Danfoss Series 45 Page 1 Service Manual Download

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Service Manual

Open Circuit Axial Piston Pumps

Series 45 E Frame

powersolutions.danfoss.com

Summary of Contents for Series 45

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

Page 2: ...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 sp...

Page 3: ...lacement 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...

Page 4: ...ntrols 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 Inspecti...

Page 5: ...utions 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...

Page 6: ...n 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 in...

Page 7: ...ak 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 i...

Page 8: ...he 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 de...

Page 9: ...ith hydraulic fluid Technical specifications Features and options Feature Unit Model E100B E130B E147C Maximum Displacement cm in 100 6 10 130 7 93 147 8 97 Flow at rated speed theoretical l min US ga...

Page 10: ...030 360 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 3...

Page 11: ...r 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 me...

Page 12: ...9E Displacement change older models 100 cc 6 5 cc rev 0 397 in rev 130 cc 147 cc Displacement limiter older models P104 046 Auxiliary mounting pads Auxiliary mounting pads are available for all radial...

Page 13: ...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 P104 048 1 2 3 Bias spring and...

Page 14: ...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 bein...

Page 15: ...LUS 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 all...

Page 16: ...iance 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 Torque Limiting Con...

Page 17: ...nical efficiency is considered constant the pump torque can be limited when pump displacement is known and pump pressure is controlled As pump displacement increases the pump outlet pressure can be li...

Page 18: ...M1 M2 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting M4 Servo pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting L1 L2 Case drain 0 300 bar 0 5000 psi 1 1 16 12 O ring fitting X1 LS sig...

Page 19: ...the inlet line for properly 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 dr...

Page 20: ...ately 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 wate...

Page 21: ...ts output flow Adjust PC and LS setting Refer to the Adjustments chapter Check LS control signal pressures Incorrect LS signal will not allow pump to operate correctly Inspect system to ensure that pr...

Page 22: ...events the pump from achieving full stroke Adjust PC and LS setting Refer to the Adjustments chapter Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure co...

Page 23: ...ntamination 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 cause...

Page 24: ...low fluid to reach normal operating temperature 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 adjustin...

Page 25: ...0 4351 psi 9 16 28 34 68 N m 25 50 lbf ft P104053 0 10 bar 0 145 psi 7 8 14 54 136 N m 40 100 lbf ft Case drain port L1 PC set screw 6 mm PC adjusting plug Service Manual Series 45 E Frame Open Circui...

Page 26: ...pressure below the PC set point 3 Loosen the LS set screw While watching the pressure gauges turn the LS adjusting plug until the desired pressure differential between port M1 or M2 and port X is achi...

Page 27: ...plug set screw and gauge locations shown Displacement Limiters E Frame open circuit pumps are available with an optional adjustable displacement limiter This adjustable stop limits the pump s maximum...

Page 28: ...isplacement limiter cross section P104 003 Dimensions P108 470E 304 11 969 302 7 max 11 92 Service Manual Series 45 E Frame Open Circuit Pumps Adjustments 28 Danfoss September 2016 AX00000024en US0401...

Page 29: ...he shaft for rust wear or contamination Polish the sealing area on the shaft if necessary 2 Lubricate the lip of the new shaft seal with clean hydraulic fluid Place a protective sleeve over the shaft...

Page 30: ...ft h3 4 inch t91 111 N m 67 82 lbf ft P104357 h9 16inch t37 50 N m 27 37 lbf ft Installation 1 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 2 Install the 4 scr...

Page 31: ...Remove the C104 plug C104A O ring and C112 LS spool from the control housing discard the O ring Note orientation of the spool for reassembly Control assembly C118 C118B C118B C118A C114 C115 C113 C11...

Page 32: ...ft 3 Install the LS spool C112 spherical end first into the LS bore Using a new O ring C105A or C106A install the plug C105 or C106 Torque the plug C105 or C106 to 10 8 13 5 N m 8 10 lbf ft For PC onl...

Page 33: ...3 16inch 10 8 13 5 N m 8 10 lbf ft 3 16inch 10 8 13 5 N m 8 10 lbf ft 3 16inch 10 8 13 5 N m 8 10 lbf ft 3 16inch 10 8 13 5 N m 8 10 lbf ft 6 mm 7 5 10 8 N m 5 5 8 lbf ft 4 mm 5 4 7 5 N m 4 5 5 lbf ft...

Page 34: ...e valve C150 from the electric control manifold Control disassembly 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 C...

Page 35: ...and torque to 2 3 4 N m 18 30 in lb 8 Install the cartridge valve C150 into the electric control manifold C152 Torque to 25 8 28 5 N m 19 21 lbf ft DO NOT OVERTORQUE the cartridge valve 9 Install the...

Page 36: ...Nm 24 in lb when it is installed in the manifold P108790 QC125 Included in overhaul seal kit Q210 C155 QC150 QC120 C154 C149 C151 C152 H020 C153 C200 C300 Item Description Wrench size Torque C149 Ori...

Page 37: ...areful not to damage or scratch seal area Right side P108840 K105 K115 K185 K175 K265 K195 Item Description Wrench size Torque K105 Magnet carrier K115 Carrier screws 4 5 Nm 3 35 lbf ft K175 O ring K1...

Page 38: ...gh the housing Torque the screws to 4 5 Nm 3 3 lbf ft W Warning Used magnet carrier screws may loosen and lead to premature failure Ensure that new screws with locking compound are utilized 2 Install...

Page 39: ...he PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 N m 8 10 lbf ft 7 Using petroleum jelly to retain them install the four O rings C200 in the recesse...

Page 40: ...Plug locations sizes and torques K040 1 1 16 inch 9 16 inch 95 135 N m 70 100 lbf ft J040 9 16 inch 1 4 inch 20 5 27 N m 15 20 lbf ft J042 9 16 inch 1 4 inch 36 50 N m 27 37 lbf ft L020 3 4 inch 5 16...

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: ...1 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 Trading Shanghai Co Ltd Building 2...

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Danfoss Series 45, Service Manual

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