Series 45

E Frame
Open Circuit
Axial Piston Pumps

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

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© 2006 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: F101 437, F101 343, F101 169, P104 356

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

Introduction Overview............................................................................................................................................................ 5
General instructions....................................................................................................................................... 5
Remove the unit................................................................................................................................... 5
Keep it clean........................................................................................................................................... 5
Lubricate moving parts...................................................................................................................... 5
Replace all O-rings and gaskets...................................................................................................... 5
Secure the unit...................................................................................................................................... 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

Detach control.................................................................................................................................................. 8
Displacement limiter...................................................................................................................................... 9
Endcap................................................................................................................................................................ 9
Bias piston, spring, and servo piston......................................................................................................10
Cylinder kit . ....................................................................................................................................................10
Input shaft........................................................................................................................................................10
Swashplate, journal bearings, and roller bearing...............................................................................11
Shaft seal .........................................................................................................................................................11
Control disassembly.....................................................................................................................................12
PC only.........................................................................................................................................................12
PC / LS..........................................................................................................................................................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
Control...............................................................................................................................................................16
Shaft ..................................................................................................................................................................16
Swashplate.......................................................................................................................................................17
Journal bearings............................................................................................................................................17
Valve plate........................................................................................................................................................18
Endcap..............................................................................................................................................................18
Shaft bearing kit............................................................................................................................................19
Servo piston kit..............................................................................................................................................19
Bias piston kit..................................................................................................................................................19
Housing ...........................................................................................................................................................20
Auxiliary pad...................................................................................................................................................20
Displacement limiter....................................................................................................................................20

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

Assembly Journal bearing .............................................................................................................................................21

Front bearing and swashplate . ...............................................................................................................21
Input shaft........................................................................................................................................................21
Cylinder kit assembly...................................................................................................................................22
Cylinder kit installation...............................................................................................................................22
Servo and bias kits........................................................................................................................................23
Valve plate........................................................................................................................................................23
Endcap..............................................................................................................................................................24
Shaft seal..........................................................................................................................................................24
PC control.........................................................................................................................................................25
LS control (optional).....................................................................................................................................25
Auxiliary pad...................................................................................................................................................26
Displacement limiter....................................................................................................................................27
Reattach the control.....................................................................................................................................27

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

Overview This manual details the major repair procedures for Frame E variable motors. 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
Series 45 Frame E Variable Motors Service Manual, 520L0606. 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 E 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 E 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.

520L0609 • Rev A-1 • August 2006 

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

Auxiliary pad If a second pump is used, you must Remove auxiliary pad
remove it. You don’t need to remove
auxiliary pads to remove the end cap. hJ130

J110
1. Remove the plate cover screws
(J130) and remove the plate cover
(J110). If you have auxiliary A pad,
J120
use a 9/16 inch hex wrench; use a
¾ inch hex wrench for auxiliary B or J100
C pad. I10 mm

2. Remove the coupling (J140) and the

J080
pad seal (J120).
dJ090
3. Remove the auxiliary pad screws
(J100) with a 10 mm internal J140
hex wrench, and remove the
adapter (J080).

4. Remove and discard the O-ring

(J090).
E101 201

Detach Control 5. Remove the control from the endcap Remove control
by removing the 4 control bolts
C300
(C300), using a 4 mm internal hex
wrench. I4 mm

6. Remove and discard the 4 O-rings

(C200).
dC200

E101 202E

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

Displacement limiter 7. Remove the adjustment seal/nut Remove displacement limiter

(L030) with a 7/8 inch wrench.
L030
h7/8 inch
The L030 adjustment seal/nut serves as
a locking seal/nut, preventing the L020 L040
screw from backing out.
L020
8. Remove the adjustment screw (L040)
and plug (L020). Discard the O-ring L020A
(L020A).

E101 203

Endcap 9. Remove the 4 endcap screws (J030) Remove endcap and components
using a 14 mm internal hex wrench.
J030
I14 mm
10. Carefully remove the endcap (J020).
Prevent the valve (B090) plate from
falling off. J020

11. Place the endcap and valve plate in B010 p

a clean area, protecting them from
contamination. B020 p

B090
12. Remove the housing O-ring (K060)
and discard.

13. Remove the tapered roller shaft K060 d

bearing cone (B020) from the shaft.
The cup (B010) will likely remain in
the end cap.

E101 205

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

Bias piston, spring, 15. Remove the bias piston (B084), Remove pistons from endcap
and servo piston spring (B083), and guide (B081). Also,
remove the servo piston (P020) and
guide (P030). B084

P020
B083

P030
B081
h1-3/8 in
h1-3/8 in

E101 222

Cylinder kit 16. Set the pump on its side. Remove cylinder block kit

17. Remove the cylinder block kit while

holding onto the front of the shaft.

C Caution 18. Set cylinder block on a clean dry

sP010
Take care that the top and surface. C
bottom of the kit do not
become contaminated or K030
scratched: this may later
lead to poor performance
or pump failure.
E101 206

Input Shaft 19. Rotate the swashplate until level. Pull Remove shaft
the input shaft (J010) out from the
shaft seal and bearing kit.

J010

E101 207

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

Swashplate, journal 20. Remove the swashplate (B040). Note Remove swashplate and bearings
bearings, and Roller the orientation for reinstallation.
bearing RB040
Reinstall the swashplate in its original
orientation to reduce start-up wear.
B071 p
21. If necessary, remove the pins (B071)
in order to remove the journal iB030
bearings (B030).

22. Remove the roller bearing cone

(B050) and cup (B060). You may B050 p
need to remove the shaft seal before
removing the cup. B060 p

K030

E101 208

Shaft Seal 23. Orient the housing shaft side up. Remove shaft seal

24. Remove the retaining-ring (K010) K010

using internal retaining ring pliers.
K020 p
25. Remove the shaft seal if necessary.

Replace the shaft seal every time the

shaft is removed from the unit.

E101 213

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

Control Disassembly PC only Disassemble the PC control

1. Remove the plug (C103) and O-ring
C103
(C103A). Discard the O-ring. Remove dC103A
C Caution the set screw (C102). Remove the C132 R
If removing the LS or PC spool (C132). Note the orientation of
spool is not possible, be the spool for reassembly. There may
C300
extremely careful when be differences in reinserting into the
flipping or relocating the same bore. Remove the adjusting C200 d
housing as not to lose or screw (C138) and O-ring (C138A).
damage the spool. Discard the O-ring. Remove the C102
C133
springs (C134, C135) along with the
C135
spring guide (C133). C
C134
C138A d

C138
E101 209

PC / LS Disassemble the PC / LS control

2. With a 3/16 inch internal hex wrench,
remove the 4 plugs (C103, C104, C103
C105, and C106) and their O-rings. C104 C103A d
Discard the O-rings. Remove the 2 dC104A C132 R
set screws (C102). Remove the spool
RC112
(C112). Note the orientation of the
spools for reassembly. There may be C105A d
C300
differences in reinserting into the
C105
same bore. Remove the spool (C132).
C102
dC106A
3. Remove the adjusting screw (C138)
and the O-ring (C138A). Discard the C106 C200 d
O-ring. Remove the springs (C134, C133
C135) and spring guide (C133).
C113 C135
4. Remove the adjusting screw (C118), C115
O-ring (C118) and 2 backup rings C114 C134
(C118B). Discard the O-ring and dC118B C138A d
backup rings. Remove the springs dC118A C138
(C114, C115) and spring guide (C113). dC118B
C118
E101 210

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 Series 45 E Frame Open Circuit Axial Piston Pump
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Disassembly

Cylinder kit Disassemble the cylinder block kit Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(K049) with the pistons (K050) from R K050
the cylinder kit.

The pistons are not selectively fitted, K049

however units with high hourly usage
may develop wear patterns. Number the K047
pistons and bores for reassembly if they
are to be reused. K046

2. Remove the ball guide (K047). P010

K041 l
3. Remove the 3 pins (K046).

Most repairs do not require block spring i K042

removal. Perform this procedure only
if you suspect problems with the block K043
spring.
K044
K045
Block spring removal
W Warning 4. Turn the block over. Using a press, E101 012

Risk of personal injury: apply pressure on the block spring

Compressing the block washer (K044) to compress the block
spring requires about 350 spring (K043). Compress the spring enough to safely remove the spiral retaining ring
to 400 N [80 to 90 lbf ]. (K045). While maintaining pressure, unwind the spiral retaining ring. Carefully release
Use a press sufficient the pressure and remove the outer block spring washer, block spring, and inner block
to maintain this force spring washer (K042) from the cylinder block. W
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 E 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 E Frame
discoloration. Discolored pistons may Slipperfoot thickness 4.91 mm
indicate excessive heat; do not reuse. [0.193 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 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

Block spring, and If cylinder kit was fully dissembled, visual Inspect block spring and washers
washers inspection of the cylinder block, spring,
and washers should indicate minimal Washer
wear. Replace if cracks or other damage i
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.

E Frame Inspect cylinder block

Minimum cylinder 76.68 mm
block height (A) [3.019 in] MB
Maximum block 25.87 mm K041
bore diameter (B) [1.018 in] i

MA

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

520L0609 • Rev A-1 • August 2006 15

 Series 45 E Frame 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. Check the inside and outside surfaces
of the springs for wear and replace if necessary. Check the spool’s outside diameter for
scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
hydraulic oil.

Inspect the PC control Inspect the PC/LS control

C103 C103
dC103A
C132 R C104 C103A d

e dC104A C132 R

RC112 e
C300
C200 d e
C105A d
C102 C105
C133 C102
C135 dC106A

C134 C106 C200 d

C138A d
C133
eC138
E101 212 C113 C135
C115
C114 C134

dC118B C138A d
dC118A C138 i
dC118B
iC118
E101 211

Shaft Check to see that the shaft (J010) and its Inspect shaft
splines are straight and free of damage
or heavy wear. Inspect the shaft surface J010
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
i
sealing area with a nonabrasive material
l
if necessary. Lubricate the shaft with a
light coat of hydraulic fluid. P104 352

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

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
that the slippers should be replaced.
Finally, check the swashplate bearing i
journal for scratches. Replace swashplate P104 353
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

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

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

Endcap Inspect the endcap (J020). Check and Inspect endcap and components
record orientation of the timing pins
(J050). Carefully check the bearing cup B020 i
(B010) for wear, and ensure that it fits
B010 i
tightly.
J050 R

J020 i

E101 219

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

Shaft bearing kit 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.

Servo Piston kit Check the servo piston (P020) for any Inspect servo piston kit
obvious wear or damage. Check the
corresponding guide (P030) for galling iP030
or excessive wear. Replace the kit if
necessary.
iP020

E101 214

Bias piston kit Inspect the bias piston (B084), bias piston Inspect bias piston kit
guide (B081), and bias spring (B083)
for abnormal wear. Replace the kit if
iB081
abnormal wear is present.

iB083

iB084

E101 215

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

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.

P104 355

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 J110
of excessive or abnormal wear. Replace
all O-rings. Replace excessively worn
parts if necessary. J120

J100

J080

dJ090 i

iJ140

E101 216

Displacement limiter Inspect the displacement limiter screw Inspect displacement limiter
threads. Ensure that the screw is not
L030 i
bent. Also, inspect the seal/nut for
irregular wear. Replace if necessary.
L040 i

L020
L020A d

E101 204

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

Journal bearing 1. Coat the journal bearings (B030) Install housing components
with hydraulic fluid and install them
into the pump housing. Punch in
retaining pins (B071) to a minimum
of 0.5 mm [0.02 in] below the
bearing surface. J010

If journal bearings are reused, reinstall

them in their original orientation and
position.
lB040

Front bearing and 2. Reinstall the front bearing kit. The

swashplate cup (B060) should be a slip fit with B071 P
lB030
the housing.

3. Coat the curved surface of the

swashplate (B040) with hydraulic
B050
fluid. Reinstall the swashplate in its
original orientation. Lubricate the B060
flat face with hydraulic oil to prevent
premature wear during start-up.
K030

Input shaft 4. Insert the input shaft (J010) through

the bearing into the housing.

E101 217

520L0609 • Rev A-1 • August 2006 21


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
22
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
5. Coat all parts with hydraulic fluid Assemble cylinder kit
prior to reassembly.
6. Install the inner block spring washer K050 l
(K042), block spring (K043), and
outer washer (K044) into the cylinder
block. Using a press, compress the
block spring enough to expose the K049 l
retaining ring groove. Wind the spiral
retaining ring (K045) into the groove
K047 l
in the cylinder block. W
K048 (L Frame only)
7. Turn the block over and install the
hold-down pins (K046) and ball K046
guide (K047) to the cylinder block. P010
K041
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 K042
the ball guide. If you’re reusing the
pistons, install them to the original K043
block bores. Lubricate the pistons,
slippers, retainer, and ball guide K044
before assembly. Set the cylinder kit
K045
aside on a clean surface until needed.
P101 356
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 Install cylinder block
end of the shaft with one hand and
Prevent shaft from rotating
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
Slightly rotate
splines into the ball guide and align cylinder block
it with the block splines. When the
cylinder block kit slides completely
over the shaft splines, reposition K030
the unit with the flange facing
P010 s
downward.
E101 218
520L0609 • Rev A-1 • August 2006
 Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

Servo and bias kits 10. Reinstall the servo guide (P030). Install piston kits
Torque the servo guide at 190 to
217 N•m [140 to 160 lbf•ft], using a
P020 B084
1-3/8-inch wrench.

11. Apply petroleum jelly to the top P030 g B083

of the servo guide (P030) to hold l
the servo piston (P020) in place for
t149 N•m B081 l
assembly and lubricate the outside [110 lbf•ft]
diameter of the servo guide with
clean hydraulic oil.

12. Reinstall the servo piston (P020) onto

the guide.

13. Reinstall the bias piston guide (B081).

Torque the bias piston guide at E101 220

149 N•m [110 lbf•ft] using a 1-3/8-inch

wrench.

14. Reinstall the bias spring (B083) onto the guide.

15. Lubricate with clean hydraulic oil and reinstall the bias piston (B084).

It is extremely important that you torque the bias and servo guides correctly as they
may back out at lower torques. The bias piston has an M6x1 thread in the small end. The
piston and spring can be held in place by running a long M6 screw through the end
construction port and engaging the bias thread.

Valve plate 16. Clean the valve plate (B090) and Install endcap components
endcap. Install the timing pins (J050)
in the endcap and verify that they J050
M
are properly oriented. The timing
pins should be 0.25 mm [0.001 in] B090 g
plus the height of the head (1.58 mm e
[0.062 in] above the valve plate Bearing kit
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 pins and bearing kit.

To insure proper pump operation, it is

E101 222E
extremely important to ensure that there
is no contamination between the endcap
and valve plate.

520L0609 • Rev A-1 • August 2006 23

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

Endcap 17. Using assembly grease to hold seals, Install endcap

install the endcap to the housing.
Ensure that the seal remains properly J030
seated and is not pinched during I14 mm
assembly. With a 14 mm internal t186 - 223 N•m
hex wrench, install and torque [137 - 165 lbf•ft]
endcap screws at 186 to 223 N•m
J020
[137 to 165 lbf•ft], using the criss
cross pattern. Retorque the first
screw to ensure proper torque K060 d
retention.

E101 258

Shaft seal 18. Cover shaft splines with an Install shaft seal and retaining ring
installation sleeve. Install a new shaft
seal (K020) with the cup side facing K010
the motor. Press seal into housing
until it bottoms out. Press evenly to K020 P
avoid binding and damaging the
seal. Install snap ring (K010).
b

E101 225

24 520L0609 • Rev A-1 • August 2006

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

PC control 19. Clean and lubricate all control parts Assemble PC (only) control
and cover with a light coating of
C103
hydraulic fluid prior to reassembly. dC103A
C132 R
20. Install the spherical end of the PC e
spool (C132) into the PC bore (refer
C300
to illustration). Install the PC plug
(C103) using a new O-ring. Torque at C200 d
10.8 to 13.5 N•m [8 to 10 lbf•ft]. Place
the two PC springs (C134, C135) C102
C133
onto the PC spring guide (C133) and
C135
install into the PC bore. Place a new
O-ring onto the PC plug (C138) and C134
C138A d
install it so that it sits one turn below
the surface of the control housing. eC138
Install and tighten set screw (C102) E101 212

at 7.5 to 10.8 N•m [5.5 to 8.0 lbf•ft] to

retain the adjusting plug.

LS control (optional) Install the PC portion as described in Assemble PC/LS control

PC control, as shown above.
C103
21. Hold the control in a horizontal tC104 C103A d
position. Install the spherical end of dC104A C132 R
the LS spool (C112) into the LS bore e
(see illustration). Using a new O-ring, RC112
install the LS plug (C104), torque at e
C105A d
10.8 to 13.5 N•m [8 to 10 lbf•ft]. Place
the 2 LS springs (C114, C115) onto C105 t
the LS spring guide (C113) and install C102
into the LS bore. Place a new O-ring dC106A
(C116) and back-up rings (C117) tC106 C200 d
onto the LS adjustment screw (C118).
C133
Install the LS plug assembly so that it
sits one turn below the surface of the C113 C135
control housing. Install and tighten C115
set screw (C102) at 7.5 to 10.8 N•m C114 C134
[5.5 to 8.0 lbf•ft]. Also, install the dC118B C138A d
plugs (C105, C106) with new O-rings.
dC118A C138 i
Torque the plugs at 10.8 to 13.5 N•m
dC118B
[8 to 10 lbf•ft].
iC118
E101 227
PC and LS spools need to be adjusted
to proper setting according to tag
nomenclature.

520L0609 • Rev A-1 • August 2006 25

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

Auxiliary pad 22. Install the adapter (J080) with Install the auxiliary pad
new O-ring (J090). Tighten the
screws (J100) at 24.4
�����������������
to 29.1 N•m hJ130
[18 to 21.5 lbf•ft] with a 10 mm
J110
internal hex wrench.

23. Test the Torque-to-Turn with the J120

unit assembled (excluding auxiliary J100
pumps). Rotate the input shaft using I10 mm
a torque wrench. t24.4 to 29.1 N•m
[18 to 21.5 lbf•ft]
Test the torque to turn the shaft (after
break-away) with swashplate at full J080
angle and the assembly well oiled. dJ090
Readings outside the table values may
indicate internal problems. If necessary, J140
disassemble pump and check.

Torque-to-turn shaft
13.5 to 24.4 N•m [120 to 216 lbf•in]

E101 229
24. Reinstall the coupling (J140).
Reinstall the auxiliary pad seal (J120)
and auxiliary pump or cover plate A pad J130 screws B and C pad J130 screws
(J110), if present, then torque the 37 to 50 N•m 91 to 111 N•m
screws (J130) to the values in the [27 to 37 lbf•ft] [67 to 82 lbf•ft]
table. For A pads, use a 9/16 inch hex
wrench. For B and C pads, use a ¾ inch hex wrench.

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

26 520L0609 • Rev A-1 • August 2006

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

Displacement limiter 26. Using a 7/8-inch wrench, torque Install the displacement limiter
the adjustment plug (L020) at
L030
41 to 95 N•m [30 to 70 lbf•ft]. h7/8 inch
t50 to 58 N•m
27. Using a 7/8-inch wrench, torque [37 to 43 lbf•ft]
the adjustment seal/nut (L030) at L040
50 to 58 N•m [37 to 43 lbf•ft].
L020
h7/8 inch
t41 to 95 N•m
[30 to 70 lbf•ft]

L020A

E101 228

Reattach the control 27. Using petroleum jelly to retain them, Install the control
Install 4 new seal rings (C200) in the
recesses on the control housing. C300
I4 mm
Install the control assembly onto the
endcap using the 4 screws (C300). t5.4 to 7.5 N•m
[4 to 5.5 lbf•ft]
Torque at 5.4 to 7.5 N•m [4 to 5.5
lbf•ft] using a criss cross pattern, and
retorque the first screw to ensure dC200
proper torque retention.

E101 224

520L0609 • Rev A-1 • August 2006 27

OUR PRODUCTS
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520L0609 • Rev A-1 • August 2006
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