Service Manual
Open Circuit Axial Piston Pumps
Series 45 F Frame
powersolutions.danfoss.com
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
Service Manual
Series 45 F Frame Open Circuit Axial Piston Pumps
Contents
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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Danfoss | September 2016 AX00000008en-US0206 | 3
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
4 | © Danfoss | September 2016 AX00000008en-US0206
W
W
W
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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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Danfoss | September 2016 AX00000008en-US0206 | 5
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
6 | © Danfoss | September 2016 AX00000008en-US0206
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
t
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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Danfoss | September 2016 AX00000008en-US0206 | 7
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.
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
1
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.
8 | © Danfoss | September 2016 AX00000008en-US0206
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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Danfoss | September 2016 AX00000008en-US0206 | 9
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
1
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
1
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
10 | © Danfoss | September 2016 AX00000008en-US0206
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
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
2
- 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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Danfoss | September 2016 AX00000008en-US0206 | 11
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.
12 | © Danfoss | September 2016 AX00000008en-US0206
P106 261E
1
2
3
4
P104 049
4
5
6
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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Danfoss | September 2016 AX00000008en-US0206 | 13
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
Plug
Spool
Spring
guide
Spring
(PC heavy)
P104 051
6
8
9
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.
14 | © Danfoss | September 2016 AX00000008en-US0206
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.
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
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.
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Danfoss | September 2016 AX00000008en-US0206 | 15
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