Related Manuals for Danfoss Series 45
Summary of Contents for Danfoss Series 45
- Page 1 Service Manual Open Circuit Axial Piston Pumps Series 45 E Frame powersolutions.danfoss.com...
- Page 2 Service Manual Series 45 E Frame Open Circuit Pumps Revision history Table of revisions Date Changed 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...
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Page 3: Table Of Contents
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... - Page 4 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...
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Page 5: Overview
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. -
Page 6: Symbols Used In Danfoss Literature
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 Lubricate with hydraulic fluid property Reusable part Apply grease / petroleum jelly... -
Page 7: General Description
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 lip- seal at the front end of the pump prevents leakage where the shaft exits the pump housing. -
Page 8: System Circuit
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. -
Page 9: Technical Specifications
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: •... - Page 10 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. 10 | © Danfoss | September 2016...
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Page 11: 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 on page 20 for recommended fluid and filter change intervals. -
Page 12: Features
P104 046 Auxiliary mounting pads Auxiliary mounting pads are available for all radial ported Series 45 pumps. These pads are typically used for mounting auxiliary hydraulic pumps. Since the auxiliary pad operates under case pressure, you must use an O-ring to seal the auxiliary pump mounting flange to the pad. -
Page 13: Input Shafts
Auxiliary pad options P104 047 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. -
Page 14: Ls Control
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. -
Page 15: Electric Proportional Controls
LS spool shifts to port system pressure to servo piston 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 ®... -
Page 16: Electronic Torque Limiting Controls (Etl)
“On”, or the Pressure Compensation pressure setting when “Off”. Electronic Torque Limiting Controls (ETL) 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 ®... - Page 17 Service Manual Series 45 E Frame Open Circuit Pumps Features the solenoid. When combined with an angle sensor, this control allows for a PC/LS control with electronic torque limiting. J-frame pump with integrated ETL control P108724 Pump torque consumption is a function of pump outlet pressure, pump displacement, and pump mechanical efficiency.
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Page 18: Pressure Measurement
Service Manual Series 45 E Frame Open Circuit 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 19: Initial Start-Up Procedures
Series 45 E Frame Open Circuit 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 20: Fluid And Filter Maintenance
Series 45 E Frame Open Circuit 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 21: Troubleshooting
Service Manual Series 45 E Frame Open Circuit 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. -
Page 22: Low Pump Output Flow
Service Manual Series 45 E Frame Open Circuit 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. External relief valve setting must be above PC setting for proper operation. -
Page 23: System Pressure Not Reaching Pc Setting
Service Manual Series 45 E Frame Open Circuit 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 24: Pc Control
Series 45 E Frame Open Circuit 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, 520L0519, for more information. Before performing adjustments, read Pressure measurement. - Page 25 Service Manual Series 45 E Frame Open Circuit Pumps Adjustments PC control adjustment PC set screw 4 mm 7 - 11 N•m [6 - 8 lbf•ft] PC adjusting plug 6 mm Case drain port L1 0 - 10 bar [0 - 145 psi] 7/8-14 54 - 136 N•m...
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Page 26: Ls Control
Series 45 E Frame Open Circuit Pumps Adjustments 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. -
Page 27: Displacement Limiters
Service Manual Series 45 E Frame Open Circuit Pumps Adjustments 8. Stop the prime mover, remove the pressure gauges, and return the system to its normal operating configuration. LS control adjustment LS set screw 4 mm 7.5 - 10.8 Nm [5.5 - 8 lbf•ft]... - Page 28 Service Manual Series 45 E Frame Open Circuit Pumps Adjustments Displacement limiter cross-section P104 003 Dimensions [11.969] 302.7 max. [11.92] P108 470E 28 | © Danfoss | September 2016 AX00000024en-US0401...
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Page 29: Minor Repair
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. Removal 1. -
Page 30: Auxiliary Pads
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Auxiliary pads You may install auxiliary mounting pads on pumps equipped with through-drive radial ported end caps. Follow these steps to either remove, replace, or exchange auxiliary mounting pads. -
Page 31: Inspection
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 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. -
Page 32: Reassembly
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 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. - Page 33 Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 8. Check and adjust the control setting. See Adjustments. Control assembly C103 inch 10.8 - 13.5 N•m C104 [8 - 10 lbf•ft] inch C103A 10.8 - 13.5 N•m [8 - 10 lbf•ft]...
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Page 34: Electric Controls
Service Manual Series 45 E Frame Open Circuit 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). -
Page 35: Reassembly
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Reassembly 1. Install the servo control orifice (G020), and torque to 2-3.4 N•m [18-30 in•lb]. Then install the orifice backup plug (G030), and torque to 2-3.4 N•m [18-30 in•lb]. -
Page 36: Electronic Torque Limiting Control
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 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. -
Page 37: Angle Sensor
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Angle Sensor Removal 1. Remove the four sensor housing screws (K195), sensor housing (K265), and sensor housing O-ring (K175). 2. Remove two locating dowels (K185). 3. Remove two magnet carrier screws (K115) and discard. Remove magnet carrier (K105) from pump swashplate through housing. -
Page 38: Reassembly
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 5. Check magnet carrier for cracks , deformations, wearing, and for contamination with magnetic particles Warning A thorough inspection with the angle sensor removed is a strong indicator of pump and hydraulic system contamination and filtration quality. -
Page 39: Servo Control Orifice
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair Servo Control Orifice 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. -
Page 40: Plug And Fitting Sizes And Torques
Service Manual Series 45 E Frame Open Circuit Pumps Minor repair 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... - Page 41 Service Manual Series 45 E Frame Open Circuit Pumps © Danfoss | September 2016 AX00000024en-US0401 | 41...
- Page 42 Service Manual Series 45 E Frame Open Circuit Pumps 42 | © Danfoss | September 2016 AX00000024en-US0401...
- Page 43 Service Manual Series 45 E Frame Open Circuit Pumps © Danfoss | September 2016 AX00000024en-US0401 | 43...
- Page 44 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.