Danfoss Series 45 Service Manual
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Danfoss Series 45 Service Manual

Open circuit axial piston pumps frame k and l
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Open Circuit Axial Piston Pumps
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Summary of Contents for Danfoss Series 45

  • Page 1 Service Manual Open Circuit Axial Piston Pumps Series 45 Frame K and L powersolutions.danfoss.com...
  • Page 2 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Revision history Table of revisions Date Changed August 2016 Updated tables and Adjustments chapter 0401 April 2016 minor deits - Engineering Tomorrow 0301 October 2014 updates for DITA CMS...

  • Page 3: Table Of Contents

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Contents Introduction Using this manual.....................................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 The system circuit.....................................7...
  • Page 4 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Contents Minor repair Shaft seal replacement.................................26 Auxiliary pads....................................26 LS and PC Controls..................................28 Electric Controls....................................30 Servo Control Orifice..................................32 Plug and fitting sizes and torques............................32 520L0532 | AX00000040en-US0401 ©...

  • Page 5: Using This Manual

    A worldwide network of Danfoss Authorized Service Centers (ASCs) is available should major repairs be needed. Contact any Danfoss ASC for details. A list of all ASCs can be found in bulletin BLN-2-40527, or in brochure SAW (Ident. No. 698266), or you can locate your nearest ASC using the distributor locator at http://www.powersolutions.danfoss.com...

  • Page 6: Symbols Used In Danfoss Literature

    The legend above defines each symbol and explains its purpose. General description Danfoss Series 45 K and L 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 .

  • Page 7: The System Circuit

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Introduction Pump and control sectional view LS control (attached to endcap) LS adjustment screw LS spool PC adjustment screw PC spool Swashplate Bias spring Servo piston Tapered roller bearing...
  • Page 8 Suction / case drain / system return P101 658E Full available flow is a function of pump displacement, operating speed, and efficiency. Refer to Series 45 Axial Piston Open Circuit Pumps Technical Information, BLN-10128 for details. 520L0532 | AX00000040en-US0401 ©...

  • Page 9: Technical Specifications

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Technical specifications General specifications Type of mounting SAE-B mounting flange. Auxiliary mounting pad options SAE-A, SAE-B, or SAE-B-B Control options PC: Pressure Compensator LS: Load Sensing (with PC)

  • Page 10: Hydraulic Parameters

    (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.

  • Page 11: Features

    P101 661 Input shafts Series 45 K and L frame pumps are available with a variety of splined, straight keyed, and tapered end shafts. For information on shafts refer to Series 45 Axial Piston Open Circuit Pumps Technical Information BLN-10128.
  • Page 12 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Features Cross-section pump: Bias spring and servo piston set swashplate position PC control The PC control is designed to maintain 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 defined by the PC adjustment screw (4) and spring (5).
  • Page 13 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Features Typical load-sensing control valve:Pressure drop across external control valve defines system demand Load Return pressure pressure Tank Load sense System pressure pressure P101 665E Cross-section LS control: LS spool shifts to port system pressure to servo piston...

  • Page 14: Electronic Controls

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Features Electronic 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 ®...
  • Page 15 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Features Electric On-Off Control Principle The Electric On/Off Control consists of an On/Off solenoid integrated into a Remote Pressure Compensated control. This control allows the pump to be operated at either the Load Sense pressure setting when On, or the Pressure Compensation pressure setting when Off.

  • Page 16: Pressure Measurement

    Service Manual Series 45 Frame K and L 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.

  • Page 17: Initial Start-Up Procedures

    Series 45 Frame K and L 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 Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.

  • Page 18: Fluid And Filter Maintenance

    Series 45 Frame K and L 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.

  • Page 19: Troubleshooting

    Service Manual Series 45 Frame K and L 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.

  • Page 20: Low Pump Output Flow

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Troubleshooting Item Description Action Check external system relief valve setting. Fluid passing through relief valve adds heat to Adjust external system relief valve setting system. following manufacturer’s recommendations.

  • Page 21: System Pressure Not Reaching Pc Setting

    Service Manual Series 45 Frame K and L 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.

  • Page 22: Adjustments

    Series 45 Frame K and L Open Circuit Axial Piston Pumps Adjustments PC control PC setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual, BLN-10128, for more information. Before performing adjustments, read Pressure measurement, for recommendations.

  • Page 23: Ls Control

    4 mm 9 N•m [7 lbf•ft] LS control The LS setting is indicated in the pump model code. Refer to the Series 45 Open Circuit Axial Piston Pumps Technical Information Manual, 520L0519, for more information. Before performing adjustments, read Pressure measurement, for recommendations.

  • Page 24: Displacement Limiter

    Service Manual Series 45 Frame K and L 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: Adjustment screw, set screw, and gauge locations shown...
  • Page 25 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Adjustments Setting range (continued) K38C 0 to 38 cm³ [0 to 2.32 in³] K45D 0 to 45 cm³ [0 to 2.75 in³] Displacement per turn L25C 1.20 cm³/rev [0.07 in³/rev] L30D 1.43 cm³/rev [0.09 in³/rev]...

  • Page 26: Minor Repair

    Shaft seal replacement A lip type shaft seal is used in the Series 45 open circuit variable pumps. This seal can be replaced without major disassembly of the unit. Replacement of the shaft seal requires removal of the pump from the machine.
  • Page 27 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair Auxiliary mounting pads J140 J095 J090 J085 J120 J110 J140 J095 J090 J100 (4pl.) J085 J095 47-61 N•m [35-45 lbf•ft] J085 J130 (2pl.) 9/16 in 37-50 N•m...

  • Page 28: Ls And Pc Controls

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair LS and PC Controls Control assembly: LS control shown; parts C106 and C112 through C118 are not used on PC control C118 C138 C117 C116...
  • Page 29 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair Inspection 1. Inspect the adjustment screws 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.

  • Page 30: Electric Controls

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair Electric Controls Control assembly C138 C118 C134 C140 C114 C145 C135 C115 C200 (3pl.) C150 Cartridge C133 3/4 in C113 24-27 N•m [18-20 lbf•ft] C102 (2pl.)
  • Page 31 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair 8. Remove the plug (C105). 9. Remove the solenoid coil nut, and electric solenoid coil (C155). Remove the cartridge valve (C150). Remove filter screen plug (C145), and O-ring (C140).

  • Page 32: Servo Control Orifice

    Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair Servo Control Orifice Control assembly C132 C103 P108 671E 3/16 in 11-14 N•m [8-10 lbf•ft] Disassembly Remove plug (C103) and PC spool (C132) from the control housing. Keep the O-ring.
  • Page 33 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps Minor repair Plug locations, sizes, and torques J041/J043/J044/J046 9/16 in 1/4 in 34-68 N•m 27-35 N•m [25-50 lbf•ft] [20-26 lbf•ft] K045 7/8 in 3/8 in 54-136 N•m [40-100 lbf•ft]...
  • Page 34 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps 520L0532 | AX00000040en-US0401 34 | © Danfoss | August 2016...
  • Page 35 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps 520L0532 | AX00000040en-US0401 | 35 © Danfoss | August 2016...
  • Page 36 Service Manual Series 45 Frame K and L Open Circuit Axial Piston Pumps 520L0532 | AX00000040en-US0401 36 | © Danfoss | August 2016...
  • Page 37 Phone: +86 21 3418 5200 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.

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