Danfoss 45 F Service guide

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Service Manual

Open Circuit Axial Piston Pumps

Series 45 F Frame

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Revision history Table of revisions

Date Changed Rev

September 2016 Added displacement limiter adjustments 0206

June 2016 Fix references to TI Manual 0205

June 2016 edits to Fan Drive Control 0204

March 2016 add Fan Drive Control 0203

September 2014 add ETL and angle sensor BB

August 2014 Danfoss layout BA

October 2012 add electric controls AF

November 2010 new back page AE

February 2010 Fix Osaka address AD

July 2009 Add Pressure change - PC adjustment specs AC

September 2007 minor edits and corrections AB

November 2006 First edition AA

2 | © Danfoss | September 2016 AX00000008en-US0206

Page 3

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Introduction

Overview..............................................................................................................................................................................................5

Safety precautions............................................................................................................................................................................5

Warranty.............................................................................................................................................................................................. 6

Symbols used in Danfoss literature............................................................................................................................................6

General description......................................................................................................................................................................... 6

System circuit.....................................................................................................................................................................................7

Technical specifications

General specifications.....................................................................................................................................................................9

Type of mounting....................................................................................................................................................................... 9

Auxiliary mounting pad options............................................................................................................................................9

Control options............................................................................................................................................................................9

Port options...................................................................................................................................................................................9

Direction of rotation...................................................................................................................................................................9

Installation position....................................................................................................................................................................9

Technical specifications............................................................................................................................................................9

Hydraulic parameters................................................................................................................................................................... 10

Inlet pressure..............................................................................................................................................................................10

Pressure compensator valve setting..................................................................................................................................10

Case pressure............................................................................................................................................................................. 10

Hydraulic fluid ...........................................................................................................................................................................11

Temperature range..................................................................................................................................................................11

Fluid viscosity.............................................................................................................................................................................11

Filtration ......................................................................................................................................................................................11

Features

Displacement limiter.....................................................................................................................................................................12

Auxiliary mounting pads.............................................................................................................................................................12

Input shafts.......................................................................................................................................................................................12

Control options...............................................................................................................................................................................12

General......................................................................................................................................................................................... 12

PC control....................................................................................................................................................................................13

LS control.....................................................................................................................................................................................13

Electric Proportional Controls..............................................................................................................................................14

Electric Proportional Control Principle............................................................................................................................. 15

Electric On/Off Controls..........................................................................................................................................................15

Electric On-Off Control Principle.........................................................................................................................................16

Fan Drive Control (FDC)..........................................................................................................................................................16

PLUS+1 Compliance...........................................................................................................................................................16

Fan Drive Control Principle .............................................................................................................................................17

S45 pump with integrated FDC control schematic.................................................................................................17

Electronic Torque Limiting Controls (ETL).......................................................................................................................17

Pressure measurement

Required tools.................................................................................................................................................................................20

Port locations and gauge installation.....................................................................................................................................20

Initial Start-Up Procedures

General...............................................................................................................................................................................................21

Start-up procedure........................................................................................................................................................................21

Fluid and Filter Maintenance

Recommendations........................................................................................................................................................................ 22

Troubleshooting

Excessive noise and/or vibration..............................................................................................................................................23

Actuator response is sluggish....................................................................................................................................................23

System operating hot...................................................................................................................................................................23

Low pump output flow................................................................................................................................................................24

Pressure or flow instability..........................................................................................................................................................24

System pressure not reaching PC setting............................................................................................................................. 25

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Page 4

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Contents

High inlet vacuum..........................................................................................................................................................................25

Adjustments

PC control..........................................................................................................................................................................................26

FDC Control......................................................................................................................................................................................27

Control Adjustment - F Frame............................................................................................................................................. 28

FDC Control Data......................................................................................................................................................................29

Fan Drive Control pressure setting guidelines...............................................................................................................29

LS control.......................................................................................................................................................................................... 29

Displacement limiter.....................................................................................................................................................................31

Minor repair

Shaft seal replacement.................................................................................................................................................................32

Removal........................................................................................................................................................................................32

Installation...................................................................................................................................................................................32

Auxiliary pads.................................................................................................................................................................................. 32

Removal........................................................................................................................................................................................32

Installation...................................................................................................................................................................................33

LS and PC Controls.........................................................................................................................................................................33

Disassembly................................................................................................................................................................................33

Inspection....................................................................................................................................................................................34

Reassembly................................................................................................................................................................................. 35

Electric Controls..............................................................................................................................................................................36

Disassembly................................................................................................................................................................................36

Inspection....................................................................................................................................................................................36

Reassembly................................................................................................................................................................................. 37

Electronic Torque Limiting Control......................................................................................................................................... 37

Repair............................................................................................................................................................................................ 37

Fan Drive Control........................................................................................................................................................................... 38

Angle Sensor....................................................................................................................................................................................40

Removal........................................................................................................................................................................................40

Inspection....................................................................................................................................................................................41

Installation...................................................................................................................................................................................41

Servo Control Orifice.....................................................................................................................................................................41

Disassembly................................................................................................................................................................................41

Reassembly................................................................................................................................................................................. 42

Plug and fitting sizes and torques........................................................................................................................................... 42

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Page 5

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Introduction

Overview

This manual includes information for the installation, maintenance, and minor repair of the Series 45 Frame F 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 Frame F 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 Global Service Partner Network is available for major repairs. Major repairs require the removal of the unit’s endcap, which voids the warranty unless done by a Global Service Partner. Danfoss Global Service Partners are trained by the factory and certified on a regular basis. You can locate your nearest Global Service Partner using the distributor locator at www.powersolutions.danfoss.com

Safety precautions

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

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

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

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

Warning

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

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Introduction

Warranty

Performing installation, maintenance, and minor repairs according to the procedures in this manual will not affect your warranty. Major repairs requiring the removal of a unit’s endcap voids the warranty unless done by a Danfoss Global Service Partner.

Symbols used in Danfoss literature

WARNING may result in injury Tip, helpful suggestion

CAUTION may result in damage to product or property

Reusable part Apply grease / petroleum jelly

Non-reusable part, use a new part Apply locking compound

Non-removable item Inspect for wear or damage

Option - either part may exist Clean area or part

Superseded - parts are not interchangeable Be careful not to scratch or damage

Measurement required Note correct orientation

Flatness specification Mark orientation for reinstallation

Parallelism specification Torque specification

External hex head Press in - press fit

Internal hex head Pull out with tool – press fit

Torx head Cover splines with installation sleeve

O-ring boss port Pressure measurement/gauge location or

Lubricate with hydraulic fluid

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.

General description

Danfoss Series 45 Frame F open circuit piston pumps convert input torque into hydraulic power. The input shaft transmits rotational force from the prime mover to the cylinder block. Tapered roller bearings support the shaft at the front and rear of the pump. The cylinder block connects to the input shaft through splines on the shaft. 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. The valve plate connects one half of the cylinder block 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 leaks from the cylinder block / valve plate and slipper / swashplate interfaces for lubrication and cooling. Case drain ports return this fluid to the reservoir.

The angle of the swashplate controls the volume of fluid displaced into the system circuit. The bias piston forces the swashplate into an inclined position (into stroke). The servo piston opposes the action of the

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Slipper

LS adjustment

PC adjustment

LS spool

PC spool

LS control (attached to endcap)

Servo piston

Swashplate

Tapered roller bearing

Shaft seal

Tapered roller bearing

Input shaf

Cylinder block

Valve plate

Cylinder block spring

Piston

Slipper retainer

Bias spring

P104 341E

Bias piston

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Introduction

bias piston and 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 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 General on page 12.

Pump and control sectional view

System circuit

The pump receives fluid directly from the reservoir through the inlet line. A screen in the inlet line protects the pump from large contaminants. The pump outlet feeds a PVG-32 multi-section, load sensing, directional control valve. The PVG valve directs pump flow to the cylinder and gear motor. A heat exchanger cools the fluid returning from the valve. A filter cleans the fluid before it returns to the reservoir.

Flow in the circuit determines the speed of the actuators. The position of the PVG valve determines the flow demand. A hydraulic pressure signal (LS signal) communicates demand to the pump control. The pump control monitors the pressure differential between pump outlet and the LS signal, and regulates servo pressure to control the swashplate angle. Swashplate angle determines pump flow.

Actuator load determines system pressure. The pump control monitors system pressure and will decrease

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the swashplate angle to reduce flow if system pressure reaches the PC setting. A system relief valve in the PVG valve acts as a back-up to control system pressure.

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System pressur e

Servo pressur e

Actuator pressur e

Load sense pressur e

Actuator retur n

Suction / case drain / system retur n

Series 45 F Frame open circuit axial piston pump with load sensing control

PVG 32 multi-sec tion load sensing contro l valve

P106 212E

Reser voir

Filter

Heat ex changer

Double-ac ting cylinder

Bi-direc tional gear moto r

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Introduction

Pictorial circuit diagram

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.

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Service Manual

Series 45 F Frame Open Circuit Axial Piston 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, we recommend you locate the pump below the lowest level of hydraulic fluid in the reservoir. The housing must always be filled with hydraulic fluid.

Technical specifications

Features and options

Model F74B F90C

Feature Unit Maximum displacement cm³ [in³] 74 [4.52] 90 [5.49] Flow at rated speed (theoretical) l/min

[US gal/min]

Input torque at maximum displacement (theoretical) N•m/bar

[lbf•in/1000 psi]

Mass moment of inertia of internal rotating components

Weight Axial ports kg [lb] 29 [63]

Radial ports 31.8 [70.1] Rotation Clockwise, Counterclockwise Mounting SAE B 2 blot, SAE-C 4 bolt Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-C System ports (type) 4-bolt split flange System ports (location) Axial, Radial Control types PC, Remote PC, LS, Electric

kg•m² [slug•ft²]

177.6 [46.9]

1.178 [719]

0.00630 [0.00465]

198 [52.3]

1.432 [874]

0.00650 [0.00480]

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Technical specifications

Features and options (continued)

Model F74B F90C

Shafts Splined 14 tooth, 17 tooth

Straight Ø 31.75 mm [1.25 in]

Displacement limiters Optional, adjustable

Ratings

Model G74B G90C

Rating Units Input speed

Working pressure continuous bar [psi] 310 [4495] 260 [3770]

External shaft loads External moment (Me) N•m [lbf•in] 300 [2655]

Bearing life at 140 bar [2030 psi] B10 hours 31 300 17 400

Mounting flange load moments

minimum min-1 (rpm) 500 500 continuous 2400 2200 maximum 2800 2600

maximum 400 [5800] 350 [5075]

Thrust in (Tin), out (Tout) N [lbf] 2900 [650]

at 210 bar [3045 psi] 1110 5700 at 260 bar [3770 psi] 4810 2490 at 310 bar [4495 psi] 3080 1636 Vibratory (continuous) N•m [lbf•in] 3730 [33 000] Shock (maximum) 13 220 [117 000]

Hydraulic parameters

Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs. speed charts.

Inlet pressure

Minimum pressure, continuous = 0.8 bar absolute [6.7 inch Hg vacuum] (at reduced maximum pump speed) Minimum pressure, cold start = 0.5 bar absolute [15.1 inch Hg vacuum]

Pressure compensator valve setting

PC control setting range

Model bar psi

F74B 100–310 1450–4495 F90C 100–260 1450–3770

Case pressure

Maximum continuous: 0.5 bar [7 psi] above inlet Intermittent: 2 bar [29 psi] cold start

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Technical specifications

Hydraulic fluid

Refer to Danfoss publication: Fluids and Filtration 520L0463. For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids, 520L0465. See Fluid and filter maintenance section for recommended fluid and filter change intervals.

Temperature range

Temperature limits

Minimum (intermittent, cold start)

Continuous¹

Maximum

Hydraulic fluid viscosity must be maintained within the prescribed limits.

As measured at the hottest point in the system, e.g. drain line.

Fluid viscosity

- 40° C [- 40° F]

82° C [180° F]

104° C [220° F]

Fluid viscosity limits

Condition mm2/s (cSt) SUS

ν min. continuous 9 58

intermittent 6.4 47

ν max. continuous 110 500

intermittent (cold start) 1000 4700

Filtration

Required cleanliness level: ISO 4406 Class 18/13 or better. Refer to Danfoss publications Fluids and Filtration 520L0463 and Design Guidelines for Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465. See Fluid and filter maintenance section for recommended fluid and filter change

intervals.

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P104 345

P106 262E

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Displacement limiter

Frame F 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 is 6.8 cm³/ turn [0.47 in³/turn] for the F90C and 6.0 cm³/turn [6.1 in³/turn] for the F74B

Displacement limiter

Auxiliary mounting pads

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, 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.

Auxiliary pad options

Input shafts

Series 45 F 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.

Control options

The Series 45 Frame F pumps have two control options, a Load Sensing (LS) control with Pressure Compensator (PC) or a PC only control.

General

The bias piston and spring (1&2) acts at all times to push the swashplate (4) 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.

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P106 261E

P104 049

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Cross-section pump

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) define.

When system pressure, acting on the non-spring end of the PC spool (6), overcomes the force of the PC spring (5), 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.

Cross-section PC control

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).

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Load pressure

Load sense pressure

System pressure

Tank

Return pressure

P101 665E

Spool

Spring guide

Spring

7LS adjusting plug

LS spring

PC adjusting plug

Plug

Spool

Spring guide

Spring (PC heavy)

P104 051

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Typical load-sensing control valve

Pressure drop across external control valve defines system demand

Cross-section LS control

LS spool shifts to port system pressure to servo piston 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 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, thus porting system pressure to the servo piston causing the pump to destroke.

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Electric Proportional Controls

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.

Page 15

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

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.

Electric On/Off Controls

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Page 16

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Electric On-Off Control Principle

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.

Fan Drive Control (FDC)

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 (software) are available on the Danfoss website, within the PLUS+1 Guide section.

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P109019

Legend

B S L1, L2 M2

= Outlet = Inlet = Case drain = System pressure

gauge port

Gain Orifice

Choke Orifice

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Fan Drive Control Principle

The Fan Drive Control is a unique electrically actuated pressure control solution that consists of a normally closed proportional solenoid and one dual diameter spool sliding in the control housing. System pressure acts on an area between the two spool diameters of the spool lands. This hydraulic force is balanced with forces of springs and the solenoid when the spool is in the metering position. When no current is sent to the solenoid it operates the pump at or below the PC setting which is adjusted mechanically with the adjustor screw and lock nut. Increasing the control current proportionally reduces the pump's outlet pressure until a minimum standby pressure is reached.

Control Block 12V and 24V

The minimum system pressure is given by swashplate moments of the pump and by servo system leakages which produce a pressure drop across the control. In addition, fan motor type and fan inertia impact minimum system pressure.

The Normally Closed Fan Drive Control coupled with a microprocessor allows the pump to operate at an infinite range of operating pressures between a minimum system pressure and PC setting.

We recommend that a relief valve be installed in the pump outlet for additional system protection.

Warning

The Fan Drive Control is intended for fan drive systems only! Use in other systems could result in system component damage or unintended machine movement. The Fan Drive Control is not intended to serve at the primary system pressure relief. Loss of the input signal to this control will cause the pump to produce maximum flow.

S45 pump with integrated FDC control schematic

Electronic Torque Limiting Controls (ETL)

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P108781

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

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 (software) 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 the solenoid. When combined with an angle sensor, this control allows for a PC/LS control with electronic torque limiting.

F Frame pump ETL

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 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.

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Features

Danfoss | September 2016 AX00000008en-US0206 | 19

Page 20

P106 263E

Legend

B = Main pressure line S = Suction line L1, L2 = Case drain lines X = Load sensing pressure port M2 = Gauge port for port B M4 = Gauge port — servo pressure

Service Manual

Series 45 F Frame Open Circuit Axial Piston 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

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 pressure 0-10 bar [0-100 psi] 7/8 - 14 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

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Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Initial Start-Up Procedures

General

Follow this procedure when starting-up a new Series 45 installation or when restarting an installation in which the pump has been removed.

Warning

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.

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 fluid. Always filter fluid through a 10 micron filter

pouring into the reservoir. Never reuse hydraulic fluid.

3. Fill the main pump housing 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 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.

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Service Manual

Series 45 F Frame Open Circuit Axial Piston 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

22 | © Danfoss | September 2016 AX00000008en-US0206

Page 23

Service Manual

Series 45 F Frame Open Circuit Axial Piston 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.

Inspect shaft couplings. A loose or incorrect shaft coupling causes

excessive noise and/or vibration.

Check shaft alignment. Misaligned shafts create excessive noise and/or

vibration.

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.

Actuator response is sluggish

Correct pump inlet pressure/vacuum conditions. Refer to the Hydraulic Parameters topic.

Repair or replace coupling and ensure that correct coupling is used.

Correct shaft misalignment.

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.

Item Description Action

Check external system relief valve setting. Low external relief valve setting slows down

system.

Check PC and LS control setting. Low PC setting prevents the pump from

achieving full stroke. Low LS setting limits output flow.

Check LS control signal pressures. Incorrect LS signal will not allow pump to

operate correctly.

Internal system leaks. Worn internal parts don’t allow the pump to

operate properly.

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.

Check external system valving. Malfunctioning valving may not allow system to

respond properly.

Check pump case pressure. High case pressure causes the system to be

sluggish.

Check pump inlet pressure/vacuum. High inlet vacuum causes low output flow. Correct inlet pressure conditions.

Adjust external relief valve setting following manufacturer’s recommendations. External relief setting must be above PC setting to operate properly.

Adjust PC and LS setting. Refer to the Adjustments chapter.

Inspect system to ensure that proper LS signal transmit to pump.

Refer to Authorized Service Center for required repair.

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.

Repair or replace system valving as required.

Correct case drain line restrictions.

System operating hot

Item Description Action

Check fluid level in reservoir. Insufficient volume of hydraulic fluid will not

meet cooling demands of system.

Inspect heat exchanger. Check air flow and input air temperature for the heat exchanger.

Danfoss | September 2016 AX00000008en-US0206 | 23

Insufficient air flow, high input air temperature, or undersized heat exchanges will not meet cooling demands of the system.

Fill reservoir to proper level. Verify proper size of reservoir.

Clean, repair, or replace heat exchanger as required. Verify proper size of heat exchanger.

Page 24

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Troubleshooting

Item Description Action

Check external system relief valve setting. Fluid passing through relief valve adds heat to

system.

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. Insufficient hydraulic fluid will limit output flow

and cause internal damage to pump.

Hydraulic fluid viscosity above acceptable limits. Fluid viscosity above acceptable limits or low

fluid temperature will not allow the pump to fill or control to operate properly.

Check external system relief valve setting. Eternal relief valve set below PC setting causes

low output flow.

Check PC and LS control setting. Low PC setting prevents the pump from

achieving full stroke. Check pump inlet pressure/vacuum. High inlet vacuum causes low output flow. Correct inlet pressure conditions. Check input speed. Low input speeds decrease flow. Adjust input speed. Check pump rotation. Incorrect rotational configuration causes low

flow.

Adjust external system relief valve setting following manufacturer’s recommendations. External relief valve setting must be above PC setting for proper operation.

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 Manual, 520L0463.

Adjust external relief valve following manufacturer’s recommendation. External relief valve setting must be above PC setting to operate properly.

Adjust PC and LS setting. Refer to the Adjustments chapter.

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 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. Check external relief valve and PC setting. Insufficient pressure differential between PC

setting and external relief valve.

Check external relief valve. Chattering external relief valve may cause

unstable feedback to pump control.

Remove blockage.

Adjust external relief valve or PC control settings to appropriate level. Relief valve setting must be above PC setting to operate properly.

Adjust or replace relief valve.

24 | © Danfoss | September 2016 AX00000008en-US0206

Page 25

Service Manual

Series 45 F Frame Open Circuit Axial Piston 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.

Inspect PC control spring. Broken, damaged, or missing spring will cause

erratic operation.

Inspect PC spool for wear. Wear of PC spool causes internal leakage in the

control. 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.

High inlet vacuum

Adjust external relief valve according to manufacturer’s recommendations. External relief valve must be set above PC setting to operate properly.

Replace the spring as required.

Replace the spool as required.

Clean PC control components, take appropriate action to eliminate contamination.

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. Inspect inlet screen. Blocked or restricted inlet screen causes high

inlet vacuum. Check inlet piping. Too many fittings, bends, or long piping causes

high inlet vacuum. Hydraulic fluid viscosity above acceptable limits. High fluid viscosity causes high inlet vacuum. Select fluid with appropriate viscosity for

Allow system to warm up before operating.

Clean screen/remove blockage.

Eliminate fittings to make path more direct.

expected operating temperature. See Hydraulic

Fluids and Lubricants Technical Information Manual, 520L0463.

Danfoss | September 2016 AX00000008en-US0206 | 25

Page 26

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

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 on page 20.

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.

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.

Warning

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 to maximum pressure and zero flow.

3. Loosen the PC set screw and turn the PC adjusting plug until the gauge at port M2 indicates the

desired setting1. Clockwise rotation increases pressure, counterclockwise rotation decreases; 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.

4. While holding the position of the PC adjusting plug, torque the PC set screw to 9 N•m [7 lbf•ft].

PC setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual setting.

26 | © Danfoss | September 2016 AX00000008en-US0206

Page 27

Gauge port M2

0 - 300 bar [0 - 4351 psi]

3/16 in

7/16-20

50 N•m

[37 lbf•ft]

Case drain port L1

0 - 10 bar [0 - 145 psi]

3/8 in

7/8-14

90 N•m

[67 lbf•ft]

LS set screw

4 mm

9 N•m

[7 lbf•ft]

P106 264E

X Port

0-300 bar

[0-5000 psi]

3/16 in

7/16-20

20 N•m

[51 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

5. Stop the prime mover, remove the pressure gauges, and return the system to its normal operating

configuration.

PC control adjustment

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 PSI/rev] AB, AC, AD, AJ, AS 8.5 bar/rev [123 PSI/rev]

FDC Control

FDC 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.

1. Install a pressure gauge in port M1 to measure system pressure. Install a pressure gauge in case drain

port L1 or L2 to measure case pressure.

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

Danfoss | September 2016 AX00000008en-US0206 | 27

mechanism while servicing.

Page 28

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

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. For more details see also pictorial instruction for FDC PC pressure setting (below).

3. Start the test with the PC adjustment screw turned in 3 revolutions from ‘0’ thread engagement. (PC

adjuster fully released - hard stop). FDC Pressure ranges: 100 bar – 310 bar

Low pressure spring set: 100-210 bar

•

3 screw turns from ‘0’ thread engagement, PC pressure is adjusted about 140 bar ± 10 bar

‒

(based on spring free length) ‘0’ thread engagement is equal to about 80-100 bar (based on spring free length)

‒

High pressure spring set: 220-310 bar

•

3 screw turns from ‘0’ thread engagement, PC pressure is adjusted about 240 bar ± 10 bar

‒

(based on spring free length) ‘0’ thread engagement is is equal to about 180-200 bar (based on spring free length)

‒

4. Disconnect Fan Drive Control signal wire from control. Start the prime mover (or vehicle engine) at

maximal allowed speed value and allow fluid to reach normal operating temperature. With the control’s signal wire disconnected, the fan drive pump will operate at the pressure value related to the prime mover (vehicle engine) speed value.

5. Loosen the lock nut and turn the PC adjusting screw until the desired the pressure delta between

gauge at port M1 and gauge at port L1 or L2 is indicated. Clockwise rotation increases pressure setting, counterclockwise rotation decreases; approximate gain 19.1 bar [277 psi] per turn. (PC sett.=p_B – p_case where p_B = outlet pressure and p_case = case pressure ).

Control Adjustment - F Frame

28 | © Danfoss | September 2016 AX00000008en-US0206

Page 29

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

FDC Control Data

Item Description Wrench Size Pressure Torque

M1 Gauge port 1/4 inch internal hex 0-400 bar [0-5801 psi] 24 Nm [17.7 lbf•ft] L1 Case drain port 3/8 inch internal hex 0-10 bar [0-100 psi] 95 Nm [70.0 lbf•ft] Lock Nut - 12 mm - 8.5 Nm [6.3 lbf•ft] Adjusting Screw - 3 mm internal hex - -

Fan Drive Control pressure setting guidelines

LS control

1. Design your system’s fan trim speed to be reached 5 bar below the PC setting

•

The PC function should not regulate maximum fan speed (maximum system pressure) in a normal duty cycle (i

2. This allows the Fan Drive Control’s PC setting to fulfill its safety functionality without altering normal

fan operation

•

The fan trim speed should be reached at Threshold current

•

Refer to the model order code or the designation on your pump’s nametag for your PC setting

3. RDM integral SCR or customer installed system pressure reliefs should have 15 bar minimum

separation from PC setting

•

This is done to prevent possible ‘talking’ between the pumps ‘PC’ function and any other system reliefs

•

Fans should be rated to operate intermittently at the System Relief Valve setting

The LS 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 on page 20

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. Tee-in a gauge to the LS / remote PC signal line (port X).

Warning

Max

> i > i

Threshold

)

Warning

Danfoss | September 2016 AX00000008en-US0206 | 29

Page 30

Gauge port M2

0 - 300 bar [0 - 4351 psi]

3/16 in

7/16-20

50 N•m

[37 lbf•ft]

Case drain port L1

0 - 10 bar [0 - 145 psi]

3/8 in

7/8-14

90 N•m

[67 lbf•ft]

LS set screw

4 mm

9 N•m

[7 lbf•ft]

P106 264E

X Port

0-300 bar

[0-5000 psi]

3/16 in

7/16-20

20 N•m

[51 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

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 M2 and port X is achieved2. Clockwise rotation increases the setting, counterclockwise rotation decreases it; approximate gain = 17 bar [250 psi] per turn.

4. While holding the position of the LS adjusting plug, torque the LS set screw to 9 N•m [7 lbf•ft].

5. Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero

flow.

6. Loosen the PC set screw and turn the PC adjusting plug until the pressure gauge at port M1 or M2

indicates the desired setting3. 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.

7. While holding the position of the PC adjusting plug, torque the PC set screw to 9 N•m [7 lbf•ft].

8. Stop the prime mover, remove the pressure gauges, and return the system to its normal operating

configuration.

LS control adjustment

The LS setting is a differential pressure. Subtract pilot pressure at port X from system pressure at port M2 to compute the actual setting.

PC setting is referenced to case pressure. Subtract case pressure from system pressure to compute the actual setting.

30 | © Danfoss | September 2016 AX00000008en-US0206

Page 31

P104 345

P108 469E

264.2 [10.4]

258.62 [10.18]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Adjustments

Displacement limiter

Series 45 F90C and F74B open circuit pumps are available with an optional adjustable displacement limiter. This adjustable stop limits the pump’s maximum displacement.

Setting range

F90C 45.6 to 90 cm³ [2.78 to 5.49 in³] F74B 34.1 to 74 cm³ [1.92 to 4.52 in³]

Displacement per turn

F90C 6.8 cm³/rev [0.41 in³/rev] F74B 6.1 cm³/rev [0.37 in³/rev]

Displacement limiter cross-section

Danfoss | September 2016 AX00000008en-US0206 | 31

Page 32

K020

K010

E101 254

Service Manual

Series 45 F Frame Open Circuit Axial Piston 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. Puncture the face of

the seal with a packing hook, or use a slide-hammer type puller to remove the seal.

Caution

Don’t damage the pump housing or shaft.

Shaft seal and retaining ring

Auxiliary pads

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 perpendicular 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.

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.

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).

32 | © Danfoss | September 2016 AX00000008en-US0206

Page 33

J095

J140

J080

J120

J110

J080

J140

J095

J110

J120

P106 267E

J080

J100

J120

J110

J130

J140

J095

J130

J100

105 N•m [77 lbf•ft]

55 N•m [40 lbf•ft]

105 N•m [77 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

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.

Installation

1. Lubricate new O-rings (J090 and J095) with petroleum jelly. Install the pad adapter to the endcap.

2. Install the 4 screws (J100 ) and torque to 55 N•m [40 lbf•ft].

3. Install the drive coupling (J140) if present.

4. Install shipping cover or auxiliary pump with seal (J120).

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 105 N•m [77 lbf•ft].

Auxiliary mounting pads

LS and PC Controls

Disassembly

1. Remove the 4 screws (C300) holding the control housing onto the endcap.

2. Remove the control and discard the 4 interface O-rings (C200).

3. Remove the PC set screw (C102), PC adjusting plug (C138), O-ring (C138A), springs (C134, C135), and

seat (C133). Discard the O-ring.

Danfoss | September 2016 AX00000008en-US0206 | 33

Page 34

12 N•m [9 lbf•ft]

6 N•m [5 lbf•ft]

12 N•m [9 lbf•ft]

9 N•m [7 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

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.

For PC only controls, skip steps 5 through 7

5. Remove the plug (C105) and O-ring (C105A), or the plug (C106) and O-ring (C106A). Discard the O-

ring (C105A or C106A).

6. 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 O-ring and backup rings.

7. Remove the plug (C104), O-ring (C104A), and LS spool (C112) from the control housing; discard the O-

ring. Note orientation of the spool for reassembly.

Control assembly

LS control shown; parts C104 through C106 and C112 through C118 are not used on PC control

Inspection

1. Inspect the adjusting plugs for wear at the tips and where they contact the seat; 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. Clean all parts and lubricate spools, springs, guides, and new O-rings with clean hydraulic fluid.

Page 35

12 N•m [9 lbf•ft]

6 N•m [5 lbf•ft]

12 N•m [9 lbf•ft]

9 N•m [7 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Reassembly

1. Install the PC spool (C132), spherical end first, into the PC bore. Using a new O-ring (C103A), install the

plug (C103). Torque the plug (C103) to 12 N•m [9 lbf•ft].

2. 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 9 N•m [7 lbf•ft].

For PC only controls, skip steps 3 through 5.

3. 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 12 N•m [9 lbf•ft].

4. Using a new O-ring (C104A), install the plug (C104). Torque the plug to 12 N•m [9 lbf•ft].

5. Place the two LS springs (C114, C115) 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 9 N•m [7 lbf•ft].

6. Using petroleum jelly to retain them, install 4 new 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 6 N•m [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 section.

Control assembly

LS control shown; parts C104 through C106 and C112 through C118 are not used on PC control

Danfoss | September 2016 AX00000008en-US0206 | 35

Page 36

P108 668E

G020

G030

C200

C102

C103

C132

C112

C104

C300

C125

C155

C150

C149

C154

C152

C151

C113

C115

C133

C135

C114

C118

C134

C138A

C138

C153

Service Manual

Series 45 F Frame Open Circuit Axial Piston 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 manifold.

Control assembly

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.

Page 37

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Reassembly

1. Install the servo control orifice (G020), and torque to 2.7 N•m [24 in•lb]. Then install the orifice backup

plug (G030), and torque to 2.7 N•m [24 in•lb].

2. Install the PC spool (C132), spherical end first, into the PC bore. Install plug (C103). Torque the plug to

12 N•m [8.9 lbf•ft].

3. 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. Install and torque the PC set screw (C102) to 9.6 N•m [7.1 lbf•ft].

4. Install the LS spool (C112), spherical end first, into the LS bore.

5. Install plug (C104). Torque the plug to 12 N•m [8.9 lbf•ft].

6. 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 9.6 N•m [7.1 lbf•ft].

7. Install the electric control manifold drain orifice (C149) and torque to 2.7 N•m [24 in•lb].

8. Install the cartridge valve (C150) into the electric control manifold (C152). Torque to 27.7 N•m [20.4

lbf•ft]. DO NOT OVERTORQUE the cartridge valve.

9. Install the electric solenoid (C155), and solenoid coil nut (C125). Torque to 8.7 N•m [6.4 lbf•ft].

10. Install plug (C153). Torque the plug to 12 N•m [8.9 lbf•ft].

11. Using petroleum jelly to retain them, install the two interface O-rings (C154) in the recesses on the

electric control manifold.

12. Install the manifold assembly onto the control housing using four screws (C151). Torque the screws to

6.4 N•m [4.7 lbf•ft]. Torque the screws in a criss-cross pattern and re-torque the first screw to ensure proper torque retention.

13. Using petroleum jelly to retain them, install the four interface O-rings (C200) in the recesses on the

control housing.

14. Install the control assembly onto the endcap using the four screws (C300). Torque the screws to 6.4

N•m [4.7 lbf•ft]. Torque screws in a criss-cross pattern and re-torque the first screw to ensure proper torque retention.

15. Check and adjust the control setting. See Adjustments section.

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-lb] when it is installed in the manifold.

Danfoss | September 2016 AX00000008en-US0206 | 37

Page 38

P108790

QC125

* Included in overhaul seal kit Q210

C155

QC150

QC120

C154

C149

C151

C152

H020

C153

*C200

C300

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Item Description Wrench size Torque

C149 Orifice 3 mm internal hex 2.7 Nm [24 in-lb] C151 Screws 6.4 Nm [4.7 lbf-ft] C152 Manifold - C153 Plug 5 mm internal hex 12 Nm [8.9 lbf-ft] C154 O-ring - C155 Solenoid - C200 O-rings - C300 Screws 6.4 Nm [4.7 lbf-ft] QC120 O-rings QC125 Nut 8.7 Nm [6.4 lbf-ft] QC150 Valve assembly 27.7 Nm [20.4 lbf-ft] H020 Manifold orifice 3 mm internal hex 2.7 Nm [24 in-lb}

Fan Drive Control

Disassembly

Use the wrench sizes and torques listed in the table.

1. Remove four screws (C300).

2. Remove the control and discard the 4 interface O-rings (C200).

3. Remove the coil plastic nut (QC125 ) Remove the coil.

Remember the correct coil connector orientation.

4. Remove the solenoid cartridge (C120). Remove O-ring (QC120).

5. Remove spring (C124) and spring guide (C123).

6. Remove the pressure limiter adjuster (C128).

7. Remove spring (C125) and spool (C122).

8. Remove plug (C107) and plug (C129).

Page 39

P109024

Left coil orientation

Right coil orientation

C129

H030

*QC120

C124

C123

G020

QC135

QC130

QC125

C300

C107

C122

C125

C128B

C128A

C128

*C200

C120

C128C

* Included in overhaul seal kit

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

9. Remove gain orifice (H030).

10. Remove servo control orifice (G020).

Inspection

1. Inspect the pressure limiter for wear. Check for contamination and damage to the O-rings, replace if

2. Inspect the control housing for damage. Check the spool bores for excessive wear. Remove debris

3. Carefully inspect the spool. Ensure the sealing lands are free of nicks , burrs and scratches. Check the

4. Check the spool for free (smooth) movement in housing bore.

5. Check the orifices (H030 and G020) for contamination, and for cavitation damage.

6. Check the solenoid cartridge for damage, bending, free pin movement.

7. Check the coil for damage Check the plastic plug for contamination.

8. Check the coil connector for contamination or overheat marks, deformation, connector pins are not

9. Check the control o-rings for damage, or cracks and replace if necessary.

10. Clean and lubricate all spools, bores, and seals with a light coating of hydraulic oil.

Item Description Wrench size Torque

G020 Servo control orifice 3 mm internal hex 2.7 N•m [2 lbf•ft] H030 Gain orifice 2,5 mm internal hex 2.7 N•m [2 lbf•ft] C129 Plug 5/16" 1/8“ internal hex 6.2 N•m [4.67 lbf•ft] C107 Plug 7/16" 3/16" internal hex 13.7 N•m [9.9 lbf•ft] C128C Nut 9/16" 17 mm exter hex 23.7 N•m [17.5 lbf•ft] C120 Solenoid cartridge 17 mm exter hex 25.75 N•m [19 lbf•ft] QC125 Coil plastic nut 26 mm 12 pt socket 3.5 N•m [2 lbf•ft] C300 Screws 4 mm internal hex 6.5 N•m [4.75 lbf•ft]

necessary.

from orifices if necessary.

ends that contact the spring guides for wear. Replace the spool if necessary.

damaged or bent, or missing. Replace the coil if necessary.

Danfoss | September 2016 AX00000008en-US0206 | 39

Page 40

Right side

P108791

K100

K110

K170

K260

K190

K180

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Reassembly

1. Install the servo control orifice (G020). Install the gain orifice (H030).

2. Install plugs (C129) and (C107).

3. Install spool (C122) spherical end first, into the spool bore. Install spring (C125).

4. Install the pressure limiter adjuster (C128).

5. Install the spring guide (C123) and spring (C124). Ensure the spring guide is properly seated on the

spools spherical head.

6. Install the solenoid cartridge with its O-ring.

7. Install the coil and O-rings. Ensure that the O-rings are correctly installed. Ensure the coil connector is in right orientation.

8. Install the coil plastic nut (QC125 ).

Use the proper wrench, do not damage the plastic nut.

9. Using petroleum jelly to retain them, install the four interface O-rings (C200) in the recesses on the control housing.

10. Install the control assembly onto the endcap using four screws (C300). Torque screws in a criss-cross

pattern and re-torque the first screw to ensure proper torque retention.

Angle Sensor

Removal

1. Remove the 4 sensor housing screws (K190), sensor housing, and sensor housing O-ring (K175).

2. Remove 2 locating dowels (K180).

3. Remove 2 magnet carrier screws (K110) and discard. Remove magnet carrier (K100) from swashplate

through housing.

Item Description Wrench size Torque

K100 Magnet carrier K110 Carrier screws - 4.5 Nm [3.35 lbf ft]

K170 O-ring - -

Page 41

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Item Description Wrench size Torque

K180 Locating dowels - K190 Screws 5.9 Nm [4.35 lbf ft] K260 Housing - -

Inspection

1. Carefully examine the angle sensor kit (K260) for mechanical damages ,cracks, or scratched surfaces.

2. Check the angle sensor connector for breaks, pin deformation, or contamination.

3. Check sensor wiring for heat damage, scuffing/chafing, or kinks.

4. Check sensor seal area for contamination and surface damage

5. Check magnet carrier (K100) for cracks , deformations, wearing, and for contamination with magnetic

particles

Warning

A thorough inspection with the angle sensor removed is a strong indicator of pump and hydraulic system contamination and filtration quality.

Servo Control Orifice

Installation

1. Using new magnet carrier screws with locking compound (K110) install the magnet carrier (K100) to

pump swashplate through the housing. Torque the screws to 4.5 Nm [3.3 lbf-ft].

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 (K180) into the dowel holes.

3. Lubricate new O-ring (K170) with petroleum jelly. Install the O-ring to the angle sensor housing

(K260) first.

4. Install angle sensor housing with O-ring to housing with 4 screws (K190) and torque to 5.9 Nm [4.4

lbf-ft].

Disassembly

1. Remove four screws (C300).

2. 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.

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Page 42

P108 669E

C103

C132

C300

C200

G020

G030

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

4. Remove backup plug (G030), and orifice (G020).

Control assembly

Reassembly

1. Install the orifice (G020), and torque to 2-3.4 N•m [18-30 in•lb]. Then install the orifice backup plug

(G030), and torque to 2-3.4 N•m [18-30 in•lb].

2. Install the PC spool (C132), spherical end first, into the PC bore. Install plug (C103). Torque the plug to

10.8 - 13.5 N•m [8 - 10 lbf•ft].

3. Using petroleum jelly to retain them, install the four O-rings (C200) in the recesses on the control housing.

4. Install the control assembly onto the endcap using four screws (C300). Torque the screws to 5.4 - 7.5 N•m [4 - 5.5 lbf•ft]. Torque screws in a criss-cross pattern and re-torque the first screw to ensure proper torque retention.

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. Individual pump configurations may be different. The illustration below shows the appropriate wrench size and torque for plugs that may be installed in the pump:

Page 43

120 N•m [155 lbf•ft]

12 N•m [9 lbf•ft]

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Minor repair

Plug locations, sizes, and torques

Danfoss | September 2016 AX00000008en-US0206 | 43

Page 44

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Page 45

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Danfoss | September 2016 AX00000008en-US0206 | 45

Page 46

Service Manual

Series 45 F Frame Open Circuit Axial Piston Pumps

Page 47

Danfoss Power Solutions GmbH & Co. OHG

Krokamp 35 D-24539 Neumünster, Germany Phone: +49 4321 871 0

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Nordborgvej 81 DK-6430 Nordborg, Denmark Phone: +45 7488 2222

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Building #22, No. 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 3418 5200

Products we offer:

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www.hydro-gear.com

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www.daikin-sauer-danfoss.com

Bent Axis Motors

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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.

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Danfoss | September 2016 AX00000008en-US0206