Danfoss J 45 Service guide

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Service Manual

Open Circuit Axial Piston Pumps

Series 45 J Frame

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Revision history Table of revisions

Date Changed Rev

September 2016 Added displacement limiter adjustments 0203

March 2016 add Fan Drive Control 0202

September 2014 add ETL and angle sensor BA

December 2012 AH

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Introduction

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

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

Unintended machine movement..........................................................................................................................................5

Flammable cleaning solvents.................................................................................................................................................5

Fluid under pressure..................................................................................................................................................................5

Personal safety............................................................................................................................................................................. 5

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

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

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

Technical Specifications

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

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

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

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

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

Hydraulic fluid ...........................................................................................................................................................................10

Temperature range..................................................................................................................................................................10

Fluid viscosity.............................................................................................................................................................................10

Filtration ......................................................................................................................................................................................10

Features

Auxiliary mounting pads.............................................................................................................................................................11

Input shafts.......................................................................................................................................................................................11

Control options...............................................................................................................................................................................11

Operation.....................................................................................................................................................................................11

PC control....................................................................................................................................................................................12

LS control.....................................................................................................................................................................................12

Electric Proportional Controls..............................................................................................................................................13

PLUS+1® Compliance......................................................................................................................................................... 13

Electric Proportional Control Principle........................................................................................................................13

Electric On/Off Controls..........................................................................................................................................................14

PLUS+1® Compliance......................................................................................................................................................... 14

Electric On-Off Control Principle....................................................................................................................................14

Fan Drive Control (FDC)..........................................................................................................................................................14

PLUS+1 Compliance...........................................................................................................................................................14

Fan Drive Control Principle .............................................................................................................................................15

S45 pump with integrated FDC control schematic.................................................................................................16

Electronic Torque Limiting Controls (ETL).......................................................................................................................16

Pressure Measurement

Required tools.................................................................................................................................................................................18

Port locations and gauge installation.....................................................................................................................................18

Initial Start-Up Procedures

General...............................................................................................................................................................................................19

Start-up procedure........................................................................................................................................................................19

J Frame pumps with radial endcap....................................................................................................................................19

Fluid and Filter Maintenance

Recommendations........................................................................................................................................................................ 20

Troubleshooting

Excessive noise and/or vibration..............................................................................................................................................21

Actuator response is sluggish....................................................................................................................................................21

System operating hot...................................................................................................................................................................21

Low pump output flow................................................................................................................................................................22

Pressure or flow instability..........................................................................................................................................................22

System pressure not reaching PC setting............................................................................................................................. 23

High inlet vacuum..........................................................................................................................................................................23

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Contents

Adjustments

PC control..........................................................................................................................................................................................24

FDC Control......................................................................................................................................................................................25

Control Adjustment.................................................................................................................................................................26

FDC Control Data......................................................................................................................................................................26

Fan Drive Control pressure setting guidelines...............................................................................................................26

LS control.......................................................................................................................................................................................... 27

Displacement limiter.....................................................................................................................................................................28

Minor Repair

Shaft seal replacement.................................................................................................................................................................30

Auxiliary pads.................................................................................................................................................................................. 31

LS and PC Controls.........................................................................................................................................................................32

Electric Controls..............................................................................................................................................................................35

Electronic Torque Limiting Control......................................................................................................................................... 36

Fan Drive Control........................................................................................................................................................................... 37

Angle Sensor....................................................................................................................................................................................39

Servo Control Orifice.....................................................................................................................................................................40

Servo Control Orifice Disassembly..................................................................................................................................... 40

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

Plug and fitting sizes and torques........................................................................................................................................... 41

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Introduction

Overview

This manual includes information for the installation, maintenance, and minor repair of the Series 45 frame J 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 J frame axial piston pumps according to the procedures in this manual will not affect your warranty.

Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing.

A worldwide network of Danfoss Authorized Service Centers (ASCs) is available for major repairs. Major repairs require the removal of the unit’s endcap, which voids the warranty unless done by an ASC. Danfoss ASCs are trained by the factory and certified on a regular basis. You can locate your nearest ASC using the distributor locator at www.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 J Frame Open Circuit Axial Piston Pumps

Introduction

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 J frame open circuit piston pumps convert input torque into hydraulic power. Rotational force is transmitted through the input shaft to the cylinder block. The input shaft is supported by tapered roller bearings at the front and rear of the pump and is splined into the cylinder block . A lipseal at the front end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one end by a ball joint. The slippers are held to the swashplate by the spring retainer and block spring. The block spring also holds the cylinder block to the valve plate. The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. Via the valve plate, one half of the cylinder block is connected to pump inlet and the other half to pump outlet. As each piston cycles in and out of its bore, fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit. A small amount of fluid is allowed to “leak” from the cylinder block/valve plate and slipper/ swashplate interfaces for lubrication and cooling. Case drain ports are provided to return this fluid to the reservoir.

The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate. The swashplate is forced into an inclined position (into stroke) by the bias spring. The servo piston opposes the action of the bias spring forcing the swashplate out of stroke when hydraulic pressure in the control circuit rises above the spring force.

The pump control, by varying the pressure at the servo piston, controls the displacement of fluid in the system circuit. Controls designed for Pressure Compensation (PC) or Load Sensing (LS) are available. For a detailed description of control operation, refer to Control options.

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LS spool

LS adjustment

PC adjustment

PC spool

Servo piston

Bias spring

Input shaft

Tapered roller bearing

Block spring

Piston

Slipper

Swashplate

Slipper retainer

Shaft seal

LS control (attached to endcap)

Cylinder block

Valve plate

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Introduction

Pump and control sectional view

System circuit

The pump receives fluid directly from the reservoir through the inlet line. A screen placed in the inlet protects the pump from large contaminants. The output of the pump is directed to a PVG-32 multisection load sensing directional control valve which directs fluid to the actuators in the system. Fluid returning from the system is cooled by a heat exchanger and cleaned by a filter before returning to the reservoir.

The speed of the actuators in the system depends on the volume of fluid being provided by the pump. The operating pressure varies depending on actuator load, but is limited to an adjustable maximum setting by the PC section of the pump control and by a system relief valve integrated into the side module of the PVG valve.

The position of the PVG valve sets the demand for flow in the system and communicates this to the pump control by means of a hydraulic signal (load sense signal). The pump will provide as much flow to the system as it demands1 while limiting the maximum pressure. Therefore flow and pressure in the system are compensated to meet requirements.

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P104 366E

System pressure

Servo pressure

Actuator pressure

Load sense pressure

Actuator return

Suction / case drain / system return

Reservoir

Filter

Double-acting cylinder

PVG 32 multi-section load sensing control valve

Bi-directional gear motor

Heat exchanger

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

Service Manual

Series 45 J 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, 520L0676 for details.

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Technical Specifications

General specifications

Features and options

Feature Unit Model

J45B J51B J60B J65C J75C

Maximum Displacement cm³ [in³] 45 [2.75]] 51 [3.11] 60 [3.66] 65 [3.97] 75 [4.58] Flow at rated speed (theoretical) l/min

[US gal/min]

Input torque at maximum displacement (theoretical)

Mass moment of inertia of internal rotating components

Weight Axial ports kg [lb] 23.13 [51]

Radial ports 26.65 [58.8] Rotation Clockwise, Counterclockwise Mounting 2 bolt SAE-B, 4 bolt SAE-C Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-C System ports (type) SAE R-ring boss. 4-bolt split flange System ports (location) Axial, Radial Control types PC, Remote PC, LS, LS with internal bleed Shafts Splined 13-tooth, 14-tooth, 15-tooth

Displacement limiters Available

N•m/bar [lbf•in/1000 psi]

kg•m² [slug•ft²]

Tapered Ø 31.75 mm [1.25 in], 1:8 taper Straight Ø 31.75 mm [1.25 in]

126.0 [33.3]

0.716 [436.9]

0.00455 [0.00336]

137.7 [36.4]

0.811 [495.1]

0.00455 [0.00336]

156.0 [41.2]

0.956 [583.6]

0.00455 [0.00336]

162.6 [42.9]

1.035 [631.4]

0.00433 [0.00319]

180 [47.5]

1.193 [728.1]

0.00433 [0.00319]

Ratings

Rating Units Model

J45B J51B J60B J65C J75C

Input speed¹ minimum min-1 (rpm) 500 500 500 500 500

continuous 2800 2700 2600 2500 2400

maximum 3360 3240 3120 3000 2880 Working pressure maximum bar [psi] 310 [4495] 310 [4495] 310 [4495] 260 [3770] 260 [3770] External shaft loads External moment (Me) N•m [lbf•in] 226 [2000] 226 [2000] 226 [2000] 226 [2000] 226 [2000]

Thrust in (Tin), out (Tout) N [lbf] 2200 [495] 2200 [495] 2200 [495] 2200 [495] 2200 [495] Bearing life at 140 bar [2030 psi] B10 hours 29 712 29 712 29 712 10 755 10 755

at 210 bar [3045 psi] 6834 6834 6834 2474 2474

at 260 bar [3770 psi] 3151 3151 3151 — —

at 310 bar [4495 psi] 1666 1666 1666 — — Mounting flange load

moments

Vibratory (continuous) N•m [lbf•in] SAE-C: 1500 [14 000], SAE-B: 735 [6500]

Shock (max) SAE-C: 5600 [50 000], SAE-B: 2600 [23 000]

1. Continuous input speeds are valid at 1 bar absolute [0 in HG vac] inlet pressure. Maximum input speeds require changing the inlet pressure or reducing pump displacement..

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Technical Specifications

Hydraulic parameters

Inlet pressure

Minimum pressure, continuous = 0.8 bar absolute [6.7 inches Hg vac.] (at reduced maximum pump speed)

Minimum pressure, cold start = 0.5 bar absolute [15.1 inches Hg vac.]

Pressure compensator valve setting

Minimum: 100 bar [1450 psi] Maximum: 310 bar [3770 psi] (depending on displacement) For more information, refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information,

520L0676.

Case pressure

Maximum continuous: 0.5 bar [7 psi] Above inlet Intermittent: 2 bar [29 psi] Cold start

Hydraulic fluid

Refer to Danfoss publication Fluids and Filtration BLN-9887 or 520L0463. For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids, 520L0465. See Fluid and filter maintenance for recommended fluid and filter change intervals.

Temperature range

Hydraulic fluid viscosity must be maintained within the prescribed limits.

Intermittent (cold start): - 40° C [- 40° F] Continuous: 82° C [180° F] Maximum: 104° C [220° F]

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

Fluid viscosity

Viscosity limits

Rating mm2/s (cSt) [SUS]

ν continuous minimum 9 [58]

maximum 110 [500]

ν intermittent minimum 6.4 [47]

maximum (cold start) 1000 [4700]

Filtration

Required cleanliness level: ISO 4406 Class 18/13 or better. Refer to Danfoss publications Fluids and Filtration BLN-9887 or 520L0463 and Design Guidelines for

Selecting and Maintaining the Required Hydraulic Fluid Cleanliness 520L0465. See Fluid and filter

maintenance for recommended fluid and filter change intervals.

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P104 361

P104 360

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Features

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, an O-ring must be used to seal the auxiliary pump mounting flange to the pad. The drive coupling is lubricated by oil from the main pump case. For details refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information, 520L0676.

Auxiliary pad options

Input shafts

Control options

Series 45 J frame pumps are available with a variety of splined, straight keyed, and tapered end shafts. For information on shafts refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information, 520L0676.

The Series 45 Frames J have three possible general control options, a Load Sensing (LS) control with

Pressure Compensator (PC), a PC only control, or an electric control.

Operation

The bias spring (1) pushes against the servo piston (2) which pulls the swashplate (3) to max angle causing the pump to stroke. Internal pressure on the servo piston acts against the bias spring to reduce the swashplate angle causing the pump to destroke. Swashplate angle determines pump outlet flow. The pump control, depending on conditions in the system circuit, sets swashplate angle by metering system pressure to the servo piston.

Cross-section pump

Bias spring and servo piston set swashplate position

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P104 049

Load pressure

Load sense pressure

System pressure

Tank

Return pressure

P101 665E

Spool

Spring guide

Spring

LS adjusting plug

LS spring

PC adjusting plug

Plug

Spool

Spring guide

Spring (PC heavy)

P104 051

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Features

PC control

The PC control design maintains a constant pressure in the hydraulic circuit as flow varies. The PC control modulates pump flow accordingly to maintain system pressure at the PC setting as the PC adjusting plug (4) and spring (5) defines.

When system pressure, acting on the non-spring end of the PC spool (6), overcomes the force of the PC spring, the spool shifts porting system pressure to the servo piston and the swashplate angle decreases. 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).

Typical load-sensing control valve

Pressure drop across external control valve defines system demand

Cross-section LS control

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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.

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Features

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 and porting system pressure to the servo piston causing the pump to destroke.

Electric Proportional Controls

PLUS+1® Compliance

All Series 45 Electric controls have met and passed the Danfoss PLUS+1® compliance standard testing, and as such, this Series 45 control is PLUS+1® compliant. PLUS+1® compliance blocks are available on the Danfoss website, within the PLUS+1 Guide section.

Electric Proportional Control Principle

The Electric Proportional Control consists of a proportional solenoid integrated into a Remote Pressure Compensated control. This control allows the pump to be operated at any pressure limit between the Load Sense and Pressure Compensation settings by varying the current sent to the solenoid.

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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Features

Electric On/Off Controls

PLUS+1® Compliance

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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Service Manual

Series 45 J 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.

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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 J Frame Open Circuit Axial Piston Pumps

Features

S45 pump with integrated FDC control schematic

Electronic Torque Limiting Controls (ETL)

PLUS+1 Compliance

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.

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P108779

(ETL Signal Port)

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Features

J-frame pump with integrated ETL control

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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P104 364

Service Manual

Series 45 J 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.

J Frame pumps with radial endcap do not have an M1 system pressure port. Measure system pressure in the hydraulic system as close to the pump as possible.

Gauge and port information

Port Purpose Range of gauge Fitting

M1 System pressure 0-300 bar [0-5000 psi] 9/16 - 18 O-ring fitting L1, L2 Case drain port 0-10 bar [0-100 psi] 7/8 - 14 O-ring fitting X 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 J 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.

J Frame pumps with radial endcap

J Frame pumps with radial endcap do not have an M1 system pressure port. Measure system pressure in the hydraulic system as close to the pump as possible.

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Service Manual

Series 45 J 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

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Service Manual

Series 45 J 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 AX00000041en-US0203 | 21

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.

Service Manual

Series 45 J 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.

22 | © Danfoss | September 2016 AX00000041en-US0203

Service Manual

Series 45 J 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 AX00000041en-US0203 | 23

PC adjusting plug

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

Case drain port L1

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

Gauge port M1

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

PC set screw

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

P104 365E

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

PC control

PC setting is indicated in the pump model code. Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual, 520L0519, for more information.

Before performing adjustments, read Pressure measurement.

1. Install a pressure gauge in port M1 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.

Caution

Contamination can damage internal components and void the manufacturer’s warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines.

2. Start the prime mover and allow fluid to reach normal operating temperature. Operate a hydraulic

function to its full extension, loading the pump at maximum pressure and zero flow.

3. Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the

pressure gauge at port M1. Clockwise rotation increases pressure, counterclockwise rotation decreases; approximate gain 42 bar [610 psi] per turn.

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

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 7.5 - 10.8 N•m [5.5 - 8

lbf•ft].

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

configuration.

PC control adjustment

24 | © Danfoss | September 2016 AX00000041en-US0203

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

Pressure change

Control option PC adjustment LS adjustment

J Frame 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

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 ).

Danfoss | September 2016 AX00000041en-US0203 | 25

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

Control Adjustment

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

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

Max

> i > i

Threshold

)

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

26 | © Danfoss | September 2016 AX00000041en-US0203

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

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

LS control

The LS setting is indicated in the pump model code. Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual, 520L0519, for more information.

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.

Before performing adjustments, read Pressure measurement.

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

L1 or L2 to measure case pressure. Tee-in a gauge to the LS/remote PC signal line (port X).

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. Slowly operate a

hydraulic function that will demand approximately half flow from the pump, but keep system pressure below the PC set point.

3. Loosen the LS set screw. While watching the pressure gauges, turn the LS adjusting plug until the

desired pressure differential between port M1 and port X is achieved. Clockwise rotation increases the setting, counterclockwise rotation will decrease it; approximate gain = 17 bar [250 psi] per turn.

The LS setting is a differential pressure. Subtract pilot pressure at port X from system pressure at port M1 to compute the actual setting.

4. While holding the position of the LS adjusting plug, torque the LS set screw to 7.5 - 10.8 N•m [5.5-8

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 desired setting is indicated on the

pressure gauge at port M1. Clockwise rotation increases pressure, counterclockwise rotation decreases it; approximate gain = 42 bar [610 psi] per turn.

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

7. While holding the position of the PC adjusting plug, torque the PC set screw to 7.5 - 10.8 N•m [5.5-8

lbf•ft].

Danfoss | September 2016 AX00000041en-US0203 | 27

LS adjusting plug

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

Case drain port L1

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

Gauge port M1

0 - 300 bar [0 - 4351 psi]

9/16-28

34-68 N•m [25-50 lbf•ft]

LS set screw

0 - 300 bar [0 - 4351 psi]

9/16-28

7.5-10.8 N•m [5.5-8 lbf•ft]

P104 367E

LS/ remote PC signal port X

P106 727E

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

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

configuration.

LS control adjustment

Displacement limiter

J Frame open circuit pumps are available with an optional adjustable displacement limiter. This adjustable stop limits the pump’s maximum displacement.

Setting range

J45B 8.4 to 45 cm³ [0.51 to 2.75 in³] J51B 13.7 to 51 cm³ [0.84 to 3.11 in³] J60B 16.8 to 60 cm³ [1.03 to 3.66 in³] J65B 25.4 to 65 cm³ [1.55 to 3.97 in³] J75B 28.4 to 75 cm³ [1.73 to 4.58 in³]

Displacement per turn

J45B 6.2 cm³/rev [0.38 in³/rev] J51B 6.2 cm³/rev [0.38 in³/rev] J60B 6.2 cm³/rev [0.38 in³/rev] J65B 7.2 cm³/rev [0.44 in³/rev] J75B 7.2 cm³/rev [0.44 in³/rev]

Displacement limiter cross-section

28 | © Danfoss | September 2016 AX00000041en-US0203

Displacement limiters are only available for endcap options V and W.

P106 728E

207.12 [8.2]

167.72 [6.6]

146.5 [5.8]

241.65 [9.5]

162.54 [6.4]

Third-angle projection mm [in]

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Adjustments

Danfoss | September 2016 AX00000041en-US0203 | 29

K020

K010

E101 187

Service Manual

Series 45 J 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.

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.

Caution

Don’t damage the pump housing or shaft.

Remove second seal if pump is so equipped. See illustration below.

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

seal.

Shaft seal and retaining ring

4. 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.

5. 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.

6. 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.

Install second seal if pump is so equipped. See illustration below.

7. Using the appropriate snap ring pliers, install the seal retaining ring.

30 | © Danfoss | September 2016 AX00000041en-US0203

K020

K010

E108 672E

K020

J085

J095

J090

J140

J080

J120

J110

J095

J080

J140

J110

J100

J095

J120

J090

J100

J110

J140

J080

J120

J095

J090

J130

3/4 inch

91 - 111 N•m

[67 - 82 lbf•ft]

8 mm

48.5 - 61 N•m

[35 - 45 lbf•ft]

E101 256

J130

/16 inch

38 - 50 N•m [27 - 37 lbf•ft]

8 mm

48.5 - 61 N•m

[35 - 45 lbf•ft]

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

8. Remove the installation sleeve.

Double seal and retaining ring

Auxiliary pads

You may install auxiliary mounting pads on pumps equipped with through-drive radial ported endcaps. Follow these steps to either remove, replace, or exchange auxiliary mounting pads.

1. Remove the screws (J130), retaining the cover plate (J110) or auxiliary pump (not shown). Remove the

shipping cover or auxiliary pump and its seal (J120).

2. Remove the drive coupling (J140) if present.

3. Remove the 4 screws (J100) retaining the pad adapter (J080) to the endcap. Discard the pad adapter

O-ring (J090) if present. Also discard the J095 O-ring.

Auxiliary mounting pads

Danfoss | September 2016 AX00000041en-US0203 | 31

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

4. Lubricate new O-ring (J090) with petroleum jelly. Install the pad adapter to the endcap.

5. Install the 4 screws (J100 ) and torque to 48.5 - 61 N•m [35 - 45 lbf•ft].

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

7. 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.

8. Install the screws (J130) and torque to 94 - 115 N•m [67 - 82 lbf•ft]. If you have an auxiliary A pad,

install the screws (J130) and torque to 37 - 50 N•m [27 - 37 lbf•ft].

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.

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.

32 | © Danfoss | September 2016 AX00000041en-US0203

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 J Frame Open Circuit Axial Piston Pumps

Minor Repair

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.

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.

Danfoss | September 2016 AX00000041en-US0203 | 33

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 J Frame Open Circuit Axial Piston Pumps

Minor Repair

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

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 J 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.

Danfoss | September 2016 AX00000041en-US0203 | 35

Service Manual

Series 45 J 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.

P108790

QC125

* Included in overhaul seal kit Q210

C155

QC150

QC120

C154

C149

C151

C152

H020

C153

*C200

C300

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

Fan Drive Control

Danfoss | September 2016 AX00000041en-US0203 | 37

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}

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).

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 J Frame Open Circuit Axial Piston Pumps

Minor Repair

9. Remove gain orifice (H030).

10. Remove servo control orifice (G020).

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]

Inspection

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

necessary.

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

from orifices if necessary.

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

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

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

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

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.

Right side

P108789

K100

K110

K180

K170

K260

K190

Service Manual

Series 45 J 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 four sensor housing screws (K190), sensor housing (K260), and sensor housing O-ring

(K170).

2. Remove two locating dowels (K180).

3. Remove two magnet carrier screws (K110) and discard. Remove magnet carrier (K100) from pump

swashplate through housing.

Screws (K110) must be discarded after disassembly. Used magnet carrier screws may loosen and lead to premature failure. Ensure that new screws with locking compound are utilized.

During O-ring removal from sensor housing, be careful not to damage or scratch seal area .

Danfoss | September 2016 AX00000041en-US0203 | 39

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

Item Description Wrench size Torque

K100 Magnet carrier K110 Carrier screws - 4.5 Nm [3.35 lbf ft] K170 O-ring - K180 Locating dowels - K190 Screws 5.9 Nm [4.35 lbf ft] K260 Housing - -

Inspection

1. Carefully examine the angle sensor housing 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 for cracks , deformations, wearing, and for contamination with magnetic

particles

Servo Control Orifice

Warning

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

Reassembly

1. Using new magnet carrier screws with locking compound (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 (K260) with O-ring (K170) to housing with 4 screws (K190) and torque to

5.9 Nm [4.4 lbf-ft].

Servo Control Orifice 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.

P108 669E

C103

C132

C300

C200

G020

G030

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

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

Control assembly

Servo Control Orifice Reassembly

1. Install the orifice (G020), and torque to 2.7 N•m [23 in•lb]. Then install the orifice backup plug (G030),

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

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

4. Install the control assembly onto the endcap using four screws (C300). Torque the screws to 6.5 N•m

Plug and fitting sizes and torques

If any plugs or fittings are removed from the unit during service, install and torque as indicated here. This drawing is a composite. Your configuration may differ but here is the appropriate wrench size and torque:

and torque to 2.7 N•m [23 in•lb].

12 N•m [8.9 lbf•ft].

housing.

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

Danfoss | September 2016 AX00000041en-US0203 | 41

J041A

J041

K040

K070A

K070

3/8 inch

55 - 135 N•m

[40 - 100 lbf•ft]

1/4 inch

27 - 47 N•m

[20 - 35 lbf•ft]

K040A

3/8 inch

55 - 135 N•m

[40 - 100 lbf•ft]

E101 257

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Minor Repair

Plug locations, sizes, and torques

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Danfoss | September 2016 AX00000041en-US0203 | 43

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Danfoss | September 2016 AX00000041en-US0203 | 45

Danfoss Power Solutions GmbH & Co. OHG

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

Danfoss Power Solutions ApS

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

Danfoss Power Solutions (US) Company

2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239 6000

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

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www.daikin-sauer-danfoss.com

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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.

We help OEMs around the world speed up system development, reduce costs and bring vehicles to market faster.

Danfoss – Your Strongest Partner in Mobile Hydraulics.

Go to www.powersolutions.danfoss.com for further product information.

Wherever off-highway vehicles are at work, so is Danfoss. We offer expert worldwide support for our customers, ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide comprehensive global service for all of our components.

Please contact the Danfoss Power Solution representative nearest you.

Local address:

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

Danfoss | September 2016 AX00000041en-US0203

Danfoss J 45 Service guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

Overview

Safety precautions

Unintended machine movement

Flammable cleaning solvents

Fluid under pressure

Personal safety

Symbols used in Danfoss literature

General description

System circuit

Technical Specifications

General specifications

Hydraulic parameters

Inlet pressure

Pressure compensator valve setting

Case pressure

Hydraulic fluid

Temperature range

Fluid viscosity

Filtration

Features

Auxiliary mounting pads

Input shafts

Control options

Operation

PC control

LS control

Electric Proportional Controls

PLUS+1® Compliance

Electric Proportional Control Principle

Electric On/Off Controls

PLUS+1® Compliance

Electric On-Off Control Principle

Fan Drive Control (FDC)

PLUS+1 Compliance

Fan Drive Control Principle

S45 pump with integrated FDC control schematic

Electronic Torque Limiting Controls (ETL)

Pressure Measurement

Required tools

Port locations and gauge installation

Initial Start-Up Procedures

General

Start-up procedure

J Frame pumps with radial endcap

Fluid and Filter Maintenance

Recommendations

Troubleshooting

Excessive noise and/or vibration

Actuator response is sluggish

System operating hot

Low pump output flow

Pressure or flow instability

System pressure not reaching PC setting

High inlet vacuum

Adjustments

PC control

FDC Control

Control Adjustment

FDC Control Data

Fan Drive Control pressure setting guidelines

LS control

Displacement limiter

Minor Repair

Shaft seal replacement

Auxiliary pads

LS and PC Controls

Electric Controls

Electronic Torque Limiting Control

Fan Drive Control

Angle Sensor

Servo Control Orifice

Servo Control Orifice Disassembly

Servo Control Orifice Reassembly

Plug and fitting sizes and torques