CONTENTS

saue

Genuine Parts
Original
Ersatzteile

Series 45

57 cc - Open Circuit
Pump
Service Parts Manual
369850 (BLN-2-41689)

October 1996

CONTENTS

Contents
Parts Identification .......................................................................................................................................... 3-4
Order Code .........................................................................................................................................................5
Control ............................................................................................................................................................ 6-7
Pressure Compensator Valve ......................................................................................................................... 6-7
Pilot Orifice ..................................................................................................................................................... 6-7
Gain Orifice ..................................................................................................................................................... 6-7
Shaft ............................................................................................................................................................. 8-17
Auxiliary Mounting ........................................................................................................................................ 8-17
End Cap ........................................................................................................................................................ 8-17
Housing ...................................................................................................................................................... 17-19
Special Hardware ....................................................................................................................................... 17-19
Shaft Seal ................................................................................................................................................... 17-19
Displacement Limiter .................................................................................................................................. 20-21
Overhaul Seal Kit ..............................................................................................................................................21

Copyright 1995, 1996 Sauer-Sundstrand. All rights reserved.

Contents subject to change. Information contained herein should be confirmed before placing orders.
Printed in U.S.A.

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
June 1995

Service Parts Identification

The following information and procedure is used to identify the module group, item number, manufactured date,
part number, and part name of the parts included in the Series 45 Open Circuit Pump.

The parts listed include all parts which may be used when performing either "Minor Repairs", "Major Repairs", or
"Conversions" on the Series 45 Open Circuit Pump.

- Nameplate -

Each unit will have a nameplate affixed to the housing. The

name plate will include the following information.
Model Code
The Sauer-Sundstrand model code completely defines the
specific unit and must be used when ordering the complete unit
for the first time or for ordering parts to service the product.
Model Number
The Sauer-Sundstrand model number is used by the factory in
manufacturing. On repeat orders, a complete unit can also be
ordered by the model mumber.
Serial Number
The Sauer-Sundstrand serial number is used to identify the
manufacturing location, manufacturing date and the unit sequence in the build. The serial number is also used to identify
the unit's warranty time period.

saue
Ames, Iowa, U.S.A.
Model Code

Neumnster, Germany
Typ

45R057 LS 25 20
NN A 1 S1N4 A1N
NNN NNN NNN
Model No.

Ident Nr

4577001
Ames, Iowa, U.S.A.
Neumnster, Germany
A
94 34
12345
Model Code
Typ
Serial No.
Fabr Nr
MADE IN U.S.A.

The letter code indicates the location of original manufacture

(assembly). "A" indicates the unit was originally assembled
in Ames, Iowa, USA.
The first number (2 digits) indicates the year of manufacture.
("94" would indicate the unit was manufactured in 1994)
The second number (2 digits) indicates the calender week of
manufacture.
The third number (5 digits) is a sequential number used to
identify a specific unit.

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

Date Code
The date code is defined as the year and week of manufacture. The same item number may list more than one
part number. This indicates that there is more than one configuration for that item number. You will see that there
are different date codes for the different part numbers. Find the date code of your unit via the nameplate to
determine which service part number you need to order.
EXAMPLE: The service part desired is Item H10N.
Order
Code
N

Item
H10N

Date Code
Begin End
89-38
87-02 89-37

Part Number
8800668
8800021

Qty. per
Description
Model/Kit
Loop flush defeat spool
1
Loop flush defeat spool (SB-8920)
1

All units using this order code with a date code of 87-02 and up to and including 89-37 must use part number
8800021. All units with a date code of 89-38 and up must use part number 8800668.

Service Bulletins
A Service Bulletin Number (SB- _ _ _ _) may follow the Description of the part you desire. You must read that
Service Bulletin prior to ordering that part. A copy of each of these Service Bulletins, as of the print date of this
bulletin, are included at the end of this manual. Service Bulletins contain more detailed information such as
interchangeability, what additional parts are involved, etc. It is suggested that you add additional Service Bulletins
to this manual as you receive them.

Procedure to Identify a Given Part/Part Number

General
The modular design of Series 45 units results in a simplified Service Parts List and Part Identification Procedure.
The same item numbers are used for same part description on all units within a product type. (Example: The lip
seal - Item Number K20 has the same item number on all pumps.)
A part number that has another number following it in parentheses is done to make this a world wide Service
Parts Manual. The first number is sold in Germany. The number in parentheses is sold in the United States.
(Example: 615427 (9009625-0108), Customers would order 9009625-0108 if ordering the part in the United
States.)
Example of a Part Identification
The nameplate on a Series 45 pump has an Order Code of 45R057 LS 25 20 NN A 1 S1N4 A1N NNN NNN NNN.
Use the following procedures to determine the part number of the drive shaft used on this pump.
1) Referring to the input shaft module, in the Order Code (see page 5), the input shaft option for this unit is
identified by the code S1N4 (45R057 LS 25 20 NN A 1 S1N4 A1N NNN NNN NNN)
2) Referring to the Service Parts List, find the shaft group. Next find the order code that relates to this unit, which
is S1N4. The shaft is found to be item J010 and part number 4570081.

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

Order Code
4 5

0 5 7

LS

2 5

2 0

NN

S1N4

A1N

NNN NNN NNN

Special Features

Series

Special Hardware
Rotation

Displacement Limiter
Pump Size (cc)

Speed Sensor
Front Flange &
Housing Ports Style

Control Type

Shaft Seal

Pressure Compensator Setting

Load Sensing Setting

End Cap Port Style

Rear Auxiliary Flange
Input Shaft

Torque Limiter Setting

Pilot Orifice

Gain Orifice

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

Control/Pressure Compensating Valve

C020
C010
C030

C040

C120

C120A
C110
H010

D000

C050
C060
C070

C080
C090

K080

G010
C100

D016
D013
D014

K090

C100A

D015

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Control
Order
Code

Item
C010
C020
C030
C040
C050
C060
C070
C080

Date Code
Begin End
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34

Part Number
5000082
612291 (9003508-0008)
4570021
001131 (9004201-5000)
4570026
4570022
4570111
4570027

Description
Set screw
Seal nut
Plug
O-ring
Spring seat
Spring
Spring
Spring guide

Qty. per
Model/Kit
1
1
1
1
1
1
1
1

LB

C090
C110
C120
C120A

94-34
94-34
94-34
94-34

4570025
4570094
327007 (9005110-4400)
001123 (9004201-2500)

Spool, LS
Orifice, 0.3mm
Plug
O-ring

1
1
1
1

LJ

C090

94-34

4570025

Spool, LS

LS

C090
C110
C120
C120A

94-34
94-34
94-34
94-34

4570025
092114 (9007712-0604
327007 (9005110-4400)
001123 (9004201-2500)

Spool, LS
Set screw
Plug
O-ring

1
1
1
1

PC

C090
C100
C100A
C110
C120
C120A

94-34
94-34
94-34
94-34
94-34
94-34

4570024
327007 (9005110-4400)
001123 (9004201-2500)
092114 (9007712-0604
327007 (9005110-4400)
001123 (9004201-2500)

Spool, PC
Plug
O-ring
Set screw
Plug
O-ring

1
1
1
1
1
1

Pressure Compensator Valve

10-28 & D2 D000
D013
D014
D015
D016
K080
K090

94-34
94-34
94-34
94-34
94-34
94-34
94-34

4510097
4570019
5000082
612291 (9003508-0008)
085043 (9004201-3700)
144725 (9004105-0110)
5000146 (9006110-0110)

PC valve kit, viton

Spring
Set screw
Seal nut
O-ring
O-ring
Back up ring

1
1
1
1
1
1
1

Orifice, 0.8mm, M6 x 6
Orifice, 0.9mm, M6 x 6
Orifice, 1.0mm, M6 x 6
Orifice, 1.1mm, M6 x 6
None

1
1
1
1
0

Pilot Orifice
A
B
C
D
G

G010
G010
G010
G010
G010

94-34
94-34
94-34
94-34
94-34

739144
4570062
4570063
4570064
None

Gain Orifice
1

H010

94-34

092114 (9007712-0604)

Set screw

H010

94-34

739136

Orifice, 0.7mm

Bold Items indicate recommended parts to be stocked for servicing

7

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

End Caps Shown Orientated

for CCW Rotation

J010

J040A

J010

J040
J020

K060

J030

J040A

J040

J040
J050

J030

J040A
J040
J050
J040

J030
J090

J080

J050

J140
J100

J040
J080

J120
J110
J130

J100

J110

J130

J120

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft/Auxiliary Flange/End Cap
Order
Code

Item
J040
J040A
J050
K060

Date Code
Begin End
94-34
94-34
94-34
94-34

Part Number
327007 (9005110-4400)
001123 (9004201-2500)
688622 (9004700-1907)
063248 (9004104-1560)

Description
Plug
O-ring
Pin
O-ring

Qty. per
Model/Kit
2
2
1
1

C3A2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570170
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570135

Shaft, 15 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 9 tooth spline

1
1
4
1
1
4
1
1
2
1

C3B2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570170
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
6472458 (9007200-5021)
4570134

Shaft, 15 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 13 tooth spline

1
1
4
1
1
4
1
1
2
1

C3N2

J010
J020
J030

94-34
94-34
94-34

4570139
4570172
5000386

Shaft, 15 tooth spline, no aux.

End cap, radial ports
Screw

1
1
4

C3N4

J010
J020
J030

94-34
94-34
94-34

4570139
Shaft, 15 tooth spline, no aux.
4570001
End cap, axial ports, no aux.
5000181 (9007314-1210) Screw

1
1
4

C3N5

J010
J020
J030

94-34
94-34
94-34

4570139
Shaft, 15 tooth spline, no aux.
1
4570185
End cap, metric axial ports, no aux. 1
5000181 (9007314-1210) Screw
4

C3T2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570170
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570137

Shaft, 15 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 11 tooth spline

1
1
4
1
1
4
1
1
2
1

Bold Items indicate recommended parts to be stocked for servicing

9

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

J012

End Caps Shown Orientated

for CCW Rotation

369850 (BLN-2-41689)
October 1996

J015

J010

J010

K060
J040A
J040

J030
J090

J080

J050

J140
J100

J040
J080

J120
J110
J130

J100

J110

J130

10

J120

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft/Auxiliary Flange/End Cap
Order
Code

Item
J040
J040A
J050
K060

Date Code
Begin End
94-34
94-34
94-34
94-34

Part Number
327007 (9005110-4400)
001123 (9004201-2500)
688622 (9004700-1907)
063248 (9004104-1560)

Description
Plug
O-ring
Pin
O-ring

Qty. per
Model/Kit
2
2
1
1

C3V2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570170
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
647248 (9007200-5021)
4570136

Shaft, 15 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 15 tooth spline

1
1
4
1
1
4
1
1
2
1

K4A2

J010
J012
J015
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44

4570159
5000364
5000365
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570135

Shaft, straight key, auxiliary

Square key
Retaining ring
End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 9 tooth spline

1
1
1
1
4
1
1
4
1
1
2
1

K4B2

J010
J012
J015
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44

4570159
5000364
5000365
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
6472458 (9007200-5021)
4570134

Shaft, straight key, auxiliary

Square key
Retaining ring
End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 13 tooth spline

1
1
1
1
4
1
1
4
1
1
2
1

Bold Items indicate recommended parts to be stocked for servicing

11

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

J012

369850 (BLN-2-41689)
October 1996

J015

J012

J015

J010
End Caps Shown Orientated
for CCW Rotation

J010

K060
J040A

J040

J030

J040A
J040
J050

J080
J040

J030

J140

J100

J090

J050

J080
J040
J120
J110
J130

J120

J100

J110

J120
J130
J110

J130

12

J080

J100

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft/Auxiliary Flange/End Cap
Order
Code

Item
J040
J040A
J050
K060

Date Code
Begin End
96-44
96-44
96-44
96-44

Part Number
327007 (9005110-4400)
001123 (9004201-2500)
688622 (9004700-1907)
063248 (9004104-1560)

Description
Plug
O-ring
Pin
O-ring

Qty. per
Model/Kit
2
2
1
1

K4C2

J010
J012
J015
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44

4570159
5000364
5000365
4570171
5000386
4570061
327627 (9004104-1540)
393694
8800406
719179 (9004100-0480)
647248 (9007200-5021)
4570133

Shaft, straight key, auxiliary

Square key
Retaining ring
End cap, radial w/aux. mounting
Screw
Adaptor flange, 'C' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 14 tooth spline

1
1
1
1
4
1
1
6
1
1
4
1

K4T2

J010
J012
J015
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44

4570159
5000364
5000365
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570137

Shaft, straight key, auxiliary

Square key
Retaining ring
End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 11 tooth spline

1
1
1
1
4
1
1
4
1
1
2
1

K4V2

J010
J012
J015
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44
96-44

4570159
5000364
5000365
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
6472458 (9007200-5021)
4570136

Shaft, straight key, auxiliary

Square key
Retaining ring
End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 15 tooth spline

1
1
1
1
4
1
1
4
1
1
2
1

K4N2

J010
J012
J015
J020
J030

96-44
96-44
96-44
96-44
96-44

4570060
5000364
5000365
4570172
5000386

Shaft, straight key, no aux.

Square key
Retaining ring
End cap, radial ports
Screw

1
1
1
1
4

Bold Items indicate recommended parts to be stocked for servicing

13

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

J012

369850 (BLN-2-41689)
October 1996

J015

J010
End Caps Shown Orientated
for CCW Rotation

J010
J040A
J040

J010

J020

J030

K060
J040A

J040

J040

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

J050

J030

J040A
J040
J050

J080
J040

J030

J140

J100

J090

J050

J080
J040
J120
J110
J130

J120

J100

J110

J120
J130
J110

J130

14

J080

J100

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft/Auxiliary Flange/End Cap
Order
Code

Item
J040
J040A
J050
K060

Date Code
Begin End
94-34
94-34
94-34
94-34

Part Number
327007 (9005110-4400)
001123 (9004201-2500)
688622 (9004700-1907)
063248 (9004104-1560)

Description
Plug
O-ring
Pin
O-ring

Qty. per
Model/Kit
2
2
1
1

K4N4

J010
J012
J015
J020
J030

94-34
94-34
94-34
94-34
94-34

4570060
5000364
5000365
4570001
5000181 (9007314-1210)

Shaft, straight key, no aux.

Square key
Retaining ring
End cap, axial ports
Screw

1
1
1
1
4

S1A2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570132
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570135

Shaft, 14 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 9 tooth spline

1
1
4
1
1
4
1
1
2
1

S1B2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570132
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
6472458 (9007200-5021)
4570134

Shaft, 14 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 13 tooth spline

1
1
4
1
1
4
1
1
2
1

S1C2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570132
4570171
5000386
4570061
327627 (9004104-1540)
393694
8800406
719179 (9004100-0480)
647248 (9007200-5021)
4570133

Shaft, 14 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'C' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 14 tooth spline

1
1
4
1
1
6
1
1
4
1

S1N2

J010
J020
J030

94-34
94-34
94-34

4570081
4570172
5000386

Shaft, 14 tooth spline, no aux.

End cap, radial ports
Screw

1
1
4

Bold Items indicate recommended parts to be stocked for servicing

15

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

J012
J014
J013

J010
End Caps Shown Orientated
for CCW Rotation

J010
J040A
J040

J010

J020

J030

K060
J040A

J040

J040
J050

J030

J040A
J040
J050
J040

J030

J140
J080

J090

J040

J100
J080

J120

J120

J110
J130

J110

J130
16

J050

J100

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft/Auxiliary Flange/End Cap
Order
Code

Item
J040
J040A
J050
K060

Date Code
Begin End
94-34
94-34
94-34
94-34

Part Number
327007 (9005110-4400)
001123 (9004201-2500)
688622 (9004700-1907)
063248 (9004104-1560)

Description
Plug
O-ring
Pin
O-ring

Qty. per
Model/Kit
2
2
1
1

S1N4

J010
J020
J030

94-34
94-34
94-34

4570081
Shaft, 14 tooth spline, no aux.
4570001
End cap, axial ports
5000181 (9007314-1210) Screw

1
1
4

S1T2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570132
4570171
5000386
4570074
327627 (9004104-1540)
393694
4460586
4800482
049874 (9007200-3716)
4570137

Shaft, 14 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'A' pad
O-ring
Screw
Cover plate
'A' pad seal
Screw
Coupling, 11 tooth spline

1
1
4
1
1
4
1
1
2
1

S1V2

J010
J020
J030
J080
J090
J100
J110
J120
J130
J140

96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12
96-12

4570132
4570171
5000386
4570075
327627 (9004104-1540)
393694
4460370
680892 (9004104-0440)
6472458 (9007200-5021)
4570136

Shaft, 14 tooth spline, auxiliary

End cap, radial w/aux. mounting
Screw
Adaptor flange, 'B' pad
O-ring
Screw
Cover plate
O-ring
Screw
Coupling, 15 tooth spline

1
1
4
1
1
4
1
1
2
1

T0N2

J010
J012
J013
J014
J020
J030

94-34
94-34
94-34
94-34
94-34
94-34

4570059
5000362
9700169
716779 (9004600-1230)
4570172
5000386

Shaft, tapered key, no aux.

Woodruff key
Slotted nut
Cotter pin
End cap, radial ports
Screw

1
1
1
1
1
4

T0N4

J010
J012
J013
J014
J020
J030

94-34
94-34
94-34
94-34
94-34
94-34

4570059
5000362
9700169
716779 (9004600-1230)
4570001
5000181 (9007314-1210)

Shaft, tapered key, no aux.

Woodruff key
Slotted nut
Cotter pin
End cap, axial ports
Screw

1
1
1
1
1
4

17

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

K122A
K122
K130

K130A
K010

K020
K120A

K124

K120

K124A

K132A
K070
K132
B083

B08

K110
K100

B030
B082

B065
B040

K040

K050
K047
K048
K046

B090
B015

18

K042
K044
K045

K049

K041

K043
Enlarged Bold type item numbers
are recommended parts to be
stocked for servicing

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Shaft Seal/Housing/Speed Sensing
Order
Code

Item
K010
K020
K040
K041
K042
K043
K044
K045
K046
K047
K048
K049
K050
K070
K080
K090
K100
K110
K120
K120A

A1N & A3N K122

K122A
K124
K124A
K130
K130A
K132
K132A
A4N

K122
K122A
K124
K124A
K130
K130A

Date Code
Begin End
94-34
94-34
94-34
94-34
95-13
95-13
95-13
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34

Qty. per
Model/Kit
1
1
1
1
1
1
1
1
3
1
1
1
9
2
1
1
1
1
1
1

Part Number
016014 (9006200-0206)
5000190
4570032
4570003
615427 (9009625-0108)
625419 (4460111)
615450 (9009625-0105)
615443 (9006250-0162)
688598 (9004875-0113)
615476 (4460180)
615468 (4460028)
4570009
4570028
011296 (9004105-0120)
144725 (9004105-0110)
5000146 (9006110-0110)
544742 (9004105-0190)
5000182
327007 (9005110-4400)
001123 (9004201-2500)

Description
Retaining ring
Lip seal
Cylinder block kit
Cylinder block
Washer
Cylinder block spring
Washer
Retaining ring
Hold down pin
Slipper retainer guide
Hold down pin retainer
Slipper retainer
Piston assembly
O-ring
O-ring
Back up ring
O-ring
Back up ring
Plug
O-ring

94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34

327007 (9005110-4400)
001123 (9004201-2500)
327007 (9005110-4400)
001123 (9004201-2500)
315325 (9005110-8700)
001149 (9004201-6200)
315325 (9005110-8700)
001149 (9004201-6200)

Plug
O-ring
Plug
O-ring
Plug
O-ring
Plug
O-ring

1
1
1
1
1
1
1
1

94-34
94-34
94-34
94-34
94-34
94-34

5000438
5000463
5000438
5000463
5000439
5000464

Plug, metric
O-ring
Plug, metric
O-ring
Plug, metric
O-ring

1
1
1
1
1
1

Bias piston kit

Rear bearing kit
Swashplate bearing
Swashplate assembly
Front bearing kit
O-ring
Spring
Valve plate, (45L057)
Valve plate, (45R057)

1
1
2
1
1
1
1
1
1

Special Hardware
NNN

B08
B015
B030
B040
B065
B082
B083
B090
B090

94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34

4570197
4510095
4570068
4570033
4510096
001156 (9004201-7500)
4570016
4570109
4570108

Bold Items indicate recommended parts to be stocked for servicing

19

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

57 cc Open Circuit Pump

L010
L020

L030
L020A
L040

L010
L020

L020A

Enlarged Bold type item numbers

are recommended parts to be
stocked for servicing

20

369850 (BLN-2-41689)
October 1996

CONTENTS

Series 45
Service Parts

saue

Genuine Parts
Original
Ersatzteile

369850 (BLN-2-41689)
October 1996

57 cc Open Circuit Pump

Displacement Limiter
Order
Code
AAA

NNN

Item
L010
L020
L020A
L030
L040

Date Code
Begin End
94-34
94-34
94-34
94-34
94-34

Part Number
4570017
4570129
001156 (9004201-7500)
076042 (9003509-0012)
689190 (9007712-1215)

Description
Servo piston
Plug
O-ring
Seal nut
Set screw

Qty. per
Model/Kit
1
1
1
1
1

L010
L020
L020A

94-34
94-34
94-34

4570017
093625 (9005100-9000)
001156 (9004201-7500)

Servo piston
Plug
O-ring

1
1
1

Overhaul seal kit

O-ring
Seal nut
O-ring
O-ring
Seal nut
O-ring
O-ring
Lip seal
O-ring
O-ring
O-ring
Back up ring
O-ring
Back up ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring

1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1

Overhaul Seal Kit

B082
C020
C040
C100A
D015
D016
J040A
K020
K060
K070
K080
K090
K100
K110
K120A
K122A
K124A
K130A
K132A
L020A

94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34
94-34

4510094
001156 (9004201-7500)
612291 (9003508-0008)
001131 (9004201-5000)
001123 (9004201-2500)
612291 (9003508-0008)
085043 (9004201-3700)
001123 (9004201-2500)
5000190
063248 (9004104-1560)
011296 (9004105-0120)
144725 (9004105-0110)
5000146 (9006110-0110)
544742 (9004105-0190)
5000182 (9006110-0110)
001123 (9004201-2500)
001123 (9004201-2500)
001123 (9004201-2500)
001149 (9004201-6200)
001149 (9004201-6200)
001156 (9004201-7500)

Bold Items indicate recommended parts to be stocked for servicing

21

CONTENTS

saue
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and
manufacture of Hydraulic Power Systems. Research and
development resources in both North America and Europe
enable SAUER-SUNDSTRAND to offer a wide range of
design solutions utilizing hydraulic power system
technology.

SAUER-SUNDSTRAND specializes in integrating a full

range of system components to provide vehicle designers
with the most advanced total-design system.
SAUER-SUNDSTRAND is Your World Source for
Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston

Pumps and Motors

Heavy Duty Bent Axis

Variable Motors

Cartridge Motors/
Compact Wheel Drives

Medium Duty Axial Piston

Pumps and Motors

Microcontrollers and
Electrohydraulic Controls

Hydrostatic Transmission
Packages

Open Circuit Axial Piston Pumps

Gear Pumps and Motors

Genuine Service Parts

Worldwide Service Support

SAUER-SUNDSTRAND provides comprehensive worldwide service for its
products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

saue
369850 (BLN-2-41689) October 1996

SAUER-SUNDSTRAND COMPANY
2800 East 13th Street
Ames IA 50010 U.S.A.
Phone: (515) 239-6000 FAX: (515) 239-6318

SAUER-SUNDSTRAND GMBH & CO.

Postfach 2460 D-24531 Neumnster
Krokamp 35 D-24539 Neumnster Germany
Phone: (04321) 871-0 Fax: (04321) 871122

saue
Series 45

Axial Piston
Open Circuit Pumps
Service Information

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 2
November 22, 1995

Contents
Safety Precautions ...................................................................................................................................... 2
Minor Repair Instructions General .......................................................................................................... 3
Gauge Installation ....................................................................................................................................... 4
Component Adjustments ............................................................................................................................. 5
1 Pressure Compensator (PC) Control Adjustment .................................................................................. 5
2 Load Sensing (LS) Control Adjustment ................................................................................................. 6
Minor Repair Instructions ............................................................................................................................ 7
1 Shaft Seal Replacement ........................................................................................................................ 7
2 Displacement Piston and Maximum Displacement Limiter .................................................................... 8
3 Bias Piston ............................................................................................................................................ 9
4 Auxiliary Pad ........................................................................................................................................ 10
5A Pressure Compensator (PC) Control Pilot Stage and Gain Orifice Removal and Installation ........... 11
5B Load Sensing (LS) Control Spool [Pressure Compensator (PC) Second Stage] Removal and
Installation ........................................................................................................................................... 12
6 Plug and Fitting Torques ...................................................................................................................... 13
Minor Repair Instructions Exploded View ............................................................................................... 15

Safety Precautions
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid under
pressure can have sufficient force to penetrate
your skin causing serious injury. This fluid may
also be hot enough to burn. Serious infection or
reactions can develop if proper medical treatment is not administered immediately.

Certain service procedures may require the vehicle/machine to be disabled (work function disconnected, etc.) while performing them in order
to prevent injury to the technician and bystanders.
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.

Copyright 1995, Sauer-Sundstrand Company.

All rights reserved. Contents subject to change. Printed in U.S.A. 1195H

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 3
November 22, 1995

Minor Repair Instructions General

Minor Repairs may be performed, following the
procedures in this document, without voiding the
unit warranty.
Cleanliness is a primary means of assuring satisfactory pump life, on either new or repaired units.
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.
It is recommended that all O-rings be replaced.
Lightly lubricate all O-rings with clean petroleum
jelly prior to assembly.

Displacement
Control Piston

Controls

Shaft
Seal

Bias Piston

Left Side View

Right Side View

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 4
November 22, 1995

Gauge Installation
M2

System
Pressure

300 bar or 5000 psi gauge

7/16 20 O-Ring Fitting

"L1" Case
"L2" Pressure

10 bar or 100 psi gauge

7/8 14 O-Ring Fitting (057)

M4

Control
Piston

300 bar or 5000 psi gauge

7/16 20 O-Ring Fitting

"X1" LS Signal

300 bar or 5000 psi gauge

Tee into LS Signal Line
7/16 20 O-Ring Fitting

LS SIGNAL PORT "X"

(PLUGGED FOR PC CONTROL)

SYSTEM PRESSURE PORT "B"

INLET PORT "S"

CASE DRAIN PORT "L1"

LEFT SIDE VIEW
BASE UNIT WITH PC / LS CONTROL AND AXIAL END CAP PORTS

SERVO PRESSURE
GAGE PORT M4

SYSTEM PRESSURE
GAGE PORT M2
CASE DRAIN PORT "L2"

RIGHT SIDE VIEW

BASE UNIT WITH PC / LS CONTROL AND AXIAL END CAP PORTS

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 5
November 22, 1995

Component Adjustments
1 Pressure Compensator (PC) Control Adjustment
WARNING
Take necessary precautions to secure the work
function so no movement occurs while performing the following procedure in order to
prevent injury to the technician and bystanders.
Install a pressure gauge in gauge port M2 to
measure system pressure. Install a pressure gauge
in case drain port L1 or L2 to measure case
pressure.

Operate the prime mover at normal speed. Loosen

the second stage adjustment seal lock nut. Turn
the second stage adjustment screw until the
system pressure gauge reads 15 bar (220 psi)
HIGHER than the case pressure gauge. Hold the
second stage adjustment screw in position and
torque the seal lock nut.

Loosen the PC adjustment seal lock nut. Turn the

PC adjustment screw counterclockwise until the
spring pressure is released, then turn an additional
two (2) turns counterclockwise. Temporarily hand
tighten the adjustment seal lock nut.

Loosen the PC adjustment seal lock nut. Operate a

hydraulic function so as to load the system at
maximum pressure and zero flow (dead-head).
Turn the PC adjustment screw clockwise until the
system pressure reaches the desired value, as
indicated on the system pressure gauge. (This
setting is referenced to case pressure.) Hold the
PC adjustment screw in position and torque the
seal lock nut.

If a remote PC control is installed, disconnect the

remote PC connection and cap the line. Plug the
remote PC port in the pump housing.

Stop the prime mover and remove the pressure

gauges installed in gauge port M2 and case drain
port L1 or L2. Reinstall the plugs in the ports.

Start the prime mover and allow the fluid to reach

normal operating temperature.

If a remote PC control is installed, reconnect the

line to the remote PC valve.

PC Adjustment Screw
4 mm int hex wrench

PC Adjustment
Seal Lock Nut
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

Remote PC Port
Second Stage
Adjustment Screw
4 mm int hex wrench

Second Stage
Adjustment
Seal-Lock Nut
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

Series 45 Open Circuit Pump with PC Control

PC Adjustment
Screw

Remote PC Port

Second Stage
Adjustment Screw
Cross-Section of PC Control

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 6
November 22, 1995

Component Adjustments
2 Load Sensing (LS) Control Adjustment
WARNING
The following procedure requires "deadheading" the pump. Take necessary precautions to
secure the work function so no movement
occurs while performing the procedure in order to prevent injury to the technician and
bystanders.
Install a pressure gauge in gauge port M2 to
measure system pressure. Install a pressure gauge
in case drain port L1 or L2 to measure case
pressure.
Loosen the PC adjustment seal lock nut. Turn the
PC adjustment screw counterclockwise until the
spring pressure is released, then turn an additional
two (2) turns counterclockwise. Temporarily hand
tighten the adjustment seal lock nut.
If a remote PC control is installed, disconnect the
remote PC connection and cap the line. Plug the
remote PC port in the pump housing.
Start the prime mover and allow the fluid to reach
normal operating temperature.

Operate the prime mover at normal speed. Loosen

the LS adjustment seal lock nut. Turn the LS
adjustment screw until the system pressure gauge
reads HIGHER than the case pressure gauge by
the amount indicated in the "Load Sensing Setting"
section of the pump model code. Hold the LS
adjustment screw in position and torque the seal
lock nut.
Loosen the PC adjustment seal lock nut. Operate a
hydraulic function so as to load the pump at
maximum pressure and zero flow (dead-head).
Turn the PC adjustment screw clockwise until the
system pressure reaches the desired value, as
indicated on the system pressure gauge. This
setting is referenced to case pressure. (If the
pressure setting does not increase in response to
turning the adjustment screw clockwise, the system
relief valve may be improperly adjusted.) Hold the
PC adjustment screw in position and torque the
seal lock nut.
Stop the prime mover and remove the pressure
gauges installed in gauge port M2 and case drain
port L1 or L2. Reinstall the plugs in the ports.
If a remote PC control is installed, reconnect the
line to the remote PC valve.

PC Adjustment Screw
4 mm int hex wrench
PC Adjustment
Seal Lock Nut
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

Remote PC Port
LS Port
LS Adjustment Screw
4 mm int hex wrench
LS Adjustment
Seal-Lock Nut
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

Series 45 Open Circuit Pump with LS Control

PC Adjustment
Screw

Remote PC Port
LS Port

LS Adjustment Screw
Cross-Section of LS Control

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 7
November 22, 1995

Minor Repair Instructions

1 Shaft Seal Replacement
A lip type shaft seal is used in the Series 45 open
circuit variable pumps. This seal can be replaced
without major disassembly of the unit.
Replacement of the shaft seal generally requires
removal of the pump from the machine.
Remove the retaining ring (item K010) from the
housing.

K010

K020

After removing the retaining ring, carefully remove

the seal (item K020) from the bore in the pump
housing. The face of the seal may be punctured with
a sharp instrument to aid in prying the seal out, or a
slide hammer type puller may be used to remove the
seal. Care must be taken so as not damage the pump
housing or shaft. Once removed, the seal is not
reusable.
Inspect the pump housing and the new seal for
damage. Inspect the sealing area on the shaft for rust,
wear, or contamination. Polish the sealing area on
the shaft if necessary.
Wrap the spline or key end of shaft with thin plastic to
prevent damage to the seal lip during installation.
Lubricate the inside diameter of the new seal with
petroleum jelly.
Press the new seal into the housing, being certain the
seal is perpendicular to the shaft. The seal lip must
face the shaft bearing. Be careful not to damage seal.
NOTE: The outside diameter of the new seal may be
coated with a sealant (such as Loctite High
Performance Sealant #59231) prior to installation.
CAUTION
Do not press the seal into the housing farther
than necessary to install the retaining ring. The
seal must not contact the shaft bearing.
Install the seal retaining ring.

5.33 mm
(.21 in)

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 8
November 22, 1995

Minor Repair Instructions

2 Displacement Piston and Maximum Displacement
Limiter
Remove the displacement piston bore plug (item
L020) with its O-ring. Remove the displacement
piston (item L010) from the pump housing.
Inspect the displacement piston for wear or damage.
Lubricate the displacement control piston with
hydraulic oil and install it into the pump housing
with the hole in the end of the piston facing the
bore plug. Install a new O-ring on the piston bore
plug, and install the plug into the pump housing.
Torque the displacement piston plug as indicated.

Loosen the seal lock nut (item L030) and remove

the nut and the limiter screw (item L040) from the
displacement piston bore plug (item L020).
Reinstall the limiter screw and seal lock nut.
WARNING
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change
in pump output and to prevent external leakage
during unit operation.
One full turn of the displacement limiter adjustment
screw will change the displacement of the 057
frame size pump by approximately 4.3 cc / revolution (0.26 in3 / revolution).

Lubricate with
hydraulic oil.
L010
L020

1-1/4 in. hex wrench

Torque: 230 Nm (170 lbsfft)
L020
L040
L030
1-1/4 in. hex wrench
Torque: 230 Nm (170 lbsfft)
6 mm int. hex wrench
19 mm hex wrench
Torque: 87 Nm (64 lbsfft)
after adjustment

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 9
November 22, 1995

Minor Repair Instructions

3 Bias Piston
Remove the bias piston guide (item B081) (with the
bias spring, bias piston, O-rings and backup
washer) from the pump housing. Remove the bias
spring (item B083) and bias piston (item L010)
from the piston guide.
Remove the backup washer (item K110), small Oring (item K100), and large O-ring (item B082) from
the piston guide.
Inspect the bias piston, piston guide, and spring for
wear or damage.

Install new O-rings and a new backup washer on

the piston guide. Install the bias spring on the
piston guide. Lubricate the bias piston with hydraulic oil and install it onto the piston guide.
Install the piston guide assembly into the pump
housing and torque as indicated.
Note: Close the hole in the piston guide with your
finger to allow air pressure to assist in
holding the piston and spring in position.

B084
Lubricate with hydraulic oil.
B083
K110
K100
B082
B081
1-1/4 in. hex wrench
Torque: 230 Nm (170 lbsfft)

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 10
November 22, 1995

Minor Repair Instructions

4 Auxiliary Pad
Remove the two (2) screws retaining the auxiliary
pump, and remove the pump with its sealing Oring. Remove the drive coupling (item J140).
Remove the four (4) screws (item J100) retaining
the pad adapter (item J080) to the pump end cap
(six [6] screws are used for the SAE "C" pad). The
pad adapter is sealed to the pump end cap with an
O-ring (item J090).
Reinstall the pad adapter with a new O-ring. Install
and torque the screws.

J140

J100

Reinstall the drive coupling. Reinstall the auxiliary

pump with a new O-ring.

J080

J090

8 mm int.
hex wrench
Torque: 75 Nm
(55 lbsfft)

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 11
November 22, 1995

Minor Repair Instructions

5A Pressure Compensator (PC) Control Pilot Stage
and Gain Orifice Removal and Installation
Remove the PC valve cartridge assembly (with Orings and backup washer) from the pump housing.
Remove and discard the small O-ring (item K080),
backup washer (item K090), and large O-ring (item
D016) found on the cartridge assembly.
Loosen the seal lock nut (item D015) and remove
the setting screw (item D014), spring (item D013),
and poppet (item D012) from the cartridge housing
(item D011).
Inspect all parts for wear or damage.

Install new O-rings and a new backup washer on

the cartridge housing. Install the poppet, spring,
and setting screw (with seal lock nut) into the
cartridge housing.
Install the cartridge assembly into the pump
housing and torque as indicated.
Check and adjust the pressure compensator
setting before putting the pump back into operation.
The control gain orifice plug (item H010) and bleed
orifice plug (item C110) are accessible after
removing the passage plug (item K120) in the
pump housing.

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)
K120
H010
3 mm int. hex wrench
Torque: 5 Nm (44 lbsfin)
Gauge Port "M4"

K080
K090
D016
D011
D012
D013
D014

11/16 in. hex wrench

Torque: 37 Nm (27 lbsfft)

D015
4 mm int hex wrench
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

K120
(Not used with
remote PC)
C110

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 12
November 22, 1995

Minor Repair Instructions

5B Load Sensing (LS) Control Spool [Pressure
Compensator (PC) Second Stage] Removal and
Installation
Remove the spool plug assembly (with O-ring,
setting screw, and seal lock nut) from the pump
housing. Remove and discard the O-ring (item
C040) from the special plug (item C030).
Remove the outer spring seat (item C050) from the
spool plug or the pump housing.
Loosen and remove the seal lock nut (item C020)
and setting screw (item C010) from the special
plug if necessary.
Remove the outer spool spring (item C060) and the
inner spool spring (item C080).
Remove the inner spring seat (item C080) and the
LS control spool or PC second stage spool (item
C090). Note the orientation of the spool.
Inspect all parts for wear or damage. Check that
the orifice in the PC second stage spool is not
plugged.

K120
C110

Install the LS control spool or the PC second stage

spool into the pump housing. Install the inner
spring seat onto the spool. If the spool is oriented
incorrectly, the inner spring seat cannot be installed onto the spool.
Install the inner and outer spool springs.
Install a new O-ring onto the special plug. Place
the outer spring seat in the special plug, and install
the plug into the pump housing and torque.
Install the setting screw and seal lock nut (if
removed) and hand tighten the seal lock nut.
Check and adjust the load sensing or second stage
setting and the pressure compensator setting
before putting the pump back into operation.
The load sensing pilot orifice plug (item G010) is
located in the LS signal port (port "X") in the pump
housing. When load sensing is not used, a plug
(item C100) is installed in this port, and the pilot
orifice is not installed.

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)
3 mm int. hex wrench
Torque: 5 Nm (44 lbsfin)

G010
(LS)
C090

C080
C070
C060
C050
C040

C100
(PC)

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)
3 mm int. hex wrench
Torque: 5 Nm (44 lbsfin)

With orifice (PC)

C030
C010
C020
Without orifice (LS)

7/8 in. hex wrench

Torque: 46 Nm (34 lbsfft)
4 mm int hex wrench
13 mm hex wrench
Torque: 23 Nm (17 lbsfft)

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 13
November 22, 1995

Minor Repair Instructions

6 Plug and Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated in the following figure.

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)

K120
(Not used with
remote PC)

K120

LS Signal Port
3/16 in. int. hex wrench
Torque: 12 Nm (9 lbsfft)

Gain Orifice
Gauge Port "M4"

J040

LS Pilot Orifice
C100
(Not used with LS)

K120
K130

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)
057: 3/8 in. int. hex wrench
Torque:
057: 12 Nm (70 lbsfft)

Port "L1"

3/16 in. int. hex wrench

Torque: 12 Nm (9 lbsfft)

Gauge Port "M2"

J040

K120
3/16 in. int. hex wrench
Torque: 12 Nm (9 lbsfft)

057: 3/8 in. int. hex wrench

Torque:
057: 12 Nm (70 lbsfft)
K130

Port "L2"

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 14
November 22, 1995

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 15
November 22, 1995

Minor Repair Instructions Exploded View 1

K120

(C110)

L030

K120
H010

L010

(L020)
L040

C010
C020
C110
C030
C040
C050
C060
(C090)
C070
C080
C090

L020
K130
K120

K010
K020

K090

J040

K080

D010

D016
D011
D012
D013
D014
D015

G010
C100
K120

K130
J040
AXIAL PORTS
J012

B084

J013

J014

B083
K110
K100
B082

(J012)

J015

B081

(J040)

(J040)
RADIAL PORTS
W/O AUX. DRIVE

Name Plate

saue
Ames, Iowa, U.S.A.
Model Code

Neumnster, Germany
Typ

45R057 LS2520
NNA3S1N4
A1 NNNN NNNNNN
Model Number
Serial Number

Model No.

Model Code

Ident Nr

4577060
A-95-02-67890

Identification Number

Serial No.
Fabr Nr
MADE IN U.S.A.

Place of Manufacture

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

BLN-10129 Page 16
November 22, 1995

Minor Repair Instructions Exploded View 2

J090
J080
J100

RADIAL PORTS
WITH AUX. DRIVE

J140
(J090)
(J080)
(J100)
(J140)
(J080)

(J100)
(J140)

(J090)

Series 45 OC PV
Minor Repair

saue

Genuine Parts
Original
Ersatzteile

Item
B081
B082
B083
B084

Description
Piston guide
O-ring
Spring
Piston

Qty
1
1
1
1

C010
C020
C030
C040
C050
C060
C070
C080
C090
C110

Set screw
Seal nut
Plug
O-ring
Spring seat
Spring
Spring
Spring guide
Spool
Orifice plug

1
1
1
1
1
1
1
1
1
1

D000
D011
D012
D013
D014
D015
D016

PC valve kit
Cartridge housing
Poppet
Spring
Set screw
Seal nut
O-ring

1
1
1
1
1
1
1

G010

Orifice plug

H010

Set screw

BLN-10129 Page 17
November 22, 1995

Item
J012
J013
J014
J040
J040A
J080
J090
J100
J140

Description
Key
Nut
Pin
Plug
O-ring
Adapter flange
O-ring
Screw
Coupling

Qty
1
1
1
2
2
1
1
4 or 6
1

K010
K020
K080
K090
K100
K110
K120
K120A
K130
K130A

Retaining ring
Lip seal
O-ring
Back up ring
O-ring
Back up ring
Plug
O-ring
Plug
O-ring

1
1
1
1
1
1
4 or 5
4
2
2

L010
L020
L020A
D030
L040

Servo piston
Plug
O-ring
Seal nut
Set screw

1
1
1
1
1

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 18
November 22, 1995

saue

Series 45 OC PV
Minor Repair
Genuine Parts
Original
Ersatzteile

BLN-10129 Page 19
November 22, 1995

saue
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and
manufacture of Hydraulic Power Systems. Research and
development resources in both North America and Europe
enable SAUER-SUNDSTRAND to offer a wide range of
design solutions utilizing hydraulic power system
technology.

SAUER-SUNDSTRAND specializes in integrating a full

range of system components to provide vehicle designers
with the most advanced total-design system.
SAUER-SUNDSTRAND is Your World Source for
Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston

Pumps and Motors

Heavy Duty Bent Axis

Variable Motors

Cartridge Motors/
Compact Wheel Drives

Medium Duty Axial Piston

Pumps and Motors

Microcontrollers and
Electrohydraulic Controls

Hydrostatic Transmission
Packages

Open Circuit Axial Piston Pumps

Gear Pumps and Motors

Genuine Service Parts

Worldwide Service Support

SAUER-SUNDSTRAND provides comprehensive worldwide service for its
products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

saue
SM-OPV45 E 09/95 369694
BLN-10129 November 1995

SAUER-SUNDSTRAND COMPANY
2800 East 13th Street Ames IA 50010 U.S.A.
Phone: (515) 239-6000 FAX: (515) 239-6618
TWX: 9105201150

SAUER-SUNDSTRAND GMBH & CO.

Krokamp 35 Postfach 2460 D-24531 Neumnster
Germany Telephone: (04321) 871-0
Telefax: (04321) 871 465 Telex: 299776

saue
Series 45

Axial Piston
Open Circuit Pumps
Repair Manual

saue
Series 45 Repair

Introduction

1. Introduction
1.1

Using This Manual

This manual provides "Major Repair" procedures for

57 cc Series 45 open circuit pumps.
Minor Repairs can be performed without removing
the end cap. These repairs may be performed without
affecting the unit warranty. Minor repairs are outlined
in the Series 45 Service Information booklet (BLN10129) and include minor adjustments and servo and
bias piston removal.
Major Repairs require the removal of the end cap.
These repairs are to be performed only by SauerSundstrand Authorized Service Centers and / or

1.2

original equipment manufacturers who have been

adequately trained by Sauer-Sundstrand to perform
these repairs.
Performing major repairs on the Series 45 products
may affect the unit warranty status, thus the factory
should be consulted prior to undertaking such repairs.
Major repair procedures, when used in conjunction
with the procedures in the Series 45 Service Information booklet (BLN-10129), provide complete service
and repair information for Series 45 products.

Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.

Disable Work Function

WARNING
Certain service procedures may require the
vehicle / machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.

Flammable Cleaning Solvents

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.

Copyright 1997, Sauer-Sundstrand Company.

All rights reserved. Contents subject to change. Printed in U.S.A.
F100 207

Fluid Under High Pressure

WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This
fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper
medical treatment is not administered immediately.

Personal Safety
WARNING
Proper safety equipment, including safety
glasses, should be used at all times.

saue
Series 45 Repair

Introduction

Contents
1. Introduction ................................................................................................................................................ 2
1.1 Using This Manual ............................................................................................................................ 2
1.2 Safety Precautions ............................................................................................................................ 2
1.3 Symbols Used in Sauer-Sundstrand Literature ................................................................................ 4
1.4 Ordering Replacement Parts and Service ........................................................................................ 4
2. General Instructions ................................................................................................................................... 5
3. Disassembly ................................................................................................................................................ 6
4. Inspection of Parts ......................................................................................................................................9
4.1 Cylinder Kit ....................................................................................................................................... 9
4.2 Valve Plate and End Cap Inspection .............................................................................................. 12
4.3 Swashplate, Bearings, Shaft, Servo and Bias Piston Inspection .................................................... 14
5. Reassembly ...............................................................................................................................................16
6. Exploded Views and Parts Lists .............................................................................................................. 20
6.1 Internal Parts .................................................................................................................................. 20
6.2 End Cap and Auxiliary Pads ........................................................................................................... 22
6.3 Name Plate ..................................................................................................................................... 23

saue
Series 45 Repair
1.3

1.4

Introduction

Symbols Used in Sauer-Sundstrand Literature

DANGER! May result in injury.

Lubricate with hydraulic fluid.

May result in immediate or premature damage.

Apply grease / petroleum jelly.

Reusable part

Apply locking compound.

Nonreusable part, use a new part.

Inspect for wear or damage.

Non-removable item

Clean area or part.

OR in drawing either option may exist.

Be careful not to scratch or damage.

Measurement required.

Note correct orientation.

Flatness specification

Mark orientation for reinstallation.

Parallelism specification

Torque specification

External hex head

Press in.

Internal hex head

Pull out with tool.

Torx head

Use installation sleeve / cone "bullet".

Ordering Replacement Parts and Service

To ensure the best performance, order genuine SauerSundstrand replacement parts. See BLN-2-41689
for a list of available service parts and service kits for
57 cc Series 45 units.

To order parts, contact Sauer-Sundstrand Extended

Customer Service (ECS) at (515) 239-6078, fax
(515) 239-6230, or your nearest Authorized Service
Center.

Some service parts may be available only in kits,

while other parts may be available on an individual
basis.

Sauer-Sundstrand provides a complete repair service for its products. Contact any Sauer-Sundstrand
Authorized Service Center for details. Sauer-Sundstrand Authorized Service Center locations are listed
in BLN-2-40527, or Publication SAW (Id. No. 698266).

saue
Series 45 Repair

General Instructions

2. General Instructions
The procedures in this manual are for the disassembly, inspection of parts, and reassembly (major repair
only) of the Series 45 variable displacement open
circuit pumps. For minor repairs, consult BLN-10129.
Remove the Pump!

Rear Face (End Cap)

Right Face

Bottom Face

Prior to performing major repairs on the Series 45

pump, remove the pump from the vehicle. Chock the
vehicle 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.
Left Face

Top Face
(Control Face)

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.

'X' Port
Front Face (Input Shaft)

E100 066E

Pump Face Orientations

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, the
pump should be covered by a protective layer of
plastic.
Mark the Orientation!
X

Using a permanent or dye marker, make an alignment mark across the end cap / housing interface as
shown at upper right to record the end cap orientation. Also place a mark on the servo piston plug and
a corresponding mark on the housing to prevent
incorrect reassembly of the servo and bias pistons.

CCW Rotation

CW Rotation
E100 067E

Replace All O-Rings!

Assembled Unit with Control Face Forward

It is recommended that all O-rings be replaced.

Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.
Lubricate Moving Parts!
During the assembly of the Series 45 pump, all parts
which have relative motion between two surfaces
should be coated with a film of clean hydraulic oil.
This will assure that these surfaces will be lubricated
during start-up. For fluid quality requirements, refer to
bulletin BLN-9887.

Orient the Pump!

For major repair, place the unit in a stable position
with the shaft pointing downward. Position the unit so
that the control face points toward the operator as
illustrated above. It will be necessary to secure the
pump to prevent personal injury and allow bolts to be
adequately torqued.
5

saue
Series 45 Repair

Disassembly

3. Disassembly
1. Remove the Second Pump / Auxiliary 'C' Pad.
If a second pump is used, it is necessary to remove
the second pump. If an SAE 'C' auxiliary pad (J080,
'C' style shown p. 22) is used, it must be removed
before proceeding to the next step. 'A' and 'B' auxiliary pad removal is not necessary to remove the end
cap. Remove the auxiliary pad with an 8 mm internal
hex wrench. Remove the gear pump coupling (J140).
2. Remove the End Cap.
Check to see that the end cap orientation is marked
as outlined on p. 5. Using a 10 mm internal hex
wrench, remove the four (4) end cap bolts (J030).
Carefully remove the end cap (J020), as it is possible
for the attached valve plate (located in the end cap)
to fall off and be damaged. Place the end cap and
valve plate in a clean area, protecting them from
contamination.

4. Remove the Interface O-rings.

Two (2) small O-rings (K070a, K070b) are present at
the interface. Remove and discard the O-rings.
5. Remove the Tapered Roller Shaft Bearing.
Slide the tapered roller shaft bearing cone (B020)
from the rear end of the shaft. The cup (B010)
component of the bearing kit will remain in the end
cap.

J140
J080

10 mm

J030

J090
J030

J020

J020
K060

B020
K070a
C090

K070b

3. Remove the Load Sensing (LS) or Pressure

Compensating (PC) Spool.
Note the two O-rings (K070a, K070b) that are present
at the interface. The O-ring located on the control
face side (see p. 5 for face orientations) of the
housing surrounds a bore that contains the LS or PC
spool (C090). If possible, remove the LS or PC spool
and inspect for excessive wear. Note the orientation
of the spool for reinsertion. If removal is not possible,
be extremely careful when flipping or relocating the
housing as to not lose or damage the spool.

J100
8 mm

E100 068

Auxiliary Pad and End Cap Removal

(CCW Rotation Shown)

saue
Series 45 Repair

Disassembly

6. Remove the Cylinder Kit.

Set the pump on its side. Slide the cylinder kit (K040)
out by carefully pushing the shaft (J010) out from the
bottom. Do not entirely remove the input shaft from
the housing at this time. Push the shaft out only far
enough so that the cylinder kit may be removed by
hand. The pistons (K050), ball guide (K047), and
slipper retainer (K049) may come apart. Keep track of
the three hold down pins (K046) located on the inside
diameter of the cylinder kit, as it is possible for these
to fall out. Set the cylinder kit aside, taking special
care to ensure that the top and bottom of the kit do not
become contaminated or scratched, as this may later
lead to poor performance or pump failure. Cylinder kit
rework specifications are located on pp. 9 - 10.

7. Remove the Bias Guide Assembly.

Return the pump to the upright disassembly position.
Using a 1-1/4 in. socket, remove the bias guide
assembly (B08) from the housing. The assembly may
be identified as the 1-1/4 in. hex plug opposite the
control face, located on the rear (end cap) face of the
housing. Be sure to remove the bias guide plug
(B081), spring (B083), and piston (B084). It may be
necessary to remove the piston and spring by reaching through the inside of the unit and pushing them
out through the bore.

K040

E100 069

Cylinder Kit Removal

1-1/4 in.

B081
B082
K100
K110
B083
1-1/4 in.
B08

B084

L020
L020A
L010

J010

8. Remove the Servo Piston and Plug.

Using a 1-1/4 in. socket, remove the servo piston plug
(L020) and servo piston (L010). The 1-1/4 in. plug is
located on the rear (end cap) face of the housing,
closest to the control face. It may be necessary to
remove the piston by reaching through the inside of
the housing. Take note of the orientation of the servo
piston. The end of the piston with the hole should be
facing upward.

E100 070

Servo and Bias Piston Removal

Note: Some models may contain servo pistons

that have two grooves about the circumference, as illustrated on p. 15.
9. Remove the Input Shaft.
The input shaft (J010) should pull out easily from the
shaft seal and bearing kit.

saue
Series 45 Repair

Disassembly

10. Remove the Swashplate.

Tilt up the far 'ear' of the swashplate (B040) and lift it
from the unit. Note the side of the swashplate face
demonstrating high wear. It is preferable to reinstall
the swashplate in the same orientation, so as to
reduce start-up wear.
11. Remove the Journal Bearings.
It is important to record the location and orientation of
the journal bearings if they are to be reused. To
remove the journal bearings (B030), which are located beneath the swashplate, simply lift them from
the housing.

B040

B030
B065

12. Remove the Front Shaft Bearing Kit.

Slide the shaft bearing kit (B065) out of the housing.
No special tools should be needed for removal, since
the bearing kit is slip fit to the housing and shaft. It may
occasionally be necessary to first remove the shaft
seal as outlined below in steps 13 and 14 prior to
removing the cup (B060).
13. Remove the Snap Ring.
Flip the pump housing upside down. Remove the
shaft seal snap ring (K010) using internal snap ring
pliers.
14. Remove the Shaft Lip Seal.
Return the housing to its original position and remove
the shaft lip seal (K020). The seal may be pressed
from the housing, if necessary. The lip seal should be
replaced every time the shaft is removed from the
unit.

K020
K010
E100 071

Swashplate, Bearing, and Seal Removal

saue
Series 45 Repair

Inspection of Parts

4. Inspection of Parts
4.1

Cylinder Kit

The cylinder kit (K040), also referred to as the 'rotating group', contains nine (9) pistons, with a swiveling
brass 'slipper' attached to each piston. The slipper
retainer (K049) holds the pistons (K050) upright and
aligned with the corresponding cylinder bores. The
slipper retainer pivots on a ball guide (K047) which
transfers the downward force of the slippers and
pistons to three hold down pins (K046). The hold
down pins then transfer the downward force to the
cylinder block spring (K043), and eventually to the
cylinder block (K041).
Disassemble the Cylinder Kit.
Remove the pistons from the cylinder kit. The pistons
and bores are not selectively fitted, so it is usually not
necessary to replace the pistons in their original
bores. However, units with high hourly usage may
begin to develop wear patterns, and it is advisable to
replace the pistons into the original bores if possible.
Remove the ball guide (K047). The three pins (K046)
may now be removed. A retainer ring (K048) is used
to hold the pins upright in place. Due to prior assembly, the retainer ring may be resting at the bottom of
the cylinder block (K041). It may be necessary to use
a packing hook to remove the retainer ring. It is not yet
necessary to disassemble the cylinder block.

K050

K049

K047
K048
K046
K040
K041

K042

K043
K044
K045
E100 072

Cylinder Kit Disassembly

Inspect the Cylinder Block.

Look at the bottom of the cylinder block. The running
surface, or face which contacts the valve plate (B090,
p. 12), should be smooth and free of nicks and burrs.
No scratches or grooves should be present, as these
may drastically affect the flow of the unit. Minimum
cylinder block height should be 62.23 mm (2.450 in.).
Running face flatness should be flat to 0.0020 mm
(0.000079 in.) convex. Maximum inside cylinder bore
diameters should measure 19.80 mm (0.7796 in.).

saue
Series 45 Repair

Inspect the Rotating Group Pistons / Slippers

Look for discoloration on the pistons. Discolored
pistons may indicate that the unit was subjected to
excessive temperature and should not be reused.
The slippers may now be inspected for signs of
excess wear or damage. The minimum slipper foot
thickness is 3.23 mm (0.127 in.). Slipper end play
should be 0.102 mm (0.004 in.) or less. Replace all
piston assemblies if brass slippers are scored, excessively rounded at the edges, or detached from the
piston.
Inspect the Ball Guide, Slipper Retainer, and
Hold Down Pins.
The ball guide should be free of nicks and scratches,
and should not be excessively scored. 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 damaged parts.

Inspection of Parts

Maximum
End Play:
0.102 mm
(0.004 in.)
Minimum
Slipper Foot
Thickness:
3.23 mm
(0.127 in.)

Slipper
K050

E100 073E

Rotating Group Piston

K041

If Needed, Fully Disassemble the Cylinder

Block.
Note: This step is not necessary for most
normal repairs and should not be performed
unless internal damage is suspected.
Compress the cylinder block spring (K043) and remove the spiral retaining ring (K045), outer washer
(K044), spring (K043), and inner washer (K042).
Visual inspection of the cylinder block, spring, and
washers should indicate minimal wear. Replace if
cracks or damage are present. Reassemble in the
reverse order.

62.23 mm
(2.450 in.)
Minimum

0.000508 to 0.00178 mm
(0.000020 to 0.000070 in.)
Convex

P100 201E

Cylinder Block Minimum Height

K041

K042

K043
K044
K045
E100 074

Cylinder Block Disassembly

10

saue
Series 45 Repair

Reassemble the Cylinder Kit.

A light coating of hydraulic fluid should be used to
coat all parts prior to reassembly. Insert the retainer
ring (K048; see p. 9 for exploded view) into the
cylinder block (K041) so that it sits just below (approximately 1/8 in.) the top surface. Insert the three
hold down pins (K046) and make sure that they sit
squarely in their respective grooves. Replace the ball
guide (K047). Insert the slipper retainer (K049) containing the slippers and pistons (K050) into the cylinder block. Once the cylinder kit has been completely
reassembled, check to be sure that the ball guide sits
squarely on all three hold down pins. The retainer ring
should still remain just below the top of the cylinder
block. The cylinder kit will not slide onto the shaft if
any of the hold down pins fall out of place.

Inspection of Parts

E100 075

Reassembled Cylinder Kit

Note: Be sure to install the slipper retainer so

that it mates correctly with the retainer guide
(concave side of the slipper retainer against
the ball guide).

11

saue
Series 45 Repair
4.2

Inspection of Parts

Valve Plate and End Cap Inspection

Remove the Components from the End Cap.

It is crucial that the condition of the valve plate (B090)
be observed upon major repair. Carefully remove the
valve plate from the end cap (J020), being careful not
to scratch the finely machined surfaces. Also remove
the rear tapered roller bearing cup (B010).
Inspect the Valve Plate.
Thickness of the valve plate should be no less than
4.950 mm (0.1949 in.). Valve plate parallelism should
be 0.0249 mm (0.00098 in.) or less. 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.
Cracks are not allowed on any surface of the part.
Run a fingernail or pencil tip across the diameter of
the sealing land surface (see illustration at right). No
deep or outstanding grooves should be felt, as these
may cause a decrease in pump flow. Lap (to within
specification) or replace if grooves or nicks are present.
Inspect the mating surfaces of the end cap and valve
plate for any possible contamination, as even a few
thousandths of an inch of foreign material may cause
improper pump operation.

4.95 mm (0.195 in.) min.

0.0249 mm
(0.00098 in.)

0.0038 mm
(0.00015 in.)
convex max.
B090

P100 202E

Valve Plate Specifications

B090

Sealing Land
Surface

P1000 203E

Valve Plate Inspection (CW Rotation Shown)

12

saue
Series 45 Repair

Inspection of Parts

Check the Timing Pin Orientation.

A timing pin (J050) located in the end cap orients the
valve plate. Check to see that the gap in the timing pin
points directly towards or away from the center of the
end cap (see right).

K060
B010
B090
J020

Replace the Valve Plate and Bearing Cup

Coat the back (steel) side of the valve plate with clean
petroleum jelly to hold it in position on the end cap.
Replace the bearing cup and then the valve plate.
The valve plate should 'snap' back into place. Check
to see that the valve plate is completely seated. If
necessary, use a soft and clean rubber mallet to tap
the valve plate back into place. The notch in the valve
plate must engage the alignment pin. The timing pin,
bearing cup, and valve plate should produce a relatively snug fit.

Note: To prevent improper pump operation it is

extremely important to ensure that there is no
contamination between the end cap and valve
plate.

P100 204

J050

End Cap and Orientation Pin Inspection

B090
B015
K060
B020

Check to be sure that the top of the timing pin sits

below the surface of the completely seated valve
plate.

B010

Discard and replace the end cap O-ring (K060).

J050
E100 076

End Cap Exploded

13

saue
Series 45 Repair
4.3

Inspection of Parts

Swashplate, Bearings, Shaft, Servo and Bias Piston Inspection

Inspect the Swashplate.

The swashplate (B040) surfaces should appear
smooth and even on the journal (curved) surfaces.
There should be no raised surfaces that might cause
damage to the journal bearings. It is normal for one
half of the flat side of the swashplate to appear to
have more wear than the other. However, the surface
should be smooth and wear depth should not be
noticeable to the touch. Inspect the rest of the swashplate for signs of damage or abnormal wear. Replace
if necessary.

B040

E100 077

Swashplate Inspection

Inspect the Journal Bearings.

Inspect the journal bearing (B030) surfaces for abnormal or excessive wear. It is normal for one bearing
to receive more wear than the other. Replace if
necessary.
Inspect the Shaft Bearing Kits.
The tapered roller bearing kits (B015, B065) consist
of a cup and cone. Both the cup and cone should be
free of excessive wear or contamination. Rotate the
bearings to check for smoothness. If a contaminated
bearing is suspected, clean with a solvent and relubricate 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.

B030

E100 078

Journal Bearing Inspection

B015
B065

E100 079

Cup and Cone Inspection

14

saue
Series 45 Repair

Inspection of Parts

Inspect the Input Shaft.

Check to see that the shaft (J010) and its splines are
straight and free of damage or heavy wear. Inspect
the shaft surface where it meets the shaft seal (K020).
If a groove that may let dirt into or hydraulic fluid out
of the unit has formed, replace the shaft. Clean the
sealing area with a nonabrasive material if necessary. Lubricate the shaft with a light coat of hydraulic
fluid.

K020
J010

E100 080

Inspect the Servo Piston.

Check the servo piston (L010) for any obvious wear
or damage. Check the corresponding housing bore
for galling or excessive wear. Replace if necessary.
Discard and replace the servo plug O-ring.

Shaft Inspection

Inspect the Bias Piston.

Inspect the bias piston (B084), guide (B081), and
spring (B083) for abnormal wear. Replace if necessary. Discard and replace the two O-rings (B082,
K100) and the backup ring (K110).

L010
D100 081

Servo Piston Inspection

Note: On reassembly, the servo piston backup

ring (K110) must be the ring located closest to
the center of the pump.

K110
B081

B082

B083

K100

B084
E100 082

Bias Piston Assembly Inspection

15

saue
Series 45 Repair

Reassembly

5. Reassembly
1. Inspect the Housing.
Inspect the housing to ensure that it is clean and free
of foreign material. It should be set in an upright and
secure position, as it was for disassembly.

B065

2. Replace the Front Bearing Kit.

The front bearing kit (B065) should be reinserted. The
cup should produce a slip fit with the housing.
3. Replace the Journal Bearings (B030).
Note: if journal bearings are being reused,
replace in original orientation and position.

E100 083

Shaft Bearing Insertion

B040

4. Lubricate the Surfaces.

The journal bearings and curved surface of the swashplate should be liberally coated with hydraulic fluid.
5. Replace the Swashplate.
The swashplate (B040) should be replaced in its
original wear orientation. To insert, tilt the swashplate
'ear' located opposite the control face so that it is
raised. Insert the opposite side towards the servo
piston.

7. Replace the Servo Piston Assembly.

Lubricate all sides of the servo piston (L010) and its
respective bore (closest to the control face) liberally
with hydraulic oil. Replace the servo piston with the
'hole end' up. Replace the plug and tighten with a 11/4 in. socket to 230 Nm (170 ftlbf).
8. Replace the Bias Piston Assembly.
Lubricate the bias piston (B084) and its respective
bore (opposite the control face) with a liberal coating
hydraulic oil. Replace the bias guide assembly (B08)
as illustrated at right. Using a 1-1/4 in. socket, tighten
to 230 Nm (170 ftlbf).

Note: It is extremely important that the bias

piston plug (B081) be correctly torqued, as it
may back out at lower torques.

E100 084

Journal Bearing and Swashplate Insertion

1-1/4 in.
230 Nm
(170 ftlbf)
B081
B082
K100
K110

1-1/4 in.
230 Nm
(170 ftlbf)

B083
L020
B084
B08

L020A
L010
J010

9. Lubricate the Swashplate.

Lubricate the flat face of the swashplate with hydraulic oil to prevent premature wear during start-up.

6. Replace the Input Shaft.

Seat the input shaft (J010) in the housing. No special
tools are needed to insert the shaft into the bearing.

B030

E100 085

Servo and Bias Piston Insertion

16

saue
Series 45 Repair

Reassembly

10. Insert the Cylinder Kit.

Set the pump on its side. Check to see that the
cylinder kit (K040) is fully assembled (see sec. 4.1).
Make sure that the hold down pins (K046) are upright
and pressed against the inside of the cylinder block.
Slide the pin retainer (K048) to the top of the block,
but below the top of the pins. Check to see that the ball
guide (K047) sits squarely on top of the pins.

K040

Insert the cylinder kit into the housing with the slippers facing the swashplate. Be careful not to let the kit
slide apart during this process. Alignment of the block
and hold down pins is crucial. Hold the input shaft and
rotate the cylinder kit for complete insertion.
11. Check the Cylinder Kit / Shaft Alignment.
Return the pump housing to its original upright position. The bottom of the cylinder kit should be relatively
flush with the shoulder of the shaft.
12. Replace the Interface O-Rings.
Lubricate the two interface O-rings (K070a, K070b)
with petroleum jelly and place them into their respective grooves on the rear (end cap) face of the housing.

E100 069

Cylinder Kit Replacement

8 mm
48 - 60 Nm
(35 - 45 ftlbf)

J100
J140

10 mm
84 - 108 Nm
(62 - 80 ftlbf)

J030

J090
J030

13. Replace the LS or PC Spool.

If the LS or PC spool (C090) was previously removed,
lubricate and reinsert it in its original orientation. If it
was not removed, check to see that it is still present.
J020

J020

14. Replace the Rear Shaft Bearing Cone (B020).

15. Inspect for Contamination.
Inspect once again to see that there is no contamination on the bottom of the cylinder kit (K040) or valve
plate (B090).

K060

B020
K070a

C090

16. Lubricate the Internal Parts.

Lubricate the bottom of the cylinder kit, valve plate,
and end cap O-ring (K060) with hydraulic oil.

17. Replace the End Cap.

Replace the end cap as marked (J020) in its original
orientation. Make sure that the valve plate is secure
in its original position and does not separate from the
end cap during installation. Refer to p. 13 to ensure
the end cap and components are fully assembled.

K070b

E100 086

Bearing, LS / PC Spool, and End Cap Replacement

17

saue
Series 45 Repair

Reassembly

Check to see that the unit control face is pointing

towards the technician. For clockwise (right-hand)
pumps, the large system inlet port on top (or side) of
the end cap should face to the right. For counterclockwise (left-hand) pumps, the large system inlet port on
top (or side) of the end cap should face to the left.

K010
K020

Insert the four (4) end cap bolts (J030), snug, and
then cross torque the bolts to 84 - 108 Nm (62 - 80
ftlbf) with a 10 mm internal hex wrench.
18. Turn the Pump Upside Down.

20. Insert a New Shaft Seal.

Replace the shaft seal (K020) with a new lip seal and
reinsert the shaft seal snap ring per diagram at right.
Do not damage or press the seal deeper than is
needed to insert the snap ring. The seal should be
perpendicular to the shaft. Be sure that the snap ring
is fully seated.
21. Replace the Auxiliary Pad.
Rotate the housing so that it is in its original upright
position with the shaft end down and the control face
towards the technician. If an auxiliary pad (J080) was
removed, replace the O-ring (J090). Replace the pad
and torque the bolts to 48 - 61 Nm (35 - 45 ftlbf) with
an 8 mm internal hex wrench.
22. Test the 'Torque-to-Turn'.
With the unit assembled (without auxiliary pumps),
apply a torque to the input shaft and rotate. The
torque required to turn the shaft after break-away for
well oiled assemblies must be 10.1 - 18.1 Nm (90 160 inlbf) or less for 57 cc units. Readings greater
than these values may indicate internal problems.
23. Replace the Coupling.
If a gear pump coupling (J140) was present on
disassembly, replace it at this time.

18

19. Cover the Input Shaft Splines.

To prevent damage during lip seal installation, use a
bullet or piece of plastic to cover the input shaft
splines.

E100 087

Shaft Lip Seal Replacement

Snap Ring

5.33 mm
(0.21 in)

Lip Seal
P100 205E

Cross Section of Shaft Seal Replacement

saue
Series 45 Repair

Notes

24. Replace the Auxiliary Pad Seal and Pump.

Replace the auxiliary pad seal (J020) and auxiliary
pump or cover plate (J110), if present. Using a 9/16 in.
hex wrench, torque to 37 - 50 Nm (27 - 37 ftlbf) for 'A'
pads or 91 - 111 Nm (67 - 82 ftlbf) for 'B' and 'C' pads.
25. Replace Other Components.
Any other external components, including the auxiliary pump (if present), that were removed prior to
disassembly should now be replaced.

19

saue
Series 45 Repair

Exploded Views and Parts Lists

6. Exploded Views and Parts Lists

6.1

Internal Parts
L010
L020
C120

L010

C120A

L020A

C040
C050
C110
C060
C070
C080
C090

K122

L020
H010

L030

K122A

K130

L020A

C020
C010
C030

L040
K130A
K010
K124
K080
D000

K020
G010 C100A

K124A

D016

C100

D011

K120A
K132A

K090
D017

D013
D014
D015

K120

K070

D012

B084

K132

B083
B030

B08

K110
K100
B082

B065

B081
B040

B060
B070

K040
K050
K047
K048
K046

B090
B015

K044
K045

B020
B010

20

K042

K049

K041

K043

E100 088

saue
Series 45 Repair

Exploded Views and Parts Lists

Parts List
Item

Description

Qty.

Control
C010
C020
C030
C040
C050
C060
C070
C080
C090
C100
C100A
C110
C120
C120A

Set screw
Seal nut
Plug
O-ring
Spring seat
Spring
Spring
Spring guide
Spool, LS or PC
Plug
O-ring
Set screw
Plug
O-ring

1
1
1
1
1
1
1
1
1
1
1
1
1
1

Pressure Compensator Valve

D000
PC valve kit, viton
D011
PC cartridge housing
D012
PC poppet
D013
Spring
D014
Set screw
D015
Seal nut
D016
O-ring
D017
Filter screen
K080
O-ring
K090
Back up ring

1
1
1
1
1
1
1
1
1
1

Pilot / Gain Orifice

G010
Orifice
H010
Orifice

1
1

Displacement Limiter
L010
Servo piston
L020
Plug
L020A
O-ring
L030
Seal nut
L040
Set screw

1
1
1
1
1

Item

Description

Qty.

Shaft Seal/Housing/Speed Sensing

K010
Snap ring
K020
Lip seal
K040
Cylinder block kit
K041
Cylinder block
K042
Washer
K043
Cylinder block spring
K044
Washer
K045
Retaining ring
K046
Hold down pin
K047
Ball guide
K048
Hold down pin retainer
K049
Slipper retainer
K050
Piston assembly
K070
O-ring
K100
O-ring
K110
Back up ring
K120
Plug
K120A
O-ring
K122
Plug
K122A
O-ring
K124
Plug
K124A
O-ring
K130
Plug
K130A
O-ring
K132
Plug
K132A
O-ring

1
1
1
1
1
1
1
1
3
1
1
1
9
2
1
1
1
1
1
1
1
1
1
1
1
1

Special Hardware
B08
Bias piston kit
B010
Tapered roller bearing cup
B015
Rear bearing kit
B020
Tapered roller bearing cone
B030
Journal bearing
B040
Swashplate assembly
B060
Tapered roller bearing cup
B065
Front bearing kit
B070
Tapered roller bearing cone
B081
Bias piston guide
B082
O-ring
B083
Spring
B084
Bias piston
B090
Valve plate

1
1
1
1
2
1
1
1
1
1
1
1
1
1

21

saue
Series 45 Repair
6.2

Exploded Views and Parts Lists

End Cap and Auxiliary Pads

J012

J015

J010
End Caps Shown Orientated
for CCW Rotation
J010
J040A
J040
J020

J030

K060
J040A

J040

J040
J050

J030

J040A
J040
J050

J040
J080

J030

A
J120
J110
J130

J090

J140

J100

J120

J050

J080
J040

J100

J110
J120

J130
J110

RC

J080
J130

J100

J100

RC
E100 089E

22

saue
Series 45 Repair

Exploded Views and Parts Lists

Parts List
Item

Description

Qty.

Shaft / Auxiliary Flange / End Cap

J010
Shaft
J012
Square key
J015
Retaining ring
J020
End cap
J030
Screw
J040
Plug
J040A
O-ring
J050
Pin
J080
Adaptor Flange / Aux. Pad
J090
O-ring
J100
Screw
J110
Cover plate
J120
Auxiliary Pad Seal
J130
Screw
J140
Coupling
K060
O-ring
RC
Running Cover

6.3

1
1
1
1
4
2
2
1
1
1
4
1
1
2
1
1
1

Name Plate
Name Plate (Typical)

saue
Ames, Iowa, U.S.A.
Model Code

Neumnster, Germany
Typ

45R057 LS 25 20
NN A 1 S1N4 A1N
NNN NNN NNN
Model
Number
Serial
Number

Model No.

Ident Nr

4577001
Ames, Iowa, U.S.A.
Germany
A
94 34 Neumnster,
12345
Model Code
Typ

Model Code

Identification
Number

Serial No.
Fabr Nr
MADE IN U.S.A.

Place of Manufacture

23

saue
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and
manufacture of Hydraulic Power Systems. Research and
development resources in both North America and Europe
enable SAUER-SUNDSTRAND to offer a wide range of
design solutions utilizing hydraulic power system
technology.

SAUER-SUNDSTRAND specializes in integrating a full

range of system components to provide vehicle designers
with the most advanced total-design system.
SAUER-SUNDSTRAND is Your World Source for
Controlled Hydraulic Power Systems.

Heavy Duty Axial Piston

Pumps and Motors

Heavy Duty Bent Axis

Variable Motors

Cartridge Motors/
Compact Wheel Drives

Medium Duty Axial Piston

Pumps and Motors

Microcontrollers and
Electrohydraulic Controls

Hydrostatic Transmission
Packages

Open Circuit Axial Piston Pumps

Gear Pumps and Motors

Genuine Service Parts

Worldwide Service Support

SAUER-SUNDSTRAND provides comprehensive worldwide service for its
products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.

Genuine Parts
Original
Ersatzteile

saue
RM-SPV45 E 6/97 300 130
BLN-10130 June 1997

SAUER-SUNDSTRAND COMPANY
2800 East 13th Street
Ames IA 50010 U.S.A.
Phone: (515) 239-6000 FAX: (515) 239-6618

SAUER-SUNDSTRAND GMBH & CO.

Postfach 2460 D-24531 Neumnster
Krokamp 35 D-24539 Neumnster Germany
Phone: (04321) 871-0 Fax: (04321) 871 465