45 Series K and L Frame Repair Manual (520L0632 REV a) (BLN-10196)

Series 45K and L Frame Open CircuitAxial Piston Pumps

Repair Manual

2 BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair Manual

© 2005 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 472, F101 473, F101 474, F101 475, P104 327

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

3BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualContents

INTRODUCTION Overview ........................................................................................................................................................... 4General instructions ...................................................................................................................................... 4Safety precautions ......................................................................................................................................... 5

Unintended machine movement ....................................................................................................... 5Flammable cleaning solvents ............................................................................................................... 5Fluid under pressure ................................................................................................................................ 5Personal safety ........................................................................................................................................... 5

Symbols used in Sauer-Danfoss literature ............................................................................................. 6

DISASSEMBLY Auxiliary pad .................................................................................................................................................... 7Control .............................................................................................................................................................. 8Endcap and roller bearing .......................................................................................................................... 8Cylinder kit ....................................................................................................................................................... 9Input shaft, swashplate, and bias spring ................................................................................................ 9Roller bearing, cup, and journal bearings ............................................................................................10Shaft seal ........................................................................................................................................................10Control housing ............................................................................................................................................11Cylinder kit disassembly ............................................................................................................................12

Block spring removal .............................................................................................................................12

INSPECTION Overview .........................................................................................................................................................13Pistons and slippers .....................................................................................................................................13Ball guide, slipper .........................................................................................................................................13Retainer, and hold-down pins ..................................................................................................................13Block spring, and washers .........................................................................................................................14Cylinder block ...............................................................................................................................................14Control ..............................................................................................................................................................15Shaft .................................................................................................................................................................15Swashplate ......................................................................................................................................................16Journal bearing .............................................................................................................................................16Valve plate .......................................................................................................................................................17Endcap .............................................................................................................................................................17Shaft bearing kits .........................................................................................................................................18Servo piston and guide ..............................................................................................................................18Housing ...........................................................................................................................................................19Auxiliary pad ..................................................................................................................................................19

ASSEMBLY Journal bearing ............................................................................................................................................20Bias spring, swashplate, and bearing ....................................................................................................20Input shaft .......................................................................................................................................................20Cylinder kit assembly ..................................................................................................................................21Cylinder kit installation ..............................................................................................................................21Valve plate and endcap .............................................................................................................................22Shaft seal .........................................................................................................................................................23Control ..............................................................................................................................................................24Auxiliary pad ..................................................................................................................................................25

4 BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualIntroduction

OVERVIEW This manual details the major repair procedures for Series 45 Frame K and L open circuit axial piston pumps. These include the complete disassembly, inspection, and reassembly of the unit. Where rework of worn or damaged components is possible, specifications are given to ensure these parts meet factory tolerances. Only Sauer-Danfoss Authorized Service Centers (ASCs) are authorized to perform major repairs. Sauer-Danfoss ASCs are trained by the factory to perform major repairs and their facilities are certified on a regular basis.

W 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 K and L Open Circuit Axial Piston Pumps Service Manual, 520L0532. 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

5BLN 10196 • 520L0632 • May 2005


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.

6 BLN 10196 • 520L0632 • May 2005


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.

7BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualDisassembly

AUXILIARY PAD

J140

J095 d

J100

J090 d

J085

J120

J110

J130

J140

J095 d

J100

J090 d

J085

J120 d

J110

J130

h 9/16 inch h ¾ inch

h8 mm h8 mm

E101 196

Remove auxiliary A pad Remove auxiliary B 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).

2. Remove the coupling (J140) and the pad seal (J120). If you have an auxiliary B pad, discard the O-ring (J120). The pad seal for an auxiliary A pad is reusable if 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).

5. Remove the coupling (J140).

8 BLN 10196 • 520L0632 • May 2005


6. Using a 5 mm internal hex wrench, remove the 4 control screws (C300) that fasten the control assembly to the endcap (J020).

7. Remove the control from endcap. Discard interface O-rings. (C200).

CONTROL

ENDCAP AND ROLLER BEARING

C200

C300I5 mm

d

P104 328

B045

B070

B020

B046

J030

I8 mm

J020

e

d

d

s

P101 351

B010

L020

L080

26 mm

Remove control

8. Remove the 4 endcap screws (J030) using an 8 mm internal hex wrench.

9. Remove the endcap. Remove the servo piston (L020) and guide (L080). Use care; valve plate (B070) may adhere to inside surface. Discard O-rings (B045, B046). Once the valve plate is removed, the check valve can be removed. Refer to Inspection, page 17, for more information.

To protect these parts from contamination, place the endcap and valve plate in a protected area.

10. Slide the rear tapered roller bearing cone (B020) from the bottom end of the shaft. The bearing cup (B010) may remain within the endcap.

Remove bearing cup if replacement is necessary. See Inspection, page 18.

Remove endcap and roller bearing

9BLN 10196 • 520L0632 • May 2005


CYLINDER KIT 11. Slide the cylinder block assembly (P010) out of the pump housing by pushing on the shaft from the bottom of the pump. Push the shaft only far enough so that the cylinder kit may be removed by hand. Keep track of the three small hold-down pins (K046) located inside the cylinder kit. Once removed, set the cylinder kit in a protected area. Contamination or scratches may lead to poor performance or pump failure.

P010i

s

K046

P104 339

Remove cylinder kit

INPUT SHAFT, SWASHPLATE, AND BIAS SPRING

pJ010

B040

B025

P101 353

12. Rotate the swashplate (B040) until level with pump housing. Pull the shaft (J010) from the shaft seal and bearing kit. Slightly compress the bias spring (B025) and lift the swashplate out. Lift the bias spring from the pump housing.

Remove shaft and swashplate

10 BLN 10196 • 520L0632 • May 2005


13. Pull to remove the front tapered roller bearing (B050). Carefully pry to remove the journal bearings (B030) and retaining pins (B071) from the pump housing. Record the location and orientation of the journal bearings if they are to be reused. If necessary, remove the front bearing cup (B060) from the pump housing.

SHAFT SEAL

ROLLER BEARING, CUP, AND JOURNAL BEARINGS

P101 352

K020 p

K010

B071

B030

B050

pB060

m

p

P101 369

14. Orient the housing with the flange facing up. Using snap-ring pliers, remove the snap ring (K010). Carefully pry out the shaft seal (K020).

If you are unable to pull the shaft seal out, try to push the seal out by going through the inside of the housing.

Remove bearings

Remove shaft seal

11BLN 10196 • 520L0632 • May 2005


CONTROL HOUSING

C112 i

C106A d

iC132

C103

dC103A

C133

C113

C134

C115

C114

C135

C117 d

dC136C116 d

C117 d

C118 iiC138

E101 192

R

R

C102

C106

Disassemble 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.

15. With a 3/16 inch internal hex wrench, remove the plugs (C103, 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

The PC and LS spools are not the same. They must be identified as to which bore they come out of.

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

17. Remove the adjusting screw (C118), O-ring (C116) and 2 backup rings (C117). Discard the O-ring and backup rings. Remove the springs (C114, C115) and spring guide (C113).

12 BLN 10196 • 520L0632 • May 2005


K045

K044

K043

K042

K041

P010

K047 l

K049 l

K050 l

P101 356

K046

K048 (L Frame only)

Disassemble cylinder kitCYLINDER KIT DISASSEMBLY

18. Remove pistons (K050) and slipper retainer (K049) from the cylinder block.

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.

19. Remove the ball guide (K047), hold-down pins (K046), and retaining ring (K048) from the cylinder block (K041).

Most repairs do not require block spring removal. Perform this procedure only if you suspect problems with the block spring.

Block spring removal20. Turn the block over. Using a press,

apply pressure on the block spring washer (K044)) to compress the block spring (K043). Compress the spring enough to safely remove the spiral retaining ring (K045). While maintaining pressure, unwind the

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.

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

13BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualInspection

BALL GUIDE, SLIPPERRETAINER, AND HOLD-DOWN PINS

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.

K Frame

Slipperfoot thickness 4.03 mm

[0.159 in]

Piston/slipper end play 0.102 mm

[0.004 in]

L Frame

Slipperfoot thickness 2.67 mm

[0.105 in]

Piston/slipper end play 0.102 mm

[0.004 in]

Inspect guide, retainer, and pins

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 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

14 BLN 10196 • 520L0632 • May 2005


BLOCK SPRING, AND WASHERS

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.

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.

C100

A

flat to 0.002 mm

[flat to 0.000080 in]

M

i

fP101 358

MB

K Frame 38 cc 45 cc

Minimum cylinder

block height (A)

56.48 mm

[2.224 in]

Maximum block bore

diameter (B)

16.44 mm

[0.65 in]

17.98 mm

[0.71 in]

L Frame 25 cc 30 cc

Minimum cylinder

block height (A)

50.8 mm

[2.00 in]

Maximum block bore

diameter (B)

13.88 mm

[0.546 in]

15.22 mm

[0.60 in]

Inspect block spring and washers

Inspect cylinder block

15BLN 10196 • 520L0632 • May 2005


Inspect the shaft for any signs of damage. Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic fluid out of the unit. If necessary, clean the sealing area with a non-abrasive material. Inspect the input splines or keyway, block spines and output splines. Replace the shaft if damaged. Ensure that the shaft’s splines are straight and lubricate the shaft with a light coating of hydraulic fluid.

SHAFT

J010

i

P101 360

l

Inspect shaft

CONTROL

C112 i

C106A d

iC132

C103

dC103A

C133

C113

C134

C115

C114

C135

C117 d

dC136C116 d

C117 d

C118 iiC138

E101 192

R

R

C102

C106

Carefully examine the LS plug for signs of wear. Also check the small tip of the LS plug for heavy wear and replace if necessary. Inspect each spool’s springs to make sure they are intact. 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 control components

16 BLN 10196 • 520L0632 • May 2005


SWASHPLATE

iP101 362

B040

JOURNAL BEARING

B030

i

P101 363

Carefully inspect each surface of the swashplate for wear. All swashplate surfaces should be smooth. Inspect the swashplate’s slipper running surface for 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

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.

17BLN 10196 • 520L0632 • May 2005


ENDCAP

B095

B090

P101 484

i

J050

Inspect the endcap. Remove the check valve (B095) to expose the spring (B090). Check and record orientation of the timing pin (J050). Inspect the check valve for wear on its sealing face and replace if necessary. Make sure the spring is undamaged. Carefully check the bearing cup 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 0.005 mm [0.0002 in] convex. A magnetic particle inspection is recommended to detect cracks. The valve plate must be replaced if any cracks exist.

B090

3.88 mm [0.153 in] min.

0.025 mm

[0.001 in]

0.005 mm

[0.00020 in]convex max

i

a

f

P101 419

18 BLN 10196 • 520L0632 • May 2005


SHAFT BEARING KITS

il

e

P101 366

The tapered roller bearing kits consist of a cup and cone. Both the cup and cone should be free of excessive wear and contamination. Rotate the bearings to check for smoothness. If a contaminated bearing is suspected, clean with a solvent and lubricate with hydraulic fluid. If the problem is not remedied by cleaning, replace the bearing. Also inspect for uneven wear. If abnormal wear is found, replace the bearing kit.

Inspect shaft bearings

Inspect the servo piston guide (L080) for abnormal wear. Check the inside diameter of the bore for galling or excessive wear. Inspect the servo piston (L020) for wear on its end and for scratches along its cylindrical surface. Replace both parts if any wear is noticeable.

SERVO PISTON AND GUIDE

L080

L020

i

P101 365

Inspect servo piston and guide

19BLN 10196 • 520L0632 • May 2005


HOUSING

i

P101 489

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

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.

J140 i

J095 d

J100

J090 d

J085

J120

J110

J130

i

E101 197

Inspect auxiliary pad components

20 BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualAssembly

1. Coat the journal bearings (B030) with hydraulic fluid and install them into the pump housing. Punch in retaining pins (B071) a minimum of 0.5 mm [0.002 in] below the bearing surface.

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

JOURNAL BEARING

INPUT SHAFT

BIAS SPRING, SWASHPLATE, AND BEARING

B060

B050

lB040

J010

B030

B025B071

l

l

P101 490

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

2. Reinstall shaft bearing cup (B060) and cone (B050). Before replacing the bias spring (B025), coat the curved surface of the swashplate (B040) with hydraulic fluid. Tilt the bias spring inward towards the center of the pump housing. To insert the swashplate, tilt the servo arm downward and into the pump housing. Make sure the cast knob on the swashplate fits over the bias spring and that it settles properly unto the journal bearings.

Install housing components

21BLN 10196 • 520L0632 • May 2005


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

5. 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

6. Turn the block over and install the retaining ring (L Frame only; K048), hold-down pins (K046), and ball guide (K047) to the cylinder block.

7. 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)

Prevent shaft from rotating

P101 491E

Slightly rotatecylinder block

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).

8. 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.

22 BLN 10196 • 520L0632 • May 2005


9. Install the inlet check valve spring (B090) and poppet (B095) into the endcap (J020). A small amount of grease will keep the poppet in position. Clean the valve plate (B070) and endcap (J020). Install the timing pin (J050) in the endcap and verify that it is properly oriented with the split facing into or out of the slot in the valve plate. The timing pin should be installed 3.6 ± 0.25 mm [0.14 ± 0.01 in] above the endcap 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, check valve, and bearing cup. Install the piston (L020) into the guide (L080), and torque the guide to 61 - 75 N•m [45 - 55 lbf•ft].

VALVE PLATE AND ENDCAP

eB070

J050 R

B020

eJ020B090

B095 g

P101 492

g

B010L080

L020

t61 - 75 N•m [45 -55 lbf•ft]

B045 g

gB046

J0308 mm47.5 to 61 N·m[35 to 45 lbf·ft]

J020

It

P101 493

Install endcap components

Install endcap10. Using assembly grease to hold seals, install the endcap to the housing. Ensure that seals remain properly seated and are not pinched during assembly. Install and torque endcap screws at 47.5 to 61 N•m [35 to 45 lbf•ft], using the criss cross pattern, and retorque the first screw to ensure proper torque retention.

23BLN 10196 • 520L0632 • May 2005


SHAFT SEAL 11. Cover shaft splines with an installation sleeve. Install a new shaft seal (K020) with the cup side facing the pump. Press seal into housing until it is deep enough to allow the retaining ring to be installed. Press evenly to avoid binding and damaging the seal. Install snap ring (K010).

Install shaft seal

E101 191

K020 P

K010

24 BLN 10196 • 520L0632 • May 2005


12. Clean and lubricate all control parts and cover with a light coating of hydraulic fluid prior to reassembly.

13. 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 (C106), torque at 10.8 to 13.5 N•m [8 to 10 lbf•ft]. Place the two LS springs (C115, C114) 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 lbf•ft].

CONTROL

C112 i

C106A d

iC132

C103

dC103A

C133

C113

C134

C115

C114

C135

C117 d

dC136C116 d

C117 d

C118 iiC138

P101 370

R

R

C102

t7.5 to 10.8 N•m [5.5 to 8.0 lbf•ft]

t10.8 to 13.5 N•m [8 to 10 lbf•ft] (C103 and C106)

C106

C200

C300I5 mm

d

P101 367

t15 to 18 N•m [11 to 13 lbf•ft]

15. Using petroleum jelly to retain them, Install the 3 seal rings (C200) in the recesses on the control housing. Install the control assembly onto the endcap using the 4 screws. Torque at 15 to 18 N•m [11 to 13 lbf•ft] using a criss cross pattern and retorque the first screw to ensure proper torque retention.

14. 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 lbf•ft]. to retain the adjusting plug.

Assemble the control

Install the control

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

nomenclature

25BLN 10196 • 520L0632 • May 2005


AUXILIARY PAD 16. Install the adapter (J085) with new O-rings (J090, J095). Tighten the screws (J100) at 67.5 to 82.5 N•m [49.8 to 60.8 lbf•ft].

17. Install the coupling (J140) onto the shaft.

18. Install the seal (J120) and plate cover (J130). If you have auxiliary pad B, install a new O-ring (J120). Tighten the plate cover screws (J130) to the specifications shown in the drawings below.

J140 i

J095 d

J100

J090 d

J085

J120

J110

J130

E101 198

t36.6 to 50.1 N•m [27.0 to 37.0 lbf•ft]

t67.5 to 82.5 N•m [49.8 to 60.8 lbf•ft]

Install auxiliary A pad

J140

J095 d

J100

J090 d

J085

J120 d

J110

J130

t61 to 73 N•m [45 to 54 lbf•ft]

t67.5 to 82.5 N•m [49.8 to 60.8 lbf•ft]

E101 223

Install auxiliary B pad

26 BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualNotes

27BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston PumpRepair ManualNotes

Sauer-Danfoss Mobile Power and Control Systems– Market Leaders Worldwide

Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market.

Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others.

We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them.

Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Sauer-Danfoss (US) Company2800 East 13th StreetAmes, IA 50010, USAPhone: +1 515 239-6000, Fax: +1 515 239 6618

Sauer-Danfoss GmbH & Co. OHGPostfach 2460, D-24531 NeumünsterKrokamp 35, D-24539 Neumünster, GermanyPhone: +49 4321 871-0, Fax: +49 4321 871 122

Sauer-Danfoss ApSDK-6430 Nordborg, DenmarkPhone: +45 7488 4444, Fax: +45 7488 4400

www.sauer-danfoss.com

OUR PRODUCTS

Hydrostatic transmissions

Hydraulic power steering

Electric power steering

Electrohydraulic power steering

Closed and open circuit axial piston pumps and motors

Gear pumps and motors

Bent axis motors

Orbital motors

Transit mixer drives

Planetary compact gears

Proportional valves

Directional spool valves

Cartridge valves

Hydraulic integrated circuits

Hydrostatic transaxles

Integrated systems

Fan drive systems

Electrohydraulics

Microcontrollers and software

Electric motors and inverters

Joysticks and control handles

Displays

Sensors

BLN 10196 • 520L0632 • May 2005

JLG/0505

Documents

45 Series K and L Frame Repair Manual (520L0632 REV a) (BLN-10196)