45 Series G Frame Repair Manual (520L0608) (15Mar2006)

7/27/2019 45 Series G Frame Repair Manual (520L0608) (15Mar2006)

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Series 45

G Frame

Open Circuit

Axial Piston Pumps

Repair Manual


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2 BLN 10228 520L0608 Dec 2004

Series 45 G Frame Open Circuit Axial Piston Pump

Repair Manual

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 arent 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 5 21, P104 467

ORGANIZATION AND

HEADINGS

To help you quickly find information in this manual, the material is divided into sections,

topics, subtopics, and details, with descriptive headings set in red type. Section titles

appear at the top of every page in large red type. Topic headings appear in the lefthand column in BOLD RED CAPITALLETTERS. Subtopic headings appear in the body

text in bold red type and detail headings in italic red type.

References (example: See Topic xyz, page XX) to sections, headings, or other publications are

also formatted in red italic type. In Portable Document Format (PDF) files, these references

represent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identified by titles set in blueitalic

type above each item. Complementary information such as notes, captions, and drawing

annotations are also set in blue type.

References (example: SeeIllustration abc, page YY) to tables, illustrations, and graphics

are also formatted in blue italic type. In PDF files, these references represent clickable

hyperlinks that jump to the corresponding document pages.

Defined terms and acronyms are set in bold blacktype in the text that defines or

introduces them. Thereafter, the terms and acronyms receive no special formatting.

Black italictype is used in the text to emphasize important information, or to set-off

words and terms used in an unconventional manner or alternative context. Redand blue

italics represent hyperlinked text in the PDF version of this document (see above).

An indented Table ofContents (TOC) appears on the next page. Tables and illustrations

in the TOC set in blue type. In the PDF version of this document, the TOC entries are

hyperlinked to the pages where they appear.

TABLES, ILLUSTRATIONS,

AND COMPLEMENTARY

INFORMATION

SPECIAL TEXT

FORMATTING

TABLE OF CONTENTS

Using this manual


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Contents

Overview ...........................................................................................................................................................5

General instructions ...................................................................................................................................... 5

Safety precautions .........................................................................................................................................6Unintended machine movement .......................................................................................................6

Flammable cleaning solvents ...............................................................................................................6

Fluid under pressure ................................................................................................................................6

Personal safety ...........................................................................................................................................6

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

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

Detach control .................................................................................................................................................9

Endcap ...............................................................................................................................................................9

Cylinder kit ......................................................................................................................................................10

Bias piston, servo piston, and optional displacement limiter .......................................................10Input 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

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 .............................................................................................................................................................19Shaft bearing kits .........................................................................................................................................20

Housing ...........................................................................................................................................................20

Auxiliary pad ..................................................................................................................................................21

DISASSEMBLY

INSPECTION

INTRODUCTION


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Contents

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

Front bearing and swashplate ................................................................................................................22

Input shaft .......................................................................................................................................................22Servo 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

ASSEMBLY


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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 aregiven to ensure these parts meet factory tolerances. Only Sauer-Danfoss Authorized

Service Centers (ASCs) are authorized to perform major repairs. Sauer-Danfoss ASCs

are trained by the factory to perform major repairs and their facilities are certified on a

regular basis.

W WarningUse of components that do not comply with rework specifications may result in loss of

performance, which may constitute a safety hazard. Do not reuse components that dont

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 serviceoperations that can be performed without removing the units endcap. Removal of the

endcap voids your warranty.

Follow these general procedures when repairing Series 45 variable displacement open

circuit pumps.

w Remove the unitPrior to performing major repairs, remove the unit from the vehicle/machine. Chock

the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that

hydraulic fluid may be under high pressure and / or hot. Inspect the outside of the pump

and fittings for damage. Cap hoses after removal to prevent contamination.

e Keep it cleanCleanliness is a primary means of assuring satisfactory pump life, on either new or

repaired units. Clean the outside of the pump thoroughly before disassembly. Take care

to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash

and air drying is usually adequate.

As with any precision equipment, all parts must be kept free of foreign materials and

chemicals. Protect all exposed sealing surfaces and open cavities from damage and

foreign material. If left unattended, cover the pump with a protective layer of plastic.

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

d Replace all O-rings and gasketsIt is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean

petroleum jelly prior to assembly.

t Secure the unitFor major repair, place the unit in a stable position with the shaft pointing downward. It

will be necessary to secure the pump while removing and torquing the endcap bolts.

GENERAL INSTRUCTIONS


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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 WarningUnintended movement of the machine or mechanism may cause injury to the technician

or bystanders. To protect against unintended movement, secure the machine or disable

/ disconnect the mechanism while servicing.

Flammable cleaning solvents

W WarningSome cleaning solvents are flammable. To avoid possible fire, do not use cleaning

solvents in an area where a source of ignition may be present.

Fluid under pressure

W WarningEscaping hydraulic fluid under pressure can have sufficient force to penetrate your skin

causing serious injury and/or infection. This fluid may also be hot enough to cause burns.

Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the

system before removing hoses, fittings, gauges, or components. Never use your hand

or any other body part to check for leaks in a pressurized line. Seek medical attention

immediately if you are cut by hydraulic fluid.

Personal safety

W WarningProtect yourself from injury. Use proper safety equipment, including safety glasses, at all

times.


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Introduction

WARNING may result in injury

CAUTION may result in damage toproduct or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option either part may exist

Superseded parts are not

interchangeable

Measurement required

Flatness specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage

Note correct orientation

Mark orientation for reinstallation

Torque specification

Press in press fit

Pull out with tool press fit

Cover splines with installationsleeve

Pressure measurement / gaugelocation or specification

SYMBOLS USED IN

SAUER-DANFOSS

LITERATURE

The symbols above appear in the illustrations and text of this manual. They are intended

to communicate helpful information at the point where it is most useful to the reader.

In most instances, the appearance of the symbol itself denotes its meaning. The legend

above defines each symbol and explains its purpose.


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Disassembly

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 265

h9/16inch

I8 mm

Remove auxiliary A pad

AUXILIARY PAD

J080

J140

J110

J130

J100

dJ095

dJ120

dJ090

J020

E101 266

h inch

I8 mm

Remove auxiliary B pad

J090d

J140

J080

J100

J120d

J110

J095d

J020

J130

I8 mm

h inch

E101 267

Remove auxiliary C pad

If a second pump is used, you must remove the second pump. You must remove auxiliary

C pad to remove the endcap. You dont 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).


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Disassembly

DETACH CONTROL 5. Remove the control from the

housing by removing the 4 control

bolts (C300), using a 4 mm internalhex wrench.

6. Remove and discard the 4 O-rings

(C200).

7. Remove the 4 endcap screws (J030)

using a 12 mm internal hex wrench.

8. Carefully remove the endcap (J020).

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

a clean area, protecting them from

contamination.

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

interface O-rings (K070).

ENDCAP

C300

C200d

I4 mm

E101 263

dK060

J030

J050J020

K070d

B090s

E101 264

I12 mm

B010

B020B015

Remove endcap and components

Remove control


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Disassembly

CYLINDER KIT 11. Tilt the housing on its side to allow

fluid to drain.

12. Remove the cylinder block kit while

holding onto the front shaft.

13. Set cylinder block on a clean, dry

surface.sP010

E101 268

Remove cylinder block kit

BIAS PISTON, SERVO

PISTON, AND OPTIONAL

DISPLACEMENT LIMITER

dL020A

L020

dK110

dK100

B083

dB082

L010B084

B081

h1-3/8 in

E101 269

h1-3/8 in

L030

L040

Remove servo and bias pistons14. Remove the bias guide plug (B081)

using a 1-3/8 inch hex wrench. Also,

remove the bias spring (B083), and

piston (B084). Discard the O-rings

(B082, K100) and backup ring (K110).

It may be necessary to remove the piston

and spring by reaching through the

inside of the unit and pushing them out

through the bore.

15. Remove the servo piston plug (L020)

and servo piston (L010) using

a 1-3/8 inch hex wrench. Discard the

O-ring (L020A).

It may be necessary to remove the piston

by reaching through the inside of the

housing.

16. Take note of the orientation of the

servo piston. The end of the piston

with the hole should be facing

upward.


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Disassembly

INPUT SHAFT, AND

SWASHPLATE

17. Rotate pump back to a position so

that the shaft is pointing down.

18. Pull the shaft (J010) from the shaft

seal.

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

to reduce start-up wear.

20. Remove the journal bearings (B030).

It is important to record the location

and orientation of the journal

bearings if they are to be reused.

21. Remove the roller bearing kit (B065)

consisting of bearing cone (B070)

and cup (B060). You may need

to remove the shaft seal before

removing the cup.

JOURNAL BEARING AND

ROLLER BEARING

B040R

J010

E101 270

Remove shaft and swashplate

B030

B060

B070

E101 271

RB065

Remove bearings


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Disassembly

22. Orient the housing shaft side up.

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

24. Remove the shaft seal (K020) if

necessary.

Replace the shaft seal every time the

shaft is removed from the unit.

SHAFT SEAL

K020p

K010

E101 272

Remove shaft seal


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Disassembly

CONTROL DISASSEMBLY

C CautionIf 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.

PC only

1. With a 3/16 inch internal hex wrench,

remove the plug (C103) and O-ring(C103A). Discard the O-ring. Remove

the set screw (C102). Remove the

spool (C132). Note the orientation of

the spool for reinsertion. There may

be differences in reinserting into the

same bore. Remove the adjusting

screw (C138) and O-ring (C138A).

Discard the O-ring. Remove the

springs (C134, C135) along with the

spring guide (C133).C

PC / LS

2. With a 3/16 inch internal hex wrench,

remove the 4 plugs (C103, C104,

C105, and C106) and their O-rings.

Discard the O-rings. Remove the

2 set screws (C102). Remove the

spool (C112). Note the orientation

of the spools for reinsertion. There

may be differences in reinserting

into the same bore. Remove the

spool (C132).C

3. Remove the adjusting screw (C138)

and the O-ring (C138A). Discard the

O-ring. Remove the springs (C134,

C135) and spring guide (C133).C

4. Remove the adjusting screw (C118),

O-ring (C118A) and 2 backup

rings (C118B). Discard the O-ring

and backup rings. Remove the

springs (C114, C115) and springguide (C113).C

C133

C135

C134C138Ad

C138

dC103A C103

C132R

C200d

C102

C300

E101 209

Disassemble the PC control

C118

dC118B

dC118B

dC118A

C114

C115

C113

RC112

C104

C103

C132R

C133

C105

C106

C105Ad

dC106A

C300

C135

C134

C138Ad

C138

C102

C200d

C103Ad

dC104A

E101 210

Disassemble the PC / LS control

C CautionIf 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.


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Disassembly

CYLINDER KIT Disassemble the cylinder block kit

1. Pull to remove the slipper retainer

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

The pistons are not selectively fitted,

however units with high hour usage

may develop wear patterns. Number the

pistons and bores for reassembly if they

are to be reused.

2. Remove the ball guide (K047).

3. Remove the 3 pins (K046).

Most repairs do not require block spring

removal. Perform this procedure only

if you suspect problems with the block

spring.

Block spring removal

4. Turn the block over. Using a press,

apply pressure on the block spring

washer (K044) to compress the block

K050

K049

K047

K046

K041

K042

K043

K044

K045

P010

i

E101 012

l

R

Disassemble the cylinder block kit

WWarningRisk of personal injury:

Compressing the block

spring requires about 350

to 400 N [80 to 90 lbf].

Use a press sufficient

to maintain this force

with reasonable effort.

Ensure the spring is

secure before attempting

to remove the spiral

retaining ring. Release the

pressure slowly after the

retaining ring is removed.

spring (K043). Compress the spring enough to safely remove the spiral retaining ring

(K045). While maintaining pressure, unwind the spiral retaining ring. Carefully release

the pressure and remove the outer block spring washer, block spring, and inner block

spring washer (K042) from the cylinder block.W


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Inspection

BALL GUIDE, SLIPPER

RETAINER, AND HOLD-

DOWN PINS

OVERVIEW

PISTONS AND SLIPPERS

After disassembly, wash all parts (including the end-cap and housing) thoroughly with

clean solvent and allow to air dry. Blow out oil passages in the housing and endcap

with compressed air. Conduct inspection in a clean area and keep all parts free fromcontamination. Clean and dry parts again after any rework or resurfacing.

i

Slipper

retainer

Ball guide

Hold down pins

P101 471

The ball guide should be free of

nicks and scratches, and should not

be excessively scored. Examine for

discoloration that may indicate excessive

heat or lack of lubrication. The slipper

retainer should be flat, and slippers

should fit in the retainer with minimal

side play. Place the hold-down pins on a

flat surface and roll them to make sure

they are straight. Discard and replace any

damaged parts.

G Frame

Slipperfoot thickness 4.41 mm

[0.174 in]

Piston/slipper end play 0.05 mm

[0.002 in]

Inspect guide, retainer, and pins

Inspect the pistons for damage and

discoloration. Discolored pistons may

indicate excessive heat; do not reuse.

Inspect the running surface of the

slippers. Replace any piston assemblies

with scored or excessively rounded

slipper edges. Measure the slipper foot

thickness. Replace any piston assemblieswith excessively worn slippers. Check the

slipper axial end-play. Replace any piston

assemblies with excessive end-play.

Minimum slipper foot thickness and

maximum axial end-play are given in the

table to the right.

K050

Slipper

Maximum end play

Minimumslipper footthickness

P104 109E

Inspect pistons


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Inspection

BLOCK SPRING, AND

WASHERS

CYLINDER BLOCK

iWasher

Cylinder block spring

Spring retainer

Retaining ring

P101 472

If cylinder kit was fully dissembled, visual

inspection of the cylinder block, spring,

and washers should indicate minimalwear. Replace if cracks or other damage

is present.

Inspect block spring and washers

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

output flow.

K041

flat to 0.002 mm

[0.000079 in]

i

fP101 067E

MB

MA

G Frame

Minimum cylinder block height (A)

(74 and 90 cc)

68.88 mm

[2.712 in]

Maximum block bore

diameter (B)

74 cc21.57 mm

[0.849 in]

90 cc22.74 mm

[0.895 in]

Inspect cylinder block


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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 spools outside diameter forscratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of

clean hydraulic oil.

C133

C135

C134C138Ad

eC138

dC103AC103

C132R

C200

d

C102

C300

E101 212

e

iC118

dC118B

dC118Bd

C118A

C114

C115

C113

RC112

C104

C103

C132R

C133

C105

C106

C105Ad

dC106A

C135

C134

C138Ad

C138i

C102

C200d

C103Ad

dC104A

E101 211

e

e

Inspect the PC control Inspect the PC/LS control

SHAFT Check to see that the shaft (J010) and its

splines are straight and free of damage

or heavy wear. Inspect the shaft surface

where it meets the shaft seal. Replace

the shaft if a groove exists at the sealing

land surface that may let dirt into or

hydraulic fluid out of the unit. Clean thesealing area with a nonabrasive material

if necessary. Lubricate the shaft with a

light coat of hydraulic fluid.

Inspect shaft

J010

i

l

P104 423


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Inspection

SWASHPLATE Carefully inspect each surface of the

swashplate for wear. All swashplate

surfaces should be smooth. Inspect theswashplates slipper running surface

for flatness and brass transfer. Excessive

brass transfer from slippers may indicate

that the slippers should be replaced.

Finally, check the swashplate bearing

journal for scratches. Replace swashplate

if necessary.

Inspect swashplate

Check the servo piston (L010) for any

obvious wear or damage. Replace piston

if necessary. Discard and replace the

servo plug O-ring (L020A).

JOURNAL BEARINGS

i

P104 335

B030

Inspect journal bearingsInspect the journal bearings for

damage or excessive wear. Replace

journal bearings if scratched, warped, or

excessively worn. The polymer wear layer

must be smooth and intact.

SERVO PISTON AND


BIAS PISTON

K110d

K100dB083

dB082

B081

B084

E101 273

L020Ad

L020

iL010

E101 274

L030

L040

O

Inspect servo piston / displacement limiter

Inspect bias pistonInspect the bias piston (B084), guide

(B081), and spring (B083) for abnormal

wear. Replace if necessary. Discard and

replace the 2 O-rings (B082, K100) and

the backup ring (K110).

On reassembly, the bias piston guide

backup ring (K110) must be the ring

located closest to the center of the

pump.

B040

i

P104 353

Swashplate is not reworkable. Servo pads extend above surface of running face, making

lapping impossible. Positioning of servo pads is extremely important. Do not remove and

repress servo pads.


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Inspection

ENDCAP Inspect the endcap (J020). Check and

record orientation of the timing pin

(J050). Carefully check the bearing cup

(B010) for wear.

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 anydiscoloration or burn marks are observed, replace the valve plate.

Run a fingernail or pencil tip across the diameter of the sealing land surface (see

illustration). No deep or outstanding grooves should be felt, as these may decrease pump

flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the

endcap and valve plate for any possible contamination; even a few thousandths of an

inch may affect pump operation.

VALVE PLATE

Inspect valve plate

Measure the thickness of the valve plate. Ensure that valve plate parallelism is equal

to or less than 0.025 mm [0.001 in]. Appearance should be flat and smooth on both

the running face and the bottom surface. The valve plate should be flat to 0.0038 mm

[0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks.The valve plate must be replaced if any cracks exist.

B090

4.95 mm [0.195 in] min.

0.025 mm

[0.001 in]

0.0038 mm

[0.00015 in]

convex max

i

a

f

P104 354E

RJ050

iB010

J020i

iB020

E101 278

B015

Inspect end cap and components


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Inspection

SHAFT BEARING KITS The tapered roller bearing kit consists

of a cup and cone. Make sure the cup

and cone are free of excessive wear orcontamination. Rotate the bearings to

check for smoothness. If a contaminated

bearing is suspected, clean with a solvent

and lubricate with hydraulic fluid.

Replace the bearing if the problem is not

remedied by cleaning.

Inspect for uneven wear. If abnormal

wear is found, replace the bearing kit.

il

e

E101 182

Inspect shaft bearings

HOUSING Inspect the housing to ensure that it is

clean and free of foreign material. Inspect

the swashplate bearing surfaces, and

endcap mating surfaces. Also inspect the

servo and bias piston bores for galling

and excessive wear.

Inspect housing

i

P104 424


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Inspection

AUXILIARY PAD Inspect sealing surfaces on the endcap

and auxiliary pad, and make sure that

they are clean and free of contaminants.Inspect the coupling (J140) for any signs

of excessive or abnormal wear. Replace

all O-rings. Replace excessively worn

parts if necessary.

Inspect auxiliary pad components

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 265

h9/16 inch

I8 mm


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Assembly

B030l

J010

B040l

E101 275

B065

B070

B060

JOURNAL BEARING

INPUT SHAFT

FRONT BEARING AND

SWASHPLATE

1. Install the journal bearings (B030)

into the pump housing.

If journal bearings are reused, reinstall

them in their original orientation and

position.

2. Reinstall the front bearing kit (B065).

The cup (B060) should be a slip fit

with the housing.

3. Coat the curved surface of the

swashplate (B040) with hydraulic

fluid. Reinstall the swashplate in its

original orientation. Lubricate the

flat face with hydraulic oil to prevent

premature wear during start-up. To

insert the swashplate, tilt the ear

located opposite the control face so

that it is raised. Insert the opposite

side towards the servo piston.

4. Insert the input shaft (J010) through

the bearing into the housing.

Install housing components

Coat all parts with new, clean hydraulic fluid before reassembly


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Repair Manual

Assembly

5. Lubricate all sides of the servo

piston (L010) and its respective bore

(closest to the control face) liberallywith hydraulic oil. Reinstall the servo

piston with the hole end up.

6. Install the displacement limiter screw

(L040) into the plug (L020) until flush

with the bottom of the plug. Install

the seal nut (L030) onto the set screw

until snug against the plug. Reinstall

the displacement limiter plug (L020)

and tighten with a 1 3/8 inch socket to

175-245 Nm [130-180 lbfft]. Once

the desired displacement limit is set,torque the seal nut (L030) using a

19 mm hex wrench at 78 to 95 Nm

[58 to 70 lbfft].

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-

rings as shown in the figure at right.

Use a 1 3/8 inch socket to tighten to

175-245 Nm [130-180 lbfft].

SERVO AND BIAS

PISTONS AND


dL020A

L020

dK110

dK100

B083

dB082

lL010B084

B081

h1-3/8 in

E101 279

h1-3/8 in

L030

L040

l

Install servo and bias pistons

It is extremely important that the bias piston plug (B081) be correctly torqued, as it may

back out at lower torques.


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Repair Manual

Assembly

8. Coat all parts with hydraulic fluid

prior to reassembly.

9. Install the inner block spring washer

(K042), block spring (K043), and

outer washer (K044) into the cylinder

block. Using a press, compress the

block spring enough to expose the

retaining ring groove. Wind the spiral

retaining ring (K045) into the groove

in the cylinder block.W

10. Turn the block over and install the

hold-down pins (K046) squarely in

their respective grooves. Install theball guide (K047) to the cylinder

block.

11. Install the pistons (K050) to the

slipper retainer (K049). Install the

piston/retainer assembly into the

cylinder block. Ensure the concave

surface of the retainer seats on

the ball guide. If youre reusing the

pistons, install them to the original

K050

K049

K047

K046

K041

K042

K043

K044

K045

P010

E101 012

l

Assemble cylinder kitCYLINDER KIT ASSEMBLY

WWarningRisk 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 slowlyafter the retaining ring is

installed.

Be sure to install the slipper retainer so it mates correctly with the ball guide (concave

side of the slipper retainer against the convex side of the ball guide).

CYLINDER KIT

INSTALLATION

Install cylinder kit12. Set the pump on its side. Secure the

end of the shaft with one hand and

keep it horizontal. Insert the cylinder

kit onto the shaft. While holding the

shaft still, slightly rotate the cylinder

block kit to help start the shaft

splines into the ball guide and alignit with the block splines. When the

cylinder block kit slides completely

over the shaft splines, reposition

the unit with the flange facing

downward.

When the pump housing is in its original

upright position, the bottom of the

cylinder kit should be relatively flush

with the shoulder of the shaft.

P010s

K030

Prevent shaft from rotating

Slightly rotate

cylinder block

E101 276

block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly.

Set the cylinder kit aside on a clean surface until needed.


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Repair Manual

Assembly

VALVE PLATE

MJ050B010i

J020i

E101 280

B090g

e

e

13. Clean the valve plate (B090) and

endcap. Install the timing pin

(J050) in the endcap and verifythat it is properly oriented. The

timing pin should be 4.6 0.25 mm

[0.181 0.001 in] above the

mounting surface. Apply a liberal

amount of assembly grease to the

backside of the valve plate surface

to hold it in position. Install the

valve plate over the timing pin and

bearing cup.

To insure proper pump operation, it is

extremely important to ensure that thereis no contamination between the endcap

and valve plate.

Install endcap components

ENDCAP 14. Install the bearing cone (B020) onto

the shaft end. Using assembly grease

to hold seals (K060, K070), install the

endcap to the housing. Ensure that

the seals remain properly seated and

are not pinched during assembly.

With a 12 mm internal hex wrench,

install and torque endcap screws

at 127 to 155 Nm [94 to 115 lbfft],

using the criss cross pattern.

Retorque the first screw to ensure

proper torque retention.

dK060

J030

J020

K070d

E101 281

I12 mm

t127 - 155 Nm[94 - 115 lbfft]

B020

Install endcap


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Repair Manual

Assembly

SHAFT SEAL 15. Cover shaft splines with an

installation sleeve. Install a new shaft

seal (K020) with the cup side facingthe pump. Press seal into housing

until it is just below the retaining

ring groove. Press evenly to avoid

binding and damaging the seal.

Install retaining ring (K010).

Install shaft seal and retaining ring

K020P

K010

E101 277

b


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Repair Manual

Assembly

Assemble PC (only) control16. Clean all control parts and cover with

a light coating of hydraulic fluid prior

to reassembly.

17. Install the spherical end of the PC

spool (C132) into the PC bore (refer

to illustration). Install the PC plug

(C103) using a new O-ring. Torque at

10.8 to 13.5 Nm [8 to 10 lbfft]. Place

the two PC springs (C134, C135)

onto the PC spring guide (C133) and

install into the PC bore. Place a new

O-ring onto the PC plug (C138) and

install it so that it sits one turn below

the surface of the control housing.Install and tighten set screw (C102)

at 7.5 to 10.8 Nm [5.5 to 8.0 lbfft] to

retain the adjusting plug.

PC CONTROL

C133

C135

C134C138Ad

eC138

dC103A C103

C132R

C200d

C102

C300

E101 212

e

iC118

dC118B

dC118B

dC118A

C114

C115

C113

RC112

tC104C103

C132R

C133

C105t

tC106

C105Ad

dC106A

C135

C134

C138A

dC138i

C102

C200d

C103Ad

dC104A

E101 227

e

e

Assemble PC/LS controlInstall the PC portion as described in

PC control, above.

18. Hold the control in a horizontal

position. Install the spherical end of

the LS spool (C112) into the LS bore

(see illustration). Using a new O-ring,

install the LS plug (C104), torque at

10.8 to 13.5 Nm [8 to 10 lbfft]. Place

the 2 LS springs (C114, C115) onto

the LS spring guide (C113) and install

into the LS bore. Place a new O-ring

(C116) and back-up rings (C117)

onto the LS adjustment screw (C118).

Install the LS plug assembly so that it

sits one turn below the surface of the

control housing. Install and tighten

set screw (C102) at 7.5 to 10.8 Nm

[5.5 to 8.0 lbfft]. Also, install the

plugs (C105, C106) with new O-rings.Torque the plugs at 10.8 to 13.5 Nm

[8 to 10 lbfft].

PC and LS spools need to be adjusted

to proper setting according to tag

nomenclature.

LS CONTROL (OPTIONAL)


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Repair Manual

Assembly

AUXILIARY PAD

Torque-to-turn shaft

13.2 to 23.5 Nm [117 to 208 lbfin]

19. Install the adapter (J080) with new

O-rings (J090, J095). Tighten the

screws (J100) at 47.5 to 61 Nm[35 to 45 lbfft] with a 8 mm internal

hex wrench.

20. Test the Torque-to-Turn with the

unit assembled (excluding auxiliary

pumps). Rotate the input shaft using

a torque wrench.

Test the torque to turn the shaft (after

break-away) with swashplate at full

angle and the assembly well oiled.

Readings outside the table values mayindicate internal problems. If necessary,

disassemble pump and check.

A pad J130 screws B and C pad J130 screws

37 to 50 Nm

[27 to 37 lbfft]

91 to 111 Nm

[67 to 82 lbfft]

21. Reinstall the coupling (J140).

Reinstall the auxiliary pad seal (J120)

and auxiliary pump or cover plate

(J110), if present, then torque the

screws (J130) to the values in the

table. For A pads, use a 9/16 inch hex

wrench. For B and C pads, use a

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.

J100

J110

J130

J140

J080

J120

dJ095

dJ090

J020

E101 265

h9/16inch

I8 mm

22. Reinstall any other external components, including the auxiliary pump (if present),

that were removed before disassembly.

Install the auxiliary pad (pad A shown)


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REATTACH THE CONTROL 23. Install 4 new seal rings (C200) in

the recesses on the control housing

using petroleum jelly to retainthem. Install the control assembly

onto the endcap using the 4 screws

(C300). Torque at 5.4 to 7.5 Nm

[4 to 5.5 lbfft] using a criss cross

pattern, and retorque the first screw

to ensure proper torque retention.

Install the control

C300

C200d

I4 mm

E101 282

t5.4 - 7.5 Nm[4 - 5.5 lbfft]


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Repair Manual

Notes


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Repair Manual

Notes


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Centers strategically located in all parts of the world.

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Ames, IA 50010, USA

Phone: +1 515 239-6000, Fax: +1 515 239 6618

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Postfach 2460, D-24531 Neumnster

Krokamp 35, D-24539 Neumnster, Germany

Phone: +49 4321 871-0, Fax: +49 4321 871 122

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45 Series G Frame Repair Manual (520L0608) (15Mar2006)

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Transcript of 45 Series G Frame Repair Manual (520L0608) (15Mar2006)