Series 45

Frame F
Open Circuit
Axial Piston Pumps

Repair Instructions
 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Using this manual

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© 2006 Sauer-Danfoss. All rights reserved. Printed in U.S.A.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.

Front cover illustrations: F101 464, F101 385, F101 186, P104 359

 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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.................................................................................................................................................. 8
Displacement limiter...................................................................................................................................... 9
Endcap................................................................................................................................................................ 9
Cylinder kit . ....................................................................................................................................................10
Input shaft, swashplate, and pistons......................................................................................................10
Journal bearings, and roller bearing.......................................................................................................11
Shaft seal .........................................................................................................................................................11
Control disassembly.....................................................................................................................................12
PC only.........................................................................................................................................................12
PC / LS..........................................................................................................................................................12
Cylinder kit.......................................................................................................................................................13
Disassemble the cylinder block kit....................................................................................................13
Block spring removal..............................................................................................................................13

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

520L0821 • Rev AA • Nov. 2006 

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Contents

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

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

 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Introduction

Overview This manual details the major repair procedures for Frame F pumps. These include the
complete disassembly, inspection, and reassembly of the unit. Where rework of worn
or damaged components is possible, this manual gives specifications to ensure these
parts meet factory tolerances. Only Sauer-Danfoss Global Service Partners are authorized
to perform major repairs. The factory trains Sauer-Danfoss Global Service Partners to
perform major repairs and certifies their facilities 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.

Series 45 Frame F Axial Piston Pump Service Manual 11005158 gives minor repair
procedures, adjustments, and troubleshooting information. Minor repairs include service
operations that you can perform 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, you must keep all parts 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

We recommend you replace all O-rings, seals, and gaskets. 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
is necessary to secure the pump while removing and torquing the endcap bolts.

520L0821 • Rev AA • Nov. 2006 

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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.

 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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.

520L0821 • Rev AA • Nov. 2006 

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly

Auxiliary pad If a second pump is used, you must Remove auxiliary pad
remove it. You don’t need to remove
auxiliary pads to remove the end cap. J130

1. Remove the cover plate screws

J110
(J130) and the cover plate (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. J120

2. Remove the coupling (J140) and the

pad seal (J120).
J100 J140
3. Remove the auxiliary pad screws 10 mm
(J100) with a 10 mm internal
hex wrench, and remove the
adapter (J080).
J080
4. Remove and discard the O-rings
(J090), and (J095).
J090

J095

E101 457E

Detach control 1. Remove the control from the endcap Remove control
by removing the 4 control bolts
C300
(C300), using a 4 mm internal hex
wrench. 4 mm

2. Remove and discard the 4 interface

O-rings (C200).

C200

E101 230

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 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly

Displacement limiter 3. Remove the adjustment seal/nut Remove displacement limiter

(L030A) with a 7/8 inch wrench.
L030A
7/8 in
The L030 adjustment seal/nut serves as
a locking seal/nut, preventing the L040 L010 L010A
7/8 in
screw from backing out.
L040
4. Remove the adjustment screw (L040) 1/4 in
with a 1/4 in. internal hex wrench.
Remove plug (L010) with a 7/8 in.
wrench. Discard the O-ring (L010A).

E101 231

Endcap 1. Remove the 4 endcap screws (J030) Remove endcap and components
using a 10 mm internal hex wrench.
J030
2. Carefully remove the endcap (J020). 10 mm
The valve plate (B090) may adhere to
the endcap. Ensure it does not fall off
and become scratched or damaged.
J020
3. Place the endcap and valve plate in
a clean area, protecting them from
contamination.
B090

4. Remove the housing O-ring (K060)

and discard.
K060
5. Remove the shaft bearing cone
(B020) from the shaft. The cup (B010)
will likely remain in the end cap; B010
remove it using a bearing puller if
B020
necessary.

E101 232

520L0821 • Rev AA • Nov. 2006 

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly

Cylinder kit 1. Set the pump on its side. Remove cylinder block kit

2. Remove the cylinder block kit (P010)

while holding onto the front of the
shaft.
C Caution
Take care that the top and 3. Set cylinder block on a clean dry P010
bottom of the kit do not surface. C
become contaminated or
scratched: this may lead
to poor performance or
pump failure. E101 233

Input shaft, 1. Rotate pump with the shaft pointing Remove shaft, swashplate, and pistons
swashplate, and down.
pistons
2. Pull the shaft (J010) from the shaft
J010
seal.

3. Lift the swashplate/piston assembly

up and remove it from the
P020
housing. Note the orientation for
reinstallation.

Reinstall swashplate in its original B080

orientation to reduce wear.

4. Remove the servo piston (P020), bias B025

spring (B025), and the bias piston B044
(B080) from the swashplate by
removing the clevis pins (B043) and B043
snap rings (B044).
B044
B040

B043

E101 234

10 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly

Journal bearings, 1. Remove the journal bearings (B030) Remove bearings

and roller bearing and, if necessary, remove the pins
(B071). B071

2. Remove the roller bearing cone

(B070) and cup (B060). You may
need to remove the shaft seal before
removing the cup. B030 B070

B060

E101 235

Shaft seal 1. Orient the housing shaft side up. Remove shaft seal

2. Remove the retaining-ring (K010) K010

using internal retaining ring pliers.
K020
3. Remove the shaft seal (K020).

Replace the shaft seal every time the

shaft is removed from the unit.

E101 236

520L0821 • Rev AA • Nov. 2006 11

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly

Control disassembly PC only Disassemble the PC control

1. Remove the plug (C103) and O‑ring
(C103A). Discard the O-ring. Remove C103
set screw (C102) with a 4 mm C103A 3/16 in
internal hex wrench. Tilt control or
C132
use a small magnet to remove the
spool (C132). Note the orientation of
the spool for reinsertion. There may C200
be differences in reinserting into the
same bore.
2. Remove the adjusting screw (C138) C102
4 mm
with a 1/4 in. internal hex wrench.
Remove and discard O-ring (C138A). C133
Remove the springs (C134, C135)
along with the spring guide (C133). C135

C134
C138A
C138
1/4 in
E101 237

PC / LS Disassemble the PC / LS control

1. Using a 3/16 inch internal hex wrench,
remove the 4 plugs (C103, C104,
C105, and C106) and their O-rings. C103 C104
C103A 3/16 in
Discard the O-rings. Using a 4 mm
internal hex wrench, remove the 2 C104A
set screws (C102). Remove the spool C132 C112
(C112). Note the orientation of the
spools for reassembly. There may be
C106A
differences in reinserting into the C200
same bore. Remove the spool (C132). C106

2. Using a 1/4 inch internal hex wrench, C105 C105A

remove the adjusting screw (C138) 3/16 in
and the O-ring (C138A). Discard the
O-ring. Remove the springs (C134, C102 C113
4 mm
C135) and spring guide (C133).
C115
3. Using a 1/4 inch internal hex wrench, C133 C114
remove the adjusting screw (C118),
C118B
O-ring (C118) and 2 backup rings C135
(C118B). Discard the O-ring and C118A
C118B
backup rings. Remove the springs
C134 C118
(C114, C115) and spring guide (C113). 1/4 in

C138A
C138
1/4 in E101 458E

12 520L0821 • Rev AA • Nov. 2006


Cylinder kit
W Warning
Risk of personal injury:
Compressing the block
spring requires a force
of 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.
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Disassembly
Disassemble the cylinder block kit Disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(P049) with the pistons (P050) from
P050
the cylinder kit.
The pistons are not selectively fitted,
however units with high hourly usage
P049
may develop wear patterns. Number the
pistons and bores for reassembly if they
are to be reused.
P047
2. Remove the ball guide (P047).
3. Remove the 3 pins (P046). P046
Most repairs do not require block spring
removal. Perform this procedure only
if you suspect problems with the block P041
spring.
P042
Block spring removal
4. Turn the block over with the running P043
sueface pointing up. Using a press,
apply pressure on the block spring P044
washer (P044) to compress the
block spring (P043). Compress the P045
spring W enough to safely remove E101 239
the spiral retaining ring (P045).
While maintaining pressure, unwind
the spiral retaining ring. Carefully
release the pressure and remove the
outer block spring washer (P044),
block spring, and inner block spring
washer (P042) from the cylinder
block.
520L0821 • Rev AA • Nov. 2006 13
 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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 F Frame
discoloration. Discolored pistons may Slipperfoot thickness (min) 4.41 mm
indicate excessive heat; do not reuse. [0.174 in]
Piston/slipper end play (max) 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
C103
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
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

14 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection

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

Spring retainer

Retaining ring

P101 472

Cylinder block Examine the running face of the cylinder block. The surface should be smooth and free
of nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce
output flow. If necessary, you may resurface the cylinder block as long as the minimum
height and flatness specifications can be maintained.

Frame F Inspect cylinder block

Minimum cylinder 68.88 mm
block height (A) [2.712 in]
K041 B
74cc Maximum block 21.56 mm
bore diameter (B) [0.849 in]
90cc Maximum block 22.74 mm
bore diameter (B) [0.895 in] A

flat to 0.002 mm check for burrs,

[0.000079 in] nicks, and scratches
P101 067E

520L0821 • Rev AA • Nov. 2006 15

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection

Control Carefully examine the PC (and LS) plug(s) for signs of wear. Also check the small tip of the
plug(s) for heavy wear and replace if necessary. Check the inside and outside surfaces
of the springs for wear and replace if necessary. Check the spool’s outside diameter for
scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
hydraulic oil.

Inspect the PC control Inspect the PC/LS control

C103 C104
C103
C103A C103A C104A
C132 C112
C132

C200
C106A
C200
C106

C102
C105
C133

C135 C102 C113

C105A

C134 C115
C138A C133 C114
C138
E101 240 C135 C118B
C118A
C134 C118B

C118
C138A
C138
E101 241

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 seal
journal. 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. E101 242

16 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection

Swashplate Carefully inspect each surface of the Inspect swashplate

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 journals for scratches. Replace
swashplate if necessary. E101 243

Frame F
Flatness 0.0025 mm
[0.001 in]
Parallelism 0.0635 mm
[0.0025 in]

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

P104 335

520L0821 • Rev AA • Nov. 2006 17

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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 exist, 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. Ensure the minimum thickness, flatness, and parallelism
specifications are met after rework.

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.
Replace the valve plate if any cracks exist.

Inspect valve plate

4.95 mm [0.195 in] min.

0.025 mm
[0.001 in]

0.0038 mm
[0.00015 in]
convex max

B090

P104 363E

Endcap Inspect the endcap (J020). Check the Inspect endcap and components
timing pin (J050). Carefully check the
bearing cup (B010) for wear, and ensure B010
that it fits tightly.
J050

J020

E101 244

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 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
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
check for smoothness. If a contaminated
bearing is suspected, clean with a solvent
and lubricate with hydraulic fluid.

Replace the bearing if cleaning does not

remedy the problem.
E101 182

Inspect for uneven wear. If abnormal

wear is found, replace the bearing kit.

Servo piston Check the servo piston (P020) for any Inspect servo piston
obvious wear or damage. Check the
corresponding endcap bore for galling
or excessive wear. Discard the piston if P020
damaged. Replace the servo piston-rings.

E101 245

Bias piston Check the bias piston (B080) for any Inspect bias piston
obvious wear or damage. Check the
corresponding endcap bore for galling
or excessive wear. Discard the piston if
damaged. Replace the bias piston-rings.

B080
E101 246

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 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Inspection

Housing Inspect the housing to ensure that it is Inspect housing

clean and free of foreign material. Inspect
the swashplate bearing surfaces, and
endcap mating surfaces.

E101 247

Auxiliary pad Inspect sealing surfaces on the endcap Inspect auxiliary pad components
and auxiliary pad, and make sure that
J130
they are clean and free of contaminants.
Inspect the coupling (J140) for any signs J110
of excessive or abnormal wear. Replace
all O-rings. Replace excessively worn
parts if necessary. J120

J140
J100

J080

J090
J095

E101 248

Displacement limiter Inspect the displacement limiter screw Inspect displacement limiter
threads. Ensure that the screw is not
bent. Also, inspect the seal/nut for
irregular wear. Replace if necessary. L030A
Replace the O-ring. L010
L010A

L040

E101 249

20 520L0821 • Rev AA • Nov. 2006


Journal bearing
Front bearing and
swashplate
C Caution
Ensure clevis pins (B043)
are seated properly in
swashplate counterbores.
Input shaft
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
1. Coat the journal bearings (B030) with Install housing components
hydraulic fluid and install them into
the pump housing.
J010
2. Punch in retaining pins (B071) to a
minimum of 0.5 mm [0.02 in] below P020
the bearing surface.
If journal bearings are reused, reinstall B080
them in their original orientation and
position.
B025
B044
1. Reinstall the front bearing kit. The
cup (B060) should be a slip fit with
B043
the housing.
2. Using a clevis pin (B043) and snap B044
ring (B044) install the servo piston B040
(P020) and bias spring (B025) to one
B043
end of the swashplate. Install the bias
piston (B080) to the other end.  C B071
B030
Swashplate is symmetrical. Servo and
bias pistons may be installed in either
end of swashplate. B050
3. Coat the surfaces of the swashplate B060
(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.
Insert the input shaft (J010) through the
bearing into the housing.
E101 250
520L0821 • Rev AA • Nov. 2006 21

Cylinder kit assembly
W Warning
Risk of personal injury:
Compressing the block
spring requires a force
of about 350 to 400 N
[80 to 90 lbf ]. Use a press
sufficient to maintain this
force with reasonable
effort. Ensure the spring is
secure before attempting
to install the spiral
retaining ring. Release the
pressure slowly after the
retaining ring is installed.
Cylinder kit
installation
22
Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly
1. Coat all parts with hydraulic fluid Assemble cylinder kit
prior to reassembly.
2. Install the inner block spring washer P050
(P042), block spring (P043), and
outer washer (P044) into the cylinder
block. Using a press, compress the
block spring enough to expose the P049
retaining ring groove. Wind the spiral
retaining ring (P045) into the groove
in the cylinder block. W P047
3. Turn the block over and install the
hold-down pins (P046) and ball P046
guide (P047) to the cylinder block.
4. Install the pistons (P050) to the
slipper retainer (P049). Install the P041
piston/retainer assembly into the
cylinder block. Ensure the concave
P042
surface of the retainer seats on
the ball guide. If you’re reusing the
pistons, install them to the original P043
block bores. Lubricate the pistons,
slippers, retainer, and ball guide P044
before assembly. Set the cylinder kit
aside on a clean surface until needed. P045
E101 251
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).
1. Set the pump on its side. Secure the Install cylinder block
end of the shaft with one hand and
Prevent shaft from rotating
keep it horizontal. Insert the cylinder
kit onto the shaft. While holding the
shaft still, slightly rotate the cylinder
block kit to help start it onto the Slightly rotate
shaft splines over the ball guide and cylinder block
align it with the block splines.
2. When the cylinder block kit slides
completely over the shaft splines,
K030
reposition the unit with the front
P010
flange facing downward.
E101 252
520L0821 • Rev AA • Nov. 2006
 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly

Valve plate and 1. Clean the valve plate (B090) and Install endcap components
endcap endcap. Install the timing pin (J050)
in the endcap. The timing pin should J050
be 3.6 mm [.01 in] ± [0.25 mm
B090
[0.001 in.] above the valve plate
surface.
Bearing kit
2. 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 kit.

To insure proper pump operation, it is

E101 253E
extremely important to ensure that there
is no contamination between the endcap
and valve plate.

Endcap 1. Lubricate O-Ring (K060) with Install endcap and components

hydraulic fluid and install into
housing. J030
10 mm
2. Install endcap (J020) with valve 203 N•m [150 lbf•ft]
plate and bearing assembly. Ensure
the valve plate does not slip during
assembly. Lower the endcap carefully J020
onto the servo and bias pistons and
ensure the pistons seat into the
bores in the endcap. Install endcap
screws (J030) using a 10 mm internal
hex wrench. Torque to 203 N•m K060
[150 lbf•ft].

E101 436

520L0821 • Rev AA • Nov. 2006 23

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly

Shaft seal 1. Cover shaft splines with an Install shaft seal and retaining ring
installation sleeve to protect the seal.
Install a new shaft seal (K020) with K010
the cup side facing the pump.
K020
2. Press seal into housing until it is
just below retaining ring groove.
Press evenly to avoid binding and
damaging the seal. Install snap ring
(K010).

E101 254

PC control 1. Clean and lubricate all control Assemble PC (only) control

parts and cover with a light coating
of clean hydraulic fluid prior to C103
3/16 in
reassembly. C103A 12 N•m [9 lbf•ft]
C132
2. Install the spherical end of the PC
spool (C132) into the PC bore (refer
to illustration). With a 3/16 internal C200
hex wrench, install the PC plug
(C103) using a new O-ring (C103A).
Torque to 12 N•m [9 lbf•ft]. Place the
C102
two PC springs (C134, C135) onto the 4 mm
PC spring guide (C133) and install 9 N•m [7 lbf•ft]
into the PC bore. Place a new O-ring C133
(C138A) onto the PC plug (C138)
C135
and install it with a 1/4 internal hex
wrench so that it sits one turn below
C134
the surface of the control housing.
C138A
Using a 4 mm internal hex wrench,
install set screw (C102). Torque to C138
1/4 in
9 N•m [7 lbf•ft]. E101 255

24 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly

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

PC control, page 24.
C103 C104
1. Hold the control in a horizontal C103A 3/16 in 3/16 in
12 N•m 12 N•m [9 lbf•ft]
position. Install the spherical end of
[9 lbf•ft] C104A
the LS spool (C112) into the LS bore
C132 C112
(see illustration). Using a new O-ring,
install the LS plug (C104) with a
3/16 internal hex wrench, torque to C106A
12 N•m [9 lbf•ft]. C200
C106

2. Place the 2 LS springs (C114, C115)

onto the LS spring guide (C113) and C105 C105A
3/16 in
install into the LS bore. Place a new
12 N•m
O-ring (C118A) and back-up rings [9 lbf•ft] C102 C113
(C118B) onto the LS adjustment 9 N•m
4 mm
screw (C118). Using a 1/4 internal hex [7 lbf•ft] C115
wrench, install the LS plug assembly
so that it sits one turn below the C133 C114
surface of the control housing. C118B
C135
C118A
3. Install and tighten set screw (C102) C118B
to 9 N•m [7 lbf•ft]. Also, install the C134 C118
plugs (C105, C106) with new O-rings, 1/4 in
using a 3/16 internal hex wrench. C138A
Torque the plugs to 12 N•m [9 lbf•ft]. C138
1/4 in E101 238

520L0821 • Rev AA • Nov. 2006 25

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly

Auxiliary pad 1. Install the adapter (J080) with new Install the auxiliary pad
O-rings (J090) and (J095). Tighten the
screws (J100) to 27 N•m [20 lbf•ft] J130
with a 10 mm internal hex wrench.
J110
2. Test torque-to-turn with the unit
assembled (excluding auxiliary
pumps) by rotating the input shaft
using a torque wrench. J120

Test the torque required to turn the shaft

(after break-away) with swashplate at
full angle and the assembly well oiled. J100 J140
Readings outside the table values may 10 mm
27 N•m
indicate internal problems. If necessary, [20 lbf•ft]
disassemble pump and check.

J080
Torque-to-turn shaft
13.5 to 24.4 N•m [120 to 216 lbf•in]
J090

J095
3. Reinstall the coupling (J140). Install
the auxiliary pad O-ring (J120) and
auxiliary pump or cover plate (J110).
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 ¾ inch hex wrench. E101 229

4. Reinstall any other external

components, including the auxiliary
A pad J130 screws B and C pad J130 screws
pump (if present), that were removed
37 to 50 N•m 91 to 111 N•m
before disassembly.
[27 to 37 lbf•ft] [67 to 82 lbf•ft]

26 520L0821 • Rev AA • Nov. 2006

 Series 45 Frame F Open Circuit Axial Piston Pump
Repair Instructions
Assembly

Displacement limiter 1. Install displacement limiter screw Install the displacement limiter
(L040) into plug (L010).
L030A
7/8 in
2. Install new O-ring (L010A) onto plug 54 N•m [40 lbf•ft]
(L010). Thread plug with limiter into L010A
L010
endcap. Torque to 77 N•m [57 lbf•ft]. 7/8 in L040
77 N•m [57 lbf•ft]
1/4 in
3. Turn adjustment / seal nut (L030A)
onto displacement limiter.

4. Using a 7/8-inch wrench, torque

the adjustment seal/nut (L030) to
54 N•m [40 lbf•ft].

Refer to Frame F Service Manual

11005158 for instructions on adjusting
displacement limiter.

E101 256

Attach the control 1. Using petroleum jelly to retain them, Install the control
install 4 new seal rings (C200) in the
recesses on the control housing. C300
4 mm
2. Install the control assembly onto the 6 N•m
[5 lbf•ft]
endcap using the 4 screws (C300)
with a 4 mm internal hex wrench.
Torque to 6 N•m [5 lbf•ft] using a
criss cross pattern, and retorque the C200
first screw to ensure proper torque
retention.

E101 257

Pump adjustment 1. Install the pump on a test stand.

2. Adjust the pump according to specifications shown in Series 45 Frame F Open Circuit
Axial Piston Pumps Service Manual 11005158.

520L0821 • Rev AA • Nov. 2006 27

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520L0821 • Rev AA • Nov. 2006
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