive systems
Electrohydraulics
Microcontrollers and software
Electric motors and inverters
Joysticks and control handles
Displays
Sensors
BLN 10238 • 520L0612 • August 2005
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