45 Series F Frame Repair Manual (520L0821 Rev AA Nov 2006)

Series 45 Frame F Open Circuit Axial Piston Pumps Repair Instructions

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

OrganizatiOn and headings

To help help you quickly fnd inormation inormation in this manual, the material is divided into sections, topics, subtopics, and details, with descriptive headings set in red type. type. Section titles appear at the top o every page in large red type. Topic headings appear in the let hand column in BOLd red CaPitaL Letters Letters.. Subtopic headings appear in the body text in bol  p and detail headings in italic red type. type. Reerences (example: SeeTopic See Topic xyz , page XX) to sections, headings, or other publications are also ormatted in red italic type. type. In Portable document Format (PdF (PdF)) fles, these reerences represent clickable hyperlinks that jump to the corresponding document pages.

taBLes, iLLustratiOns, and COmPLementary inFOrmatiOn

Tables, illustrations, Tables, illustrations, and graphics in this manual are are identifed by titles set inblue in blue italic type above each item. Complementary inormation such as notes, captions, and drawing annotations are also set in blue type. type. Reerences (example: See Illustration abc , page YY) to tables, illustrations, and graphics are also ormatted in blue italic type. type. In PDF fles, these reerences represent clickable hyperlinks that jump to the corresponding document pages.

sPeCiaL text FOrmatting

Defned terms and acronyms are set in bol blc p blc p in the text that defnes or introduces them. Thereater, Thereater, the terms and acronyms receive no special ormatting. Black italic type italic type is used in the text to emphasize important inormation, or to set-o words and terms used in an unconventional manner or alternative context.Red context.Red and and blue italics represent hyperlinked text in the PDF version o this document (see above).

taBLe OF COntents

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

© 2006 Sauer-Danos Sauer-Danoss. s. All rights reser ved. Printed in U.S.A. Sauer-Danoss accepts no responsibility or possible errors in catalogs, brochures Sauer-Danoss brochures and other printed material. Sauer-Danoss Sauer-Dano ss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations aren’t in conict with agreed specifcations. All trademarks in this material are properties o their respective owners. Sauer-Danoss Sauer-Danoss and the Sauer-Danoss logotype are trademarks o the Sauer-Danoss Group. Front cover illustrations: F101 464, F101 385, F101 1 86, P104 359

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50L081 • Rev AA • Nov. 2006

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

intrOduCtiOn

Overview ................ ................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ......................... ......5 5 General instructions ................. .................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................... ... 5 Saety precautions ................. .................................... ...................................... ...................................... ...................................... ...................................... ...................................... ......................... ......6 6 Unintended machine movement .................................................... ....................................................................... ...................................... ................................6 .............6 Flammable cleaning solvents.......................................... ............................................................ ..................................... ...................................... ................................6 .............6 Fluid under pressure.............................................. ................................................................. ...................................... ...................................... ...................................... ......................... ......6 6 Personal saety ................... ...................................... ...................................... ...................................... ...................................... ...................................... ..................................... ......................... .......6 6 Symbols used in Sauer-Danoss literature................. literature.................................... ...................................... ...................................... ......................................7 ...................7

disassemBLy

Auxiliary pad ................... ...................................... ...................................... ...................................... ...................................... ..................................... ..................................... ...................................8 ................8 Detach control................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...............................8 ............8 Displacement limiter ................ ................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................... ... 9 Endcap............................... Endcap............ ...................................... ...................................... ...................................... ...................................... ..................................... ..................................... ...................................9 ................9 Cylinder kit ................... ...................................... ...................................... ..................................... ..................................... ...................................... ...................................... ....................................10 .................10 Input shat, swashplate, and pistons............ pistons............................... ...................................... ...................................... ...................................... .................................10 ..............10 Journal bearings, and roller bearing ......................... ............................................ ...................................... ...................................... ...................................... ....................11 .11 Shat seal ................... ..................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................11 .11 Control disassembly ................. .................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................12 .12 PC only ................... ..................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................12 .12 PC / LS ................ ................................... ...................................... ...................................... ...................................... ...................................... ..................................... ..................................... ........................12 .....12 Cylinder kit ................. ................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................13 .13 Disassemble the cylinder block kit ................................ .................................................. ..................................... ...................................... ..............................13 ...........13 Block spring removal ................. .................................... ...................................... ...................................... ..................................... ..................................... .................................13 ..............13

insPeCtiOn

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

50L081 • Rev AA • Nov. 2006



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

assemBLy



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

50L081 • Rev AA • Nov. 2006

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

Overview

This manual details the major major repair procedures or or Frame F pumps. pumps. These include the complete disassembly, inspection, and reassembly o the unit. Where rework o worn or damaged components is possible, this manual gives specifcations to ensure these parts meet actory actor y tolerances. Only Sauer-Danoss Global Service Partners are authorized to perorm major repairs. The actory trains Sauer-Danoss Global Service Ser vice Partners to perorm major repairs and certifes their acilities on a regular basis.

W

Warning Use o components that do not comply with rework specifcations may result in loss o perormance, which may constitute a saety hazard. Do not reuse components that don’t comply to given specifcations: replace replace with genuine Sauer-Danoss service par ts. Series 45 Frame F Axial Piston Pump Service Manual 11005158 gives minor repair procedures, adjustments, adjustments, and troubleshooting inormation. Minor repairs include service ser vice operations that you can perorm without removing the unit’s endcap. Removal Removal o the endcap voids your warranty.

generaL instruCtiOns

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

w Remove the unit Prior to perorming major repairs, remove the unit rom the vehicle/machine. Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic uid may be under high pressure and/or hot. Inspect the outside o the pump and fttings or damage. Cap hoses ater a ter removal to prevent contamination.

e Keep it clean Cleanliness is a primary means o assuring satisactory pump lie, on either new or repaired units. Clean the outside o the pump thoroughly beore disassembly. Ta Take ke care to avoid contamination o the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate. As with any precision equipment, you must keep all parts  ree o oreign materials and chemicals. Protect all exposed sealing suraces and open cavities rom damage and oreign material. I let unattended, cover the pump with a protective layer o plastic.

l Lubricate moving parts During assembly, coat all moving parts with a flm o clean hydraulic oil. This assures that these parts will be lubricated during start-up.

d Replace all O-Rings and gaskets We recommend you replace all O-rings, seals, and gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly assembly..

t Secure the unit For major repair, repair, place the unit in a stable position with the shat pointing downward. It is necessary to secure the pump while removing and torquing the endcap bolts.

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5


saFety PreCautiOns

Always consider saety precautions beore beginning a service procedure. Protect yoursel your sel and other ot herss rom injur i njury. y. Take the ollowing general precautions whenever servicing a hydraulic system. u c o W w Unintended movement o the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, movement, secure the machine or disable/ disconnect the mechanism while ser vicing. Flbl cl ol W w Some cleaning solvents are ammable. To avoid possible fre, do not use cleaning solvents in an area where a source o ignition may be present. Fl  p W w Escaping hydraulic uid under pressure can have sufcient orce to penetrate your skin causing serious injury and/or inection. This uid may also be hot enough to cause burns. Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the system beore removing hoses, fttings, gauges, or components. Never use your hand or any other body part par t to check or leaks in a pressurized line. Seek medical attention immediately i you are cut by hydraulic uid. Pol f W w Protect yoursel rom injury. Use Use proper saety equipment, including saety glasses, at all times.

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50L081 • Rev AA • Nov. 2006


symBOLs used in sauer-danFOss Literature



WARNING may result in injury



Tip, helpul suggestion



CAUTION may result in damage to product or property



Lubricate with hydraulic uid



Apply grease / petroleum jelly



Apply locking compound



Inspect or wear or damage



Clean area or part



Reusable part



Non-reusable part, use a new part



Non-removable item



Option – either part may exist





Be careul not to scratch or damage

Superseded – parts are not interchangeable



Note correct orientation



Measurement required



Mark orientation or reinstallation



Flatness specifcation



Torque specifcation



Parallelism Paralleli sm specifcation



Press in – press ft



External hex head



Pull out with tool – press ft



Internal hex head





Cover splines with installation sleeve

Torx To rx head



Pressure measurement / gauge location or specifcation



O-ring boss port

The symbols above appear appear in the illustrations and text o this manual. manual. They are intended to communicate helpul inormation at the point where it is most useul to the reader. In most instances, the appearance o the symbol itsel denotes its meaning. The The legend above defnes each symbol and explains its purpose.

50L081 • Rev AA • Nov. 2006



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

auxiLiary Pad

I a second pump is used, you you must remove it. You don’t need to remove auxiliary pads to remove the end cap. 1.

2.

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

Remove auxiliary pad J130

J110

J120

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

J100

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-rings (J090), and (J095).

10 mm

J080

J090

J095

E101 457E

detaCh COntrOL

1.

2.

Remove the control rom the endcap by removing the 4 control bolts (C300), using a 4 mm internal hex wrench.

Remove control C300 4 mm

Remove and discard the 4 interace O-rings (C200). C200

E101 230

8

50L081 • Rev AA • Nov. 2006


disPLaCement Limiter

3.

Remove the adjustment seal/nut (L030A) with a 7 /8 inch wrench.

Remove displacement limiter L030A 7/8 in

The L030 adjustment seal/nut serves as a locking seal/nut, preventing the L040 screw rom backing out.

L010

L010A

7/8 in L040

4.

Remove the adjustment screw (L040) with a 1/4 in. internal hex wrench. Remove plug (L010) with a 7/8 in. wrench. Discard Discard the O-ring (L010A).

1/4 in

E101 231

endCaP

1.

Remove the 4 endcap screws (J030) using a 10 mm internal hex wrench.

Remove endcap and components J030

2.

10 mm

Careully remove the endcap (J020). The valve plate plate (B090) may adhere to to the endcap. Ensure Ensure it does not all o and become scratched or damaged.

J020

3.

4.

Place the endcap and valve plate in a clean area, protecting them rom contamination.

B090

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

5.

Remove the shat bearing cone (B020) rom the shat. The The cup (B010) will likely remain in the end cap; remove it using a bearing puller i necessary.

B010 B020

E101 232

50L081 • Rev AA • Nov. 2006




CyLinder kit

1.

Set the pump on its side.

2.

Remove the cylinder block kit (P010) while holding onto the ront o the shat.

3.

Set cylinder block on a clean dry surace. C

C Caution Take care care that the top and bottom o the kit do not become contaminated or scratched: this may lead to poor perormance or pump ailure.

inPut shaFt, swashPLate, and PistOns

Remove cylinder block kit

P010

E101 233

1.

Rotate pump with the shat pointing down.

2.

Pull the shat (J010) rom the shat seal.

3.

Lit the swashplate/piston assembly up and remove it rom the housing. Note Note the orientation or reinstallation.

Reinstall swashplate in its original orientation to reduce wear wear.. 4.

Remove the servo piston (P020), bias spring (B025), and the bias piston (B080) rom the swashplate by removing the clevis pins (B043) and snap rings (B044).

Remove shaft, swashplate, and pistons

J010

P020

B080

B025 B044

B043

B044 B040 B043

E101 234

10

50L081 • Rev AA • Nov. 2006


JOurnaL Bearings, and rOLLer Bearing

1.

2.

Remove the journal bearings (B030) and, i necessary, remove the pins (B071). Remove the roller bearing cone (B070) and cup (B060). You may need to remove the shat seal beore removing the cup.

Remove bearings B071

B030

B070

B060

E101 235

shaFt seaL

1.

Orient the housing shat side up.

2.

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

3.

Remove the shat seal (K020).

Remove shaft seal K010

K020

Replace the shat seal every time the shat is removed rom the unit.

E101 236

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11


COnt ntrO rOL L di disa sass sse emBL BLy y

PC ol l  1. Remove the plug (C103) and O-ring (C103A). Discard the O-ring. Remove set screw (C102) with a 4 mm internal hex wrench. Tilt control or use a small magnet to remove the spool (C132). Note the orientation o the spool or reinsertion. There may be dierences in reinserting into the same bore. 2. Remove the adjusting screw (C138) with a 1/4 in. internal hex wrench. Remove and discard O-ring (C138A). Remove the springs (C134, C135) along with the spring guide (C133).

Disassemble the PC control C103 3/16 in

C103A

C132

C200

C102 4 mm

C133 C135

C134 C138A C138 1/4 in E101 237

PC / Ls 1. Using a 3 /16 inch internal hex wrench, remove the 4 plugs (C103, C104, C105, and C106) and their O-rings. Discard the O-rings. Using a 4 mm internal hex wrench, remove the 2 set screws (C102). Remove the spool (C112). Note Note the orientation o the spools or reassembly. There may be dierences in reinserting into the same bore. Remove Remove the spool (C132). 2.

Using a 1/4 inch internal hex wrench, remove the adjusting screw (C138) and the O-ring (C138A). Discard the O-ring. Remove Remove the springs (C134, C135) and spring guide (C133).

Disassemble the PC / LS control

C103

C104

3/16 in

C103A

C104A C132

C112

C106A C200 C106

C105 C105A 3/16 in

C102 4 mm

C113

C115

3.

Using a 1/4 inch internal hex wrench, remove the adjusting screw (C118), O-ring (C118) and 2 backup rings (C118B). Discard Discard the O-ring and backup rings. Remove the springs (C114, C115) and spring guide (C113).

C133

C114 C118B

C135

C118A C118B

C134

C118 1/4 in C138A

C138 1/4 in

1

50L081 • Rev AA • Nov. 2006

E101 458E


CyLinder kit

dbl  cl bloc  1. Pull to remove the slipper retainer (P049) with the pistons (P050) rom the cylinder kit.

Disassemble the cylinder block kit P050

The pistons are not selectively ftted, ftted, however units with high hourly usage may develop wear patterns. Number the pistons and bores or reassembly i they are to be reused.

P049

P047

2.

Remove the ball guide (P047).

3.

Remove the 3 pins (P046).

Most repairs do not require block spring removal. Perorm this procedure only i you suspect problems with the block spring.

P046

P041

P042

Bloc p ol 4. Turn the block over with the running Risk o personal injury: sueace pointing up. Using a press, Compressing the block apply pressure on the block spring spring requires a orce washer (P044) to compress the o about 350 to 400 N block spring (P043). Compress the [80 to 90 lb]. Use a press spring W enough to saely remove sufcient to maintain this the spiral retaining ring (P045). orce with reasonable While maintaining pressure, unwind eort. Ensure the spring is the spiral retaining ring. Careully secure beore attempting release the pressure and remove the to remove the spiral outer block spring washer (P044), retaining ring. Release the block spring, and inner block spring pressure slowly ater the washer (P042) rom the cylinder retaining ring is removed removed.. block.

W Warning

50L081 • Rev AA • Nov. 2006

P043

P044

P045 E101 239

1

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

Overview

Ater disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow to air dry. dr y. Blow out oil passages in the housing and endcap with compressed air. Conduct inspection in a clean area and keep all parts ree rom contamination. Clean and dry parts again ater any rework or resuracing.

PistOns and sLiPPers

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

F F Slip Sl ippe per roo oott thic thickn knes esss (min (min))

4.41 4. 41 mm mm [0.174 in]

Piston/slip Pisto n/slipper per end play (max) 0.05 mm

Inspect the running surace o the slippers. Replace any piston assemblies with scored or excessively rounded slipper edges. Measure the slipper oot thickness. Replace any piston assemblies with excessively worn slippers. Check the slipper axial end-play. Replace any piston assemblies with excessive end-play.

[0.002 in]

Inspect pistons Maximum end play Minimum slipper foot thickness

Slipper C103

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

BaLL guide, sLiPPer retainer, and hOLddOwn Pins

The ball guide should be ree o nicks and scratches, and should not be excessively scored. Examine or discoloration that may indicate excessive heat or lack o lubrication. The The slipper retainer should be at, and slippers should ft in the retainer with minimal side play. Place the hold-down pins on a at surace and roll them to make sure they are straight. Discard and replace any damaged parts.

P104 109E

Inspect guide, retainer, and pins Slipper retainer

Ball guide

Hold down pins

P101 471

1

50L081 • Rev AA • Nov. 2006


BLOCk sPring and washers

I cylinder kit was ully disassembled, visual inspection o the cylinder block, spring, and washers should indicate minimal wear. Replace i cracks or other damage is present.

Inspect block spring and washers Washer

Cylinder block spring Spring retainer Retaining ring

P101 472

CyLinder BLOCk

Examine the running ace o the cylinder block. The surace should be smooth and ree o nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce output ow. I necessary, you may resurace the cylinder block as long as the minimum height and atness specifcations can be maintained. F F

Inspect cylinder block

Minimum cylinder

68.88 mm

block height (A)

[2.712 in]

74cc Maximum block 21.56 mm bore diameter (B)

B

K041

[0.849 in]

90cc Maximum block 22.74 mm bore diameter (B)

A

[0.895 in]

flat to 0.002 mm [0.000079 in]

check for burrs, nicks, and scratches P101 067E

50L081 • Rev AA • Nov. 2006

15


COntrOL

Careully examine the PC (and LS) plug(s) or signs o wear. Also check the small tip o the plug(s) or heavy wear and replace i necessar y. Check the inside and outside suraces o the springs or wear and replace i necessary. Check the spool’s spool’s outside diameter or scratches and / or burrs. Clean and coat all spools, bores, bores, and seals with a light coating o hydraulic oil.

Inspect the PC control

Inspect the PC/LS control C104

C103

C103

C104A

C103A

C103A C132

C112 C132

C200 C106A C200 C106

C102 C105 C133 C102

C135

C113

C105A C115

C134 C138A

C133

C114

C138 E101 240

C118B

C135

C118A C118B

C134

C118 C138A C138 E101 241

shaFt

1

Check to see that the shat (J010) and its splines are straight and ree o damage or heavy wear. Inspect the shat sha t seal journal. Replace the shat i a groove exists at the sealing land surace that may let dirt into or hydraulic uid out o the unit. Clean the sealing area with a nonabrasive material i necessary. necessar y. Lubricate the shat with a light coat o hydraulic uid.

50L081 • Rev AA • Nov. 2006

Inspect shaft J010

E101 242


swashPLate

Careully inspect each surace o the swashplate or wear. All swashplate suraces should be smooth. Inspect the swashplate’s swashplate’s slipper running surace or atness and brass transer. Excessive brass transer rom slippers may indicate that the slippers should be replaced. Finally, check the swashplate bearing journals or scratches. Replace Replace swashplate i necessary.

Inspect swashplate

E101 243

F F Flatness

0.0025 mm [0.001 in]

Parallelism

0.0635 mm [0.0025 in]

JOurnaL Bearings

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

Inspect journal bearings

P104 335

50L081 • Rev AA • Nov. 2006

1


vaLve PLate

Inspect the valve plate or scratches and grooves. Check the plate or evidence o any cavitation along the running ace o the valve plate. I pitting rom cavitation exists, replace the valve plate. Check or excess wear on the brass running ace. I any discoloration or burn marks exist, replace the valve plate. Run a fngernail or pencil tip across the diameter o the sealing land surace (see illustration). No deep or outstanding grooves should be elt, as these may decrease pump ow. Lap or replace i grooves or nicks are present. Inspect the mating suraces o t he endcap and valve plate or any possible contamination; even a ew thousandths o an inch may aect pump operation. Ensure the minimum thickness, atness, and parallelism specifcations are met ater rework. Measure the thickness o the valve plate. Ensure Ensure that valve plate parallelism is equal to or less than 0.025 mm [0.001 in]. Appearance should be at and smooth on both the running ace and the t he bottom surace. The The valve plate should be at to 0.0038 mm [0.00015 in] convex. A magnetic particle inspection is recommended to detect cracks. Replace the valve plate i any cracks exist. Inspect valve plate 4.95 mm [0.195 in] min.

0.025 mm [0.001 in]

0.0038 mm [0.00015 in] convex max

B090

P104 363E

endCaP

Inspect the endcap (J020). Check the timing pin (J050). Careully check the bearing cup (B010) or wear, and ensure that it fts tightly.

Inspect endcap and components B010

J050

J020

E101 244

18

50L081 • Rev AA • Nov. 2006


shaFt Bearing kits

The tapered roller bearing kit consists o a cup and cone. Make sure the cup and cone are ree o excessive wear or contamination. Rotate the bearings to check or smoothness. I a contaminated bearing is suspected, clean with a solvent and lubricate with hydraulic uid.

Inspect shaft bearings

Replace the bearing i cleaning does not remedy the problem. E101 182

Inspect or uneven wear. I abnormal wear is ound, replace the bearing kit.

servO PistOn

Check the servo piston (P020) or any obvious wear or damage. Check the corresponding endcap bore or galling or excessive wear. Discard the piston i damaged. Replace the servo piston-rings.

Inspect servo piston

P020

E101 245

Bias PistOn

Check the bias piston (B080) or any obvious wear or damage. Check the corresponding endcap bore or galling or excessive wear. Discard the piston i damaged. Replace the bias piston-rings.

Inspect bias piston

B080 E101 246

50L081 • Rev AA • Nov. 2006

1


hOusing

Inspect the housing to ensure that it is clean and ree o oreign material. Inspect the swashplate bearing suraces, and endcap mating suraces.

Inspect housing

E101 247

auxiLiary Pad

Inspect sealing suraces on the endcap and auxiliary pad, and make sure that they are clean and ree o contaminants. Inspect the coupling (J140) or any signs o excessive or abnormal wear. Replace all O-rings. Replace excessively worn parts i necessary.

Inspect auxiliary pad components J130 J110

J120

J100

J140

J080

J090 J095

E101 248


Inspect the displacement limiter screw threads. Ensure that the screw is not bent. Also, inspect the seal/nut or irregular wear. Replace i necessary. Replace the O-ring.

Inspect displacement limiter

L030A L010 L010A L040

E101 249

0

50L081 • Rev AA • Nov. 2006

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

JOurnaL Bearing

1.

Coat the journal bearings (B030) with hydraulic uid and install them into the pump housing.

Install housing components

J010

2.

Punch in retaining pins (B071) to a minimum o 0.5 mm [0.02 in] below the bearing surace.

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

P020

B080

B025

FrOnt Bearing and swashPLate

1.

2.

C Caution Ensure clevis pins (B043) are seated properly in swashplate counterbores.

Using a clevis pin (B043) and snap ring (B044) install the servo piston (P020) and bias spring (B025) to one end o the swashplate. Install the bias piston (B080) to the other end. C

Swashplate is symmetrical. Servo and bias pistons may be installed in either end o swashplate. 3.

inPut shaFt

Reinstall the ront bearing kit. The cup (B060) should be a slip ft with the housing.

Coat the suraces o the swashplate (B040) with hydraulic uid. Reinstall Reinstall the swashplate in its original orientation. Lubricate Lubricate the at ace with hydraulic oil to prevent premature wear during start-up.

B044

B043

B044 B040

B043 B071 B030

B050

B060

Insert the input shat (J010) through the bearing into the housing. E101 250

50L081 • Rev AA • Nov. 2006

1


CyLinder kit assemBLy

1.

Coat all parts with hydraulic uid prior to reassembly reassembly..

W Warning

2.

Install the inner block spring washer (P042), block spring (P043), and outer washer (P044) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove. Wind Wind the spiral retaining ring (P045) into the groove in the cylinder block. W

Risk o personal injury: Compressing the block spring requires a orce o about 350 to 400 N [80 to 90 lb]. Use a press sufcient to maintain this orce with reasonable eort. Ensure the spring is secure beore attempting 3. to install the spiral retaining ring. Release the pressure slowly ater the retaining ring is installed. 4.

Assemble cylinder kit

P050

P049

P047

Turn the block over and install the hold-down pins (P046) and ball guide (P047) to the cylinder block. Install the pistons (P050) to the slipper retainer (P049). Install the piston/retainer assembly into the cylinder block. Ensure the concave surace o the retainer seats on the ball guide. I you’re reusing the pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide beore assembly. Set the cylinder kit aside on a clean surace sur ace until needed.

P046

P041

P042

P043

P044

P045 E101 251

Be sure to install the slipper retainer so it mates correctly with the ball guide (concave side o the slipper retainer against the convex side o the ball guide).

CyLinder kit instaLLatiOn

1.

2.

Set the pump on its side. Secure the end o the shat with one hand and keep it horizontal. Insert the cylinder kit onto the shat. sh at. While holding the shat still, slightly rotate the cylinder block kit to help start it onto the shat splines over the ball guide and align it with the block splines. When the cylinder block kit slides completely over the shat splines, reposition the unit with the ront ange acing downward.

Install cylinder block Prevent shaft from rotating

Slightly rotate cylinder block

K030 P010 E101 252



50L081 • Rev AA • Nov. 2006


vaLve PLate and endCaP

1.

Clean the valve plate (B090) and endcap. Install the timing pin (J050) in the endcap. The timing pin should be 3.6 mm [.01 in] ± [0.25 mm [0.001 in.] above the valve plate surace.

Install endcap components J050 B090

Bearing kit

2.

Apply a liberal amount o assembly grease to the backside o the valve plate surace to hold it in position. Install the valve plate over the timing pin 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.

endCaP

1.

Lubricate O-Ring (K060) with hydraulic uid and install into housing.

E101 253E

Install endcap and components J030 10 mm

2.

Install endcap (J020) with valve plate and bearing assembly. Ensure the valve plate does not slip during assembly. Lower the endcap careully onto the servo and bias pistons and ensure the pistons seat into the bores in the endcap. Install endcap screws (J030) using a 10 mm internal hex wrench. Torque to 203 N•m [150 lb•t].

203 N•m [150 lbf•ft]

J020

K060

E101 436

50L081 • Rev AA • Nov. 2006




shaFt seaL

1.

Cover shat splines with an installation sleeve to protect the seal. Install a new shat seal (K020) with the cup side acing the pump.

Install shaft seal and retaining ring K010

K020

2.

Press seal into housing until it is just below retaining ring groove. groove. Press evenly to avoid binding and damaging the seal. Install snap ring (K010).

E101 254

PC COntrOL

1.

2.



Clean and lubricate all control parts and cover with a light coating o clean hydraulic uid prior to reassembly. Install the spherical end o the PC spool (C132) into the PC bore (reer to illustration). With With a 3/16 internal hex wrench, install the PC plug (C103) using a new O-ring (C103A). Torque To rque to 12 N•m [9 lb•t]. Place the two PC springs (C134, C135) onto the PC spring guide (C133) and install into the PC bore. Place a new O-ring (C138A) onto the PC plug (C138) and install it with a 1/4 internal hex wrench so that it sits one turn below the surace o the control housing. Using a 4 mm internal hex wrench, install set screw (C102). Torque to 9 N•m [7 lb•t].

50L081 • Rev AA • Nov. 2006

Assemble PC (only) control control

C103A

C103 3/16 in 12 N•m [9 lbf•ft] C132

C200

C102 4 mm 9 N•m [7 lbf•ft] C133 C135 C134 C138A C138 1/4 in

E101 255


Ls COntrOL (OPtiOnaL)

Install the PC portion as described in PC control , page 24. 24.

Assemble PC/LS control control C103

1.

2.

Hold the control in a horizontal position. Install Install the spherical end o the LS spool (C112) into the LS bore (see illustration). Using a new O-ring, install the LS plug (C104) with a 3/16 internal hex wrench, torque torque to 12 N•m [9 lb•t]. Place the 2 LS springs (C114, C115) onto the LS spring guide (C113) and install into the LS bore. Place a new O-ring (C118A) and back-up rings (C118B) onto the LS adjustment screw (C118). Using a 1/4 internal hex wrench, install the LS plug assembly so that it sits one turn below the surace o the control housing.

C103A

3/16 in 12 N•m [9 lbf•ft]

C132

C104 3/16 in 12 N•m [9 lbf•ft] C104A C112

C106A C200

C106

C105 C105A 3/16 in 12 N•m [9 lbf•ft] C102 4 mm 9 N•m [7 lbf•ft]

C113 C115

C133

C114 C118B

C135

3.

Install and tighten set screw (C102) to 9 N•m [7 lb•t]. Also, install the plugs (C105, C106) with new O-rings, using a 3/16 internal hex wrench. Torque To rque the plugs to 12 N•m [9 lb•t]. lb•t].

50L081 • Rev AA • Nov. 2006

C118A C118B

C134

C138 1/4 in

C118 1/4 in C138A E101 238

5


auxiLiary Pad

1.

2.

Install the adapter (J080) with new O-rings (J090) and (J095). Tighten the screws (J100) to 27 N•m [20 lb•t] with a 10 mm internal hex wrench. Test torque-to-turn with the unit assembled (excluding auxiliary pumps) by rotating the input shat using a torque wrench.

Test the torque torque required to turn the shat (ater break-away) with pl  fll l and the assembly ll ol. ol. Readings outside the table values may indicate internal problems. I necessary, necessar y, disassemble pump and check.

Install the auxiliary pad J130

J110

J120

J100 10 mm 27 N•m [20 lbf•ft]

J140

J080

toq-o- f 13.5 to 24.4 N•m [120 to 216 l b•in] J090

3.

4.



J095

Reinstall the coupling (J140). Install the auxiliary pad O-ring (J120) and auxiliary pump or cover plate (J110). Torque To rque the screws (J130) to the values in the table. For a pads, use a 9 /16 inch hex wrench. For B and C pads, use a ¾ inch hex wrench. Reinstall any other external components, including including the auxiliary pump (i present), that were removed beore disassembly disassembly..

50L081 • Rev AA • Nov. 2006

E101 229

a p p J1 J10 0 c c  

B   C p p J1 J10 0 c c  

37 to 50 N•m

91 to 111 N•m

[27 to 37 lb•t]

[67 to 82 lb•t]



1.

2.

Install displacement limiter screw (L040) into plug (L010). Install new O-ring (L010A) onto plug (L010). Thread plug with limiter into endcap. Torque to 77 N•m [57 lb•t].

3.

Turn adjustment / seal nut (L030A) onto displacement limiter limiter..

4.

Using a 7 /8-inch wrench, torque the adjustment seal/nut (L030) to 54 N•m [40 lb•t].

Install the displacement limiter L030A 7/8 in 54 N•m [40 lbf•ft] L010 7/8 in 77 N•m [57 lbf•ft]

L010A L040 1/4 in

Reer to Frame F Service Manual 11005158 or instructions on adjusting displacement limiter limiter..

E101 256

attaCh the COntrOL

1.

Using petroleum jelly to retain them, install 4 new seal rings (C200) in the recesses on the control housing.

Install the control C300 4 mm

2.

Install the control assembly onto the endcap using the 4 screws (C300) with a 4 mm internal hex wrench. Torque To rque to 6 N•m [5 lb•t] using a criss cross pattern, and retorque the frst screw to ensure proper torque retention.

6 N•m [5 lbf•ft]

C200

E101 257

PumP adJustment

1.

Install the pump on a test stand.

2.

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

50L081 • Rev AA • Nov. 2006



Our PrOduCts Hydrostatic transmissions Hydraulic power steering Electric power steering Electrohydraulic power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Orbital motors Transit mixer mixer drives Planetary compact gears Proportional valves Directional spool valves Cartridge valves

s-dfo mobl Po  Cool s – m L wol Sauer-Danoss is a comprehensive supplier providing complete systems to the global mobile market. Sauer-Danoss serves markets such as agriculture, construction, road building, material handling, municipal, orestry, tur care, and many others. We oer our customers optimum solutions or their needs and develop new products and systems in close cooperation and partnership with them. Sauer-Danoss specializes in integrating a ull range o system components to provide vehicle designers with the most advanced total system design. Sauer-Danoss provides comprehensive worldwide service or its products through an extensive network o Global Service Partners strategically located in all parts o the world.

Hydraulic integrated circuits Hydrostatic transaxles

Local address:

Integrated systems Fan drive systems Electrohydraulics Microcontrollers and sotware Electric motors and inverters Joysticks and control handles Displays Sensors

50L081 • Rev AA • Nov. 2006

Sauer-Danoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000 Fax: +1 515 239-6618

Sauer-Danoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444 Fax: +45 7488 4400

Sauer-Danoss GmbH & Co. OHG Postach 2460, D-24531 Neumünster Krokamp 35, D-24539 Neumünster, Germany Phone: +49 4321 871-0 Fax: +49 4321 871 122

Sauer-Danoss-Daikin LTD Sannomiya Grand Bldg. 8F 2-2-21 Isogami-dori, Chuo-ku Kobe, Hyogo 651-0086, Japan Phone: +81 78 231 5001 Fax: +81 78 231 5004

www.sauer-danoss.com

45 Series F Frame Repair Manual (520L0821 Rev AA Nov 2006)

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