Danfoss J 45 Service guide

Service Manual

Open Circuit Axial Piston Pumps

Series 45 J Frame

powersolutions.danfoss.com

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
Contents
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

W 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

W 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

W 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

W 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

CAUTION may result in damage to product or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option - either part may exist

Superseded - parts are not interchangeable Measurement required

Flatness specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage Note correct orientation

Mark orientation for reinstallation Torque specification

Press in - press fit

Pull out with tool – press fit

Cover splines with installation sleeve

Pressure measurement/gauge location or specification

The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.

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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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Introduction

Pump and control sectional view

LS control

(attached to endcap)

LS spool

PC spool

LS adjustment

PC adjustment

Bias spring

Servo piston				Slipper
		Piston

		Shaft seal
	Valve plate	Input shaft
	Block
	spring
	Tapered	Tapered
	roller
		roller
	bearing
		bearing

Cylinder block		Swashplate
	Slipper retainer

P104 362

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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Service Manual

Series 45 J Frame Open Circuit Axial Piston Pumps

Introduction

Pictorial circuit diagram

Double-acting cylinder

PVG 32 multi-section load sensing control valve

P104 366E

Bi-directional gear motor

System pressure

Servo pressure

Actuator pressure

Load sense pressure

Actuator return

Suction / case drain / system return

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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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	126.0	137.7	156.0	162.6	180
		[US gal/min]	[33.3]	[36.4]	[41.2]	[42.9]	[47.5]
Input torque at maximum displacement		N•m/bar	0.716	0.811	0.956	1.035	1.193
(theoretical)		[lbf•in/1000 psi]	[436.9]	[495.1]	[583.6]	[631.4]	[728.1]
Mass moment of inertia of internal rotating		kg•m²	0.00455	0.00455	0.00455	0.00433	0.00433
components		[slug•ft²]	[0.00336]	[0.00336]	[0.00336]	[0.00319]	[0.00319]
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
		Tapered	Ø 31.75 mm [1.25 in], 1:8 taper
		Straight	Ø 31.75 mm [1.25 in]
Displacement limiters			Available

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

P104 361

Input shafts

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.

Control options

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

2

1

3

P104 360

Bias spring and servo piston set swashplate position

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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

4

6

5

P104 049

PC spool shifts to port system pressure to servo piston

LS control

The LS control design matches pump flow with system demand. The LS control senses the flow demand of the system as a pressure drop across the External Control Valve (ECV). As the ECV opens and closes, the pressure delta across the valve changes. When opening, the delta decreases. When closing, the delta increases. The LS control then increases or decreases pump flow to the system until the pressure delta becomes equal to the LS setting as defined by the LS adjusting plug (7) and spring (8).

Typical load-sensing control valve

Load	Return
pressure	pressure
	Tank

Load sense	System	P101 665E
pressure	pressure

Pressure drop across external control valve defines system demand

Cross-section LS control

Spring Spring	LS spring
guide
Spool	LS adjusting
Plug	plug

	PC adjusting
Plug	plug

Spool	Spring	Spring
		(PC heavy)
	guide	P104 051

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.

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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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Series 45 J Frame Open Circuit Axial Piston Pumps

Features

Electric On/Off Controls

PLUS+1® Compliance

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

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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