Series 45

G Frame
Open Circuit
Axial Piston Pumps

Repair Manual
 Series 45 G 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
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, 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
hyperlinks that jump to the corresponding document pages.

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
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).

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.

© 2004 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 522, F101 523, F101 521, P104 467

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 Series 45 G 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

Detach control ................................................................................................................................................. 9
Endcap ............................................................................................................................................................... 9
Cylinder kit ......................................................................................................................................................10
Bias piston, servo piston, and optional displacement limiter .......................................................10
Input shaft, and swashplate ......................................................................................................................11
Journal bearing and roller bearing ........................................................................................................11
Shaft seal .........................................................................................................................................................12
Control disassembly ....................................................................................................................................13
PC only ........................................................................................................................................................13
PC / LS .........................................................................................................................................................13
Cylinder kit ......................................................................................................................................................14
Disassemble the cylinder block kit ...................................................................................................14
Block spring removal .............................................................................................................................14
Overview .........................................................................................................................................................15

INSPECTION Pistons and slippers .....................................................................................................................................15

Ball guide, slipper .........................................................................................................................................15
Retainer, and hold-down pins ..................................................................................................................15
Block spring, and washers .........................................................................................................................16
Cylinder block ...............................................................................................................................................16
Control..............................................................................................................................................................17
Shaft .................................................................................................................................................................17
Swashplate......................................................................................................................................................18
Journal bearings ...........................................................................................................................................18
Servo piston and displacement limiter ................................................................................................18
Bias piston .......................................................................................................................................................18
Valve plate.......................................................................................................................................................19
Endcap .............................................................................................................................................................19
Shaft bearing kits .........................................................................................................................................20
Housing ...........................................................................................................................................................20
Auxiliary pad ..................................................................................................................................................21

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

ASSEMBLY Journal bearing ............................................................................................................................................22

Front bearing and swashplate ................................................................................................................22
Input shaft .......................................................................................................................................................22
Servo and bias pistons and displacement limiter ............................................................................23
Cylinder kit assembly ..................................................................................................................................24
Cylinder kit installation ..............................................................................................................................24
Valve plate.......................................................................................................................................................25
Endcap .............................................................................................................................................................25
Shaft seal .........................................................................................................................................................26
PC control ........................................................................................................................................................27
LS control (optional) ....................................................................................................................................27
Auxiliary pad ..................................................................................................................................................28
Reattach the control ....................................................................................................................................29

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

OVERVIEW This manual details the major repair procedures for Series 45 Frame G 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 G Variable Motors Service Manual, 520L0605. 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 G 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 G 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 G 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 265
E101 266

E101 267

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

DETACH CONTROL 5. Remove the control from the Remove control

housing by removing the 4 control
bolts (C300), using a 4 mm internal C300
hex wrench. I4 mm

6. Remove and discard the 4 O-rings

(C200). C200 d

E101 263

ENDCAP 7. Remove the 4 endcap screws (J030) Remove endcap and components
using a 12 mm internal hex wrench.
J030
8. Carefully remove the endcap (J020). I12 mm
Prevent the valve plate (B090) from
falling off. Also, the timing pin (J050)
should remain in the end cap.

9. Place the endcap and valve plate in

J020
a clean area, protecting them from J050
contamination.
B090 s
10. Remove the bearing kit (B015)
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

B015 B020

K070 d

E101 264

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

CYLINDER KIT 11. Tilt the housing on its side to allow Remove cylinder block kit
fluid to drain.

12. Remove the cylinder block kit while

holding onto the front shaft.

13. Set cylinder block on a clean, dry

sP010
surface.

E101 268

BIAS PISTON, SERVO 14. 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).
L030
dB082 L040
It may be necessary to remove the piston
and spring by reaching through the dK100 L020
inside of the unit and pushing them out dK110 h1-3/8 in
through the bore.
B083 dL020A
15. Remove the servo piston plug (L020)
and servo piston (L010) using
B084 L010
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.

16. Take note of the orientation of the

servo piston. The end of the piston
with the hole should be facing
upward.
E101 269

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

INPUT SHAFT, AND 17. Rotate pump back to a position so Remove shaft and swashplate
SWASHPLATE that the shaft is pointing down.

18. Pull the shaft (J010) from the shaft

seal.
J010
19. 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 B040 R
to reduce start-up wear.

E101 270

JOURNAL BEARING AND 20. Remove the journal bearings (B030). Remove bearings
ROLLER BEARING It is important to record the location
and orientation of the journal B070
bearings if they are to be reused.
RB065
B060
21. Remove the roller bearing kit (B065)
consisting of bearing cone (B070) B030
and cup (B060). You may need
to remove the shaft seal before
removing the cup.

E101 271

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

SHAFT SEAL 22. Orient the housing shaft side up. Remove shaft seal

23. Remove the retaining-ring (K010) K010

using internal retaining ring pliers.
K020 p
24. Remove the shaft seal (K020) if
necessary.

Replace the shaft seal every time the

shaft is removed from the unit.

E101 272

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

CONTROL DISASSEMBLY PC only Disassemble the PC control

1. With a 3/16 inch internal hex wrench,
C Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
flipping or relocating the
housing as not to lose or
damage the spool.
C103
remove the plug (C103) and O-ring dC103A
(C103A). Discard the O-ring. Remove C132 R
the set screw (C102). Remove the
spool (C132). Note the orientation of
C300
the spool for reinsertion. There may
be differences in reinserting into the C200 d
same bore. Remove the adjusting
C102
screw (C138) and O-ring (C138A).
C133
Discard the O-ring. Remove the
C135
springs (C134, C135) along with the
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 dC104A C132 R
2 set screws (C102). Remove the
RC112
spool (C112). Note the orientation
of the spools for reinsertion. There C105A d
C300
may be differences in reinserting
C105
into the same bore. Remove the
C Caution spool (C132). C C102
dC106A
If removing the LS or PC
spool is not possible, be 3. Remove the adjusting screw (C138) C106 C200 d
extremely careful when and the O-ring (C138A). Discard the C133
flipping or relocating the O-ring. Remove the springs (C134,
C113 C135
housing as not to lose or C135) and spring guide (C133). C
damage the spool. C115
4. Remove the adjusting screw (C118), C114 C134
O-ring (C118A) and 2 backup dC118B C138A d
rings (C118B). Discard the O-ring dC118A C138
and backup rings. Remove the dC118B
springs (C114, C115) and spring
C118
guide (C113). C E101 210

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 Series 45 G 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
(K049) with the pistons (K050) from R K050
the cylinder kit.

The pistons are not selectively fitted, K049

however units with high hour 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 G 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 G Frame
discoloration. Discolored pistons may Slipperfoot thickness 4.41 mm
indicate excessive heat; do not reuse. [0.174 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 G 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.

G Frame Inspect cylinder block

Minimum cylinder block height (A) 68.88 mm
(74 and 90 cc) [2.712 in] MB
21.57 mm
74 cc K041
Maximum block bore [0.849 in]
i
diameter (B) 22.74 mm
90 cc
[0.895 in]
MA

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

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 Series 45 G 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
clean 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
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.

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 Series 45 G 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
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

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.

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 Series 45 G 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 end cap and components
record orientation of the timing pin
(J050). Carefully check the bearing cup iB020
(B010) for wear. B015
iB010

RJ050
J020 i

E101 278

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

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.

P104 424

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 Series 45 G 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
they are clean and free of contaminants. J130
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 265

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

Coat all parts with new, clean hydraulic fluid before reassembly

JOURNAL BEARING 1. Install the journal bearings (B030) Install housing components
into the pump housing.

If journal bearings are reused, reinstall

them in their original orientation and
position.
J010

FRONT BEARING AND 2. Reinstall the front bearing kit (B065).

SWASHPLATE The cup (B060) should be a slip fit
with the housing. B040 l

3. Coat the curved surface of the

swashplate (B040) with hydraulic B030 l
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’ B070
located opposite the control face so B065
that it is raised. Insert the opposite
B060
side towards the servo piston.

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

the bearing into the housing.

E101 275

22 BLN 10228 • 520L0608 • Dec 2004

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

SERVO AND BIAS 5. Lubricate all sides of the servo Install servo and bias pistons
PISTONS AND piston (L010) and its respective bore
DISPLACEMENT LIMITER (closest to the control face) liberally B081
with hydraulic oil. Reinstall the servo
h1-3/8 in
piston with the ‘hole end’ up.
L030
dB082 L040
6. Install the displacement limiter screw
(L040) into the plug (L020) until flush dK100 L020
with the bottom of the plug. Install dK110 h1-3/8 in
the seal nut (L030) onto the set screw
until snug against the plug. Reinstall B083 dL020A
the displacement limiter plug (L020)
and tighten with a 1 3/8 inch socket to lL010
B084
175-245 N•m [130-180 lbf•ft]. Once l
the desired displacement limit is set,
torque the seal nut (L030) using a
19 mm hex wrench at 78 to 95 N•m
[58 to 70 lbf•ft].

7. Lubricate the bias piston (B084) and

its respective bore (opposite the
control face) with a liberal coating of
hydraulic oil. Reinstall the bias plug
(B081) and spring (B083) with new O-
E101 279
rings as shown in the figure at right.
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.

BLN 10228 • 520L0608 • Dec 2004 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 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
8. Coat all parts with hydraulic fluid Assemble cylinder kit
prior to reassembly.
K050
9. Install the inner block spring washer
(K042), block spring (K043), and
K049
outer washer (K044) into the cylinder
block. Using a press, compress the
K047
block spring enough to expose the
retaining ring groove. Wind the spiral
retaining ring (K045) into the groove K046
in the cylinder block. W
P010
10. Turn the block over and install the K041 l
hold-down pins (K046) squarely in
their respective grooves. Install the
K042
ball guide (K047) to the cylinder
block.
K043
11. Install the pistons (K050) to the
K044
slipper retainer (K049). Install the
piston/retainer assembly into the K045
cylinder block. Ensure the concave
E101 012
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.
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).
12. Set the pump on its side. Secure the Install cylinder kit
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
splines into the ball guide and align
it with the block splines. When the Slightly rotate
cylinder block
cylinder block kit slides completely
over the shaft splines, reposition
K030
the unit with the flange facing
downward.
P010 s
E101 276
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.
BLN 10228 • 520L0608 • Dec 2004
 Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

VALVE PLATE 13. Clean the valve plate (B090) and Install endcap components
endcap. Install the timing pin
(J050) in the endcap and verify
B090 g
that it is properly oriented. The
timing pin should be 4.6 ± 0.25 mm e
[0.181 ± 0.001 in] above the
mounting surface. Apply a liberal B010 i
MJ050
amount of assembly grease to the
backside of the valve plate surface
J020 i
to hold it in position. Install the e
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 E101 280
and valve plate.

ENDCAP 14. 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
I12 mm
the seals remain properly seated and
t127 - 155 N•m
are not pinched during assembly.
[94 - 115 lbf•ft]
With a 12 mm internal hex wrench,
install and torque endcap screws
at 127 to 155 N•m [94 to 115 lbf•ft],
using the criss cross pattern. J020
Retorque the first screw to ensure
proper torque retention.
dK060
B020

K070 d

E101 281

BLN 10228 • 520L0608 • Dec 2004 25

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

SHAFT SEAL 15. 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 pump. Press seal into housing
until it is just below the retaining
K020 P
ring groove. Press evenly to avoid
binding and damaging the seal. b
Install retaining ring (K010).

E101 277

26 BLN 10228 • 520L0608 • Dec 2004

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

PC CONTROL 16. Clean all control parts and cover with Assemble PC (only) control
a light coating of hydraulic fluid prior
C103
to reassembly. dC103A
C132 R
17. 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
C102
the two PC springs (C134, C135)
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, above.
C103
18. 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.

BLN 10228 • 520L0608 • Dec 2004 27

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

AUXILIARY PAD 19. 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.

20. 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 the shaft (after J100

break-away) with swashplate at full J140 I8 mm
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
13.2 to 23.5 N•m [117 to 208 lbf•in]
dJ090

21. 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. Also, the B and C
pads use an O-ring (J120) instead
of a pad seal as shown. Replace this
O-ring upon re-installation. E101 265

A pad J130 screws B and C pad J130 screws

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

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

28 BLN 10228 • 520L0608 • Dec 2004

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

REATTACH THE CONTROL 23. Install 4 new seal rings (C200) in Install the control
the recesses on the control housing
using petroleum jelly to retain
them. Install the control assembly C300
onto the endcap using the 4 screws I4 mm
(C300). Torque at 5.4 to 7.5 N•m t5.4 - 7.5 N•m
[4 to 5.5 lbf•ft] using a criss cross [4 - 5.5 lbf•ft]
C200 d
pattern, and retorque the first screw
to ensure proper torque retention.

E101 282

BLN 10228 • 520L0608 • Dec 2004 29

 Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Notes

30 BLN 10228 • 520L0608 • Dec 2004

Series 45 G Frame Open Circuit Axial Piston Pump
Repair Manual
Notes

BLN 10228 • 520L0608 • Dec 2004 31

OUR PRODUCTS
Hydrostatic transmissions
Hydraulic power steering
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pumps and motors
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BLN 10228 • 520L0608 • Dec 2004
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