Series 45 Frame E Axial Piston Open Circuit Pump Service Manual
Contents
1. 4 108 13 5Nem cago fS y B 10 Ibf ft 7 EN C113 013 C300 7c O9 e C135 4mm Cl om k 3 E 5 4 7 5Nem 114 8 _C134 4 5 5 lbfeft 11C118B e amp Tlaga o 1384 M c118B gaeli c118 lt E101226 LS control shown parts C104 through C106 and C112 through C118 are not used on PC control 32 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Electric Controls Disassembly 1 Remove four screws C300 2 Remove the control and discard the four O rings C200 3 Remove set screws C102 PC adjusting plug C138 with O ring C138A springs C134 C135 and seat C133 Discard the O ring if it is damaged 4 Remove plug C103 Remove PC spool C132 Note orientation of the spool for reassembly 5 Remove plug G030 and orifice G020 6 Remove LS adjusting plug C118 springs C114 C115 and seat C113 7 Remove plug C104 and spool C112 Note the orientation of the spool for reassembly 8 Remove four screws C151 Remove the manifold C152 and discard the two interface O rings C154 9 For electric proportional controls only Remove the electric control manifold drain orifice C149 10 Remove plug C153 Remove the cartridge valve nut C125 electric solenoid C155 and cartridge valve C150 from the electric control manifold2. Legend B Main pressure line S Suction line L1 L2 Case drain lines X Load sensing pressure port M1 CW endcap system pressure gauge M2 Gauge port for port B M4 Gauge port servo pressure Same pressure 18 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Initial Start Up Procedures General Start up procedure Follow this procedure when starting up a new Series 45 installation or when restarting an installation in which the pump has been removed 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 Prior to installing the pump inspect for damage incurred during shipping Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 1 Connect the pump to the prime mover Ensure that pump shaft is properly aligned with the shaft of the prime mover e 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 fluid Always filter fluid through a 10 micron filter pouring into the reservoir Never reuse hydraulic fluid 3 Fill the main pump housi
3. woe Reservoir P104 045E L E System pressure Ooo Servo pressure Actuator pressure EN Load sense pressure V auctum m eee AR ee Actuator return T Heat exchanger Filter Suction case drain system return 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Technical specifications General specifications Type of mounting SAE C mounting flange Auxiliary mounting pad options SAE A SAE B SAE B B SAE C SAE C C Control options PC Pressure Compensator LS Load Sensing with PC Port options Inlet and system ports SAE flanged ports code 61 Inlet Code 62 outlet 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 recommended that the pump always be located below the lowest level of hydraulic fluid in the reservoir The housing must always be filled with hydraulic fluid Technical specifications Features and options Feature Unit Model E100B E130B
4. sss 14 Electric Proportional Controls 5 Electric On Off Controls scl S Electronic Torque Limiting Controls ETL sscssssecsssessccseccsssecssssssesssecsssssecsssecesssecesssececsueesssusecssnecessueesssneeessneesssnteeses 16 PLUSH COnm pleat CO sneinen inana RE AAA ERATA ERTA G 16 Pressure measurement Required tools ss 18 Port locations and gauge installation sssssscccsssccsssecsssssecsseccssseeessseccssusecssussesssecsssuteccsneesssuecessuecessseeesutecssneesesnecssaseessee 18 Initial Start Up Procedures ec E 19 Start up DIOCOeGU e n RR RUN ERREUR RR EAE ARRO E EN DENES 19 Fluid and Filter Maintenance Recommendations eines mi eoe bo e eee redeo Xd ee AIRE SERPENS 20 Troubleshooting Excessive noise and or VIDFAtION ssssesccccssesssecsssesesconsssssccsssessscessssesccsnseseccesneseseesnsessscessesececsnsessscessesecsesssessecesneeeseesseeeesens 21 Actuator response is sluggish 21 Systemrop r ting hO et Rani e Eow pump output flQWisa cocti titer Oe e tote EAA NN T ATA REE Pressure or flow instability System pressure not reaching PC Setting ecssssscccsscsssssccssecsssssecsssssesssecsssssecssecssssescssnecessueeessscecsuseessnseeccuseessaseeesaneessase 23 Figg im let eU T 23 520L0606 Rev 0300 August 2015 3
5. J140 Some auxiliary A pads S J120 do not have this coupling Installation 1 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 2 Install the 4 screws J100 and torque to 47 5 61 Nem 35 45 Ibf ft 3 Install the drive coupling J140 if present 4 Install shipping cover with seal J120 or auxiliary pump with O ring customer supplied o Caution Shipping cover is intended only to retain coupling during shipment and storage Do not operate pump with coupling and shipping cover installed 5 Install the screws J130 and torque to 94 115 Nem 67 82 Ibf ft If you have an auxiliary A pad install the screws J131 and torque to 37 50 Nem 27 37 Ibf ft 520L0606 Rev 0300 August 2015 29 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair LS and PC Controls Disassembly 1 Remove the 4 screws C300 holding the control housing onto the end cap Remove the control and discard the 4 interface O rings C200 Remove the PC set screw C102 PC adjusting plug C138 O ring C138A springs C134 C135 and seat C133 Discard the O ring 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 For PC only controls skip steps 5 through 7 Remove the plug C105 and O ring C105A or the plug C106 an
6. Service Manual Series 45 E Frame Open Circuit Pumps Contents Adjustments Minor repair PE CONTE m M 24 ESCONO eiie b ssepe tau iu M Eu LA LINE 26 Shaft seal replacement ettet tont e eee iiit a E eee esee pb erre E 28 hcl 28 cla PH 28 PIDIEISSe o t 29 hue ii as Installation LS and PC Controls 30 Disassembly 30 obierit 31 PEGET o e EEA A E AE EAA T 31 Electre GOMER ONS m 33 DVISASSEMIIDLY m ine 33 lere eC M 33 bCEEr qjegenee E E ERS 34 Electronic Torque Limiting Control 35 Repair 35 Angle Sensor 36 Removal 36 Inspection 136 ECET DIY ER 37 Servo Control Orifice ssaa renoier aE Eo oS aa E a SEa OOSA Enans earita EaSI Ta SEARES istata iant 38 Plug anid fitting Sizes and Ores sais csssseccssscassascsssnscecsasaccovsgusnsecgavsscccasdenacesdoasbcavayacanvagsascbsqasanconsdascobngunuscecgsussonsyoonotecgedoeds 39 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Introduction Overvie
7. Cross section PC control P104 049 PC spool shifts to port system pressure to servo piston LS control The LS control design matches pump flow with system demand The LS control senses the flow demand of the system 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 flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjusting plug 7 and spring 8 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 previously described The LS spool 9 controls the load sensing function The PC spool has priority over the LS spool Through internal porting system pressure upstream of ECV is applied to the non spring end of the LS spool and through 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 flow to the hydraulic system When the flow being delivered exceeds demand the pressure
8. 520L0606 Rev 0300 August 2015 35 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Angle Sensor Removal 1 Remove the four sensor housing screws K195 sensor housing K265 and sensor housing O ring K175 2 Remove two locating dowels K185 3 Remove two magnet carrier screws K115 and discard Remove magnet carrier K105 from pump swashplate through housing Screws K115 must be discarded after disassembly Used magnet carrier screws may loosen and lead to premature failure Ensure that new screws with locking compound are utilized During O ring removal from sensor housing be careful not to damage or scratch seal area K265 K195 Right side vA d Se S P108840 Item Description Wrench size Torque K105 Magnet carrier K115 Carrier screws 4 5 Nm 3 35 Ibf ft K175 O ring E K185 Locating dowels K195 Screws 5 9 Nm 4 35 Ibf ft K265 Housing d Inspection 36 520L0606 Rev 0300 August 2015 Zones Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Carefully examine the angle sensor housing for mechanical damages cracks or scratched surfaces Check the angle sensor connector for breaks pin deformation or contamination Check sensor wiring for heat damage scuffing chafing or kinks Check sensor seal area for contamination and surface damage Ud UN Check magnet carrier for
9. Pressure drop across external control valve defines system demand Cross section LS control Spring Spring guide LS spring Spool LS adjusting Plug plug PC adjusting Plug plug Spool t Spring Spring PC heavy guide P104 051 LS spool shifts to port system pressure to servo piston Electric Proportional Controls Plus 1 Compliance All Series 45 Electric controls have met and passed the Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section Electric Proportional Control Principle The Electric Proportional Control consists of a proportional solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at any pressure limit between the Load Sense and Pressure Compensation settings by varying the current sent to the solenoid OC_PropCtr _Je v_ Electric On Off Controls PLUS 1 Compliance All Series 45 Electric controls have met and passed the Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section 520L0606 Rev 0300 August 2015 15 Service Manual Series 45 E Frame Open Circuit Pumps Features Electric On Off Control Princ
10. Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Low LS setting limits output flow Adjust PC and LS setting Refer to the Adjustments chapter Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system to ensure that proper LS signal transmit to pump Internal system leaks Worn internal parts don t allow the pump to operate properly Refer to Authorized Service Center for required repair Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Check external system valving Malfunctioning valving may not allow system to respond properly Repair or replace system valving as required Check pump case pressure High case pressure causes the system to be sluggish Correct case drain line restrictions Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pre
11. Control disassembly C138A P108 668E N 138 Inspection 1 Inspect the adjusting plugs for wear at the tips and where they contact the springs replace as necessary 2 Inspect the springs and spring guides for wear or damage replace as necessary 3 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 4 Inspect the control housing for damage Check the spool bores for excessive wear 5 Remove debris from orifices if necessary Ensure the servo control orifice backup plug is clean and remove debris if necessary 6 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0606 Rev 0300 August 2015 33 Devt Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Reassembly 1 Install the servo control orifice G020 and torque to 2 3 4 Nem 18 30 in lb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 in Ib Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw C138 and thread it into the PC bore until flush then make another full turn
12. Inspect PC spool for wear Wear of PC spool causes internal leakage in the control Replace the spool as required Inspect PC spool for proper orientation Improper orientation results in poor operation Correct orientation of spool Check PC control for contamination Contamination may interfere with movement of the PC spool Clean PC control components take appropriate action to eliminate contamination High inlet vacuum o Caution High inlet vacuum causes cavitation which can damage internal pump components Item Description Action Check fluid temperature Low temperature increases viscosity High fluid viscosity causes high inlet vacuum Allow system to warm up before operating Inspect inlet screen Blocked or restricted inlet screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Too many fittings bends or long piping causes high inlet vacuum Eliminate fittings to make path more direct Hydraulic fluid viscosity above acceptable limits High fluid viscosity causes high inlet vacuum Select fluid with appropriate viscosity for expected operating temperature See Hydraulic Fluids and Lubricants Technical Information Manudl 520L0463 520L0606 Rev 0300 August 2015 23 Service Manual Series 45 E Frame Open Circuit Pumps Adju
13. Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft 4 Install the LS spool C112 spherical end first into the LS bore Install plug C104 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Place the two LS springs C114 C115 onto the spring guide C113 and install into the LS bore Thread adjusting screw C118 into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft Install the electric control manifold drain orifice C149 and torque to 2 3 4 Nem 18 30 inelb 8 Install the cartridge valve C150 into the electric control manifold C152 Torque to 25 8 28 5 N m 12 13 14 15 19 21 Ibf ft DO NOT OVERTORQUE the cartridge valve Install the electric solenoid C155 and solenoid coil nut C125 Torque to 6 8 9 5 Nem 5 7 Ibf ft 10 11 Install plug C153 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Using petroleum jelly to retain them install the two interface O rings C154 in the recesses on the electric control manifold Install the manifold assembly onto the control housing using four screws C151 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque the screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Using petroleum jelly to retain them install the four interface O rings C200 in the recesses on the control housing Ins
14. 396 3500 Thrust in Tin out Tout N Ibf 2846 640 1735 390 2113 475 Thrust out Tout 7740 1740 6672 1500 7117 1600 Bearing life at 140 bar 2030 psi B10 hours 77 200 32 700 21 600 at 210 bar 3045 psi 19 800 8400 5500 at 260 bar 3770 psi 9700 4116 2700 at 310 bar 4495 psi 5400 2300 Mounting flange load Vibratory continuous Nem Ibf in 1920 17 000 moments Shock max 6779 60 000 1 Input speeds are valid at 1 bar absolute 0 in Hg vac inlet pressure See Inlet pressure vs speed charts in the Series 45 Technical Information Manual 520L0519 10 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Technical specifications Hydraulic parameters Inlet pressure Minimum pressure continuous 0 8 bar absolute 6 7 inch Hg vac at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 15 1 inch Hg vac Pressure compensator valve setting Setting 100 and 130 cc 147 cc Minimum 100 bar 1450 psi Maximum 310 bar 4495 psi 260 bar 3770 psi Case pressure Maximum continuous 0 5 bar 7 psi Above inlet Intermittent 2 bar 29 psi Cold start Hydraulic fluid Refer to Danfoss publication Fluids and Filtration BLN 9887 or 520L0463 For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465 See Fluid and Filter Maintenance on page 20 for recommended fl
15. 8 13 5 Nem 8 10 Ibf ft Place the two LS springs C134 C135 onto the spring guide C113 and install into the LS bore Place a new O ring C118A and back up rings C118B onto the LS adjusting screw and thread it into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft 520L0606 Rev 0300 August 2015 31 ones Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 6 Using petroleum jelly to retain them install the 4 interface O rings C200 in the recesses on the control housing 7 Install the control assembly onto the endcap using the 4 screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 lbf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 8 Check and adjust the control setting See Adjustments Control assembly C103 6 5 einch 2610 8 13 5 Nem C104 8 10 Ibfeft 3 6inch Oo C103A 10 8 13 5 Nem L Z 8 10 Ibf ft pow C104A e lt C105 4 C112 d 3Aeinch 7610 8 13 5 Nem 8 10 Ibf ft M C105A C102 Ne a 6 mm g C106 3 jl 2S 9 75 108 Nem 3heinch 205 5 5 8 Ibf ft SG i C106A
16. exchanger and cleaned by a filter before returning to the reservoir The speed of the actuators in the system depends on the volume of fluid 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 flow 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 flow to the system as it demands while limiting the maximum pressure Therefore flow and pressure in the system are compensated to meet requirements Full available flow is a function of pump displacement operating speed and efficiency Refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519 for details l E Frame Series 45 Double acting cylinder open circuit axial I piston pump with load sensing control fPvG32 multi section load sensing 7 35 YD control 7 valve i 4 U f Bi directional gear motor
17. fluid temperature will not allow the pump to fill or control to operate properly Fill the reservoir to proper level Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manudl 520L0463 Check external system relief valve setting Eternal relief valve set below PC setting causes low output flow Adjust external relief valve following manufacturer s recommendation External relief valve setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Adjust PC and LS setting Refer to the Adjustments chapter Check pump inlet pressure vacuum Check input speed High inlet vacuum causes low output flow Low input speeds decrease flow Correct inlet pressure conditions Adjust input speed Check pump rotation Incorrect rotational configuration causes low flow Use pump with appropriate rotational configuration Pressure or flow instability Item Description Action Check for air in system Air in system causes erratic operation Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression Check control spools Sticking control spools cause erratic operation Inspect spools for free movement
18. in bore Clean or replace Check LS setting Low LS setting may cause instability Adjust LS setting to proper level See the Adjustments chapter Check LS signal line Blocked LS signal line interferes with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differential between PC setting and external relief valve Adjust external relief valve or PC control settings to appropriate level Relief valve setting must be above PC setting to operate properly Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace relief valve 22 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Troubleshooting System pressure not reaching PC setting Item Description Action Check PC control setting System pressure will not rise above PC setting Adjust PC to appropriate setting Refer to the Adjustments chapter Check external relief valve External relief valve setting below PC setting presents pressure compensation Adjust external relief valve according to manufacturer s recommendations External relief valve must be set above PC setting to operate properly Inspect PC control spring Broken damaged or missing spring will cause erratic operation Replace the spring as required
19. 0 August 2015 19 Service Manual Series 45 E Frame Open Circuit Pumps Fluid and Filter Maintenance Recommendations To ensure optimum life of Series 45 products perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Water in the fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Change the fluid and filter per the vehicle machine manufacturer s recommendations or at these intervals Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater that the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replace all fluid lost during filter change Fluid and filter change interval Reservoir type Maximum change interval Sealed 2000 hours Breather 500 hours 20 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Fr
20. 130 cc 147 cc 8 4 cc rev 0 513 in rev Displacement limiter f P107 779E Displacement change older models 100 cc 130 cc 147 cc 6 5 cc rev 0 397 in rev Displacement limiter older models Auxiliary mounting pads are available for all radial ported Series 45 pumps These pads are typically used P104 046 for mounting auxiliary hydraulic pumps Since the auxiliary pad operates under case pressure you must use an O ring to seal the auxiliary pump mounting flange to the pad Oil from the main pump case lubricates the drive coupling For details refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519 12 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Features Input shafts Control options Auxiliary pad options jo SE z7 Zs 3 P104 047 Series 45 E frame pumps are available with a variety of splined and straight keyed shafts For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519 The Series 45 Frames E have three possible control options a Load Sensing LS control with Pressure Compensator PC a PC only control or an electric control General The bia
21. 45 E Frame Open Circuit Pumps Minor repair Inspection 1 Inspect the adjusting plugs for wear at the tips and where they contact the springs replace as necessary Inspect the springs and spring guides for wear or damage replace as necessary 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 4 Inspect the control housing for damage Check the spool bores for excessive wear Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid Reassembly 1 Install the PC spool C132 spherical end first into the PC bore Using a new O ring C1034 install the plug C103 Torque the plug C103 to 10 8 13 5 Nem 8 10 Ibf ft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft Install the LS spool C112 spherical end first into the LS bore Using a new O ring C105A or C106A install the plug C105 or C106 Torque the plug C105 or C106 to 10 8 13 5 Nem 8 10 Ibf ft For PC only controls skip steps 15 through 17 4 Using a new O ring C104A install the plug C104 Torque the plug to 10
22. 9 16 inch 95 135 Nem 70 100 Ibfeft P104060 520L0606 Rev 0300 August 2015 39 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors PLUS 1 GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Comatrol www comatrol com Schwarzm ller Inverter www schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 D 24539 Neum nster Germany Phone 49 4321 8710 Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Danfoss Your Strongest Partner in Mobile Hydraulic
23. E147C Maximum Displacement cm in 100 6 10 130 7 93 147 8 97 Flow at rated speed theoretical l min 245 286 309 US gal min 64 7 75 6 81 6 Input torque at maximum displacement theoretical N m bar 1 592 2 069 2 340 Ibf in 1000 psi 972 1263 1428 Mass moment of inertia of internal rotating kg m 0 0128 0 0128 0 0128 components slugeft 0 0094 0 0094 0 0094 Weight Axial ports kg Ib 51 3 113 Radial ports 54 9 121 Rotation Clockwise Counterclockwise Mounting SAE C Auxiliary mounting SAE A SAE B SAE BB SAE C SAE CC System ports type 4 bolt split flange 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Technical specifications Features and options continued Feature Unit Model E100B E130B E147C System ports location Axial Radial Control types PC Remote PC LS LS with internal bleed Shafts Splined 13 tooth 14 tooth 17 tooth Straight 0 38 08 mm 1 5 in Displacement limiters Optional adjustable Ratings Rating Units Model E100B E130B E147C Input speed minimum min 1 rpm 500 500 500 continuous 2450 2200 2100 maximum 2880 2600 2475 Working pressure continuous bar psi 310 4495 310 4495 260 3770 maximum 400 5800 400 5800 350 5075 External shaft loads External moment Me Nem Ibf in 455 4030 360 3190
24. MAKING MODERN LIVING POSSIBLE Denpi Service Manual Open Circuit Axial Piston Pumps Series 45 E Frame powersolutions danfoss com Service Manual Series 45 E Frame Open Circuit Pumps Revision history Table of revisions Date Changed Rev August 2015 Danfoss Layout 0300 October 2012 add new control types AG November 2010 new last page AE February 2010 fix Osaka address AD March 2008 add displacement limiter specs AC March 2005 First edition A 2 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Contents Introduction el 5 Safety precautions 5 Unintended machine movement 5 Flammable cleaning solvents 5 Fluid under pressure 5 Personal safety 5 Symbols used in Danfoss literature eseccssssccssssccsseesssssecssseessssseccsusecssussessnscessueesesusecssuseessusecssusecssuscecsuseessneesesuseessneessueessases 6 eroe rade 7 rie 8 Technical specifications eT Een Te i ooo E Re 9 Type OF MOLI TLIC sasssas ze ccusscctsshccnsssdctes M 9 Auxiliary mounting pad OPTIONS sssssccssesscssseccsssseccsecsssssesssecesssecsssscsssnsecsssseecsuseessaseessssecessseessuseessnseessneeeesuseersaeeessaneets 9 Co
25. ain port L1 0 10 bar 0 145 psi 63 7 8 14 54 136 Nem 40 100 Ibf ft P104054 Gauge port M2 0 300 bar 0 4351 psi 9 16 18 34 68 N m 25 50 Ibf ft Q S I Adjusting plug set screw and gauge locations shown 520L0606 Rev 0300 August 2015 27 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Shaft seal replacement The Series 45 open circuit variable pumps use a lip type shaft seal You can replace this seal without major disassembly of the unit Replacing the shaft seal requires removing the pump from the machine 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 o Caution Don t damage the pump housing or shaft 3 Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal Shaft seal and retaining ring P104055 Installation 1 Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary 2 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during installation 3 Keeping the seal p
26. ame Open Circuit Pumps Troubleshooting Excessive noise and or vibration Item Description Action Check fluid level in reservoir Insufficient hydraulic fluid causes cavitation Fill the reservoir to proper level Check for air in system Air in system causes noisy erratic control Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Improper inlet conditions cause erratic behavior and low output flow Correct pump inlet pressure vacuum conditions Refer to the Hydraulic Parameters topic Inspect shaft couplings A loose or incorrect shaft coupling causes excessive noise and or vibration Repair or replace coupling and ensure that correct coupling is used Check shaft alignment Misaligned shafts create excessive noise and or vibration Correct shaft misalignment Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Actuator response is sluggish Item Description Action Check external system relief valve setting Low external relief valve setting slows down system
27. be limited when pump displacement is known and pump pressure is controlled As pump displacement increases the pump outlet pressure can be limited using the PRV to result in a constant torque limit Pump outlet pressure is equal to the load sense pressure which is limited with the PRV plus the margin pressure setting of the pump Pump Outlet Pressure bar x Pump Displacement T ee 62 8 x Pump Mechanical Ef ficiency 96 520L0606 Rev 0300 August 2015 17 Service Manual Series 45 E Frame Open Circuit Pumps Pressure measurement Required tools The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown Calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges Port locations and gauge installation The illustration below shows gauge port locations Recommended pressure gauges and fittings are in the table Gauge and port information Port Purpose Range of gauge Fitting M1 M2 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting M4 Servo pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting L1 L2 Case drain 0 300 bar 0 5000 psi 1 1 16 12 O ring fitting x1 LS signal 0 300 bar 0 5000 psi 7 16 20 O ring fitting tee into LS signal line Gauge port locations P104 052
28. cracks deformations wearing and for contamination with magnetic particles A Warning A thorough inspection with the angle sensor removed is a strong indicator of pump and hydraulic system contamination and filtration quality Reassembly 1 Using new magnet carrier screws with locking compound K115 install the magnet carrier K105 to pump swashplate through the housing Torque the screws to 4 5 Nm 3 3 Ibf ft A Warning Used magnet carrier screws may loosen and lead to premature failure Ensure that new screws with locking compound are utilized 2 Install the locating dowels K185 into the dowel holes 3 Lubricate new O ring K175 with petroleum jelly Install the O ring to the angle sensor housing K265 first 4 Install angle sensor housing K265 with O ring K175 to housing with 4 screws K195 and torque to 5 9 Nm 4 4 Ibf ft 520L0606 Rev 0300 August 2015 37 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Servo Control Orifice 1 Remove four screws C300 Remove the control and discard the four O rings C200 3 Remove PC plug C103 and PC spool C132 from the control housing Note the orientation of the spool for reassembly Remove backup plug G030 and orifice G020 Install the orifice G020 and torque to 2 3 4 Nem 18 30 in Ib Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb Install
29. d O ring C106A Discard the O ring C105A or C106A Remove the LS set screw C102 LS adjusting plug C118 O ring C118A back up rings C118B springs C114 C115 and seat C113 Discard the C118A O ring Remove the C104 plug C104A O ring and C112 LS spool from the control housing discard the O ring Note orientation of the spool for reassembly Control assembly C103 6 6inch 72 10 8 13 5 Nem C104 8 10 Ibf ft 3heinch 0 C g gt 10 8 13 5 Nem Z 8 10 Ibfeft C104A e di C105 C112 4 9 3A6inch i 7 10 8 13 5 Nem 8 10 Ibf ft C105A J C102 Tti d D cun g C106 S 29 8 2 7 5 10 8 Nem heinch 5 5 8 Ibfeft Ss 10 8 13 5 Nem C99 5 DES M 8 10lbPf E AA 033 Bon m C113 C115 79 qcus 94mm B 2654 7 5 Nem Cdu4 6 amp 4 5 5 bf ft E 0134 C1188 e d C138A llcaigaa e o S c1188 G cus jc lt E101226 LS control shown parts C104 through C106 and C112 through C118 are not used on PC control 30 520L0606 Rev 0300 August 2015 Zonen Service Manual Series
30. ded 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 flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A 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 A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 520L0606 Rev 0300 August 2015 5 Service Manual Series 45 E Frame Open Circuit Pumps Introduction Symbols used in Danfoss literature A EJ ep 4 S Q oO OR WARNING may result in injury CAUTION may result in damage to product or property R
31. 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 flow until the delta across the ECV becomes equal to the LS setting When flow 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 flow 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 destroke Typical load sensing control valve O Load Return pressure pressure Tank a VA EJ Load sense O System pressure pressure P101 665E 14 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Features
32. e 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 1 P C setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 4 While holding the position of the PC adjusting plug torque the PC set screw to 7 5 10 8 Nem 5 5 8 Ibf ft 5 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration Pressure change Control option PC adjustment LS adjustment LS LD LB LE PC RP 42 bar rev 609 PSI rev 17 2 bar rev 250 PSI rev BB BC BP BS 36 bar rev 534 PSl rev AB AC AD AJ AS 8 5 bar rev 123 PSl rev 24 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Adjustments PC control adjustment PC set screw 4mm 7 11 Nem 6 8 Ibf ft ORAO PC adjusting plug Case drain port L1 0 10 bar 0 145 psi 7 8 14 54 136 Nem 40 100 Ibf ft Gauge M2 0 300 bar 0 4351 psi 9 16 28 34 68 Nem 25 50 Ibf ft ol OG P104053 520L0606 Rev 0300 August 2015 25 ones Service Manual Series 45 E Frame Open Circuit Pumps Adjustments LS control The LS setting is indicated in the pump model code Refer to the Series 45 Open Circuit Axial Piston Pumps Tec
33. erpendicular 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 1 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 4 Using the appropriate snap ring pliers install the seal retaining ring 5 Remove the installation sleeve 28 520L0606 Rev 0300 August 2015 Denise Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Auxiliary pads You may install auxiliary mounting pads on pumps equipped with through drive radial ported end caps Follow these steps to either remove replace or exchange auxiliary mounting pads Removal 1 Remove the screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its seal J120 2 Remove the drive coupling J140 if present 3 Remove the 4 screws J100 retaining the pad adapter J080 to the endcap Discard the pad adapter O ring J090 if present Auxiliary mounting pads die 26 47 5 61 Nem 35 45 Ibf ft J130 Finch Nu 2191 111 Nem 3 67 82 Ibfeft S J131 l NG guo O Pain S 76137 50 Nem 27 37 lbfeft P104357
34. eusable part Non reusable part use a new part Non removable item Option either part may exist Superseded parts are not interchangeable Measurement required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port gt B ra S co A D r 9 AE Tip helpful suggestion Lubricate with hydraulic fluid 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 specification Press in press fit Pull out with tool press fit Cover splines with installation sleeve Pressure measurement gauge 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 520L0606 Rev 0300 August 2015 Denpi Service Manual Series 45 E Frame Open Circuit Pumps Introduction General description Danfoss Series 45 E frame open circuit piston pumps convert input torque into hydraulic power Rotational force is transmitted thro
35. hnical Information Manual 520L0519 for more information Before performing adjustments read Pressure measurement 1 Install a pressure gauge in port M1 or 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 Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings 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 o Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 2 Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydraulic function that will demand approximately half flow 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 adjusting plug until the desired pressure differential between port M1 or M2 and port X is achieved 1 Clockwise rotation increases the setting counterclockwise rotation will decrease it approximate gai
36. iple The Electric On Off Control consists of an On Off solenoid integrated into a Remote Pressure Compensated control This control allows the pump to be operated at either the Load Sense pressure setting when On or the Pressure Compensation pressure setting when Off MULT U DN OFF Electronic Torque Limiting Controls ETL PLUS 1 Compliance All Series 45 Electric controls have met and passed the Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section Electric Torque Limiting Control Principle The Electronic Torque Limiting control consists of a normally closed proportional relief valve PRV integrated into a Pressure Compensated Load Sensing control This control operates as a PC LS control with the additional ability to limit load sense pressure using the integrated PRV by varying the current to 16 520L0606 Rev 0300 August 2015 Denpi Service Manual Series 45 E Frame Open Circuit Pumps Features the solenoid When combined with an angle sensor this control allows for a PC LS control with electronic torque limiting x M2 ma P104 025 Pump torque consumption is a function of pump outlet pressure pump displacement and pump mechanical efficiency When pump mechanical efficiency is considered constant the pump torque can
37. n 17 bar 250 psi per turn 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 4 While holding the position of the LS adjusting plug torque the LS set screw to 9 5 Nem 7 Ibf ft 5 Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 26 520L0606 Rev 0300 August 2015 Dont Service Manual Series 45 E Frame Open Circuit Pumps Adjustments 6 Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M2 2 Clockwise rotation increases pressure counterclockwise rotation decreases it approximate gain 42 bar 610 psi per turn 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 2 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 7 While holding the position of the PC adjusting plug torque the PC set screw to 9 5 Nem 7 Ibf ft 8 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration LS control adjustment LS set screw 4 mm 7 5 10 8 Nm 5 5 8 Ibf ft LS adjusting plug 6mm Case dr
38. ng with clean hydraulic fluid Pour filtered 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 fittings and be certain it is free of restrictions and air leaks 5 To ensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at the system pressure gauge port to monitor system pressure during start up Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While watching the pressure gauge installed at the system pressure gauge port jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels minimum 11 bar 160 psi 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 the Troubleshooting chapter 8 Operate the hydraulic system for at least fifteen minutes under light load conditions 9 Check and adjust control settings as necessary after installation Refer to the Adjustments chapter 10 Shut down the prime mover and remove the pressure gauge Replace the plug at port the system pressure gauge port 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 520L0606 Rev 030
39. re in the control circuit rises above the spring force The pump control by varying the pressure at the servo piston controls the displacement of fluid 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 on page 13 Pump and control sectional view LS control attached to endcap LS spool LS adjustment PC spool PC adjustment Lifting lug Servo piston guide Adjustable DS displacement limiter 7 LL Servo piston Slipper retainer Valve plate 1 Shaft seal Cylinder block Input shaft Block L spring Tapered roller M x idis 2 R bearing 7 Swashplate Slipper Bias spring Piston Bias piston PER Bias piston guide 520L0606 Rev 0300 August 2015 7 Devt Service Manual Series 45 E Frame Open Circuit Pumps Introduction System circuit Pictorial circuit diagram The pump receives fluid 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 fluid to the actuators in the system Fluid returning from the system is cooled by a heat
40. ritrol optighis sores tees iiie Dr ere pies tto tee see tet T E eise Eee t ege 9 POPEOP TOMS m C 9 Direction Of err ifo c S 9 IristallatioriposltlODi cnr titor Rave reed ra s ROGA cV a hoc sc eve vis regu OT 9 Technical specifications ecssssccssssccsessssssecsssessccnsecssssecssusecssnseessnecsssuseccsnseessuecessuecessuesesusecssnseeesueccsnsesssueessueeessneesesneeesaneees 9 Hydraulic parameters T1 Inlet pressure sss wel Pressure compensator valve setting 11 Case pressure sse 11 Hydraulic TCHiGh cs sszssccadsdesecaas uceeseanstaetedeuceasaayndenvesccosteecoaqerensvanctuscchqadesiaascst os uegnossancayiiaesugaisodictuasiacsasaerateteansaaschyalecvedsertbescenasnscy 11 Temiperaturetatige eset ied tuna Ei ata eR ina 11 FIA VIS COSIEY MEER 11 Lii T 11 Features Displacement liriiter ardores reset steer eese eive etes retis eet eoa tees copus r eint p ani keen Ped eei 12 Auxiliary mounting pad c 12 Input shafteas saniert ti epe dtr sut Berat i d mea sre gun Meo ed tiere antes tn P E EAE 13 ee ni livoico m 13 ce 13 PE CONTO Mee M 13 LS control
41. s Go to www powersolutions danfoss com for further product information Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Danfoss Power Solution representative nearest you Local address Danfoss Power Solutions Trading Danfoss Danfoss Shanghai Co Ltd Power Solutions GmbH amp Co OHG Power Solutions ApS Building 22 No 1000 Jin Hai Rd Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District DK 6430 Nordborg Denmark Phone 45 7488 2222 Shanghai China 201206 Phone 86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 520L0606 Rev 0300 August 2015 www danfoss com Danfoss A S 2015
42. s piston and 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 piston and spring to reduce the swashplate angle causing the pump to destroke Swashplate angle determines pump outlet flow The pump control depending on conditions in the system circuit sets swashplate angle by metering system pressure to the servo piston Cross section pump P104 048 Bias spring and servo piston set swashplate position PC control The PC control design maintains a constant pressure in the hydraulic circuit as flow varies The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as the PC adjusting plug 4 and spring 5 defines 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 520L0606 Rev 0300 August 2015 13 Devt Service Manual Series 45 E Frame Open Circuit Pumps Features 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
43. ssure conditions System operating hot Item Check fluid level in reservoir Description Insufficient volume of hydraulic fluid will not meet cooling demands of system Action Fill reservoir to proper level Verify proper size of reservoir Inspect heat exchanger Check air flow and input air temperature for the heat exchanger Insufficient air flow high input air temperature or undersized heat exchanges will not meet cooling demands of the system Clean repair or replace heat exchanger as required Verify proper size of heat exchanger 520L0606 Rev 0300 August 2015 21 ZDonfsi Service Manual Series 45 E Frame Open Circuit Pumps Troubleshooting Item Description Action Check external system relief valve setting Fluid passing through relief valve adds heat to system Adjust external system relief valve setting following manufacturer s recommendations External relief valve setting must be above PC setting for proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions Low pump output flow Item Description Action Check fluid level in reservoir Hydraulic fluid viscosity above acceptable limits Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Fluid viscosity above acceptable limits or low
44. stments PC control PC setting is indicated in the pump model code Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual 520L0519 for more information Before performing adjustments read Pressure measurement 1 Install a pressure gauge in port M1 or M2 to measure system pressure Install a pressure gauge in case drain port L1 or L2 to measure case pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings 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 manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 2 Start the prime mover and allow fluid to reach normal operating temperature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 3 Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M1 or M2 1 Clockwise rotation increases pressure counterclockwise rotation decreases approximate gain 42 bar 610 psi per turn If th
45. tall the control assembly onto the endcap using the four screws C300 Torque the screws to 5 4 7 5 N m A 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Check and adjust the control setting See Adjustments 34 520L0606 Rev 0300 August 2015 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Electronic Torque Limiting Control Repair Disassembly inspection and reassembly steps are the same as the steps in the previous topic Electric Controls This includes repair of the spools and plugs The solenoid C155 nut QC125 and O rings QC120 for the valve are available as separate repair parts The valve is only available as a complete assembly QC150 If it is necessary to remove the orifice H020 use a 3 mm internal hex wrench Torque it to 2 7 Nm 24 in Ib when it is installed in the manifold Included in overhaul seal kit Q210 P108790 Item Description Wrench size Torque C149 Orifice 3mm internal hex 2 7 Nm 24 in Ib C151 Screws 6 4 Nm 4 7 Ibf ft C152 Manifold C153 Plug 5mm internal hex 12 Nm 8 9 Ibf ft C154 O ring C155 Solenoid C200 O rings C300 Screws 6 4 Nm 4 7 Ibf ft QC120 O rings QC125 Nut 8 7 Nm 6 4 Ibf ft QC150 Valve assembly 27 7 Nm 20 4 Ibf ft H020 Manifold orifice 3mm internal hex 2 7 Nm 24 in lb
46. the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Using petroleum jelly to retain them install the four O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 lbf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Control assembly P108 669E 38 520L0606 Rev 0300 August 2015 ouf Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Plug and fitting sizes and torques If any plugs or fittings are removed from the unit during service install and torque as indicated here This drawing is a composite Your configuration may differ but here is the appropriate wrench size and torque Plug locations sizes and torques K040 1 1 16 inch 9 16 inch S 95 135 Nem CD 70 100 Ibfeft L020 3 4 inch 9 5 16 inch z 41 95 Nem 30 70 Ibf ft 9 16 inch 1 4 inch Bic Z 20 5 27 Nem J041 15 20 Ibfeft i i K amp T J042 9 9 16 inch 9 16 inch 6 1 4 inch 1 4 inch Z 36 50 Nem 20 5 27 Nem 27 37 Ibf ft 15 20 Ibf ft K070 amp 69 1 1 16 inch 9
47. ugh 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 fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit A small amount of fluid 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 fluid to the reservoir The volume of fluid 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 piston and spring The servo piston opposes the action of the bias piston and spring forcing the swashplate out of stroke when hydraulic pressu
48. uid and filter change intervals Temperature range Intermittent cold start 40 C 40 F Continuous 82 C 180 F Maximum 104 C 220 F 1 Hydraulic fluid viscosity must be maintained within the prescribed limits 2 As measured at the hottest point in the system e g drain line Fluid viscosity Viscosity limits Rating mm2 s cSt SUS v continuous minimum 9 58 maximum 110 500 v intermittent minimum 6 4 47 maximum cold start 1000 4700 Filtration Required cleanliness level ISO 4406 Class 18 13 or better Refer to 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 Filter Maintenance on page 20 for recommended fluid and filter change intervals 520L0606 Rev 0300 August 2015 11 Service Manual Series 45 E Frame Open Circuit Pumps Features Displacement limiter Auxiliary mounting pads Frame E Series 45 pumps are available with an optional adjustable maximum displacement limiter The adjustable stop limits the pump s maximum displacement The displacement change per turn of the displacement limiter adjustment screw is shown below Setting range 100 cc 40 to 100 cm 2 44 to 6 1 in 130 cc 70 to 130 cm 4 27 to 7 93 in 147 cc 87 to 147 cm 5 31 to 8 97 in Displacement change 100 cc
49. w Safety precautions This manual includes information for the installation maintenance and minor repair of the Series 45 frame E open circuit axial piston pumps The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures Performing installation maintenance and minor repair of Series 45 E frame axial piston pumps according to the procedures in this manual will not affect your warranty Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance 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 filter and when removing hoses or plumbing A worldwide network of Danfoss Authorized Service Centers ASCs is available for major repairs Major repairs require the removal of the unit s endcap which voids the warranty unless done by an ASC Danfoss ASCs are trained by the factory and certified on a regular basis You can locate your nearest ASC using the distributor locator at www powersolutions danfoss com Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take these general precautions whenever servicing a hydraulic system Unintended machine movement A Warning Uninten
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