Danfoss Series 45 E Frame Service guide
Service Manual
Open Circuit Axial Piston Pumps
Series 45 E Frame
powersolutions.danfoss.com
Service Manual
Series 45 E Frame Open Circuit Pumps
Revision history Table of revisions
Date Changed Rev
September 2016 Replaced the ETL schematic 0401
August 2016 Added displacement limiter adjustments 0301
August 2015 Danfoss Layout 0300
October 2012 add new control types AG
November 2010 new last page AE
February 2010 fix Osaka address AD
March 2008 add displacement limiter specs AC
March 2005 First edition A
2 | © Danfoss | September 2016 AX00000024en-US0401
Service Manual
Series 45 E Frame Open Circuit 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......................................................................................................................................................................... 7
System circuit.....................................................................................................................................................................................8
Technical specifications
General specifications.....................................................................................................................................................................9
Type of mounting....................................................................................................................................................................... 9
Auxiliary mounting pad options............................................................................................................................................9
Control options............................................................................................................................................................................9
Port options...................................................................................................................................................................................9
Direction of rotation...................................................................................................................................................................9
Installation position....................................................................................................................................................................9
Technical specifications............................................................................................................................................................9
Hydraulic parameters................................................................................................................................................................... 11
Inlet pressure..............................................................................................................................................................................11
Pressure compensator valve setting..................................................................................................................................11
Case pressure............................................................................................................................................................................. 11
Hydraulic fluid ...........................................................................................................................................................................11
Temperature range
Fluid viscosity.............................................................................................................................................................................11
Filtration ......................................................................................................................................................................................11
Features
Displacement limiter.....................................................................................................................................................................12
Auxiliary mounting pads.............................................................................................................................................................12
Input shafts.......................................................................................................................................................................................13
Control options...............................................................................................................................................................................13
General......................................................................................................................................................................................... 13
PC control....................................................................................................................................................................................13
LS control.....................................................................................................................................................................................14
Electric Proportional Controls..............................................................................................................................................15
Electric On/Off Controls..........................................................................................................................................................15
Electronic Torque Limiting Controls (ETL).......................................................................................................................16
PLUS+1® Compliance......................................................................................................................................................... 16
Electric Torque Limiting Control Principle................................................................................................................. 16
Pressure measurement
Required tools.................................................................................................................................................................................18
Port locations and gauge installation.....................................................................................................................................18
Initial Start-Up Procedures
General...............................................................................................................................................................................................19
Start-up procedure........................................................................................................................................................................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
(1)
.............................................................................................................................................................11
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Service Manual
Series 45 E Frame Open Circuit Pumps
Contents
Adjustments
PC control..........................................................................................................................................................................................24
LS control.......................................................................................................................................................................................... 26
Displacement Limiters................................................................................................................................................................. 27
Minor repair
Shaft seal replacement.................................................................................................................................................................29
Removal........................................................................................................................................................................................29
Installation...................................................................................................................................................................................29
Auxiliary pads.................................................................................................................................................................................. 30
Removal........................................................................................................................................................................................30
Installation...................................................................................................................................................................................30
LS and PC Controls.........................................................................................................................................................................30
Disassembly................................................................................................................................................................................30
Inspection....................................................................................................................................................................................31
Reassembly................................................................................................................................................................................. 32
Electric Controls..............................................................................................................................................................................34
Disassembly................................................................................................................................................................................34
Inspection....................................................................................................................................................................................34
Reassembly................................................................................................................................................................................. 35
Electronic Torque Limiting Control......................................................................................................................................... 36
Repair............................................................................................................................................................................................ 36
Angle Sensor....................................................................................................................................................................................37
Removal........................................................................................................................................................................................37
Inspection....................................................................................................................................................................................37
Reassembly................................................................................................................................................................................. 38
Servo Control Orifice.....................................................................................................................................................................39
Plug and fitting sizes and torques........................................................................................................................................... 40
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Service Manual
Series 45 E Frame Open Circuit Pumps
Introduction
Overview
This manual includes information for the installation, maintenance, and minor repair of the Series 45
frame E open circuit axial piston pumps. The manual includes a description of the units and their
individual components, troubleshooting information, and minor repair procedures. Performing
installation, maintenance, and minor repair of Series 45 E frame axial piston pumps according to the
procedures in this manual will not affect your warranty.
Performing minor repairs requires the unit to be removed from the vehicle/machine. Thoroughly clean
the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest
enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially
important when changing the system filter and when removing hoses or plumbing.
A worldwide network of Danfoss Authorized Service Centers (ASCs) is available for major repairs. Major
repairs require the removal of the unit’s endcap, which voids the warranty unless done by an ASC.
Danfoss ASCs are trained by the factory and certified on a regular basis. You can locate your nearest ASC
using the distributor locator at www.powersolutions.danfoss.com
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 E Frame Open Circuit 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.
6 | © Danfoss | September 2016 AX00000024en-US0401
LS adjustment
PC adjustment
LS control
(attached to endcap)
P104001E
Piston
Slipper
Swashplate
Tapered
roller
bearing
Bias piston guide
Bias piston
Bias spring
Tapered
roller
bearing
Block
spring
Cylinder block
Valve plate
Input shaft
Shaft seal
Slipper retainer
Servo piston
Servo piston guide
Lifting lug
PC spool
LS spool
Adjustable
displacement
limiter
Service Manual
Series 45 E Frame Open Circuit Pumps
Introduction
General description
Danfoss Series 45 E frame open circuit piston pumps convert input torque into hydraulic power.
Rotational force is transmitted 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 piston and spring. The servo piston
opposes the action of the bias piston and spring forcing the swashplate out of stroke when hydraulic
pressure in the control circuit rises above the spring force.
The pump control, by varying the pressure at the servo piston, controls the displacement of fluid in the
system circuit. Controls designed for Pressure Compensation (PC) or Load Sensing (LS) are available. For a
detailed description of control operation, refer to Control options on page 13.
Pump and control sectional view
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E Frame Series 45
open circuit axial
piston pump with
load sensing control
P104 045E
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
Service Manual
Series 45 E Frame Open Circuit Pumps
Introduction
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 demands while limiting the maximum pressure. Therefore flow and pressure in the
system are compensated to meet requirements.
Full available flow is a function of pump displacement, operating speed, and efficiency. Refer to Series 45
Axial Piston Open Circuit Pumps Technical Information, 520L0519 for details.
Pictorial circuit diagram
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Service Manual
Series 45 E Frame Open Circuit Pumps
Technical specifications
General specifications
Type of mounting
SAE-C mounting flange.
Auxiliary mounting pad options
SAE-A, SAE-B, SAE-B-B, SAE-C, SAE C-C
Control options
PC: Pressure Compensator
LS: Load Sensing (with PC)
Port options
Inlet and system ports:
SAE flanged ports, code 61 Inlet Code 62 outlet.
•
Axial (end) ports or radial (side) ports.
•
All other ports:
SAE straight thread O-ring boss.
•
Direction of rotation
Clockwise or counterclockwise.
Installation position
Installation position is discretionary. To satisfy inlet pressure conditions, it is recommended that the
pump always be located below the lowest level of hydraulic fluid in the reservoir. The housing must
always be filled with hydraulic fluid.
Technical specifications
Features and options
Feature Unit Model
E100B E130B E147C
Maximum Displacement cm³ [in³] 100 [6.10] 130 [7.93] 147 [8.97]
Flow at rated speed (theoretical) l/min
[US gal/min]
Input torque at maximum displacement (theoretical) N•m/bar
[lbf•in/1000 psi]
Mass moment of inertia of internal rotating
components
Weight Axial ports kg [lb] 51.3 [113]
Radial ports 54.9 [121]
Rotation Clockwise, Counterclockwise
Mounting SAE-C
Auxiliary mounting SAE-A, SAE-B, SAE-BB, SAE-C, SAE-CC
System ports (type) 4-bolt split flange
System ports (location) Axial, Radial
Control types PC, Remote PC, LS, LS with internal bleed
kg•m²
[slug•ft²]
245
[64.7]
1.592
[972]
0.0128
[0.0094]
286
[75.6]
2.069
[1263]
0.0128
[0.0094]
309
[81.6]
2.340
[1428]
0.0128
[0.0094]
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Service Manual
Series 45 E Frame Open Circuit Pumps
Technical specifications
Features and options (continued)
Feature Unit Model
E100B E130B E147C
Shafts Splined 13-tooth, 14-tooth, 17-tooth
Straight Ø 38.08 mm [1.5 in]
Displacement limiters Optional, adjustable
Ratings
Rating Units Model
E100B E130B E147C
Input speed¹ minimum min-1 (rpm) 500 500 500
continuous 2450 2200 2100
maximum 2880 2600 2475
Working pressure continuous bar [psi] 310 [4495] 310 [4495] 260 [3770]
maximum 400 [5800] 400 [5800] 350 [5075]
External shaft loads External moment (Me) N•m [lbf•in] 455 [4030] 360 [3190] 396 [3500]
Thrust in (Tin), out (Tout) N [lbf] 2846 [640] 1735 [390] 2113 [475]
Thrust out (Tout) 7740 [1740] 6672 [1500] 7117 [1600]
Bearing life at 140 bar [2030 psi] B10 hours 77 200 32 700 21 600
at 210 bar [3045 psi] 19 800 8400 5500
at 260 bar [3770 psi] 9700 4116 2700
at 310 bar [4495 psi] 5400 2300 —
Mounting flange load
moments
Vibratory (continuous) N•m [lbf•in] 1920 [17 000]
Shock (max) 6779 [60 000]
(1) Input speeds are valid at 1 bar absolute [0 in Hg vac] inlet pressure. See Inlet pressure vs. speed charts
in the Series 45 Technical Information Manual 520L0519.
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Service Manual
Series 45 E Frame Open Circuit Pumps
Technical specifications
Hydraulic parameters
Inlet pressure
Minimum pressure, continuous = 0.8 bar absolute [6.7 inch Hg vac] (at reduced maximum pump speed)
Minimum pressure, cold start = 0.5 bar absolute [15.1 inch Hg vac]
Pressure compensator valve setting
Setting 100 and 130 cc 147 cc
Minimum 100 bar [1450 psi]
Maximum 310 bar [4495 psi] 260 bar [3770 psi]
Case pressure
Maximum continuous: 0.5 bar [7 psi] Above inlet
Intermittent: 2 bar [29 psi] Cold start
Hydraulic fluid
Refer to Danfoss publication Fluids and Filtration BLN-9887 or 520L0463. For information on
biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465. See Fluid and Filter Maintenance
on page 20 for recommended fluid and filter change intervals.
Temperature range
(1)
Intermittent (cold start): - 40° C [- 40° F]
Continuous: 82° C [180° F]
Maximum
(2)
: 104° C [220° F]
(1) Hydraulic fluid viscosity must be maintained within the prescribed limits.
(2) As measured at the hottest point in the system, e.g. drain line.
Fluid viscosity
Viscosity limits
Rating mm2/s (cSt) [SUS]
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 on page 20 for recommended
fluid and filter change intervals.
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P107 779E
P104 046
Service Manual
Series 45 E Frame Open Circuit Pumps
Features
Displacement limiter
Frame E Series 45 pumps are available with an optional adjustable maximum displacement limiter. The
adjustable stop limits the pump’s maximum displacement. The displacement change per turn of the
displacement limiter adjustment screw is shown below.
Setting range
100 cc 40 to 100 cm³ [2.44 to 6.1 in³]
130 cc 70 to 130 cm³ [4.27 to 7.93 in³]
147 cc 87 to 147 cm³ [5.31 to 8.97 in³]
Displacement change
100 cc 8.4 cc/rev [0.513 in³/rev]
130 cc
147 cc
Displacement limiter
Auxiliary mounting pads
Displacement change - older models
100 cc 6.5 cc/rev [0.397 in³/rev]
130 cc
147 cc
Displacement limiter - older models
Auxiliary mounting pads are available for all radial ported Series 45 pumps. These pads are typically used
for mounting auxiliary hydraulic pumps.
Since the auxiliary pad operates under case pressure, you must use an O-ring to seal the auxiliary pump
mounting flange to the pad. Oil from the main pump case lubricates the drive coupling. For details refer
to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519.
12 | © Danfoss | September 2016 AX00000024en-US0401
P104 047
P104 048
1
2
3
Service Manual
Series 45 E Frame Open Circuit Pumps
Features
Auxiliary pad options
Input shafts
Series 45 E frame pumps are available with a variety of splined and straight keyed shafts. For information
on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information 520L0519.
Control options
The Series 45 Frames E have three possible control options, a Load Sensing (LS) control with Pressure
Compensator (PC), a PC only control, or an electric control.
General
The bias piston and spring (1) acts at all times to push the swashplate (2) to maximum angle causing the
pump to stroke. The servo piston (3) acts against the bias piston and spring to reduce the swashplate
angle causing the pump to destroke. Swashplate angle determines pump outlet flow. The pump control,
depending on conditions in the system circuit, sets swashplate angle by metering system pressure to the
servo piston.
Cross-section pump
Bias spring and servo piston set swashplate position
PC control
The PC control design maintains a constant pressure in the hydraulic circuit as flow varies. The PC control
modulates pump flow accordingly to maintain system pressure at the PC setting as the PC adjusting plug
(4) and spring (5) defines.
When system pressure, acting on the non-spring end of the PC spool (6), overcomes the force of the PC
spring, the spool shifts porting system pressure to the servo piston and the swashplate angle decreases.
When system pressure drops below the PC setting, the PC spring shifts the spool in the opposite
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Danfoss | September 2016 AX00000024en-US0401 | 13
P104 049
4
5
6
Load
pressure
Load sense
pressure
System
pressure
Tank
Return
pressure
P101 665E
2
2
Service Manual
Series 45 E Frame Open Circuit Pumps
Features
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).
The LS control consists of two spool valves that connect the servo piston either to pump case or system
pressure. The PC spool (6) controls the pressure-compensating function of the control as previously
described. The LS spool (9) controls the load-sensing function. The PC spool has priority over the LS spool.
Through internal porting, system pressure (upstream of ECV) is applied to the non-spring end of the LS
spool, and through hydraulic line connected at port X, LS pressure (downstream of ECV) is applied to the
spring end. This arrangement allows the LS spool to act on the delta between system pressure and LS
pressure. The LS spring sets the threshold of operation (LS setting).
Because the swashplate is biased to maximum angle, the pump attempts to deliver full flow to the
hydraulic system. When the flow being delivered exceeds demand, the pressure delta across the ECV is
great enough to overcome spring force and shift the LS spool porting system pressure to the servo
piston. The pump de-strokes reducing flow until the delta across the ECV becomes equal to the LS
setting. When flow being delivered is less than demand, the delta across the ECV drops below the LS
setting and the LS spring shifts the spool connecting the servo piston to pump case. The pump strokes
increasing flow until the delta across the ECV becomes equal to the LS setting.
When the external control valve is placed in neutral, it connects the LS signal line to drain. With no LS
pressure acting on the non-spring end of the LS spool, the pump adjusts stroke to whatever position
necessary to maintain system pressure at the LS setting. The pump is now in standby mode.
Because of the series arrangement of the LS and PC spools, the PC spool will override the LS spool. If at
any time system pressure reaches the PC setting, the PC spool will shift blocking the passage that
connects the LS spool with the servo piston and porting system pressure to the servo piston causing the
pump to destroke.
Typical load-sensing control valve
14 | © Danfoss | September 2016 AX00000024en-US0401
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