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 inormation inormation 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 let 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. Reerences (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 reerences 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 inormation such as notes, captions, and drawing annotations are also set in blue type. type. Reerences (example: See Illustration abc , page YY) to tables, illustrations, and graphics are also ormatted in blue italic type. type. In PDF fles, these reerences represent clickable hyperlinks that jump to the corresponding document pages.
sPeCiaL text FOrmatting
Defned terms and acronyms are set in bol blc p blc p in the text that defnes or introduces them. Thereater, Thereater, the terms and acronyms receive no special ormatting. Black italic type italic type is used in the text to emphasize important inormation, 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-Danos Sauer-Danoss. s. All rights reser ved. Printed in U.S.A. Sauer-Danoss accepts no responsibility or possible errors in catalogs, brochures Sauer-Danoss brochures and other printed material. Sauer-Danoss Sauer-Dano 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 conict with agreed specifcations. All trademarks in this material are properties o their respective owners. Sauer-Danoss Sauer-Danoss and the Sauer-Danoss logotype are trademarks o the Sauer-Danoss Group. Front cover illustrations: F101 464, F101 385, F101 1 86, P104 359
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Contents
intrOduCtiOn
Overview ................ ................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ......................... ......5 5 General instructions ................. .................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................... ... 5 Saety precautions ................. .................................... ...................................... ...................................... ...................................... ...................................... ...................................... ......................... ......6 6 Unintended machine movement .................................................... ....................................................................... ...................................... ................................6 .............6 Flammable cleaning solvents.......................................... ............................................................ ..................................... ...................................... ................................6 .............6 Fluid under pressure.............................................. ................................................................. ...................................... ...................................... ...................................... ......................... ......6 6 Personal saety ................... ...................................... ...................................... ...................................... ...................................... ...................................... ..................................... ......................... .......6 6 Symbols used in Sauer-Danoss 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 shat, swashplate, and pistons............ pistons............................... ...................................... ...................................... ...................................... .................................10 ..............10 Journal bearings, and roller bearing ......................... ............................................ ...................................... ...................................... ...................................... ....................11 .11 Shat 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 Shat .................. ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... .............................16 ..........16 Swashplate................. ................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................17 .17 Journal bearings .................. ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ..........................17 .......17 Valve Valv e plate.................. .................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................18 .18 Endcap............................... Endcap............ ...................................... ...................................... ...................................... ...................................... ..................................... ..................................... .................................18 ..............18 Shat bearing kits ................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... .......................19 ....19 Servo piston ................. .................................... ...................................... ..................................... ..................................... ...................................... ...................................... ....................................19 .................19 Bias piston .................. .................................... ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................19 .19 Housing .................. ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... .......................20 ....20 Auxiliary pad ................... ...................................... ...................................... ...................................... ...................................... ..................................... ..................................... .................................20 ..............20 Displacement limiter ................ ................................... ...................................... ...................................... ...................................... ...................................... ...................................... ....................20 .20
50L081 • 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 shat .................. ..................................... ...................................... ...................................... ...................................... ...................................... ...................................... ......................................21 ...................21 Cylinder kit assembly ................ ................................... ...................................... ...................................... ...................................... ...................................... ......................................22 ...................22 Cylinder kit installation .................. ..................................... ...................................... ...................................... ...................................... ...................................... ................................22 .............22 Valve plate and endcap ................. .................................... ...................................... ...................................... ...................................... ...................................... ................................23 .............23 Endcap................................ Endcap............. ...................................... ...................................... ..................................... ..................................... ...................................... ...................................... ................................23 .............23 Shat 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
50L081 • 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-Danoss Global Service Partners are authorized to perorm major repairs. The actory trains Sauer-Danoss Global Service Ser vice Partners to perorm 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 perormance, which may constitute a saety hazard. Do not reuse components that don’t comply to given specifcations: replace replace with genuine Sauer-Danoss service par ts. Series 45 Frame F Axial Piston Pump Service Manual 11005158 gives minor repair procedures, adjustments, adjustments, and troubleshooting inormation. Minor repairs include service ser vice operations that you can perorm 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 perorming 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 ater a ter removal to prevent contamination.
e Keep it clean Cleanliness is a primary means o assuring satisactory pump lie, on either new or repaired units. Clean the outside o the pump thoroughly beore 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 suraces and open cavities rom damage and oreign material. I let 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 shat pointing downward. It is necessary to secure the pump while removing and torquing the endcap bolts.
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5
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Introduction
saFety PreCautiOns
Always consider saety precautions beore 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. Flbl 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 sufcient orce to penetrate your skin causing serious injury and/or inection. This uid may also be hot enough to cause burns. Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the system beore 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. Pol f W w Protect yoursel rom injury. Use Use proper saety equipment, including saety glasses, at all times.
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Introduction
symBOLs used in sauer-danFOss Literature
WARNING may result in injury
Tip, helpul 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 careul 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 helpul inormation at the point where it is most useul 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.
50L081 • 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 interace O-rings (C200). C200
E101 230
8
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Disassembly
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
Careully 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 shat bearing cone (B020) rom the shat. The The cup (B010) will likely remain in the end cap; remove it using a bearing puller i necessary.
B010 B020
E101 232
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Disassembly
CyLinder kit
1.
Set the pump on its side.
2.
Remove the cylinder block kit (P010) while holding onto the ront o the shat.
3.
Set cylinder block on a clean dry surace. 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 perormance or pump ailure.
inPut shaFt, swashPLate, and PistOns
Remove cylinder block kit
P010
E101 233
1.
Rotate pump with the shat pointing down.
2.
Pull the shat (J010) rom the shat seal.
3.
Lit 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
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Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Disassembly
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 shat seal beore removing the cup.
Remove bearings B071
B030
B070
B060
E101 235
shaFt seaL
1.
Orient the housing shat side up.
2.
Remove the retaining-ring (K010) using internal retaining ring pliers.
3.
Remove the shat seal (K020).
Remove shaft seal K010
K020
Replace the shat seal every time the shat is removed rom the unit.
E101 236
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Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Disassembly
COnt ntrO rOL L di disa sass sse emBL BLy y
PC ol 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 dierences 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 dierences 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
50L081 • Rev AA • Nov. 2006
E101 458E
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Disassembly
CyLinder kit
dbl cl 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. Perorm this procedure only i you suspect problems with the block spring.
P046
P041
P042
Bloc p ol 4. Turn the block over with the running Risk o personal injury: sueace 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 saely remove sufcient to maintain this the spiral retaining ring (P045). orce with reasonable While maintaining pressure, unwind eort. Ensure the spring is the spiral retaining ring. Careully secure beore 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 ater the washer (P042) rom the cylinder retaining ring is removed removed.. block.
W Warning
50L081 • Rev AA • Nov. 2006
P043
P044
P045 E101 239
1
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
Overview
Ater 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 ater any rework or resuracing.
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 roo 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 surace 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 surace 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
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
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 surace 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 resurace 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
50L081 • Rev AA • Nov. 2006
15
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
COntrOL
Careully 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 suraces 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 shat (J010) and its splines are straight and ree o damage or heavy wear. Inspect the shat sha t seal journal. Replace the shat i a groove exists at the sealing land surace 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 shat with a light coat o hydraulic uid.
50L081 • Rev AA • Nov. 2006
Inspect shaft J010
E101 242
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
swashPLate
Careully inspect each surace o the swashplate or wear. All swashplate suraces should be smooth. Inspect the swashplate’s swashplate’s slipper running surace or atness and brass transer. Excessive brass transer 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
50L081 • Rev AA • Nov. 2006
1
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
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 surace (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 suraces o t he endcap and valve plate or any possible contamination; even a ew thousandths o an inch may aect pump operation. Ensure the minimum thickness, atness, and parallelism specifcations are met ater 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 surace. 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). Careully check the bearing cup (B010) or wear, and ensure that it fts tightly.
Inspect endcap and components B010
J050
J020
E101 244
18
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
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
50L081 • Rev AA • Nov. 2006
1
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Inspection
hOusing
Inspect the housing to ensure that it is clean and ree o oreign material. Inspect the swashplate bearing suraces, and endcap mating suraces.
Inspect housing
E101 247
auxiLiary Pad
Inspect sealing suraces 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
disPLaCement Limiter
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
50L081 • 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 surace.
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 suraces 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 shat (J010) through the bearing into the housing. E101 250
50L081 • Rev AA • Nov. 2006
1
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
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 sufcient to maintain this orce with reasonable eort. Ensure the spring is secure beore attempting 3. to install the spiral retaining ring. Release the pressure slowly ater 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 surace 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 beore assembly. Set the cylinder kit aside on a clean surace 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 shat with one hand and keep it horizontal. Insert the cylinder kit onto the shat. sh at. While holding the shat still, slightly rotate the cylinder block kit to help start it onto the shat splines over the ball guide and align it with the block splines. When the cylinder block kit slides completely over the shat 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
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
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 surace.
Install endcap components J050 B090
Bearing kit
2.
Apply a liberal amount o assembly grease to the backside o the valve plate surace 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 careully 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
50L081 • Rev AA • Nov. 2006
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
shaFt seaL
1.
Cover shat splines with an installation sleeve to protect the seal. Install a new shat 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 (reer 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 surace o the control housing. Using a 4 mm internal hex wrench, install set screw (C102). Torque to 9 N•m [7 lb•t].
50L081 • 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
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
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 surace 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].
50L081 • Rev AA • Nov. 2006
C118A C118B
C134
C138 1/4 in
C118 1/4 in C138A E101 238
5
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
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 shat using a torque wrench.
Test the torque torque required to turn the shat (ater break-away) with pl fll l and the assembly ll ol. ol. 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
toq-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 beore disassembly disassembly..
50L081 • Rev AA • Nov. 2006
E101 229
a p p J1 J10 0 c c
B C p p J1 J10 0 c c
37 to 50 N•m
91 to 111 N•m
[27 to 37 lb•t]
[67 to 82 lb•t]
Series 45 Frame F Open Circuit Axial Piston Pump Repair Instructions Assembly
disPLaCement Limiter
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
Reer 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..
50L081 • Rev AA • Nov. 2006
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50L081 • Rev AA • Nov. 2006
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