Danfoss 45 Frame K2 Series User Manual Download

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Service Manual

Open Circuit Axial Piston Pumps

Series 45 Frame K2

powersolutions.danfoss.com

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Summary of Contents for 45 Frame K2 Series

Page 1: ...Service Manual Open Circuit Axial Piston Pumps Series 45 Frame K2 powersolutions danfoss com...

Page 2: ...Revision history Table of revisions Date Changed Rev April 2017 First edition 0101 Service Manual Series 45 Frame K2 Open Circuit Axial Piston Pumps 2 Danfoss April 2017 AX00000301en US0101...

Page 3: ...ration 9 Features Displacement limiter 10 Auxiliary mounting pads 10 Input shafts 11 Control options 11 Operation 11 General 11 PC control 12 LS control 12 Electronic Controls 13 Electric Dump Valve P...

Page 4: ...ection 28 Reassembly 28 Auxiliary pads 28 Disassembly 28 Inspection 29 Assembly 29 LS and PC Controls 29 Electric Controls 33 Fan Drive Control 34 Servo Control Orifice 36 Servo Control Orifice Disass...

Page 5: ...stributor locator at http www powersolutions danfoss com Safety precautions Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the fol...

Page 6: ...ents 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 ar...

Page 7: ...te Valve plate Endcap axial ported Slipper Slipper retainer Cylinder block Shaft seal Tapered roller bearing LS spool LS adjustment PC adjustment PC spool LS control attached to endcap Service Manual...

Page 8: ...th hydraulic fluid Technical specifications Ratings Description Unit K2 Frame 25C 30C 38C 45C Maximum Displacement cm3 in3 25 1 53 30 1 83 38 2 32 45 2 75 Working Input Speed Minimum min 1 rpm 500 500...

Page 9: ...range Intermittent cold start 40 C 40 F Continuous 104 C 219 F Maximum 115 C 239 F Hydraulic fluid viscosity must be maintained within the prescribed limits Fluid viscosity Viscosity limits Rating mm...

Page 10: ...pumps are available with an optional adjustable maximum displacement limiter The adjustable stop limits the pump s maximum displacement Adjustable displacement limiter P109048 Kit size Displacement pe...

Page 11: ...n Manual 520L0519 for more extensive control options Operation General The bias spring acts at all times to push the swashplate to maximum angle causing the pump to stroke The servo piston acts agains...

Page 12: ...s 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 adjustment screw and...

Page 13: ...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 caus...

Page 14: ...a pressure drop across the control In addition fan motor type and fan inertia impact minimum system pressure The Normally Closed Fan Drive Control coupled with a microprocessor allows the pump to oper...

Page 15: ...ontrol When open the solenoid valve allows flow from the incoming load sense pressure to dump to case This reduces the pressure in the LS spring cavity shifting the LS spool and allows the pump to de...

Page 16: ...re 0 300 bar 0 5000 psi 7 16 20 O ring fitting L1 L2 Case drain port 0 10 bar 0 100 psi 7 8 14 O ring fitting X LS signal 0 300 bar 0 5000 psi 7 16 20 O ring fitting tee into LS signal line The M2 por...

Page 17: ...dial Port Description Mounting Diameter B Outlet SAE J1926 1 3125 12 L1 Case drain SAE J1926 0 875 14 L2 Case drain SAE J1926 0 875 14 S Inlet SAE J1926 1 875 12 Service Manual Series 45 Frame K2 Open...

Page 18: ...tightened fittings and be certain it is free of restrictions and air leaks 5 To ensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge a...

Page 19: ...Change the fluid and filter per the vehicle machine manufacturer s recommendations or at these intervals Change the fluid more frequently if it becomes contaminated with foreign matter dirt water gre...

Page 20: ...er to the Adjustments chapter Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system to ensure that proper LS signal transmit to pump Internal sy...

Page 21: ...external relief valve following manufacturer s recommendation External relief valve setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pu...

Page 22: ...nation Contamination may interfere with movement of the PC spool Clean PC control components take appropriate action to eliminate contamination High inlet vacuum C CAUTION High inlet vacuum causes cav...

Page 23: ...rature Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 3 Loosen the PC set screw and turn the PC adjustment screw until the desired setting is ind...

Page 24: ...warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 2 Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydra...

Page 25: ...16 18 1 4 inch internal hex 51 N m 38 lbf ft M14 4 mm internal hex 31 N m 23 lbf ft L1 Case drain port 10 bar 100 psi 7 8 14 3 8 internal hex 95 N m 70 lbf ft X LS remote PC signal port LS adj screw L...

Page 26: ...sealing area on the shaft if necessary Reassembly 1 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft end to prevent damage to the seal during...

Page 27: ...t the seal nut L030 for irregular wear Replace if necessary Replace the O ring L010A Reassembly 1 Install displacement limiter screw L040 into plug L010 2 Install new O ring L010A onto plug L010 Threa...

Page 28: ...screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its sealing O ring J120 Discard the O ring 2 Remove the drive coupling J140 3 Re...

Page 29: ...39 lbf ft Inspection Inspect sealing surfaces on the endcap and auxiliary pad and make sure that they are clean and free of contaminants Inspect the coupling J140 for any signs of excessive or abnorm...

Page 30: ...the O ring C105A or C106A 6 Remove the LS set screw C102 LS adjusting plug C118 O ring C118A back up rings C118B springs C114 C115 and seat C113 Discard the O ring and backup rings 7 Remove the plug...

Page 31: ...ll turn Install and torque the PC set screw C102 to 9 N m 7 lbf ft For PC only controls skip steps 3 through 5 3 Install the LS spool C112 spherical end first into the LS bore Using a new O ring C105A...

Page 32: ...f ft 12 N m 9 lbf ft 12 N m 9 lbf ft 6 N m 5 lbf ft 12 N m 9 lbf ft 9 N m 7 lbf ft LS control shown parts C104 through C106 and C112 through C118 are not used on PC control Service Manual Series 45 Fr...

Page 33: ...alve C150 from the electric control manifold Control assembly P108 668E G020 G030 C200 C102 C103 C132 C112 C104 C300 C125 C155 C150 C149 C154 C152 C151 C113 C115 C133 C135 C114 C118 C134 C138A C138 C1...

Page 34: ...t 10 Install plug C153 Torque the plug to 12 N m 8 9 lbf ft 11 Using petroleum jelly to retain them install the two interface O rings C154 in the recesses on the electric control manifold 12 Install t...

Page 35: ...ary 2 Inspect the control housing for damage Check the spool bores for excessive wear Remove debris from orifices if necessary 3 Carefully inspect the spool Ensure the sealing lands are free of nicks...

Page 36: ...do not damage the plastic nut 9 Using petroleum jelly to retain them install the four interface O rings C200 in the recesses on the control housing 10 Install the control assembly onto the endcap usi...

Page 37: ...C300 Torque the screws to 6 5 N m 4 8 lbf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Plug and fitting sizes and torques If any plugs or f...

Page 38: ...Service Manual Series 45 Frame K2 Open Circuit Axial Piston Pumps 38 Danfoss April 2017 AX00000301en US0101...

Page 39: ...Service Manual Series 45 Frame K2 Open Circuit Axial Piston Pumps Danfoss April 2017 AX00000301en US0101 39...

Page 40: ...r Solutions ApS Nordborgvej 81 DK 6430 Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Tradi...

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