45 Series E Frame Repair Manual (520L0609 Rev a-1 August 2006)

Series 45E Frame Open CircuitAxial Piston Pumps

Repair Manual

� 5�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair Manual

© 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

OrganizatiOn and headings

To help you quickly find information in this manual, the material is divided into sections, topics, subtopics, and details, with descriptive headings set in red type. Section titles appear at the top of every page in large red type. Topic headings appear in the left hand column in BOLd red CaPitaL Letters. Subtopic headings appear in the body text in bold red type and detail headings in italic red type.

References (example: See Topic xyz, page XX) to sections, headings, or other publications are also formatted in red italic type. In Portable document Format (PdF) files, these references represent clickable hyperlinks that jump to the corresponding document pages.

Tables, illustrations, and graphics in this manual are identified by titles set in blue italic type above each item. Complementary information such as notes, captions, and drawing annotations are also set in blue type.

References (example: See Illustration abc, page YY) to tables, illustrations, and graphics are also formatted in blue italic type. In PDF files, these references represent clickable hyperlinks that jump to the corresponding document pages.

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

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

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

taBLes, iLLustratiOns, and COmPLementary inFOrmatiOn

sPeCiaL text FOrmatting

taBLe OF COntents

Using this manual

�5�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualContents

intrOduCtiOn Overview ........................................................................................................................................................... 5General instructions ...................................................................................................................................... 5

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

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

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

disassemBLy Auxiliary pad .................................................................................................................................................... 8Detach control ................................................................................................................................................. 8Displacement limiter ..................................................................................................................................... 9Endcap................................................................................................................................................................ 9Bias piston, spring, and servo piston .....................................................................................................10Cylinder kit .....................................................................................................................................................10Input shaft .......................................................................................................................................................10Swashplate, journal bearings, and roller bearing ..............................................................................11Shaft seal ........................................................................................................................................................11Control disassembly ....................................................................................................................................12

PC only ........................................................................................................................................................12PC / LS .........................................................................................................................................................12

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

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

� 5�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualContents

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

55�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualIntroduction

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

Minor repair procedures, adjustments, and troubleshooting information are given in the Series 45 Frame E Variable Motors Service Manual, 5�0L0606. Minor repairs include service operations that can be performed without removing the unit’s endcap. Removal of the endcap voids your warranty.

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

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

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

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

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

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

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

generaL instruCtiOns

6 5�0L0609 • Rev A-1 • August 2006


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

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

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

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

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

�5�0L0609 • Rev A-1 • August 2006


WARNING may result in injury

CAUTION may result in damage to product or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option – either part may exist

Superseded – parts are not interchangeable

Measurement required

Flatness specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage

Note correct orientation

Mark orientation for reinstallation

Torque specification

Press in – press fit

Pull out with tool – press fit

Cover splines with installation sleeve

Pressure measurement / gauge location or specification

symBOLs used in sauer-danFOss Literature

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

� 5�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualDisassembly

auxiLiary Pad If a second pump is used, you must remove it. You don’t need to remove auxiliary pads to remove the end cap.

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

2. Remove the coupling (J140) and the pad seal (J120).

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

4. Remove and discard the O-ring (J090).

J140

dJ090

J100

hJ130

J120

J110

J080

E101 201

I10 mm

Remove auxiliary pad

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

6. Remove and discard the 4 O-rings (C200).

Remove control

C300

dC200

I4 mm

E101 202E

95�0L0609 • Rev A-1 • August 2006


endCaP

disPLaCement Limiter

9. Remove the 4 endcap screws (J030) using a 14 mm internal hex wrench.

10. Carefully remove the endcap (J020). Prevent the valve (B090) plate from falling off.

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

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

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

B090

K060 d

E101 205

J030

J020

B020 p

B010 p

I14 mm

Remove endcap and components

7. Remove the adjustment seal/nut (L030) with a 7/8 inch wrench.

The L030 adjustment seal/nut serves as a locking seal/nut, preventing the L020 screw from backing out.

8. Remove the adjustment screw (L040) and plug (L020). Discard the O-ring (L020A).

E101 203

L030

L040

L020

L020A

h7/8 inch

Remove displacement limiter

10 5�0L0609 • Rev A-1 • August 2006


CyLinder kit

inPut shaFt

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

C CautionTake care that the top and

bottom of the kit do not become contaminated or

scratched: this may later lead to poor performance

or pump failure.

sP010

K030

E101 206

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

17. Remove the cylinder block kit while holding onto the front of the shaft.

18. Set cylinder block on a clean dry surface. C

Remove shaft

J010

E101 207

E101 222

P020

P030

B084

B083

B081h1-3/8 in

h1-3/8 in

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

Bias PistOn, sPring, and servO PistOn

Remove pistons from endcap

115�0L0609 • Rev A-1 • August 2006


shaFt seaL

swashPLate, jOurnaL Bearings, and rOLLer Bearing

K030

RB040

B050 p

B060 p

iB030

E101 208

B071 p

Remove swashplate and bearings20. Remove the swashplate (B040). Note the orientation for reinstallation.

Reinstall the swashplate in its original orientation to reduce start-up wear.

21. If necessary, remove the pins (B071) in order to remove the journal bearings (B030).

22. Remove the roller bearing cone (B050) and cup (B060). You may need to remove the shaft seal before removing the cup.

23. Orient the housing shaft side up.

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

25. Remove the shaft seal if necessary.

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

Remove shaft seal

E101 213

K020 p

K010

1� 5�0L0609 • Rev A-1 • August 2006


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 only1. 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 reassembly. 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 / Ls2. 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 reassembly. There may be differences in reinserting into the same bore. Remove the spool (C132).

3. Remove the adjusting screw (C138) and the O-ring (C138A). Discard the O-ring. Remove the springs (C134, C135) and spring guide (C133).

4. Remove the adjusting screw (C118), O-ring (C118) and 2 backup rings (C118B). Discard the O-ring and backup rings. Remove the springs (C114, C115) and spring guide (C113).

C133

C135

C134C138A d

C138

dC103AC103

C132 R

C200 d

C102

C300

E101 209

Disassemble the PC control

C118

dC118B

dC118B

dC118A

C114

C115

C113

RC112

C104

C103

C132 R

C133

C105

C106

C105A d

dC106A

C300

C135

C134

C138A d

C138

C102

C200 d

C103A d

dC104A

E101 210

Disassemble the PC / LS control

1�5�0L0609 • Rev A-1 • August 2006


CyLinder kit disassemble the cylinder block kit1. Pull to remove the slipper retainer

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

The pistons are not selectively fitted, however units with high hourly 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 removal4. 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

W WarningRisk of personal injury:

Compressing the block spring requires about 350

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

with reasonable effort. Ensure the spring is

secure before attempting to remove the spiral

retaining ring. Release the pressure slowly after the

retaining ring is removed.

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

1� 5�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualInspection

BaLL guide, sLiPPer retainer, and hOLd-dOwn Pins

Overview

PistOns and sLiPPers

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

i

Slipperretainer

Ball guide

Hold down pins

P101 471

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

e Frame

Slipperfoot thickness 4.91 mm

[0.193 in]

Piston/slipper end play 0.05 mm

[0.002 in]

Inspect guide, retainer, and pins

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

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

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

K050

Slipper

Maximum end play

Minimumslipper footthickness

P104 109E

Inspect pistons

155�0L0609 • Rev A-1 • August 2006


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 minimal wear. Replace if cracks or other damage is present.

Inspect block spring and washers

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

K041

flat to 0.002 mm

[0.000079 in]

i

fP101 067E

MB

MA

e Frame

Minimum cylinder

block height (A)

76.68 mm

[3.019 in]

Maximum block

bore diameter (B)

25.87 mm

[1.018 in]

Inspect cylinder block

16 5�0L0609 • Rev A-1 • August 2006


shaFt

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.

C133

C135

C134C138A d

eC138

dC103AC103

C132 R

C200 d

C102

C300

E101 212

e

iC118

dC118B

dC118B

dC118A

C114

C115

C113

RC112

C104

C103

C132 R

C133

C105

C106

C105A d

dC106A

C135

C134

C138A d

C138 i

C102

C200 d

C103A d

dC104A

E101 211

e

e

Inspect the PC control Inspect the PC/LS control

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

J010

i

P104 352

l

Inspect shaft

1�5�0L0609 • Rev A-1 • August 2006


swashPLate

jOurnaL Bearings

B040

i

P104 353

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

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.

Inspect swashplate

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.

1� 5�0L0609 • Rev A-1 • August 2006


endCaP

J050 R

B010 i

E101 219

J020 i

B020 i

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

Inspect endcap and components

Inspect the valve plate for scratches and grooves. Check the plate for evidence of any cavitation along the running face of the valve plate. If pitting from cavitation exists, replace the valve plate. Check for excess wear on the brass running face. If any discoloration or burn marks are observed, replace the valve plate.

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

vaLve PLate

Inspect valve plate

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

B090

4.95 mm [0.195 in] min.

0.025 mm

[0.001 in]

0.0038 mm

[0.00015 in]convex max

i

a

f

P104 354E

195�0L0609 • Rev A-1 • August 2006


shaFt Bearing kit

servO PistOn kit

Bias PistOn kit

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

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

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

il

e

E101 182

Inspect shaft bearings

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

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

iP030

iP020

E101 214

iB081

iB083

iB084

E101 215

Inspect servo piston kit

Inspect bias piston kit

�0 5�0L0609 • Rev A-1 • August 2006


hOusing

auxiLiary Pad

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

L030 i

L040 i

L020

L020A d

E101 204

Inspect displacement limiter

P104 355

i

Inspect the housing to ensure that it is clean and free of foreign material. Inspect the swashplate bearing surfaces, and endcap mating surfaces.

Inspect housing

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.

iJ140

dJ090

J100

J130

J120

J110

J080

i

E101 216

Inspect auxiliary pad components

�15�0L0609 • Rev A-1 • August 2006

Series 45 E Frame Open Circuit Axial Piston PumpRepair ManualAssembly

jOurnaL Bearing

inPut shaFt

FrOnt Bearing and swashPLate

1. Coat the journal bearings (B030) 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.

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

2. Reinstall the front bearing kit. 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.

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

K030

lB040

J010

B050

B060

lB030B071 P

E101 217

Install housing components

�� 5�0L0609 • Rev A-1 • August 2006


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

6. 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

7. Turn the block over and install the hold-down pins (K046) and ball guide (K047) to the cylinder block.

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 the ball guide. If you’re reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder kit aside on a clean surface until needed. K045

K044

K043

K042

K041

P010

K047 l

K049 l

K050 l

P101 356

K046

K048 (L Frame only)

P010 s

K030

Prevent shaft from rotating

Slightly rotatecylinder block

E101 218

Assemble cylinder kit

Install cylinder block

CyLinder kit assemBLy

W WarningRisk of personal injury:

Compressing the block spring requires about 350

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

reasonable effort. Ensure the spring is secure before

attempting to install the spiral retaining ring.

Release the pressure slowly after the retaining ring is

installed.

CyLinder kit instaLLatiOn

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 end of the shaft with one hand and keep it horizontal. Insert the cylinder kit onto the shaft. While holding the shaft still, slightly rotate the cylinder block kit to help start the shaft splines into the ball guide and align it with the block splines. When the cylinder block kit slides completely over the shaft splines, reposition the unit with the flange facing downward.

��5�0L0609 • Rev A-1 • August 2006


vaLve PLate

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

11. Apply petroleum jelly to the top of the servo guide (P030) to hold the servo piston (P020) in place for assembly and lubricate the outside 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 149 N•m [110 lbf•ft] using a 1-3/8-inch wrench.

servO and Bias kits

16. Clean the valve plate (B090) and endcap. Install the timing pins (J050) in the endcap and verify that they are properly oriented. The timing pins should be 0.25 mm [0.001 in] plus the height of the head (1.58 mm [0.062 in] above the valve plate 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 extremely important to ensure that there is no contamination between the endcap and valve plate.

Install endcap components

E101 220

P020

P030 g

B084

B083

B081 l t149 N•m [110 lbf•ft]

l

Install piston kits

B090 g

J050

Bearing kit

E101 222E

e

M

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.

�� 5�0L0609 • Rev A-1 • August 2006


shaFt seaL

K020 P

K010

E101 225

b

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

Install shaft seal and retaining ring

K060 d

J030

J020

I14 mm

E101 258

t186 - 223 N•m [137 - 165 lbf•ft]

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

endCaP Install endcap

�55�0L0609 • Rev A-1 • August 2006


Assemble PC (only) control19. Clean and lubricate all control parts and cover with a light coating of hydraulic fluid prior to reassembly.

20. 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 N•m [8 to 10 lbf•ft]. 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 N•m [5.5 to 8.0 lbf•ft] to retain the adjusting plug.

PC COntrOL

C133

C135

C134C138A d

eC138

dC103AC103

C132 R

C200 d

C300

E101 212

e

C102

iC118

dC118B

dC118B

dC118A

C114

C115

C113

RC112

tC104

C103

C132 R

C133

C105 t

tC106

C105A d

dC106A

C135

C134

C138A d

C138 i

C102

C200 d

C103A d

dC104A

E101 227

e

e

Assemble PC/LS controlInstall the PC portion as described in PC control, as shown above.

21. 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 N•m [8 to 10 lbf•ft]. 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 N•m [5.5 to 8.0 lbf•ft]. Also, install the plugs (C105, C106) with new O-rings. Torque the plugs at 10.8 to 13.5 N•m [8 to 10 lbf•ft].

PC and LS spools need to be adjusted to proper setting according to tag nomenclature.

Ls COntrOL (OPtiOnaL)

�6 5�0L0609 • Rev A-1 • August 2006


auxiLiary Pad

torque-to-turn shaft

13.5 to 24.4 N•m [120 to 216 lbf•in]

22. Install the adapter (J080) with new O-ring (J090). Tighten the screws (J100) at 24.4 to 29.1 N•m24.4 to 29.1 N•m [18 to 21.5 lbf•ft] with a 10 mm internal hex wrench.

23. 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 may indicate internal problems. If necessary, disassemble pump and check.

a pad j1�0 screws B and C pad j1�0 screws

37 to 50 N•m

[27 to 37 lbf•ft]

91 to 111 N•m

[67 to 82 lbf•ft]

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.

24. 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

J140

dJ090

J100

hJ130

J120

J110

J080

E101 229

I10 mm

t24.4 to 29.1 N•m [18 to 21.5 lbf•ft]

Install the auxiliary pad

��5�0L0609 • Rev A-1 • August 2006


26. Using a 7/8-inch wrench, torque the adjustment plug (L020) at 41 to 95 N•m [30 to 70 lbf•ft].

27. Using a 7/8-inch wrench, torque the adjustment seal/nut (L030) at 50 to 58 N•m [37 to 43 lbf•ft].

disPLaCement Limiter

I4 mm

t5.4 to 7.5 N•m [4 to 5.5 lbf•ft]

C300

dC200

E101 224

reattaCh the COntrOL 27. Using petroleum jelly to retain them, Install 4 new seal rings (C200) in the recesses on the control housing. Install the control assembly onto the endcap using the 4 screws (C300). 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 proper torque retention.

Install the control

E101 228

L030

L040

L020

L020A

t50 to 58 N•m [37 to 43 lbf•ft]

h7/8 inch

t41 to 95 N•m [30 to 70 lbf•ft]

h7/8 inch

Install the displacement limiter

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5�0L0609 • Rev A-1 • August 2006

45 Series E Frame Repair Manual (520L0609 Rev a-1 August 2006)

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