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Service Manual 

Series 45 J Frame Open Circuit Axial Piston Pumps

520L0607

 • Rev AI • Sep 2013

8

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 

multi-section 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

1

 while limiting the maximum pressure. Therefore flow and pressure in the 

system are compensated to meet requirements.

1

 Full available flow is a function of pump displacement, operating speed, and efficiency. Refer to

 

Series 45 Axial 

Piston Open Circuit Pumps Technical Information,

 

520L0676

 

for details.

Introduction (continued)

System Circuit

Pictorial circuit diagram

P104 366E

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

J Frame Series 45
open circuit axial
piston pump with
load sensing control

Содержание 45 J Series

Страница 1: ...powersolutions danfoss com MAKING MODERN LIVING POSSIBLE Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps...

Страница 2: ...foss conversion AI December 2012 9 Displacement limiter is available change to max pressure AH October 2012 various add electric controls AG November 2010 last new last page AF February 2010 last Fix...

Страница 3: ...ns 9 Hydraulic parameters 10 Inlet pressure 10 Pressure compensator valve setting 10 Case pressure 10 Hydraulic fluid 10 Fluid viscosity 10 Filtration 10 Auxiliary mounting pads 11 Input shafts 11 Con...

Страница 4: ...Rev AI Sep 2013 4 Contents continued Adjustments Minor repair PC control 21 LS control 22 Shaft seal replacement 23 Auxiliary pads 24 LS and PC Controls 25 LS and PC Controls continued 26 Electric Co...

Страница 5: ...you are cut by hydraulic fluid Personal safety Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Introduction Overview Safety Precautions This manu...

Страница 6: ...roduct or property Reusable part Non reusable part use a new part Non removable item Option either part may exist Superseded parts are not interchangeable Measurement required Flatness specification P...

Страница 7: ...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...

Страница 8: ...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 lo...

Страница 9: ...dial Control types PC Remote PC LS LS with internal bleed Shafts Splined 13 tooth 14 tooth 15 tooth Tapered 31 75 mm 1 25 in 1 8 taper Straight 31 75 mm 1 25 in Displacement limiters Available Ratings...

Страница 10: ...S continuous minimum 9 58 maximum 110 500 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 Fl...

Страница 11: ...rcuit Pumps Technical Information 520L0676 Auxiliary mounting pads are available for all radial ported Series 45 pumps These pads are typically used for mounting auxiliary hydraulic pumps Since the au...

Страница 12: ...metering system pressure to the servo piston 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 m...

Страница 13: ...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 hydrau...

Страница 14: ...pump to be operated at any pressure limit between the Load Sense and Pressure Compensation settings by varying the current sent to the solenoid Electric On Off Controls PLUS 1 Compliance All Series 4...

Страница 15: ...tect gauges The illustration below shows gauge port locations Recommended pressure gauges and fittings are in the table Gauge port locations Pressure measurement Required Tools Port Locations and Gaug...

Страница 16: ...e watching the pressure gauge installed at M1 jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels minimum 11 bar 160 psi Once system pressure is estab...

Страница 17: ...he filter Replace all fluid lost during filter change To ensure optimum life of Series 45 products perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit fail...

Страница 18: ...scription Action Check external system relief valve setting Low external relief valve setting slows down system Adjust external relief valve setting following manufacturer s recommendations External r...

Страница 19: ...r to proper level Hydraulic fluid viscosity above acceptable limits Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allo...

Страница 20: ...setting presents pressure compensation Adjust external relief valve according to manufacturer s recommendations External relief valve must be set above PC setting to operate properly Inspect PC contr...

Страница 21: ...ystem relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation 4 While holding the position of the PC adjusting plug torque the PC set scr...

Страница 22: ...to the LS remote PC signal line port X C 2 Start the prime mover and allow fluid to reach normal operating temperature Slowly operate a hydraulic function that will demand approximately half flow from...

Страница 23: ...h a packing hook or use a slide hammer type puller to remove the seal Installation 4 Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contaminati...

Страница 24: ...liary mounting pads Installation 4 Lubricate new O ring J090 with petroleum jelly Install the pad adapter to the endcap 5 Install the 4 screws J100 and torque to 48 5 61 N m 35 45 lbf ft 6 Install the...

Страница 25: ...gs C114 C115 and seat C113 Discard the C118A O ring 7 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 Inspe...

Страница 26: ...until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 N m 5 5 8 lbf ft For PC only controls skip steps 15 through 17 15 Install the LS spool C112 spherical end f...

Страница 27: ...and discard the two interface O rings C154 9 For electric proportional controls only Remove the electric control manifold drain orifice C149 10 Remove plug C153 Remove the cartridge valve nut C125 ele...

Страница 28: ...5 5 8 lbf ft 7 Install the electric control manifold drain orifice C149 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...

Страница 29: ...rol Orifice Reassembly 1 Install the 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 2 Install the PC spool C132 spherica...

Страница 30: ...d torque as indicated here This drawing is a composite Your configuration may differ but here is the appropriate wrench size and torque J041A J041 K040 K070A K070 3 8 inch 55 135 N m 40 100 lbf ft 1 4...

Страница 31: ...Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps 520L0607 Rev AI Sep 2013 31 Notes...

Страница 32: ...ase contact the Danfoss Power Solution representative nearest you Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydrau...

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