Series 45

K and L Frame
Open Circuit
Axial Piston Pumps

Repair Manual
 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Using this manual

ORGANIZATION AND To help you quickly find information in this manual, the material is divided into sections,
HEADINGS topics, subtopics, and details, with descriptive headings set in red type. Section titles
appear at the top of every page in large red type. Topic headings appear in the left
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AND COMPLEMENTARY type above each item. Complementary information such as notes, captions, and drawing
INFORMATION annotations are also set in blue type.

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SPECIAL TEXT Defined terms and acronyms are set in bold black type in the text that defines or
FORMATTING introduces them. Thereafter, the terms and acronyms receive no special formatting.

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TABLE OF CONTENTS An indented Table of Contents (TOC) appears on the next page. Tables and illustrations
in the TOC set in blue type. In the PDF version of this document, the TOC entries are
hyperlinked to the pages where they appear.

© 2005 Sauer-Danfoss. All rights reserved. Printed in U.S.A.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.

Front cover illustrations: F101 472, F101 473, F101 474, F101 475, P104 327

2 BLN 10196 • 520L0632 • May 2005

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Contents

INTRODUCTION Overview ........................................................................................................................................................... 4

General instructions ...................................................................................................................................... 4
Safety precautions ......................................................................................................................................... 5
Unintended machine movement ....................................................................................................... 5
Flammable cleaning solvents ............................................................................................................... 5
Fluid under pressure ................................................................................................................................ 5
Personal safety ........................................................................................................................................... 5
Symbols used in Sauer-Danfoss literature............................................................................................. 6

DISASSEMBLY Auxiliary pad .................................................................................................................................................... 7

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

INSPECTION Overview .........................................................................................................................................................13

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

ASSEMBLY Journal bearing ............................................................................................................................................20

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

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

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

W Warning
Use of components that do not comply with rework specifications may result in loss of
performance, which may constitute a safety hazard. Do not reuse components that don’t
comply to given specifications: replace with genuine Sauer-Danfoss service parts.

Minor repair procedures, adjustments, and troubleshooting information are given in the
Series 45 Frame K and L Open Circuit Axial Piston Pumps Service Manual, 520L0532. Minor
repairs include service operations that can be performed without removing the unit’s
endcap. Removal of the endcap voids your warranty.

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

w Remove the unit

Prior to performing major repairs, remove the unit from the vehicle/machine. Chock
the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that
hydraulic fluid may be under high pressure and / or hot. Inspect the outside of the pump
and fittings for damage. Cap hoses after removal to prevent contamination.

e Keep it clean
Cleanliness is a primary means of assuring satisfactory pump life, on either new or
repaired units. Clean the outside of the pump thoroughly before disassembly. Take care
to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash
and air drying is usually adequate.

As with any precision equipment, all parts must be kept free of foreign materials and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material. If left unattended, cover the pump with a protective layer of plastic.

l Lubricate moving parts

During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that
these parts will be lubricated during start-up.

d Replace all O-Rings and gaskets

It is recommended that all O-rings be replaced. Lightly lubricate all O-rings with clean
petroleum jelly prior to assembly.

t Secure the unit

For major repair, place the unit in a stable position with the shaft pointing downward. It
will be necessary to secure the pump while removing and torquing the endcap bolts.

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.

Unintended machine movement

W Warning
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable
/ disconnect the mechanism while servicing.

Flammable cleaning solvents

W Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.

Fluid under pressure

W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin
causing serious injury and/or infection. This fluid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the
system before removing hoses, fittings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.

Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Introduction

SYMBOLS USED IN  WARNING may result in injury  Tip, helpful suggestion

SAUER-DANFOSS
LITERATURE  CAUTION may result in damage to  Lubricate with hydraulic fluid
product or property
 Apply grease / petroleum jelly
 Reusable part
 Apply locking compound
 Non-reusable part, use a new part
 Inspect for wear or damage
 Non-removable item
 Clean area or part
 Option – either part may exist
 Be careful not to scratch or damage
 Superseded – parts are not
interchangeable  Note correct orientation

 Measurement required  Mark orientation for reinstallation

 Flatness specification  Torque specification

 Parallelism specification  Press in – press fit

 External hex head  Pull out with tool – press fit

 Internal hex head  Cover splines with installation

sleeve
 Torx head
 Pressure measurement / gauge
 O-ring boss port location or specification

The symbols above appear in the illustrations and text of this manual. They are intended
to communicate helpful information at the point where it is most useful to the reader.
In most instances, the appearance of the symbol itself denotes its meaning. The legend
above defines each symbol and explains its purpose.

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

AUXILIARY PAD If a second pump is used, you must remove it. You don’t need to remove auxiliary pads to
remove the end cap.

1. Remove the plate cover screws (J130) and remove the plate cover (J110).

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

3. Remove the auxiliary pad screws (J100) with an 8 mm internal hex wrench and
remove the adapter (J080).

4. Remove and discard the O-rings (J090, J095).

5. Remove the coupling (J140).

Remove auxiliary A pad Remove auxiliary B pad

J130 J130
h 9/16 inch h ¾ inch

J110 J110

J120 J120 d

J100 J100
h8 mm h8 mm

J085 J085

J090 d J090 d

J095 d J095 d

J140 J140

E101 196

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

CONTROL 6. Using a 5 mm internal hex wrench, Remove control

remove the 4 control screws (C300)
that fasten the control assembly to
the endcap (J020). d
C200
7. Remove the control from endcap.
Discard interface O-rings. (C200).

C300
I5 mm
P104 328

ENDCAP AND ROLLER 8. Remove the 4 endcap screws (J030) Remove endcap and roller bearing
BEARING using an 8 mm internal hex wrench.
J030
9. Remove the endcap. Remove the I8 mm
servo piston (L020) and guide (L080).
Use care; valve plate (B070) may
adhere to inside surface. Discard
O-rings (B045, B046). Once the valve J020
plate is removed, the check valve can e
be removed. Refer to Inspection, page
17, for more information.
B046
d
To protect these parts from L080
contamination, place the endcap and B010
26 mm
valve plate in a protected area.
B020 L020
10. Slide the rear tapered roller bearing
cone (B020) from the bottom end B070
of the shaft. The bearing cup (B010) s
may remain within the endcap. B045
d
Remove bearing cup if replacement is
necessary. See Inspection, page 18.

P101 351

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

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

P104 339

INPUT SHAFT, 12. Rotate the swashplate (B040) until Remove shaft and swashplate
SWASHPLATE, AND BIAS level with pump housing. Pull the
SPRING shaft (J010) from the shaft seal
and bearing kit. Slightly compress
the bias spring (B025) and lift the
swashplate out. Lift the bias spring
from the pump housing.
pJ010

B040

B025

P101 353

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

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

B050
p

pB060

P101 369

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

If you are unable to pull the shaft seal

out, try to push the seal out by going
through the inside of the housing.

P101 352

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

CONTROL HOUSING 15. With a 3/16 inch internal hex wrench, Disassemble control
remove the plugs (C103, C106) and
their O-rings. Discard the O-rings.
C118 i
C Caution Remove the 2 set screws (C102). iC138
If removing the LS or PC Remove the spool (C112). Note
spool is not possible, be the orientation of the spools for C117 d
dC136
extremely careful when reinsertion. There may be differences C116 d
flipping or relocating the in reinserting into the same bore. C135
housing as not to lose or Remove the spool (C132). C C117 d
damage the spool.
The PC and LS spools are not the same.
They must be identified as to which bore C114
C134
they come out of.
C115
16. Remove the adjusting screw (C138) C133
and the O-ring (C138A). Discard the C113
O-ring. Remove the springs (C134,
C135) and spring guide (C133).

17. Remove the adjusting screw (C118),

O-ring (C116) and 2 backup rings
(C117). Discard the O-ring and C102
backup rings. Remove the springs
(C114, C115) and spring guide (C113).

iC132
R C112 i

dC103A R

C106A d
C103
C106

E101 192

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Disassembly

CYLINDER KIT 18. Remove pistons (K050) and slipper Disassemble cylinder kit
DISASSEMBLY retainer (K049) from the cylinder
block.
K050 l
The pistons are not selectively fitted,
however units with high hourly usage
may develop wear patterns. Number the
K049 l
pistons and bores for reassembly if they
are to be reused.
K047 l
19. Remove the ball guide (K047), hold-
down pins (K046), and retaining K048 (L Frame only)
ring (K048) from the cylinder
block (K041). K046
P010
K041
Most repairs do not require block spring
removal. Perform this procedure only
if you suspect problems with the block
spring.

K042
W Warning Block spring removal
Risk of personal injury: 20. Turn the block over. Using a press, K043
Compressing the block apply pressure on the block spring
spring requires about 350 washer (K044)) to compress the K044
to 400 N [80 to 90 lbf ]. block spring (K043). Compress the
K045
Use a press sufficient spring enough to safely remove the P101 356
to maintain this force spiral retaining ring (K045). While
with reasonable effort. maintaining pressure, unwind the
Ensure the spring is spiral retaining ring. Carefully release the pressure and remove the outer block
secure before attempting spring washer, block spring , and inner block spring washer (K042) from the cylinder
to remove the spiral block. W
retaining ring. Release the
pressure slowly after the
retaining ring is removed.

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

OVERVIEW After disassembly, wash all parts (including the end-cap and housing) thoroughly with
clean solvent and allow to air dry. Blow out oil passages in the housing and endcap
with compressed air. Conduct inspection in a clean area and keep all parts free from
contamination. Clean and dry parts again after any rework or resurfacing.

PISTONS AND SLIPPERS Inspect the pistons for damage and K Frame
discoloration. Discolored pistons may Slipperfoot thickness 4.03 mm
indicate excessive heat; do not reuse. [0.159 in]
Piston/slipper end play 0.102 mm
Inspect the running surface of the [0.004 in]
slippers. Replace any piston assemblies
with scored or excessively rounded L Frame
slipper edges. Measure the slipper foot Slipperfoot thickness 2.67 mm
thickness. Replace any piston assemblies [0.105 in]
with excessively worn slippers. Check the Piston/slipper end play 0.102 mm
slipper axial end-play. Replace any piston [0.004 in]
assemblies with excessive end-play.
Inspect pistons
Minimum slipper foot thickness and
Maximum end play
maximum axial end-play are given in the
 
table to the right.
Minimum Slipper
slipper foot
thickness
K050


P104 109E

BALL GUIDE, SLIPPER The ball guide should be free of Inspect guide, retainer, and pins
RETAINER, AND HOLD- nicks and scratches, and should not
DOWN PINS be excessively scored. Examine for Slipper
discoloration that may indicate excessive retainer
heat or lack of lubrication. The slipper i
retainer should be flat, and slippers
should fit in the retainer with minimal Ball guide
side play. Place the hold-down pins on a
flat surface and roll them to make sure
Hold down pins
they are straight. Discard and replace any
damaged parts.
P101 471

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

BLOCK SPRING, AND If cylinder kit was fully dissembled, visual Inspect block spring and washers
WASHERS inspection of the cylinder block, spring,
and washers should indicate minimal Washer
wear. Replace if cracks or other damage i
is present.
Cylinder block spring

Spring retainer

Retaining ring

P101 472

CYLINDER BLOCK Examine the running face of the cylinder block. The surface should be smooth and free
of nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce
output flow.

K Frame 38 cc 45 cc Inspect cylinder block

Minimum cylinder 56.48 mm
block height (A) [2.224 in] MB
Maximum block bore 16.44 mm 17.98 mm
diameter (B) [0.65 in] [0.71 in] C100
i

AM
L Frame 25 cc 30 cc
Minimum cylinder 50.8 mm
block height (A) [2.00 in] flat to 0.002 mm
f
Maximum block bore 13.88 mm 15.22 mm [flat to 0.000080 in]
P101 358
diameter (B) [0.546 in] [0.60 in]

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

CONTROL Carefully examine the LS plug for signs Inspect control components
of wear. Also check the small tip of the
LS plug for heavy wear and replace if
necessary. Inspect each spool’s springs iC138
C118 i
to make sure they are intact. Check
the inside and outside surfaces of the C117 d
springs for wear and replace if necessary. dC136
Check the spool’s outside diameter for C116 d
scratches and / or burrs. Clean and coat C135
all spools, bores, and seals with a light C117 d
coating of hydraulic oil.
C114
C134

C115
C133
C113

C102

iC132
R C112 i

dC103A R

C106A d
C103
C106

E101 192

SHAFT Inspect the shaft for any signs of damage. Inspect shaft
Replace the shaft if a groove exists at
the sealing land surface that may let dirt i
into or hydraulic fluid out of the unit. If l
necessary, clean the sealing area with
a non-abrasive material. Inspect the
input splines or keyway, block spines
and output splines. Replace the shaft if
damaged. Ensure that the shaft’s splines
are straight and lubricate the shaft with a J010
light coating of hydraulic fluid.
P101 360

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

SWASHPLATE Carefully inspect each surface of the Inspect swashplate

swashplate for wear. All swashplate
surfaces should be smooth. Inspect the
swashplate’s slipper running surface for
brass transfer. Excessive brass transfer
from slippers may indicate that the B040
slippers should be replaced. Finally,
check the swashplate bearing journal i
P101 362
for scratches. Replace swashplate if
necessary

JOURNAL BEARING Inspect the journal bearings for Inspect journal bearings
damage or excessive wear. Replace
i
journal bearings if scratched, warped, or
excessively worn. The polymer wear layer
must be smooth and intact.
B030

P101 363

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

VALVE PLATE Inspect the valve plate for scratches and grooves. Check the plate for evidence of
any cavitation along the running face of the valve plate. If pitting from cavitation
exists, replace the valve plate. Check for excess wear on the brass running face. If any
discoloration or burn marks are observed, replace the valve plate.

Run a fingernail or pencil tip across the diameter of the sealing land surface (see
illustration). No deep or outstanding grooves should be felt, as these may decrease pump
flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the
endcap and valve plate for any possible contamination; even a few thousandths of an
inch may affect pump operation.

Measure the thickness of the valve plate. Ensure that valve plate parallelism is equal
to or less than 0.025 mm [0.001 in]. Appearance should be flat and smooth on both
the running face and the bottom surface. The valve plate should be flat to 0.005 mm
[0.0002 in] convex. A magnetic particle inspection is recommended to detect cracks. The
valve plate must be replaced if any cracks exist.

Inspect valve plate

3.88 mm [0.153 in] min.

a 0.025 mm
[0.001 in]

i f 0.005 mm
[0.00020 in]
convex max

B090

P101 419

ENDCAP Inspect the endcap. Remove the check Inspect endcap and components
valve (B095) to expose the spring (B090).
B095
Check and record orientation of the
timing pin (J050). Inspect the check valve J050 B090
for wear on its sealing face and replace
i
if necessary. Make sure the spring is
undamaged. Carefully check the bearing
cup for wear, and ensure that it fits
tightly.

P101 484

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

SHAFT BEARING KITS The tapered roller bearing kits consist of Inspect shaft bearings
a cup and cone. Both the cup and cone
should be free of excessive wear and
contamination. Rotate the bearings to e
check for smoothness. If a contaminated i
bearing is suspected, clean with a solvent
l
and lubricate with hydraulic fluid. If the
problem is not remedied by cleaning,
replace the bearing. Also inspect for
uneven wear. If abnormal wear is found,
P101 366
replace the bearing kit.

SERVO PISTON AND Inspect the servo piston guide (L080) Inspect servo piston and guide
GUIDE for abnormal wear. Check the inside
i
diameter of the bore for galling or
excessive wear. Inspect the servo piston
(L020) for wear on its end and for
L020
scratches along its cylindrical surface.
Replace both parts if any wear is
noticeable. L080
P101 365

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Inspection

HOUSING Inspect the housing to ensure that it is Inspect housing

clean and free of foreign material. Inspect i
the swashplate, bearing surfaces, and
endcap mating surfaces.

P101 489

AUXILIARY PAD Inspect sealing surfaces on the endcap Inspect auxiliary pad components
and auxiliary pad and make sure that J130
they are clean and free of contaminants.
Inspect the coupling (J140) for any signs
of excessive or abnormal wear. Replace J110
all O-rings. Replace excessively worn
parts if necessary.
J120

J100

J085

i
J090 d

J095 d

J140 i

E101 197

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

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

If journal bearings are reused, reinstall J010

them in their original orientation and
position.

BIAS SPRING, 2. Reinstall shaft bearing cup (B060) lB040

SWASHPLATE, AND and cone (B050). Before replacing
BEARING the bias spring (B025), coat the B071 B025
curved surface of the swashplate
l
(B040) with hydraulic fluid. Tilt the
bias spring inward towards the B030
center of the pump housing. To l
insert the swashplate, tilt the servo
arm downward and into the pump
housing. Make sure the cast knob B050
on the swashplate fits over the bias
spring and that it settles properly
unto the journal bearings. B060

INPUT SHAFT 3. Insert the input shaft (J010) through

the bearing into the housing.

P101 490

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 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

CYLINDER KIT ASSEMBLY 4. Coat all parts with hydraulic fluid Assemble cylinder kit
prior to reassembly.

W Warning 5. Install the inner block spring washer K050 l

Risk of personal injury: (K042), block spring (K043), and
Compressing the block outer washer (K044) into the cylinder
spring requires about 350 block. Using a press, compress the
to 400 N [80 to 90 lbf ]. block spring enough to expose the K049 l
Use a press sufficient to retaining ring groove. Wind the spiral
maintain this force with retaining ring (K045) into the groove
K047 l
reasonable effort. Ensure in the cylinder block. W
the spring is secure before K048 (L Frame only)
attempting to install 6. Turn the block over and install the
the spiral retaining ring. retaining ring (L Frame only; K048), K046
Release the pressure slowly hold-down pins (K046), and ball P010
after the retaining ring is guide (K047) to the cylinder block. K041
installed.
7. Install the pistons (K050) to the
slipper retainer (K049). Install the
piston/retainer assembly into the
cylinder block. Ensure the concave K042
surface of the retainer seats on
the ball guide. If you’re reusing the K043
pistons, install them to the original
block bores. Lubricate the pistons, K044
slippers, retainer, and ball guide
K045
before assembly. Set the cylinder kit
P101 356
aside on a clean surface until needed.

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

CYLINDER KIT 8. Set the pump on its side. Secure the Install cylinder block
INSTALLATION end of the shaft with one hand and
Prevent shaft from rotating
keep it horizontal. Insert the cylinder
kit onto the shaft. While holding the
shaft still, slightly rotate the cylinder
block kit to help start the shaft
splines into the ball guide and align Slightly rotate
cylinder block
it with the block splines. When the
cylinder block kit slides completely
over the shaft splines, reposition
the unit with the flange facing
downward.
P101 491E

BLN 10196 • 520L0632 • May 2005 21

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

VALVE PLATE AND 9. Install the inlet check valve spring Install endcap components
ENDCAP (B090) and poppet (B095) into the
eB070
endcap (J020). A small amount
g
of grease will keep the poppet in
position. Clean the valve plate (B070)
L020
and endcap (J020). Install the timing B020
pin (J050) in the endcap and verify
that it is properly oriented with the L080 B010
t61 - 75 N•m
split facing into or out of the slot [45 -55 lbf•ft] B095 g
in the valve plate. The timing pin
B090
should be installed 3.6 ± 0.25 mm eJ020
J050 R
[0.14 ± 0.01 in] above the endcap
surface. Apply a liberal amount of
assembly grease to the backside of
the valve plate surface to hold it in
position. Install the valve plate over
the timing pin, check valve, and
P101 492
bearing cup. Install the piston (L020)
into the guide (L080), and torque the
guide to 61 - 75 N•m [45 - 55 lbf•ft].

10. Using assembly grease to hold Install endcap

seals, install the endcap to the
J030
housing. Ensure that seals remain
I 8 mm
properly seated and are not pinched
t 47.5 to 61 N·m
during assembly. Install and torque [35 to 45 lbf·ft]
endcap screws at 47.5 to 61 N•m
[35 to 45 lbf•ft], using the criss cross
pattern, and retorque the first screw
to ensure proper torque retention.
J020

gB046

B045 g

P101 493

22 BLN 10196 • 520L0632 • May 2005

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

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

E101 191

BLN 10196 • 520L0632 • May 2005 23

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

CONTROL 12. Clean and lubricate all control parts Assemble the control
and cover with a light coating of
hydraulic fluid prior to reassembly.
C118 i
iC138
13. Hold the control in a horizontal
position. Install the spherical end of C117 d
the LS spool (C112) into the LS bore dC136
C116 d
(see illustration). Using a new O-ring,
C135
install the LS plug (C106), torque at
C117 d
10.8 to 13.5 N•m [8 to 10 lbf•ft]. Place
the two LS springs (C115, C114) onto
the LS spring guide (C113) and install C114
into the LS bore. Place a new O-ring C134
(C116) and back-up rings (C117)
C115
onto the LS adjustment screw (C118). C133
Install the LS plug assembly so that it
C113
sits one turn below the surface of the
control housing. Install and tighten
set screw (C102) at 7.5 to 10.8 N•m
[5.5 to 8 lbf•ft].

PC and LS spools need 14. Install the spherical end of the PC C102
to be adjusted to proper spool (C132) into the PC bore (refer
t7.5 to 10.8 N•m
setting according to tag to illustration). Install the PC plug
[5.5 to 8.0 lbf•ft]
nomenclature (C103) using a new O-ring. Torque at
10.8 to 13.5 N•m [8 to 10 lbf•ft]. Place
iC132
the two PC springs (C134, C135)
R C112 i
onto the PC spring guide (C133) and
dC103A R
install into the PC bore. Place a new
O-ring onto the PC plug (C138) and C106A d
install it so that it sits one turn below C103
the surface of the control housing. C106
t10.8 to 13.5 N•m
Install and tighten set screw (C102) [8 to 10 lbf•ft]
at 7.5 to 10.8 N•m [5.5 to 8 lbf•ft]. to (C103 and C106)
retain the adjusting plug. P101 370

15. Using petroleum jelly to retain them, Install the control

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

C300
I5 mm
t15 to 18 N•m
[11 to 13 lbf•ft]
P101 367

24 BLN 10196 • 520L0632 • May 2005

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Assembly

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

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

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

Install auxiliary A pad Install auxiliary B pad

J130 J130
t36.6 to 50.1 N•m t61 to 73 N•m
[27.0 to 37.0 lbf•ft] [45 to 54 lbf•ft]

J110 J110

J120 J120 d

J100 J100
t67.5 to 82.5 N•m t67.5 to 82.5 N•m
[49.8 to 60.8 lbf•ft] [49.8 to 60.8 lbf•ft]
J085 J085

J090 d J090 d

J095 d J095 d

J140 i J140

E101 223
E101 198

BLN 10196 • 520L0632 • May 2005 25

 Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Notes

26 BLN 10196 • 520L0632 • May 2005

Series 45 K and L Frame Open Circuit Axial Piston Pump
Repair Manual
Notes

BLN 10196 • 520L0632 • May 2005 27

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
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Sauer-Danfoss is a comprehensive supplier providing complete
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building, material handling, municipal, forestry, turf care, and many
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Phone: +49 4321 871-0, Fax: +49 4321 871 122

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Phone: +45 7488 4444, Fax: +45 7488 4400
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