Displacement Piston

Cylinder Block Kit

Tapered Roller
Bearing
Valve Plate
Piston
Shaft Seal
Swashplate
Tapered Roller
Bearing
Series 45
Frame K and L
Open Circuit
Axial Piston Pumps
Service Manual
2 3 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Contents
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Contents
INTRODUCTION Using this manual ............................................................................................................................................................. 4
Safety precautions ............................................................................................................................................................ 4
Unintended machine movement.......................................................................................................................... 4
Flammable cleaning solvents ................................................................................................................................. 4
Fluid under pressure.................................................................................................................................................. 4
Personal safety ............................................................................................................................................................. 4
Symbols used in Sauer-Danfoss literature................................................................................................................ 5
General description.......................................................................................................................................................... 6
Pump and control sectional view ............................................................................................................. 6
The system circuit ............................................................................................................................................................. 7
Pictorial circuit diagram................................................................................................................................ 7
TECHNICAL
SPECIFICATIONS
General specifcations ..................................................................................................................................................... 8
Type of mounting........................................................................................................................................................ 8
Auxiliary mounting pad options............................................................................................................................ 8
Control options............................................................................................................................................................ 8
Port options................................................................................................................................................................... 8
Direction of rotation................................................................................................................................................... 8
Installation position.................................................................................................................................................... 8
Technical specifcations ............................................................................................................................................ 8
Ratings ................................................................................................................................................................ 8
Hydraulic parameters....................................................................................................................................................... 9
Inlet pressure................................................................................................................................................................ 9
Pressure compensator valve setting.................................................................................................................... 9
Case pressure................................................................................................................................................................ 9
Hydraulic fuid ............................................................................................................................................................. 9
Temperature range1 .................................................................................................................................................. 9
Fluid viscosity ............................................................................................................................................................... 9
Viscosity limits.................................................................................................................................................. 9
Filtration ........................................................................................................................................................................ 9
FEATURES Displacement limiter......................................................................................................................................................10
Auxiliary mounting pads ..............................................................................................................................................10
Input shafts........................................................................................................................................................................10
Displacement limiter ...................................................................................................................................10
Auxiliary mounting pads............................................................................................................................10
Control options ................................................................................................................................................................12
Cross-section PC control.............................................................................................................................12
Operation.....................................................................................................................................................................12
General....................................................................................................................................................................12
PC control...............................................................................................................................................................12
Cross-section pump.....................................................................................................................................12
Cross-section LS control .............................................................................................................................13
LS control ...............................................................................................................................................................13
Typical load-sensing control valve..........................................................................................................13
2001 Sauer-Danfoss. 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 can be made
without subsequent changes being necessary in specifcations already agreed. 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. All rights reserved. Printed in U.S.A. (0402H)
2 3 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Contents
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Contents
PRESSURE
MEASUREMENT
Port locations and gauge installation......................................................................................................................14
Required tools ..................................................................................................................................................................14
Gauge and port information.....................................................................................................................14
Gauge port locations, radial ported units ............................................................................................14
Gauge port locations, axial ported units ..............................................................................................14
INITIAL START-UP
PROCEDURES
General................................................................................................................................................................................15
Start-up procedure.........................................................................................................................................................15
FLUID AND FILTER
MAINTENANCE
Recommendations..........................................................................................................................................................16
Fluid and flter change interval ................................................................................................................16
TROUBLESHOOTING Excessive noise and / or vibration.............................................................................................................................17
Actuator response is sluggish.....................................................................................................................................17
System operating hot ....................................................................................................................................................18
Low pump output fow.................................................................................................................................................18
Pressure or fow instability...........................................................................................................................................18
System pressure not reaching PC setting...............................................................................................................19
High inlet vacuum...........................................................................................................................................................19
ADJUSTMENTS
MINOR REPAIR Shaft seal replacement..................................................................................................................................................22
Removal ........................................................................................................................................................................22
Installation...................................................................................................................................................................22
Shaft seal and retaining ring.....................................................................................................................22
Auxiliary pads ...................................................................................................................................................................23
Removal ........................................................................................................................................................................23
Auxiliary mounting pads............................................................................................................................23
Installation...................................................................................................................................................................23
Control.................................................................................................................................................................................24
Disassembly ................................................................................................................................................................24
Inspection....................................................................................................................................................................24
Control assembly ..........................................................................................................................................24
Reassembly..................................................................................................................................................................25
Control assembly ..........................................................................................................................................25
Plug and ftting sizes and torques.............................................................................................................................26
Plug locations, sizes, and torques............................................................................................................26
PC control...........................................................................................................................................................................20
PC control adjustment ................................................................................................................................20
LS / PC control ..................................................................................................................................................................21
LS control adjustment .................................................................................................................................21
4 5 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction Introduction
USING THIS MANUAL This manual includes information for the normal operation, maintenance, and service
of the Series 45 frame K and L open circuit pumps. The manual includes a description
of the units and their individual components, troubleshooting information, adjustment
instructions and minor repair procedures. Unit warranty obligations should not be
affected if maintenance, adjustment and minor repairs are performed according to the
procedures described in this manual.
Many service and adjustment activities can be performed without removing the unit
from the vehicle or machine. However, adequate access to the unit must be available,
and the unit must be thoroughly cleaned before beginning maintenance, adjustment,
or repair activities. Since dirt and contamination are the greatest enemies of any type of
hydraulic equipment, follow cleanliness requirements strictly. This is especially important
when changing the system flter and when removing hoses or plumbing.
A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is available
should major repairs be needed. Contact any Sauer-Danfoss ASC for details. A list of all
ASCs can be found in bulletin BLN-2-40527, or in brochure SAW (Ident. No. 698266), or
you can locate your nearest ASC using the distributor locator at www.sauer-danfoss.com.
SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever servicing
a hydraulic system.
Unintended machine movement
A WARNING
Unintended movement of the machine or mechanism may cause injury to the technician
or bystanders. To protect against unintended movement, secure the machine or disable
/ disconnect the mechanism while servicing.
Flammable cleaning solvents
A WARNING
Some cleaning solvents are fammable. To avoid possible fre, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid under pressure
A WARNING
Escaping hydraulic fuid under pressure can have suffcient force to penetrate your skin
causing serious injury and/or infection. This fuid may also be hot enough to cause burns.
Use caution when dealing with hydraulic fuid under pressure. Relieve pressure in the
system before removing hoses, fttings, gauges, or components. Never use your hand
or any other body part to check for leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fuid.
Personal safety
A WARNING
Protect yourself from injury. Use proper safety equipment, including safety glasses, at
all times.
4 5 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction
@ WARNING may result in injury
@ CAUTION may result in damage to
product or property
_ Reusable part
_ Non-reusable part, use a new part
_ Non-removable item
_ Option either part may exist
_ Superseded parts are not
interchangeable
_ Measurement required
_ Flatness specifcation
_ Parallelism specifcation
_ External hex head
_ Internal hex head
_ Torx head
_ O-ring boss port
_ Tip, helpful suggestion
_ Lubricate with hydraulic fuid
_ Apply grease / petroleum jelly
_ Apply locking compound
_ Inspect for wear or damage
_ Clean area or part
_ Be careful not to scratch or damage
_ Note correct orientation
_ Mark orientation for reinstallation
_ Torque specifcation
_ Press in press ft
_ Pull out with tool press ft
_ Cover splines with installation
sleeve
_ Pressure measurement / gauge
location or specifcation
SYMBOLS USED IN
SAUER-DANFOSS
LITERATURE
The symbols above can be found 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 is provided to defne each symbol and explain its purpose.
6 7 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction
Sauer-Danfoss Series 45 K and L frame open circuit piston pumps convert input torque
into hydraulic power. Rotational force is transmitted through the input shaft to the
cylinder block. The input shaft is supported by tapered roller bearings at the front and
rear of the pump and is splined into the cylinder block . A lip-seal at the front end of the
pump prevents leakage where the shaft exits the pump housing. The spinning cylinder
block contains nine reciprocating pistons. Each piston has a brass slipper connected at
one end by a ball joint. The slippers are held to the swashplate by the spring retainer
and block spring. The block spring also holds the cylinder block to the valve plate.
The reciprocating movement of the pistons occurs as the slippers slide against the
inclined swashplate during rotation. Via the valve plate, one half of the cylinder block
is connected to pump inlet and the other half to pump outlet. As each piston cycles
in and out of its bore, fuid is drawn from the inlet and displaced to the outlet thereby
imparting power into the system circuit. A small amount of fuid is allowed to leak from
the cylinder block / valve plate and slipper / swashplate interfaces for lubrication and
cooling. Case drain ports are provided to return this fuid to the reservoir.
The volume of fuid displaced into the system circuit is controlled by the angle of the
swashplate. The swashplate is forced into an inclined position (into stroke) by the bias
spring. The servo piston opposes the action of the bias spring forcing the swashplate out
of stroke when hydraulic pressure in the control circuit rises above the spring force.
The pump control, by varying the pressure at the servo piston, controls the displacement
of fuid in the system circuit. Controls designed for Pressure Compensation (PC) or
Load Sensing (LS) are available. For a detailed description of control operation, refer to
Control options, operation, page 12.
GENERAL DESCRIPTION
Pump and control sectional view
Servo piston
Tapered roller bearing
Shaft seal
LS adjustment screw
LS spool
PC adjustment screw
PC spool
Swashplate
Input shaft
Cylinder block
Piston
Slipper
Valve plate
Bias spring
Block spring
Slipper retainer
LS control
(attached to endcap)
Endcap
(axial ported)
P101 659E
6 7 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Introduction
THE SYSTEM CIRCUIT The pump receives fuid directly from the reservoir through the inlet line. A screen
placed in the inlet protects the pump from large contaminants. The output of the pump
is directed to a PVG-32 multi-section load sensing directional control valve which directs
fuid to the actuators in the system. Fluid returning from the system is cooled by a heat
exchanger and cleaned by a flter before returning to the reservoir.
The speed of the actuators in the system depends on the volume of fuid being provided
by the pump. The operating pressure varies depending on actuator load, but is limited to
an adjustable maximum setting by the PC section of the pump control and by a system
relief valve integrated into the side module of the PVG valve.
The position of the PVG valve sets the demand for fow in the system and communicates
this to the pump control by means of a hydraulic signal (load sense signal). The pump will
provide as much fow to the system as it demands
1
while limiting the maximum pressure.
Therefore fow and pressure in the system are compensated to meet requirements.
Pictorial circuit diagram
System pressure
Servo pressure
Actuator pressure
Load sense pressure
Actuator return
Suction / case drain /
system return
K/L Frame Series 45
open circuit axial
piston pump with
load sensing control
PVG 32
mulit-section
load
sensing
control
valve
P101 658E
Reservoir
Filter
Heat exchanger
Double-acting cylinder
Bi-directional
gear motor
1
Full available fow is a function of pump displacement, operating speed, and effciency. Refer to Series 45 Axial
Piston Open Circuit Pumps Technical Information, BLN-10128 for details.
8 9 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Technical specifcations Technical specifcations
n o i t a c i f i c e p S n o i t a c i f i c e p S n o i t a c i f i c e p S n o i t a c i f i c e p S n o i t a c i f i c e p S t i n U t i n U t i n U t i n U t i n U L e m a r F L e m a r F L e m a r F L e m a r F L e m a r F K e m a r F K e m a r F K e m a r F K e m a r F K e m a r F
t n e m e c a l p s i D m c
3
n i [
3
] ] 3 5 . 1 [ 5 2 ] 3 8 . 1 [ 0 3 ] 2 3 . 2 [ 8 3 ] 5 7 . 2 [ 5 4
d e e p S t u p n I
m u m i n i M
n i m
1 -
) m p r (
0 0 5 0 0 5 0 0 5 0 0 5
d e e p S t u p n I d e t a R n i m
1 -
) m p r ( 0 0 2 3 0 0 2 3 0 5 6 2 0 5 6 2 d e e p S t u p n I
m u m i x a M
n i m
1 -
) m p r (
* * 0 0 6 3 * * 0 0 6 3 * * 0 0 8 2 * * 0 0 8 2
e r u s s e r p g n i k r o w ) k a e p ( m u m i x a M
] i s p [ r a b
] 5 7 0 5 [ 0 5 3 ] 0 5 3 4 [ 0 0 3 ] 5 7 0 5 [ 0 5 3 ] 0 5 3 4 [ 0 0 3
e r u s s e r p g n i k r o w s u o u n i t n o C
] i s p [ r a b
] 0 7 7 3 [ 0 6 2 ] 5 4 0 3 [ 0 1 2 ] 0 7 7 3 [ 0 6 2 ] 5 4 0 3 [ 0 1 2
d e e p s d e t a r t a w o l F ] n i m / l a g [ n i m / l ] 3 . 0 2 [ 2 . 6 7 ] 0 . 4 2 [ 0 . 0 9 ] 9 . 8 2 [ 3 . 8 0 1 ] 6 . 3 3 [ 0 . 6 2 1
t a e u q r o t t u p n i l a c i t e r o e h T
t n e m e c a l p s i d m u m i x a m
r a b / m N
] i s p 0 0 0 1 / n i f b l [
5 9 3 . 0
] 3 4 2 [
7 7 4 . 0
] 1 9 2 [
5 0 6 . 0
] 9 6 3 [
6 1 7 . 0
] 7 3 4 [
l a n r e t n i f o a i t r e n i f o t n e m o m s s a M
s t n e n o p m o c g n i t a t o r
m g k
2
t f m b l [
2
]
6 1 0 0 . 0
] 7 3 0 . 0 [
5 1 0 0 . 0
] 5 3 0 . 0 [
7 1 0 0 . 0
] 0 4 0 . 0 [
0 2 0 0 . 0
] 7 4 0 . 0 [
t h g i e W
s t r o p l a i x A
] m b l [ g k
] 2 4 [ 9 1 ] 2 4 [ 9 1 ] 2 4 [ 9 1 ] 2 4 [ 9 1
t h g i e W
s t r o p l a i d a R
] m b l [ g k
] 3 5 [ 4 2 ] 3 5 [ 4 2 ] 3 5 [ 4 2 3 5 [ 4 2
GENERAL SPECIFICATIONS Type of mounting
SAE-B mounting fange.
Auxiliary mounting pad options
SAE-A, SAE-B, or SAE-B-B
Control options
PC: Pressure Compensator
LS: Load Sensing (with PC)
Port options
Inlet and system ports: SAE fanged ports, code 61 or O-ring boss ports.
Axial (end) ports or radial (side) ports.
All other ports: SAE straight thread O-ring boss.
Direction of rotation
Clockwise or counterclockwise.
Installation position
Installation position is discretionary. To satisfy inlet pressure conditions, it is recom-
mended that the pump always be located below the lowest level of hydraulic fuid in the
reservoir. The housing must always be flled with hydraulic fuid.
Technical specifcations
Ratings
8 9 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Technical specifcations
HYDRAULIC
PARAMETERS
Inlet pressure
Minimum pressure, continuous = 0.8 bar absolute [23.2 in Hg]
(at reduced maximum pump speed)
Minimum pressure, cold start = 0.5 bar absolute [14.8 in Hg]
Pressure compensator valve setting
Minimum: 100 bar [1450 psi]
Maximum: 260 bar [3770 psi]
Case pressure
Maximum continuous: 0.5 bar [7 psi] Above inlet
Intermittent: 2 bar [29 psi] Cold start
Hydraulic fuid
Refer to Sauer-Danfoss publication Fluids and Filtration BLN-9887 or 520L0463. For
information on biodegradable fuids refer to Biodegradable Hydraulic Fluids 520L0465. See
Fluid and flter maintenance, page 16 for recommended fuid and flter change intervals.
Temperature range
1
Intermittent (cold start): - 40 C [- 40 F]
Continuous: 82 C [180 F]
Maximum:
2
104 C [220 F]
Fluid viscosity
1
Hydraulic fuid viscosity must be maintained within the prescribed limits.
2
As measured at the hottest point in the system, e.g. drain line.
Filtration
Required cleanliness level: ISO 4406 Class 18/13 or better. Refer to Sauer-Danfoss
publications Fluids and Filtration BLN-9887 or 520L0463 and Design Guidelines for
Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465. See Fluid and
flter maintenance, page 16 for recommended fuid and flter change intervals.
g n i t a R g n i t a R g n i t a R g n i t a R g n i t a R m mm mm mm mm m
2 2222
] S U S [ ) t S c ( s / ] S U S [ ) t S c ( s / ] S U S [ ) t S c ( s / ] S U S [ ) t S c ( s / ] S U S [ ) t S c ( s /
s u o u n i t n o c
m u m i n i m ] 8 5 [ 9
s u o u n i t n o c
m u m i x a m ] 0 0 5 [ 0 1 1
t n e t t i m r e t n i
m u m i n i m ] 7 4 [ 4 . 6
t n e t t i m r e t n i m u m i x a m
) t r a t s d l o c (
] 0 0 7 4 [ 0 0 0 1
Viscosity limits
10 11 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features Features
DISPLACEMENT LIMITER
AUXILIARY MOUNTING
PADS
INPUT SHAFTS Series 45 K and L frame pumps are available with a variety of splined, straight keyed, and
tapered end shafts. For information on shafts refer to Series 45 Axial Piston Open Circuit
Pumps Technical Information BLN-10128.
Frame K and L Series 45 pumps are
available with an optional maximum
displacement limiter. If installed, this
longer servo piston will limit the
maximum displacement to 92%. This
displacement limiter is not adjustable.
Auxiliary mounting pads are available for
all radial ported Series 45 pumps. These
pads are typically used for mounting
auxiliary hydraulic pumps.
Since the auxiliary pad operates under
case pressure, an O-ring must be used
to seal the auxiliary pump mounting
fange to the pad. The drive coupling is
lubricated by oil from the main pump
case. For details refer to Series 45 Axial
Piston Open Circuit Pumps Technical
Information BLN-10128.
P101 660
Displacement limiter
P101 661
Auxiliary mounting pads
10 11 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features
NOTES
12 13 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features
The Series 45 Frames K and L have two possible control options, a Load Sensing (LS)
control with Pressure Compensator (PC) or a PC only control.
CONTROL OPTIONS
System pressure
Servo pressure
Case pressure
P101 662E
4 5 6
PC spool shifts to port system pressure to
servo piston
Cross-section PC control
1 3 2
P101 663
Bias spring and servo piston set swashplate
position
Cross-section pump Operation
General
The bias spring (1) acts at all times to push
the swashplate (2) to maximum angle
causing the pump to stroke. The servo
piston (3) acts against the bias spring to
reduce the swashplate angle causing the
pump to de-stroke. Swashplate angle
determines pump outlet fow. The pump
control, depending on conditions in the
system circuit, sets swashplate angle by
metering system pressure to the servo
piston.
PC control
The PC control is designed to maintain a constant pressure in the hydraulic circuit as fow
varies. The PC control modulates pump fow accordingly to maintain system pressure at
the PC setting as defned by the PC adjustment screw (4) and spring (5).
When system pressure, acting on the
non-spring end of the PC spool (6),
overcomes the force of the PC spring,
the spool shifts porting system pressure
to the servo piston and the swashplate
angle decreases. When system pressure
drops below the PC setting, the PC
spring shifts the spool in the opposite
direction connecting the servo piston
to pump case and the swashplate angle
increases. The swashplate is maintained
at whatever angle is required to keep
system pressure at the PC setting.
12 13 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Features
CONTROL OPTIONS
(continued)
LS control
The LS control is designed to match
pump fow with system demand. The
fow demand of the system is sensed by
the LS control as a pressure drop across
the External Control Valve (ECV). As the
ECV opens and closes, the pressure delta
across the valve changes. When opening,
the delta decreases. When closing, the
delta increases. The LS control then
increases or decreases pump fow to the
system until the pressure delta becomes
equal to the LS setting as defned by the
LS adjustment screw (7) and spring (8).
LS pressure
Case pressure
System pressure
Servo pressure
7 8 9
6 5 4
P101 664E
LS spool shifts to port system pressure to
servo piston
Cross-section LS control
Load
pressure
Load sense
pressure
System
pressure
Tank
Return
pressure
P101 665E
Typical load-sensing control valve
Pressure drop across external control valve
defnes system demand
The LS control consists of two spool
valves that connect the servo piston
either to pump case or system pressure.
The PC spool (6) controls the pressure-
compensating function of the control as
described in the previous section. The
LS spool (9) controls the load-sensing
function. The PC spool has priority over
the LS spool.
Via internal porting, system pressure
(upstream of ECV) is applied to the
non-spring end of the LS spool and via
hydraulic line connected at port X, LS
pressure (downstream of ECV) is applied
to the spring end. This arrangement allows the LS spool to act on the delta between system
pressure and LS pressure. The LS spring sets the threshold of operation (LS setting).
Because the swashplate is biased to maximum angle, the pump attempts to deliver
full fow to the hydraulic system. When the fow being delivered exceeds demand, the
pressure delta across the ECV is great enough to overcome spring force and shift the
LS spool porting system pressure to the servo piston. The pump de-strokes reducing
fow until the delta across the ECV becomes equal to the LS setting. When fow being
delivered is less than demand, the delta across the ECV drops below the LS setting and
the LS spring shifts the spool connecting the servo piston to pump case. The pump
strokes increasing fow until the delta across the ECV becomes equal to the LS setting.
When the external control valve is placed in neutral, it connects the LS signal line to drain.
With no LS pressure acting on the non-spring end of the LS spool, the pump adjusts
stroke to whatever position necessary to maintain system pressure at the LS setting. The
pump is now in standby mode.
Because of the series arrangement of the LS and PC spools, the PC spool will override
the LS spool. If at any time system pressure reaches the PC setting, the PC spool will
shift blocking the passage that connects the LS spool with the servo piston and porting
system pressure to the servo piston causing the pump to de-stroke.
14 15 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
REQUIRED TOOLS
PORT LOCATIONS AND
GAUGE INSTALLATION
The service procedures described in this manual can be performed using common
mechanics hand tools. Special tools, if required are shown. Calibrate pressure gauges
frequently to ensure accuracy. Use snubbers to protect gauges.
Gauge port locations are shown below. Recommended pressure gauges and fttings are
detailed in the table.
Gauge and port information
LS signal port X
SAE J1926/1, 0.4375-20
Inlet port S
SAE J1926/1, 1.875-12
System gauge port M2
SAE J1926/1, 0.4375-20
Case drain port L1
SAE J1926/1, 0.875-14
Outlet port B
SAE J1926/1, 1.3125-12
Case drain port L2
SAE J1926/1, 0.875-14 P101 634E
Inlet port S
SAE J1926/1, 1.875-12
System gauge port M2
SAE J1926/1, 0.4375-20
Case drain port L1
SAE J1926/1, 0.875-14
Outlet port B
SAE J1926/1, 1.3125-12
Case drain port L2
SAE J1926/1, 0.875-14
P101 635E
t r o P t r o P t r o P t r o P t r o P e s o p r u P e s o p r u P e s o p r u P e s o p r u P e s o p r u P e g u a g f o e g n a R e g u a g f o e g n a R e g u a g f o e g n a R e g u a g f o e g n a R e g u a g f o e g n a R g n i t t i F g n i t t i F g n i t t i F g n i t t i F g n i t t i F
2 M e r u s s e r p m e t s y S ] i s p 0 0 0 5 - 0 [ r o r a b 0 0 3 - 0 g n i t t i f g n i r - o 0 2 - 6 1 / 7
4 M e r u s s e r p o v r e S ] i s p 0 0 0 5 - 0 [ r o r a b 0 0 3 - 0 g n i t t i f g n i r - o 0 2 - 6 1 / 7
2 L , 1 L e r u s s e r p e s a C ] i s p 0 0 1 - 0 [ r o r a b 0 1 - 0 g n i t t i f g n i r - o 4 1 - 8 / 7
1 X l a n g i s S L ] i s p 0 0 0 5 - 0 [ r o r a b 0 0 3 - 0
g n i t t i f g n i r - o 0 2 - 6 1 / 7
) e n i l l a n g i s S L o t n i e e t (
Gauge port locations, axial ported units
Gauge port locations, radial ported units
Pressure measurement
14 15 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Initial start-up procedures
Follow this procedure when starting-up a new Series 45 installation or when restarting
an installation in which the pump has been removed.
AWARNING
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.
Prior to installing the pump, inspect for damage incurred during shipping. Make certain
all system components (reservoir, hoses, valves, fttings, heat exchanger, etc.) are clean
prior to flling with fuid.
GENERAL
START-UP PROCEDURE 1. Connect the pump to the prime mover. Ensure that pump shaft is properly aligned
with the shaft of the prime mover.
CAUTION
Incorrect shaft alignment
may result in damage
to drive shaft, bearings,
or seal which can cause
external oil leakage.
2. Fill the reservoir with recommended hydraulic fuid. Always flter fuid through a 10
micron flter pouring into the reservoir. Never reuse hydraulic fuid.
3. Fill the main pump housing with clean hydraulic fuid. Pour fltered oil directly into
the upper most case drain port.
4. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for
properly tightened fttings and be certain it is free of restrictions and air leaks.
5. To ensure the pump stays flled with oil, install the case drain line in the upper most
case drain port.
6. Install a gauge at port M2 to monitor system pressure during start up.
Note: Follow recommendations in the vehicle / machine operators manual for prime
mover start up procedures.
7. While watching the pressure gauge installed at M2, jog the prime mover or run at
the lowest possible speed until system pressure builds to normal levels (minimum 11
bar [160psi]). Once system pressure is established, increase to full operating speed. If
system pressure is not maintained, shut down the prime mover, determine cause, and
take corrective action. Refer to Troubleshooting, page 17.
8. Operate the hydraulic system for at least ffteen minutes under light load conditions.
9. Check and adjust control settings as necessary after installation. Refer to
Adjustments, page 20.
10. Shut down the prime mover and remove the pressure gauge. Replace plug at port M2.

11. Check the fuid level in the reservoir; add clean fltered fuid if necessary.
The pump is now ready for operation.
16 17 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Fluid and flter maintenance
To ensure optimum life of Series 45 products, perform regular maintenance of the fuid
and flter. Contaminated fuid is the main cause of unit failure. Take care to maintain fuid
cleanliness when servicing.

Check the reservoir daily for proper fuid level, the presence of water, and rancid fuid
odor. Water in the fuid may be noted by a cloudy or milky appearance or free water
in the bottom of the reservoir. Rancid odor indicates the fuid has been exposed to
excessive heat. Change the fuid immediately if these conditions occur. Correct the
problem immediately.
RECOMMENDATIONS
e p y T r i o v r e s e R e p y T r i o v r e s e R e p y T r i o v r e s e R e p y T r i o v r e s e R e p y T r i o v r e s e R
e g n a h C m u m i x a M e g n a h C m u m i x a M e g n a h C m u m i x a M e g n a h C m u m i x a M e g n a h C m u m i x a M
l a v r e t n I l a v r e t n I l a v r e t n I l a v r e t n I l a v r e t n I
d e l a e S s r u o H 0 0 0 2
r e h t a e r B s r u o H 0 0 5
Fluid and flter change interval Change the fuid and flter per the
vehicle / machine manufacturers
recommendations or at these intervals:
Change the fuid more frequently if it
becomes contaminated with foreign
matter (dirt, water, grease, etc.) or if the
fuid is subjected to temperature levels greater that the recommended maximum.
Note: Dispose of used hydraulic fuid properly. Never reuse hydraulic fuid.
Change flters whenever the fuid is changed or when the flter indicator shows that it is
necessary to change the flter. Replace all fuid lost during flter change.
16 17 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
EXCESSIVE NOISE AND /
OR VIBRATION
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. r i o v r e s e r n i l e v e l d i u l f k c e h C
l l i w d i u l f c i l u a r d y h t n e i c i f f u s n I
. n o i t a t i v a c e s u a c
. l e v e l r e p o r p o t r i o v r e s e r e h t l l i F
. m e t s y s n i r i a r o f k c e h C
, y s i o n e s u a c l l i w m e t s y s n i r i A
. l o r t n o c c i t a r r e
. s g n i t t i f n e t h g i t d n a r i a e g r u P
. s k a e l r o f t e l n i k c e h C
/ e r u s s e r p t e l n i p m u p k c e h C
. m u u c a v
l l i w s n o i t i d n o c t e l n i r e p o r p m I
w o l d n a r o i v a h e b c i t a r r e e s u a c
. w o l f t u p t u o
/ e r u s s e r p t e l n i p m u p t c e r r o C
o t r e f e R . s n o i t i d n o c m u u c a v
, s r e t e m a r a p c i l u a r d y H . 9 e g a p
. s g n i l p u o c t f a h s t c e p s n I
t f a h s t c e r r o c n i r o e s o o l A
e v i s s e c x e e s u a c l l i w g n i l p u o c
. n o i t a r b i v r o / d n a e s i o n
d n a g n i l p u o c e c a l p e r r o r i a p e R
s i g n i l p u o c t c e r r o c t a h t e r u s n e
. d e s u g n i e b
. t n e m n g i l a t f a h s k c e h C
e t a e r c l l i w s t f a h s d e n g i l a s i M
. n o i t a r b i v r o / d n a e s i o n e v i s s e c x e
. t n e m n g i l a s i m t f a h s t c e r r o C
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
. s t i m i l e l b a t p e c c a
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
d i u l f w o l r o s t i m i l e l b a t p e c c a
e h t w o l l a t o n l l i w e r u t a r e p m e t
e t a r e p o o t l o r t n o c r o l l i f o t p m u p
. y l r e p o r p
e r o f e b p u m r a w o t m e t s y s w o l l A
e h t h t i w d i u l f e s u r o n o i t a r e p o
r o f e d a r g y t i s o c s i v e t a i r p o r p p a
. s e r u t a r e p m e t g n i t a r e p o d e t c e p x e
e e S 5 4 s e i r e S , s d i u l F c i l u a r d y H
l a u n a M n o i t a m r o f n I l a c i n h c e T ,
. 8 2 1 0 1 - N L B
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
e v l a v f e i l e r m e t s y s l a n r e t x e k c e h C
. g n i t t e s
g n i t t e s e v l a v f e i l e r l a n r e t x e w o L
. m e t s y s n w o d w o l s l l i w
r e p g n i t t e s e v l a v f e i l e r l a n r e t x e t s u j d A
. s n o i t a d n e m m o c e r s ' r e r u t c a f u n a m
e v o b a e b t s u m g n i t t e s f e i l e r l a n r e t x E
. n o i t a r e p o r e p o r p r o f g n i t t e s C P
. g n i t t e s l o r t n o c S L d n a C P k c e h C
e h t t n e v e r p l l i w g n i t t e s C P w o L
w o L . e k o r t s l l u f g n i v e i h c a m o r f p m u p
. w o l f t u p t u o t i m i l l l i w g n i t t e s S L
o t r e f e R . g n i t t e s S L d n a C P t s u j d A
s t n e m t s u j d A . 0 2 e g a p ,
. s e r u s s e r p l a n g i s l o r t n o c S L k c e h C
w o l l a t o n l l i w l a n g i s S L t c e r r o c n I
. y l t c e r r o c e t a r e p o o t p m u p
r e p o r p t a h t e r u s n e , m e t s y s t c e p s n I
. p m u p e h t o t d e t t i m s n a r t s i l a n g i s S L
. s k a e l m e t s y s l a n r e t n I
w o l l a t o n l l i w s t r a p l a n r e t n i n r o W
. y l r e p o r p e t a r e p o o t p m u p e h t
r e t n e C e c i v r e S d e z i r o h t u A o t r e f e R
. d e r i u q e r s a s r i a p e r r o f
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
. s t i m i l e l b a t p e c c a
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
d i u l f w o l r o s t i m i l e l b a t p e c c a
e h t w o l l a t o n l l i w e r u t a r e p m e t
e t a r e p o o t l o r t n o c r o l l i f o t p m u p
. y l r e p o r p
e r o f e b p u m r a w o t m e t s y s w o l l A
e h t h t i w d i u l f e s u r o n o i t a r e p o
r o f e d a r g y t i s o c s i v e t a i r p o r p p a
. s e r u t a r e p m e t g n i t a r e p o d e t c e p x e
e e S 5 4 s e i r e S , s d i u l F c i l u a r d y H
l a u n a M n o i t a m r o f n I l a c i n h c e T ,
. 8 2 1 0 1 - N L B
. g n i v l a v m e t s y s l a n r e t x e k c e h C
t o n y a m g n i v l a v g n i n o i t c n u f l a M
. y l r e p o r p d n o p s e r o t m e t s y s w o l l a
g n i v l a v m e t s y s e c a l p e r r o r i a p e R
. d e r i u q e r s a
. e r u s s e r p e s a c p m u p k c e h C
e h t e s u a c l l i w e r u s s e r p e s a c h g i H
. h s i g g u l s e b o t m e t s y s
. s n o i t c i r t s e r e n i l n i a r d e s a c t c e r r o C
/ e r u s s e r p t e l n i p m u p k c e h C
. m u u c a v
w o l e s u a c l l i w m u u c a v t e l n i h g i H
. w o l f t u p t u o
. s n o i t i d n o c e r u s s e r p t e l n i t c e r r o C
ACTUATOR RESPONSE IS
SLUGGISH
18 19 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
SYSTEM OPERATING HOT
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. r i o v r e s e r n i l e v e l d i u l f k c e h C
c i l u a r d y h f o e m u l o v t n e i c i f f u s n I
g n i l o o c t e e m t o n l l i w d i u l f
. m e t s y s f o s d n a m e d
y f i r e V . l e v e l r e p o r p o t r i o v r e s e r l l i F
. r i o v r e s e r f o e z i s r e p o r p
r i a k c e h C . r e g n a h c x e t a e h t c e p s n I
r o f e r u t a r e p m e t r i a t u p n i d n a w o l f
. r e g n a h c x e t a e h e h t
r i a t u p n i h g i h , w o l f r i a t n e i c i f f u s n I
t a e h d e z i s r e d n u r o , e r u t a r e p m e t
g n i l o o c t e e m t o n l l i w r e g n a h c x e
. m e t s y s e h t f o s d n a m e d
t a e h e c a l p e r r o , r i a p e r , n a e l C
y f i r e V . d e r i u q e r s a r e g n a h c x e
. r e g n a h c x e t a e h f o e z i s r e p o r p
e v l a v f e i l e r m e t s y s l a n r e t x e k c e h C
. g n i t t e s
e v l a v f e i l e r h g u o r h t g n i s s a p d i u l F
. m e t s y s o t t a e h s d d a
e v l a v f e i l e r m e t s y s l a n r e t x e t s u j d A
s ' r e r u t c a f u n a m r e p g n i t t e s
f e i l e r l a n r e t x E . s n o i t a d n e m m o c e r
C P e v o b a e b t s u m g n i t t e s e v l a v
. n o i t a r e p o r e p o r p r o f g n i t t e s
/ e r u s s e r p t e l n i p m u p k c e h C
. m u u c a v
o t t a e h s d d a m u u c a v t e l n i h g i H
. m e t s y s
m u u c a v / e r u s s e r p t e l n i t c e r r o C
. s n o i t i d n o c
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. r i o v r e s e r n i l e v e l d i u l f k c e h C
t i m i l l l i w d i u l f c i l u a r d y h t n e i c i f f u s n I
l a n r e t n i e s u a c d n a w o l f t u p t u o
. p m u p o t e g a m a d
. l e v e l r e p o r p o t r i o v r e s e r e h t l l i F
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
. s t i m i l e l b a t p e c c a
e l b a t p e c c a e v o b a y t i s o c s i v d i u l F
e r u t a r e p m e t d i u l f w o l r o s t i m i l
r o l l i f o t p m u p e h t w o l l a t o n l l i w
. y l r e p o r p e t a r e p o o t l o r t n o c
e r o f e b p u m r a w o t m e t s y s w o l l A
e h t h t i w d i u l f e s u r o n o i t a r e p o
r o f e d a r g y t i s o c s i v e t a i r p o r p p a
. s e r u t a r e p m e t g n i t a r e p o d e t c e p x e
e e S 5 4 s e i r e S , s d i u l f c i l u a r d y H
l a u n a M n o i t a m r o f n I l a c i n h c e T ,
. 8 2 1 0 1 - N L B
e v l a v f e i l e r m e t s y s l a n r e t x e k c e h C
. g n i t t e s
C P w o l e b t e s e v l a v f e i l e r l a n r e t x E
. w o l f t u p t u o w o l e s u a c l l i w g n i t t e s
r e p e v l a v f e i l e r l a n r e t x e t s u j d A
. n o i t a d n e m m o c e r s ' r e r u t c a f u n a m
t s u m g n i t t e s e v l a v f e i l e r l a n r e t x E
r e p o r p r o f g n i t t e s C P e v o b a e b
. n o i t a r e p o
. g n i t t e s l o r t n o c S L d n a C P k c e h C
e h t t n e v e r p l l i w g n i t t e s C P w o L
. e k o r t s l l u f g n i v e i h c a m o r f p m u p
. w o l f t u p t u o t i m i l l l i w g n i t t e s S L w o L
o t r e f e R . g n i t t e s S L d n a C P t s u j d A
s t n e m t s u j d A . 0 2 e g a p ,
/ e r u s s e r p t e l n i p m u p k c e h C
. m u u c a v
w o l e s u a c l l i w m u u c a v t e l n i h g i H
. w o l f t u p t u o
. s n o i t i d n o c e r u s s e r p t e l n i t c e r r o C
. d e e p s t u p n i k c e h C . w o l f e s a e r c e d s d e e p s t u p n i w o L . d e e p s t u p n i t s u j d A
. n o i t a t o r p m u p k c e h C
n o i t a r u g i f n o c l a n o i t a t o r t c e r r o c n I
. w o l f w o l e s u a c l l i w
e t a i r p o r p p a h t i w p m u p e s U
. n o i t a r u g i f n o c l a n o i t a t o r
LOW PUMP OUTPUT
FLOW
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. m e t s y s n i r i a r o f k c e h C
c i t a r r e e s u a c l l i w m e t s y s n i r i A
. n o i t a r e p o
o t m e t s y s g n i w o l l a , C P e t a v i t c A
r o f e n i l t e l n i k c e h C . r i a d e e l b
r i a f o e c r u o s e t a n i m i l e d n a s k a e l
. n o i s s e r g n i
. s l o o p s l o r t n o c k c e h C
e s u a c l l i w s l o o p s l o r t n o c g n i k c i t S
. n o i t a r e p o c i t a r r e
t n e m e v o m e e r f r o f s l o o p s t c e p s n I
s a e c a l p e r r o n a e l C . e r o b n i
. d e d e e n
PRESSURE OR FLOW
INSTABILITY
18 19 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Troubleshooting
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. g n i t t e s l o r t n o c C P k c e h C
e s i r t o n l l i w e r u s s e r p m e t s y S
. g n i t t e s C P e v o b a
. g n i t t e s e t a i r p o r p p a o t C P t s u j d A
o t r e f e R s t n e m t s u j d A . 0 2 e g a p ,
. e v l a v f e i l e r l a n r e t x e k c e h C
w o l e b g n i t t e s e v l a v f e i l e r l a n r e t x E
e r u s s e r p t n e v e r p l l i w g n i t t e s C P
. n o i t a s n e p m o c
r e p e v l a v f e i l e r l a n r e t x e t s u j d A
. s n o i t a d n e m m o c e r s ' r e r u t c a f u n a m
t e s e b t s u m e v l a v f e i l e r l a n r e t x E
r e p o r p r o f g n i t t e s C P e v o b a
. n o i t a r e p o
. g n i r p s l o r t n o c C P t c e p s n I
g n i s s i m r o , d e g a m a d , n e k o r B
. n o i t a r e p o c i t a r r e e s u a c l l i w g n i r p s
. d e r i u q e r s a g n i r p s e c a l p e R
. r a e w r o f l o o p s C P t c e p s n I
e s u a c l l i w l o o p s C P e h t f o r a e W
. l o r t n o c e h t n i e g a k a e l l a n r e t n i
. d e r i u q e r s a l o o p s e h t e c a l p e R
r e p o r p r o f l o o p s C P t c e p s n I
. n o i t a t n e i r o
n i t l u s e r l l i w n o i t a t n e i r o r e p o r p m I
. n o i t a r e p o r o o p
. l o o p s f o n o i t a t n e i r o t c e r r o C
r o f l o r t n o c C P k c e h C
. n o i t a n i m a t n o c
h t i w e r e f r e t n i y a m n o i t a n i m a t n o C
. l o o p S C P e h t f o t n e m e v o m
, s t n e n o p m o c l o r t n o c C P n a e l C
o t n o i t c a e t a i r p o r p p a e k a t
. n o i t a n i m a t n o c e t a n i m i l e
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. e r u t a r e p m e t d i u l f k c e h C
s e s a e r c n i e r u t a r e p m e t w o L
y t i s o c s i v d i u l f h g i H . y t i s o c s i v
. m u u c a v t e l n i h g i h s e s u a c
e r o f e b p u m r a w o t m e t s y s w o l l A
. n o i t a r e p o
. n e e r c s t e l n i t c e p s n I
n e e r c s t e l n i d e t c i r t s e r r o d e k c o l B
. m u u c a v t e l n i h g i h e s u a c l l i w
. e g a k c o l b e v o m e r / n e e r c s n a e l C
. g n i p i p t e l n i k c e h C
g n o l r o , s d n e b , s g n i t t i f y n a m o o T
. m u u c a v t e l n i h g i h e s u a c l l i w g n i p i p
h t a p e k a m o t s g n i t t i f e t a n i m i l E
. t c e r i d e r o m
e v o b a y t i s o c s i v d i u l f c i l u a r d y H
. s t i m i l e l b a t p e c c a
h g i h s e s u a c y t i s o c s i v d i u l f h g i H
. m u u c a v t e l n i
e t a i r p o r p p a h t i w d i u l f t c e l e S
g n i t a r e p o d e t c e p x e r o f y t i s o c s i v
e e S . e r u t a r e p m e t , s d i u l f c i l u a r d y H
n o i t a m r o f n I l a c i n h c e T 5 4 s e i r e S
l a u n a M . 8 2 1 0 1 - N L B ,
SYSTEM PRESSURE NOT
REACHING PC SETTING
HIGH INLET VACUUM
CAUTION
High inlet vacuum causes
cavitation which can
damage internal pump
components.
m e t I m e t I m e t I m e t I m e t I n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t p i r c s e D n o i t c A n o i t c A n o i t c A n o i t c A n o i t c A
. g n i t t e s S L k c e h C . y t i l i b a t s n i e s u a c y a m g n i t t e s S L w o L
e e S . l e v e l r e p o r p o t g n i t t e s S L t s u j d A
s t n e m t s u j d A . 0 2 e g a p ,
. e n i l l a n g i s S L k c e h C
l l i w e n i l l a n g i s S L d e k c o l B
S L r e p o r p h t i w e r e f r e t n i
. n o i t a r e p o
. e g a k c o l b e v o m e R
C P d n a e v l a v f e i l e r l a n r e t x e k c e h C
. g n i t t e s
l a i t n e r e f f i d e r u s s e r p t n e i c i f f u s n I
l a n r e t x e d n a g n i t t e s C P n e e w t e b
. e v l a v f e i l e r
C P r o e v l a v f e i l e r l a n r e t x e t s u j d A
. l e v e l e t a i r p o r p p a o t s g n i t t e s l o r t n o c
e v o b a e b t s u m g n i t t e s e v l a v f e i l e R
. n o i t a r e p o r e p o r p r o f g n i t t e s C P
. e v l a v f e i l e r l a n r e t x e k c e h C
e v l a v f e i l e r l a n r e t x e g n i r e t t a h C
o t k c a b d e e f e l b a t s n u e s u a c y a m
. l o r t n o c p m u p
. e v l a v f e i l e r e c a l p e r r o t s u j d A
PRESSURE OR FLOW
INSTABILITY (continued)
20 21 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Adjustments Adjustments
PC CONTROL PC setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial
Piston PumpsTechnical Information Manual, BLN-10128, for more information.
Note: Before performing adjustments, read page 14, Pressure measurement, for
recommendations.
A WARNING
Escaping hydraulic fuid
under pressure can have
suffcient force to
penetrate your skin
causing serious injury
and/or infection. Relieve
pressure in the system
before removing hoses,
fttings, gauges, or
components.
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.
CAUTION
Contamination can
damage internal
components and void the
manufacturers warranty.
Take precautions to ensure
system cleanliness when
removing and reinstalling
system lines.
1. Install a pressure gauge in port M2
to measure system pressure. Install a
pressure gauge in case drain port L1
or L2 to measure case pressure. A
2. Start the prime mover and allow
fuid to reach normal operating
temperature. Operate a hydraulic
function to its full extension, loading
the pump at maximum pressure and
zero fow.
3. Loosen the PC set screw and turn
the PC adjustment screw until
the desired setting is indicated
on the pressure gauge at port M2

. Clockwise rotation will increase
pressure, counterclockwise rotation
will decrease; approximate gain =
35 bar [507 psi] per turn.
Note: If the pressure does not increase, an
external system relief valve may require
adjustment. External system relief valve
must be set above the PC setting for proper
operation.
4. While holding the position of the PC
adjustment screw, torque the PC set
screw to 7-11 Nm [6-8 lbfft].
1
P C setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual setting.
Adjustment screw, set screw, and gauge
locations shown
PC control adjustment
P101 652E
PC adjustment screw
6mm
PC set screw
4mm
7-11 Nm [6-8 lbfft]
Case drain port L1
0-10 bar [0-100 psi]
7/8-14
3/8 in
54-136 Nm
[40-100 lbfft]

Gauge port M2
0-300 bar [0-5000 psi]
9/16-18
1/4 in
34-68 Nm
[25-50 lbfft]

M14
6mm
27-35 Nm
[20-26 lbfft]
5. Stop the prime mover, remove the pressure gauges, and return the system to its
normal operating confguration.
20 21 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Adjustments
LS CONTROL The LS setting is indicated in the pump model code. Refer to the Series 45 Open Circuit
Axial Piston Pumps Technical Information Manual, BLN-10128, for more information.
Note: Before performing adjustments, read page 14, Pressure measurement, for
recommendations.
1. Install a pressure gauge in port M2
to measure system pressure. Install
a pressure gauge in drain port L1 or
L2 to measure case pressure. Tee-in
a gauge to the LS / remote PC signal
line (port X). A
2. Start the prime mover and allow fuid
to reach normal operating temperature.
Slowly operate a hydraulic function
which will demand approximately half
fow from the pump, but keep system
pressure below the PC set point.
3. Loosen the LS set screw. While
watching the pressure gauges, turn
the LS adjustment screw until the
desired pressure differential between
port M2 and port X is achieved
1
.
Clockwise rotation will increase
the setting, counterclockwise
rotation will decrease; approximate
gain = 12 bar [170 psi] per turn.
A WARNING
Escaping hydraulic fuid
under pressure can have
suffcient force to
penetrate your skin
causing serious injury
and/or infection. Relieve
pressure in the system
before removing hoses,
fttings, gauges, or
components.
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.
CAUTION
Contamination can
damage internal
components and void the
manufacturers warranty.
Take precautions to ensure
system cleanliness when
removing and reinstalling
system lines.
4. While holding the position of the LS adjustment screw, torque the LS set screw to
7-11 Nm [6-8 lbfft].
5. Operate a hydraulic function to its full extension loading the pump at maximum
pressure and zero fow.
6. Loosen the PC set screw and turn the PC adjustment screw until the desired setting is
indicated on the pressure gauge at port M2
2
. Clockwise rotation will increase pressure,
counterclockwise rotation will decrease; approximate gain = 35 bar [507 psi] per turn.
Note: If the pressure does not increase, an external system relief valve may require adjustment.
External system relief valve must be set above the PC setting for proper operation.
7. While holding the position of the PC adjustment screw, torque the PC set screw to
7-11Nm [6-8 lbfft].
8. Stop the prime mover, remove the pressure gauges, and return the system to its
normal operating confguration.
LS control adjustment
Adjustment screw, set screw, and gauge
locations shown
LS adjustment screw
6mm
P101 636E
LS/remote PC
signal port X
LS set screw
4mm
7-11 Nm [6-8 lbfft]
Case drain port L1
0-10 bar [0-100 psi]
7/8-14
3/8 in
54-136 Nm
[40-100 lbfft]

Gauge port M2
0-300 bar [0-5000 psi]
9/16-18
1/4 in
34-68 Nm
[25-50 lbfft]

M14
6mm
27-35 Nm
[20-26 lbfft]
1
The LS setting is a differential pressure. Subtract pilot pressure at port X from system pressure at port M2 to
compute the actual setting.
2
PC setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual setting.
22 23 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair Minor repair
SHAFT SEAL
REPLACEMENT
A lip type shaft seal is used in the Series 45 open circuit variable pumps. This seal can be
replaced without major disassembly of the unit. Replacement of the shaft seal requires
removal of the pump from the machine.
CAUTION
Premature bearing failure
can result if the shaft seal
contacts the shaft bearing.
Press the seal into the
housing only far enough
to clear the retaining ring
groove.
Removal
1. Using the appropriate snap-ring
pliers, remove the retaining ring
(K010) from the housing.
2. Remove the shaft seal (K020) from
the bore in the pump housing and
discard. Avoid damaging the pump
housing or shaft.
_ Puncture the face of the seal with
a packing hook, or use a slide-hammer
type puller to remove the seal.
Installation
3. Inspect the pump housing and new
Shaft seal and retaining ring
seal for damage. Inspect the sealing area on the shaft for rust, wear, or contamination.
Polish the sealing area on the shaft if necessary.
4. Lubricate the lip of the new shaft seal with clean hydraulic fuid. Place a protective
sleeve over the shaft end to prevent damage to the seal during installation.
5. Keeping the seal perpindicular to the shaft, press the new seal into the housing just
far enough to clear the retaining ring groove. Install seal with the cupped side
toward the shaft bearing. Do not damage the seal during installation.
6. Using the appropriate snap ring pliers, install the seal retaining ring.
7. Remove the installation sleeve.
K010
K020
P101 637

22 23 BLN-10197 520L0532 April 2002

Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
AUXILIARY PADS Auxiliary mounting pads may be installed on pumps equipped with through-drive radial
ported endcaps. Follow these steps to either remove, replace, or exchange auxiliary
mounting pads.
Removal
1. Remove two screws (J130) retaining the cover plate (J110) or auxiliary pump (not
shown). Remove the shipping cover or auxiliary pump and its sealing O-ring (J120).
Discard the O-ring.
2. Remove the drive coupling (J140).
3. Remove the four screws (J100) retaining the pad adapter (J085) to the endcap.
Discard the two pad adapter O-rings (J090, J095).
Installation
4. Lubricate new O-rings with petroleum jelly. Install the pad adapter to the endcap.
5. Install the four screws and torque to 47-61 Nm [35-45 lbfft].
5. Install the drive coupling.
6. Install shipping cover or auxiliary pump with new O-ring.
7. Install two screws (J130) and torque to 37-50 Nm [27-37 lbfft].
Auxiliary mounting pads
CAUTION
Shipping cover is intended
only to retain coupling
during shipment and
storage. Do not operate
pump with coupling and
shipping cover installed.
J095
J090
J120
J110
J085
J140
J140
J085
J120
J110
J095
J090
J100 (4pl.)
8mm
47-61 Nm
[35-45 lbfft]

J085
J095
J100 (4pl.)
8mm
47-61 Nm
[35-45 lbfft]

J130 (2pl.)
Nm
[27-37 lbfft]

9/16 in
37-50
24 25 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
CONTROL Disassembly
1. Remove the four screws (C300)
holding the control housing onto the
end cap.
2. Remove the control and discard the
three interface O-rings (C200).
3. Remove the PC set screw (C102),
PC adjustment screw (C138), O-ring
(C136), springs (C135, C134), and seat
(C133). Discard the O-ring.
4. Remove the plug (C103), O-ring
(C103A), and PC spool (C132) from
the control housing; discard the O-
ring. Note orientation of the spool for
reassembly.
5. Remove the plug (C107) and O-ring
(C107A); discard the O-ring.
Note: For PC only controls, skip steps 6
and 7.
6. Remove the LS set screw (C102),
LS adjustment screw (C118), O-ring
(C116), back-up rings (C117), springs
(C114, C115), and seat (C113); discard
the O-ring.
7. Remove the plug (C106), O-ring
(C106A), and LS spool (C112) from
the control housing; discard the
O-ring. Note orientation of the spool
for reassembly.
C117
C118
6mm

C116
C117
C114
C115
C113
C200

C138
6mm
C136
C135
C134
C133
C132
C103A
C112
C106A
C106
3/16 in
11-14 Nm
[8-10 lbfft]

C103
3/16 in
11-14 Nm
[8-10 lbfft]

C300 (4pl.)
5mm
15-18 Nm
[11-13 lbfft]

C102 (2pl.)
4mm
7-11 Nm
[6-8 lbfft]

P101 667
C107A
C107
3/16 in
11-14 Nm
[8-10 lbfft]

Control assembly
LS control shown; parts C106 and C112 through
C118 are not used on PC control
Inspection
8. Inspect the adjustment screws for wear at the tips and where they contact the
springs; replace as necessary
9. Inspect the springs and spring guides for wear or damage; replace as necessary.
10. Carefully inspect the spools. Ensure the sealing lands are free of nicks and scratches.
Check the ends that contact the spring guides for wear. Replace spools as necessary.
11. Inspect the control housing for damage. Check the spool bores for excessive wear.
12. Clean all parts and lubricate spools, springs, guides and new O-rings with clean
hydraulic fuid.
24 25 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
Reassembly
13. Install the PC spool, spherical end
frst, into the PC bore. The PC spool is
the shorter of the two. Using a new
O-ring, install the plug (C103). Torque
to 11-14 Nm [8-10 lbfft].
14. Place the two PC springs onto the
spring guide and install into the PC
bore. Place a new O-ring onto the PC
adjustment screw and thread it into
the PC bore until fush, then make
another full turn. Install and torque
the set screw to 7-11 Nm [6-8 lbfft].
Note: For PC only controls, skip steps 15
and 16.
15. Install the LS spool, spherical end
frst, into the LS bore. The LS spool is
the longer of the two. Using a new
O-ring, install the plug (C106). Torque
to 11-14 Nm [8-10 lbfft].
16. Place the two LS springs onto the
spring guide and install into the LS
bore. Place a new O-ring and back-
up rings onto the LS adjustment
screw and thread it into the LS bore
until fush, then make another full
turn. Install and torque the set screw
to 7-11 Nm [6-8 lbfft].
17. Using a new O-ring, install the
plug (C107). Torque to 11-14 Nm
[8-10 lbfft].
18. Using petroleum jelly to retain them,
install the three interface O-rings
CONTROL
(continued)
C117
C118
6mm

C116
C117
C114
C115
C113
C200

C138
6mm
C136
C135
C134
C133
C132
C103A
C112
C106A
C106
3/16 in
11-14 Nm
[8-10 lbfft]

C103
3/16 in
11-14 Nm
[8-10 lbfft]

C300 (4pl.)
5mm
15-18 Nm
[11-13 lbfft]

C102 (2pl.)
4mm
7-11 Nm
[6-8 lbfft]

P101 667
C107A
C107
3/16 in
11-14 Nm
[8-10 lbfft]

Control assembly
LS control shown; parts C106 and C112 through
C118 are not used on PC control
(C200) in the recesses on the control housing.
19. Install the control assembly onto the endcap using the four screws (C300). Torque to
15-18 Nm [11-13 lbfft]. Torque screws in a criss-cross pattern and re-torque the frst
screw to ensure proper torque retention.
20. Check and adjust the control setting. See Adjustments, page 20.
26 27 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
PLUG AND FITTING SIZES
AND TORQUES
If any plugs or fttings are removed from the unit during service, install and torque
as indicated here. This drawing is a composite. Your confguration may differ but the
appropriate wrench size and torque can be found here.
Plug locations, sizes, and torques
J041/J043/J044/J046
M14
6mm
27-35 Nm
[20-26 lbfft]

9/16 in
1/4 in
34-68 Nm
[25-50 lbfft]

J080/J081/J082
M18
8mm
41-95 Nm
[30-70 lbfft]

M14
6mm
27-35 Nm
[20-26 lbfft]

J040
(M14)
6mm
27-35 Nm
[20-26 lbfft]

K040
7/8 in
3/8 in
54-136 Nm
[40-100 lbfft]

K045
7/8 in
3/8 in
54-136 Nm
[40-100 lbfft]

P101 642
26 27 BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
BLN-10197 520L0532 April 2002
Series 45 Frame K and L Open Circuit Axial Piston Pumps
Service Manual
Minor repair
NOTES
Sauer-Danfoss Hydraulic Power Systems
Market Leaders Worldwide
Sauer-Danfoss is a comprehensive supplier providing complete
systems to the global mobile market.
Sauer-Danfoss serves markets such as agriculture, construction, road
building, material handling, municipal, forestry, turf care, and many
others.
We offer our customers optimum solutions for their needs and
develop new products and systems in close cooperation and
partnership with them.
Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
total system design.
Sauer-Danfoss provides comprehensive worldwide service for its
products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
Sauer-Danfoss (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sauer-Danfoss (Neumnster) GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
Sauer-Danfoss (Nordborg) A/S
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
www.sauer-danfoss.com
OUR PRODUCTS
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BLN-10197 520L0532 April 2002