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Series 45

E Frame
Open Circuit
Axial Piston Pumps
Repair Manual
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair 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 arent in confict with agreed specifcations. 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 fnd 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) fles, these references
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taBLes, iLLustratiOns,
and COmPLementary
inFOrmatiOn
sPeCiaL text
FOrmatting
taBLe OF COntents
Using this manual
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
intrOduCtiOn Overview ........................................................................................................................................................... 5
General instructions ...................................................................................................................................... 5
Remove the unit .................................................................................................................................. 5
Keep it clean .......................................................................................................................................... 5
Lubricate moving parts ..................................................................................................................... 5
Replace all O-rings and gaskets ..................................................................................................... 5
Secure the unit ..................................................................................................................................... 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
Bias piston, spring, and servo piston .....................................................................................................10
Cylinder kit .....................................................................................................................................................10
Input shaft .......................................................................................................................................................10
Swashplate, 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 kit ...........................................................................................................................................19
Servo piston kit .............................................................................................................................................19
Bias piston kit .................................................................................................................................................19
Housing ...........................................................................................................................................................20
Auxiliary pad ..................................................................................................................................................20
Displacement limiter ...................................................................................................................................20
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Contents
assemBLy Journal bearing ............................................................................................................................................21
Front bearing and swashplate ................................................................................................................21
Input shaft .......................................................................................................................................................21
Cylinder kit assembly ..................................................................................................................................22
Cylinder kit installation ..............................................................................................................................22
Servo and bias kits .......................................................................................................................................23
Valve plate .......................................................................................................................................................23
Endcap..............................................................................................................................................................24
Shaft seal .........................................................................................................................................................24
PC control ........................................................................................................................................................25
LS control (optional) ....................................................................................................................................25
Auxiliary pad ..................................................................................................................................................26
Displacement limiter ...................................................................................................................................27
Reattach the control ....................................................................................................................................27
5 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
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, specifcations 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 certifed on a regular basis.
A Warning
Use of components that do not comply with rework specifcations may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that dont
comply to given specifcations: 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, 50L0606. Minor repairs include service
operations that can be performed without removing the units endcap. Removal of the
endcap voids your warranty.
Follow these general procedures when repairing Series 45 variable displacement open
circuit pumps.
@ 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 fuid may be under high pressure and / or hot. Inspect the outside of the pump
and fttings for damage. Cap hoses after removal to prevent contamination.
_ Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life, on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
and air drying is usually adequate.
As with any precision equipment, all parts must be kept free of foreign materials and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the pump with a protective layer of plastic.
_ Lubricate moving parts
During assembly, coat all moving parts with a flm of clean hydraulic oil. This assures that
these parts will be lubricated during start-up.
_ Replace all O-Rings and gaskets
It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean
petroleum jelly prior to assembly.
_ Secure the unit
For major repair, place the unit in a stable position with the shaft pointing downward. It
will be necessary to secure the pump while removing and torquing the endcap bolts.
generaL instruCtiOns
6 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
saFety PreCautiOns Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.
unintended machine movement
A 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
A warning
Some cleaning solvents are fammable. To avoid possible fre, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure
A warning
Escaping hydraulic fuid under pressure can have suffcient force to penetrate your skin
causing serious injury and/or infection. This fuid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fuid under pressure. Relieve pressure in the
system before removing hoses, fttings, 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 fuid.
Personal safety
A warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction
@ 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 specifcation
_ Parallelism specifcation
_ External hex head
_ Internal hex head
_ Torx head
_ O-ring boss port
_ Tip, helpful suggestion
_ Lubricate with hydraulic fuid
_ 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 specifcation
_ Press in press ft
_ Pull out with tool press ft
_ Cover splines with installation
sleeve
_ Pressure measurement / gauge
location or specifcation
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 defnes each symbol and explains its purpose.
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
auxiLiary Pad If a second pump is used, you must
remove it. You dont 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
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
9 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
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
h
7
/8 inch
Remove displacement limiter
10 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CyLinder kit
inPut shaFt
15. Remove the bias piston (B084),
spring (B083), and guide (B081). Also,
remove the servo piston (P020) and
guide (P030).
Caution
Take 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.
Remove shaft
J010
E101 207
E101 222
P020
P030
B084
B083
B081
h1-
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
11 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
shaFt seaL
swashPLate, jOurnaL
Bearings, and rOLLer
Bearing
K030
RB040
B050 p
B060 p
iB030
E101 208
B071 p
Remove swashplate and bearings 20. 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 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
COntrOL disassemBLy
Caution
If removing the LS or PC
spool is not possible, be
extremely careful when
fipping or relocating the
housing as not to lose or
damage the spool.
PC only
1. 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).
PC / Ls
2. With a
3
/16 inch internal hex wrench,
remove the 4 plugs (C103, C104,
C105, and C106) and their O-rings.
Discard the O-rings. Remove the 2
set screws (C102). Remove the spool
(C112). Note the orientation of the
spools for 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
C134
C138A d
C138
dC103A
C103
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 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly
CyLinder kit disassemble the cylinder block kit
1. Pull to remove the slipper retainer
(K049) with the pistons (K050) from
the cylinder kit.
The pistons are not selectively ftted,
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 removal
4. Turn the block over. Using a press,
apply pressure on the block spring
washer (K044) to compress the block
K050
K049
K047
K046
K041
K042
K043
K044
K045
P010
i
E101 012
l
R
Disassemble the cylinder block kit
A Warning
Risk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf ].
Use a press suffcient
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. A
1 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BaLL guide, sLiPPer
retainer, and hOLd-
dOwn Pins
Overview
PistOns and sLiPPers
After disassembly, wash all parts (including the end-cap and housing) thoroughly with
clean solvent and allow to air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.
i
Slipper
retainer
Ball guide
Hold down pins
P101 471
The ball guide should be free of
nicks and scratches, and should not
be excessively scored. Examine for
discoloration that may indicate excessive
heat or lack of lubrication. The slipper
retainer should be fat, and slippers
should ft in the retainer with minimal
side play. Place the hold-down pins on a
fat 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
Minimum
slipper foot
thickness

P104 109E
Inspect pistons
15 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
BLOCk sPring, and
washers
CyLinder BLOCk
i
Washer
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 fow.
K041
flat to 0.002 mm
[0.000079 in]
i
f
P101 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 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
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 spools outside diameter for
scratches and / or burrs. Clean and coat all spools, bores, and seals with a light coating of
hydraulic oil.
C133
C135
C134
C138A d
eC138
dC103A
C103
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 fuid out of the unit. Clean the
sealing area with a nonabrasive material
if necessary. Lubricate the shaft with a
light coat of hydraulic fuid.
J010
i
P104 352
l
Inspect shaft
1 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
swashPLate
jOurnaL Bearings
B040
i
P104 353
Carefully inspect each surface of the
swashplate for wear. All swashplate
surfaces should be smooth. Inspect the
swashplates slipper running surface
for fatness 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 bearings Inspect 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 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
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 fts
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 fngernail 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
fow. 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 fat and smooth on both
the running face and the bottom surface. The valve plate should be fat 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
19 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
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 fuid.
Replace the bearing if the problem is not
remedied by cleaning,
Inspect for uneven wear. If abnormal
wear is found, replace the bearing kit.
i
l
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 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection
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
1 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
jOurnaL Bearing
inPut shaFt
FrOnt Bearing and
swashPLate
1. Coat the journal bearings (B030)
with hydraulic fuid 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 ft with
the housing.
3. Coat the curved surface of the
swashplate (B040) with hydraulic
fuid. Reinstall the swashplate in its
original orientation. Lubricate the
fat 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
lB030
B071 P
E101 217
Install housing components
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
5. Coat all parts with hydraulic fuid
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. A
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 youre 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 rotate
cylinder block
E101 218
Assemble cylinder kit
Install cylinder block
CyLinder kit assemBLy
A Warning
Risk of personal injury:
Compressing the block
spring requires about 350
to 400 N [80 to 90 lbf ].
Use a press suffcient 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 fange facing
downward.
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
vaLve PLate
10. Reinstall the servo guide (P030).
Torque the servo guide at 190 to
217 Nm [140 to 160 lbfft], 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 Nm [110 lbfft] 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 Nm
[110 lbfft]
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.
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
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 Nm
[137 - 165 lbfft]
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 Nm
[137 to 165 lbfft], using the criss
cross pattern. Retorque the frst
screw to ensure proper torque
retention.
endCaP Install endcap
5 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
Assemble PC (only) control 19. Clean and lubricate all control parts
and cover with a light coating of
hydraulic fuid 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 Nm [8 to 10 lbfft]. Place
the two PC springs (C134, C135)
onto the PC spring guide (C133) and
install into the PC bore. Place a new
O-ring onto the PC plug (C138) and
install it so that it sits one turn below
the surface of the control housing.
Install and tighten set screw (C102)
at 7.5 to 10.8 Nm [5.5 to 8.0 lbfft] to
retain the adjusting plug.
PC COntrOL
C133
C135
C134
C138A d
eC138
dC103A
C103
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 control Install 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 Nm [8 to 10 lbfft]. Place
the 2 LS springs (C114, C115) onto
the LS spring guide (C113) and install
into the LS bore. Place a new O-ring
(C116) and back-up rings (C117)
onto the LS adjustment screw (C118).
Install the LS plug assembly so that it
sits one turn below the surface of the
control housing. Install and tighten
set screw (C102) at 7.5 to 10.8 Nm
[5.5 to 8.0 lbfft]. Also, install the
plugs (C105, C106) with new O-rings.
Torque the plugs at 10.8 to 13.5 Nm
[8 to 10 lbfft].
PC and LS spools need to be adjusted
to proper setting according to tag
nomenclature.
Ls COntrOL (OPtiOnaL)
6 50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
auxiLiary Pad
torque-to-turn shaft
13.5 to 24.4 Nm [120 to 216 lbfin]
22. Install the adapter (J080) with
new O-ring (J090). Tighten the
screws (J100) at 24.4 to 29.1 Nm 24.4 to 29.1 Nm
[18 to 21.5 lbfft] 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 j10 screws B and C pad j10 screws
37 to 50 Nm
[27 to 37 lbfft]
91 to 111 Nm
[67 to 82 lbfft]
wrench. For B and C pads, use a 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 Nm
[18 to 21.5 lbfft]
Install the auxiliary pad
50L0609 Rev A-1 August 2006
Series 45 E Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly
26. Using a
7
/8-inch wrench, torque
the adjustment plug (L020) at
41 to 95 Nm [30 to 70 lbfft].
27. Using a
7
/8-inch wrench, torque
the adjustment seal/nut (L030) at
50 to 58 Nm [37 to 43 lbfft].
disPLaCement Limiter
I4 mm
t5.4 to 7.5 Nm
[4 to 5.5 lbfft]
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 Nm [4 to 5.5
lbfft] using a criss cross pattern, and
retorque the frst screw to ensure
proper torque retention.
Install the control
E101 228
L030
L040
L020
L020A
t50 to 58 Nm
[37 to 43 lbfft]
h
7
/8 inch
t41 to 95 Nm
[30 to 70 lbfft]
h
7
/8 inch
Install the displacement limiter
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2800 East 13th Street
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Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
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DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
www.sauer-danfoss.com
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50L0609 Rev A-1 August 2006