Series 45 J Frame Open Circuit Axial Piston Pumps
Contents
1. Using a new O ring C104A install the plug C104 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Place the two LS springs C114 C115 onto the spring guide C113 and install into the LS bore Place a new O ring C118A and back up rings C118B onto the LS adjusting screw and thread it into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft Using petroleum jelly to retain them install the 4 interface O rings C200 in the recesses on the control housing Control assembly C103 9 3heinch 3Ae inch 7 45 10 8 13 5 Nem 9 CIO3A i 8 10 Ibf ft C132 amp iC104A e a a are C105 8 C112 o 3heinch i 2 10 8 13 5 Nem S CqoE 8 10 Ibf ft f v C102 l C106A d ISl rmi EMO S PELE 2175 108 Nm 9 3 einch Pas 5 5 8 Ibf ft 4 10 8 13 5N m cago fS o w 8 10 Ibf ft S Hes f C300 9 4mm eise 5 4 7 5 Nem c14 4 5 5 Ibf ft C118B8 o y C118A ilct1887 pi Mea E101 226 LS control shown parts C104 through C106 and C112 through C118 are not used on PC control 19 Install the control assembl2. Start up Procedure O Caution Incorrect shaft alignment may result in damage to drive shaft bearings or seal which can cause external oil leakage Follow this procedure when starting up a new Series 45 installation or when restarting an installation in which the pump has been removed A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Prior to installing the pump inspect for damage incurred during shipping Make certain all system components reservoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid 1 Connect the pump to the prime mover Ensure that pump shaft is properly aligned with the shaft of the prime mover 2 Fill the reservoir with recommended hydraulic fluid Always filter fluid through a 10 micron filter pouring into the reservoir Never reuse hydraulic fluid 3 Fill the main pump housing with clean hydraulic fluid Pour filtered oil directly into the upper most case drain port 4 Fill the inlet line leading from the pump to the reservoir Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks 5 Toensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at port M1 to monito
3. Incorrect LS signal will not allow pump to operate correctly Worn internal parts don t allow the pump to operate properly Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Inspect system to ensure that proper LS signal transmit to pump Refer to Authorized Service Center for required repair Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Check external system valving Malfunctioning valving may not allow system to respond properly Repair or replace system valving as required Check pump case pressure High case pressure causes the system to be sluggish Correct case drain line restrictions Check pump inlet pressure vacuum High inlet vacuum causes low output flow Correct inlet pressure conditions 18 520L0607 Rev Al Sep 2013 Deve Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Troubleshooting continued System Operating Hot Low Pump Output Flow Pressure or Flow Instability Item Check fluid level in reservoir Description Insufficient volume of hydraulic fluid will not meet cooling demands of system Action Fill reservoir to proper level Verify proper size of re
4. Mounting 2 bolt SAE B 4 bolt SAE C Auxiliary mounting SAE A SAE B SAE BB SAE C System ports type SAE R ring boss 4 bolt split flange System ports location Axial Radial Control types PC Remote PC LS LS with internal bleed Splined 13 tooth 14 tooth 15 tooth Shafts Tapered 31 75 mm 1 25 in 1 8 taper Straight 31 75 mm 1 25 in Displacement limiters Available Ratings Model Rating Units J45B J51B J60B J65C J75C minimum 500 500 500 500 500 Input speed continuous min rpm 2800 2700 2600 2500 2400 maximum 3360 3240 3120 3000 2880 Working z 310 310 310 260 260 pressure Iesum bar Ipsil 4495 4495 4495 3770 3770 226 226 226 226 226 External shaft Dtemalmoment M Nem bin t2000 20001 2000 2000 2000 loads 2200 2200 2200 2200 2200 Thrust in T out T N lbf 495 495 495 495 495 at 140 bar 2030 psi 29712 20712 29712 10 755 10 755 1 p at 210 bar 3045 psi 6834 6834 6834 2474 2474 Bearing life E B hours at 260 bar 3770 psi 315 315 215 at 310 bar 4495 psi 1666 1666 1666 Vibratory SAE C 1500 14 000 SAE B 735 6500 Mounting flange continuous Nem Ibf in load moments Shock max SAE C 5600 50 000 SAE B 2600 23 000 1 Continuous input speeds are valid at 1 bar absolute 0 in HG vac inlet pressure Maximum input speeds require changing the inlet pressure or reducing pump displacement 520L0607 Rev Al
5. Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Technical specifications Hydraulic Parameters Inlet pressure Minimum pressure continuous 0 8 bar absolute 6 7 inches Hg vac at reduced maximum pump speed Minimum pressure cold start 0 5 bar absolute 15 1 inches Hg vac Pressure compensator valve setting Minimum 100 bar 1450 psi Maximum 310 bar 3770 psi depending on displacement For more information refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information 520L0676 Case pressure Maximum continuous 0 5 bar 7 psi Above inlet Intermittent 2 bar 29 psi Cold start Hydraulic fluid Refer to Danfoss publication Fluids and Filtration BLN 9887 or 520L0463 For information on biodegradable fluids refer to Biodegradable Hydraulic Fluids 520L0465 See Fluid and filter maintenance page 17 for recommended fluid and filter change intervals Temperature range Intermittent cold start 40 C 40 F Continuous 82 C 180 F Maximum 104 C 220 F Fluid viscosity Viscosity limits Rating mm s cSt SUS minimum 9 58 v continuous maximum 110 500 minimum 6 4 47 v intermittent TERRIER 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 Maintai
6. ma N J110 oe N J140 J100 3085 a 8mm Q EN 8 48 5 61 Nem hs 09 e 35 45 Ibf ft hs inch NC J110 38 50 Nem 27 37 lbfeft E101 256 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 Nem 35 45 Ibf ft 6 Install the drive coupling J140 if present Shipping cover is intended only to retain coupling during shipment and storage Do not operate pump with coupling and shipping cover installed 7 Install shipping cover or auxiliary pump with seal J120 8 Install the screws J130 and torque to 94 115 Nem 67 82 Ibf ft If you have an auxiliary A pad install the screws J130 and torque to 37 50 Nem 27 37 Ibf ft 24 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued LS and PC Controls Disassembly Control assembly 1 Remove the 4 screws C300 holding the C103 control housing onto the end cap 9 3 sinch 75 10 8 13 5 Nem 2 Remove the control and discard the 4 C104 8 10 Ibf ft interface O rings C200 9 3h inch 10 8 13 5 Nem TES MSS QE 3 Remove the PC set screw C102 PC adjusting 8 10 Ibf ft z C1328 plug C138 O ring C138A springs C13
7. 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 15 Check and adjust the control setting See Adjustments page 21 22 28 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued Servo Control Orifice Disassembly 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 Note the orientation of the spool for reassembly 4 Remove backup plug G030 and orifice G020 Reassembly 1 Install the orifice G020 and torque to 2 3 4 Nem 18 30 inelb Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft Using petroleum jelly to retain them install the four O rings C200 in the recesses on the control housing Install the control assembly onto the endcap using four screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention Control assembly P108 6
8. com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Danfoss Your Strongest Partner in Mobile Hydraulics Go to www powersolutions danfoss com for further product information Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Danfoss Power Solution representative nearest you Local address Danfoss Danfoss Danfoss Power Solutions GmbH amp Co OHG Power Solutions ApS Power Solutions Krokamp 35 Nordborgvej 81 22F Block C Yishan Rd D 24539 Neum nster Germany Phone 49 4321 8710 DK 6430
9. disable disconnect the mechanism while servicing If the pressure does not increase an external system relief valve may require adjustment External system relief valve must be set above the PC setting for proper operation Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines The LS setting is indicated in the pump model code Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual 520L0676 for more information Before performing adjustments read page 15 Pressure measurement 1 Install a pressure gauge in port M1 to measure system pressure Install a pressure gauge in drain port L1 or L2 to measure case pressure Tee in a gauge to the LS remote PC signal line port X A0 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 the pump but keep system 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 and port X is achieved Clockwise rotation increases the setting counterclockwise rotation will decrease it approximate gain 17 bar 250 psi per turn 4 While holding the position of the LS adjusting p
10. or milky appearance or free water in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Change the fluid and filter per the Fluid and filter change interval vehicle machine manufacturer s recommendations or at these intervals Reservoirtype Maximum change interval Sealed 2000 hours Change the fluid more frequently if it becomes Breather 500 hours contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater that the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter Replace all fluid lost during filter change 520L0607 Rev Al Sep 2013 17 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Troubleshooting Excessive Noise and or Vibration Actuator Response is Sluggish Item Check fluid level in reservoir Description Insufficient hydraulic fluid causes cavitation Action Fill the reservoir to proper level Check for air in system Air in system causes noisy erratic control Purge air and tighten fittings Check inlet for leaks Check pump inlet pressure vacuum Inspect shaft co
11. the housing just far enough to clear the retaining ring groove O Install seal with the cupped side toward the shaft bearing Do not damage the seal during installation Install second seal if pump is so equipped See illustration below 7 Using the appropriate snap ring pliers install the seal retaining ring 8 Remove the installation sleeve Double seal and retaining ring E108 672E 520L0607 Rev Al Sep 2013 23 Dont Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair Auxiliary pads J130 3 inch 2 91 111 Nem 67 82 Ibfeft Caution You may install auxiliary mounting pads on pumps equipped with through drive radial ported endcaps Follow these steps to either remove replace or exchange auxiliary mounting pads Removal 1 Remove the screws J130 retaining the cover plate J110 or auxiliary pump not shown Remove the shipping cover or auxiliary pump and its seal J120 2 Remove the drive coupling J140 if present 3 Remove the 4 screws J100 retaining the pad adapter J080 to the endcap Discard the pad adapter O ring J090 if present Also discard the J095 O ring Auxiliary mounting pads 8mm 48 5 61 Nem 35 45 lbfft oF P gt P J140 N P 9 J090 OK R AP J120 J080 P J095 9 C2
12. 4 A C135 and seat C133 Discard the O ring jicioaa e B E C105 4 Remove the plug C103 O ring C103A and 8 cu2 d E S sinch PC spool C132 from the control housing E Discard the O ring Note orientation of the E T spool for reassembly f SEN J C106A Kes For PC only controls skip steps 5 through 7 M 9 6 mm C106 3 29 5 75 108N m 9 3As inch es 5 5 8 Ibf ft 5 Remove the plug C105 and O ring C105A Z108 135N or the plug C106 and O ring C106A Discard 8 10 Ibf ft E C200 i the O ring C105A or C106A i amp 33 co C113 6 Remove the LS set screw C102 LS adjusting g C135 9 4 mm plug C118 O ring C118A back up rings 72 54 7 5 Nem C118B springs C114 C115 and seat C113 Ci 1 8 C134 4 5 5 Ibfeft S EL EC Discard the C118A O ring Slci8B o 3 o 61384 B 7 Remove the C104 plug C104A O ring and 1j C118A C112 LS spool from the control housing C118B e C138 E discard the O ring Note orientation of the spool for reassembly cus E101 226 LS control shown parts C104 through C106 and C112 through C118 are not used on PC control Inspection 8 Inspect the adjusting plugs for wear at the tips and where they cont
13. 69E 520L0607 Rev Al Sep 2013 29 Dont Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued Plug and fitting sizes and If any plugs or fittings are removed from the unit during service install and torque as indicated torques here This drawing is a composite Your configuration may differ but here is the appropriate wrench size and torque Plug locations sizes and torques K040 J041 Ca 3 inch 9 A inch SS 2 55 135Nem 427 47 Nem CD 40 100 Ibf ft 20 35 Ibf ft E K040A K070 Ce 3 inch 55 135 Nem 40 100 Ibfeft E101 257 30 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Notes 520L0607 Rev Al Sep 2013 31 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors e PLUS41 GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Comatrol www comatrol com Schwarzmiiller Inverter www schwarzmueller inverter com Turolla www turollaocg com Valmova www valmova
14. J Frame Open Circuit Axial Piston Pumps Introduction Overview Safety Precautions This manual includes information for the installation maintenance and minor repair of the Series 45 frame J open circuit axial piston pumps The manual includes a description of the units and their individual components troubleshooting information and minor repair procedures Performing installation maintenance and minor repair of Series 45 J frame axial piston pumps according to the procedures in this manual will not affect your warranty Performing minor repairs requires the unit to be removed from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Danfoss Authorized Service Centers ASCs is available for major repairs Major repairs require the removal of the unit s endcap which voids the warranty unless done by an 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 Danfoss com Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take these general precautions whenever servicing a hydraulic system
15. MAKING MODERN LIVING POSSIBLE Service Manual C ER Ph pm p A mn D Rew 49 Open Circuit Axial Piston Pumps powersolutions danfoss com Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps History of Revisions Table of Revisions Date Page Changed Rev September 2013 Danfoss conversion Al 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 Osaka address AE July 2009 20 Pressure change PC adjustment specs AD March 2007 21 typo in illustration set screw torque is 7 5 10 8Nm AB 5 5 8 Ibf ft May 2005 First edition A Front cover illustrations F301320 S45 FRAME J 2 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Contents Introduction Technical Specifications Features Pressure Measurement Initial Start up Procedures Fluid and Filter Maintenance Troubleshooting Overview Safety precautions Unintended machine movement Flammable cleaning solvents Fluid under pressure Personal safety Symbols used in Danfoss literature General description System circuit General specifications Hydraulic parameters Inlet pressure Pressure compensator valve setting Case pressure Hydraulic fluid Fluid viscosity Filt
16. Nordborg Denmark Phone 45 7488 2222 Shanghai 200233 China 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 subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 520L0607 Rev Al Sep 2013 www danfoss com O Danfoss A S 2013 09
17. S setting to proper level See Adjustments page 21 Check LS signal line Blocked LS signal line interferes with proper LS operation Remove blockage Check external relief valve and PC setting Insufficient pressure differential between PC setting and external relief valve Adjust external relief valve or PC control settings to appropriate level Relief valve setting must be above PC setting to operate properly Check external relief valve Chattering external relief valve may cause unstable feedback to pump control Adjust or replace relief valve Item Check PC control setting Description System pressure will not rise above PC setting Action Adjust PC to appropriate setting Refer to Adjustments page 21 Check external relief valve External relief valve setting below PC 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 control spring Inspect PC spool for wear Inspect PC spool for proper orientation Broken damaged or missing spring will cause erratic operation Wear of PC spool causes internal leakage in the control Improper orientation results in poor operation Replace the spring as required Replace the spool as required Correct orientation of spool Check PC control for c
18. Unintended machine movement A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks ina pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 520L0607 Rev Al Sep 2013 5 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Introduction continued Symbols used in Danfoss Literature These symbols are in the illustrations and text of this manual They communicate helpful information at the point where it is most useful to the reader In most instances the appearan
19. a PC only control or an electric control Operation The bias spring 1 pushes against the servo piston 2 which pulls the swashplate 3 to max angle causing the pump to stroke Internal pressure on the servo piston acts against the bias spring to reduce the swashplate angle causing the pump to destroke Swashplate angle determines pump outlet flow The pump control depending on conditions in the system circuit sets swashplate angle by 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 maintain system pressure at the PC setting as the PC adjusting plug 4 and spring 5 defines When system pressure acting on the non spring end of the PC spool 6 overcomes the force of the PC spring the spool shifts porting system pressure to the servo piston and the swashplate angle decreases When system pressure drops below the PC setting the PC spring shifts the spool in the opposite 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 Cross section pump 2 1 3 LJ Zz P104 360 B
20. act the springs replace as necessary 9 Inspect the springs and spring guides for wear or damage replace as necessary 10 Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary 11 Inspect the control housing for damage Check the spool bores for excessive wear 12 Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0607 Rev Al Sep 2013 25 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued LS and PC Controls continued Reassembly 13 14 Install the PC spool C132 spherical end first into the PC bore Using a new O ring C103A install the plug C103 Torque the plug C103 to 10 8 13 5 Nem 8 10 Ibfeft Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft For PC only controls skip steps 15 through 17 15 16 17 18 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 Nem 8 10 Ibf ft
21. ce of the symbol itself denotes its meaning The legend below defines the symbol and explains its purpose A a Q o o amp RI WARNING may result in injury CAUTION may result in damage to product 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 Parallelism specification External hex head Internal hex head Torx head O ring boss port amp gt i G E E DJ s NJ be A Ry 59 E Tip helpful suggestion Lubricate with hydraulic fluid Apply grease petroleum jelly Apply locking compound Inspect for wear or damage Clean area or part Be careful not to scratch or damage Note correct orientation Mark orientation for reinstallation Torque specification Press in press fit Pull out with tool press fit Cover splines with installation sleeve Pressure measurement gauge location or specification 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Introduction continued General Description Danfoss Series 45 J frame open circuit piston pumps convert input torque into hydraul
22. draulic pressure in the control circuit rises above the spring force The pump control by varying the pressure at the servo piston controls the displacement of fluid in the system circuit Controls designed for Pressure Compensation PC or Load Sensing LS are available For a detailed description of control operation refer to Control options operation page 12 Pump and control sectional view LS control attached to endcap LS spool LS adjustment PC adjustment PC spool Bias spring Servo piston Piston Shaft seal Valve plate Goo shaft Block gt i spring Tapered 7777 H Tapered Slipper roller r roller bearing N bearing Cylinder block Swashplate Slipper retainer P104 362 520L0607 Rev Al Sep 2013 7 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Introduction continued System Circuit Pictorial circuit diagram 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 b
23. g configuration PC control adjustment Gauge port M1 0 300 bar 0 4351 psi 9 16 28 34 68 Nem 25 50 Ibf ft 4 PC set screw 0 300 bar 0 4351 psi 6 9 16 28 Z 34 68 Nem 25 50 Ibf ft PC adjusting plug 0 300 bar 0 4351 psi 3 9 16 28 Z 34 68 Nem 25 50 Ibf ft Case drain port L1 0 300 bar 0 4351 psi 9 16 28 34 68 Nem 25 50 Ibf ft oi E P104 365E Pressure change Control option LS LD LB LE PC RP BB BC BP BS AB AC AD AJ AS PC adjustment 42 bar rev 609 PSI rev 36 bar rev 534 PSl rev 8 5 bar rev 123 PSI rev LS adjustment JFrame 17 2 bar rev 250 PSI rev 1 PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 520L0607 Rev Al Sep 2013 21 Ionen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Adjustment continued LS Control A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or
24. gs for wear at the tips and where they contact the springs replace as necessary Inspect the springs and spring guides for wear or damage replace as necessary Carefully inspect the spools Ensure the sealing lands are free of nicks and scratches Check the ends that contact the spring guides for wear Replace spools as necessary Inspect the control housing for damage Check the spool bores for excessive wear Remove debris from orifices if necessary Ensure the servo control orifice backup plug is clean and remove debris if necessary Clean all parts and lubricate spools springs guides and new O rings with clean hydraulic fluid 520L0607 Rev Al Sep 2013 27 Deve Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued Electric Controls Reassembly continued 1 Install the servo control orifice G020 and torque to 2 3 4 Nem 18 30 in Ib Then install the orifice backup plug G030 and torque to 2 3 4 Nem 18 30 inelb 2 Install the PC spool C132 spherical end first into the PC bore Install plug C103 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft 3 Place the two PC springs C134 C135 onto the spring guide C133 and install into the PC bore Place a new O ring C138A onto the PC adjusting screw C138 and thread it into the PC bore until flush then make another full turn Install and torque the PC set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf f
25. ias spring and servo piston set swashplate position Cross section PC control P104 049 PC spool shifts to port system pressure to servo piston 12 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Features continued Control Options continued Typical load sensing control valve LS control The LS control design matches pump flow with Load Return system demand The LS control senses the flow QO pressure pressure demand of the system as a pressure drop across the External Control Valve ECV As the ECV opens and closes the pressure delta across the valve changes When opening the delta decreases 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 adjusting plug 7 and spring 8 Load sense System pressure pressure P101665E Pressure drop across external control valve defines system demand The LS control consists of two spool valves that Cross section LS control connect the servo piston either to pump case or system pressure The PC spool 6 controls the Spring Spring pressure compensating function of the control guide LS spring as previously described The LS spool 9 controls Plu Spool LS adjusting the load se
26. ic 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 The spinning cylinder block contains nine reciprocating pistons Each piston has a brass slipper connected at one end by a ball joint The slippers are held to the swashplate by the spring retainer and block spring The block spring also holds the cylinder block to the valve plate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation Via the valve plate one half of the cylinder block is connected to pump inlet and the other half to pump outlet As each piston cycles in and out of its bore fluid is drawn from the 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 lubrication and cooling Case drain ports are provided to return this fluid to the reservoir The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate The swashplate is forced into an inclined position into stroke by the bias spring The servo piston opposes the action of the bias spring forcing the swashplate out of stroke when hy
27. liance blocks are available on the Danfoss website within the PLUS 1 Guide section Ul COMPLIANT 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 14 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame 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 Port Locations and Gauge The illustration below shows gauge port locations Recommended pressure gauges and fittings are in Installation the table Gauge and port information Port Purpose Range of gauge Fitting M1 System pressure 0 300 bar 0 5000 psi 9 16 18 O ring fitting Lij La Case drain port 0 10 bar 0 100 psi 7 8 14 O ring fitting 2 D 7 16 20 O ring fitting X LS signal 0 300 bar 0 5000 psi tee into LS signal line Gauge port locations P104 364 520L0607 Rev Al Sep 2013 15 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Install Start up Procedures General
28. lug torque the LS set screw to 7 5 10 8 Nem 5 5 8 Ibf ft 5 Operate a hydraulic function to its full extension loading the pump at maximum pressure and zero flow 6 Loosen the PC set screw and turn the PC adjusting plug until the desired setting is indicated on the pressure gauge at port M12 Clockwise rotation increases pressure counterclockwise rotation decreases it approximate gain 42 bar 610 psi per turn 7 While holding the position of the PC adjusting plug torque the PC set screw to 7 5 10 8 Nem 5 5 8 Ibf ft 8 Stop the prime mover remove the pressure gauges and return the system to its normal operating configuration LS control adjustment Gauge port M1 0 300 bar 0 4351 psi 9 16 28 Z 34 68 Nem 25 50 Ibf ft LS remote PC signal port X LS set screw D 0 300 bar 0 4351 psi 9 16 28 7 5 10 8 Nem 5 5 8 Ibf ft LS adjusting plug 0 300 bar 0 4351 psi 9 16 28 Z 34 68 Nem 25 50 Ibf ft Case drain port L1 0 300 bar 0 4351 psi 9 16 28 Z 34 68 Nem 25 50 Ibf ft P104 367E TheLS setting is a differential pressure Subtract pilot pressure at port X from system pressure at port M1 to compute the actual setting PC setting is referenced to case pressure Subtract case pressure from system pressure to compute the actual setting 22 520L0607 Rev Al Se
29. lve set below PC setting causes low output flow Low PC setting prevents the pump from achieving full stroke High inlet vacuum causes low output flow Adjust external relief valve following manufacturer s recommendation External relief valve setting must be above PC setting to operate properly Adjust PC and LS setting Refer to Adjustment page 21 Correct inlet pressure conditions Check input speed Low input speeds decrease flow Adjust input speed Check pump rotation Incorrect rotational configuration causes low flow Use pump with appropriate rotational configuration Item Check for air in system Description Air in system causes erratic operation Action Activate PC allowing system to bleed air Check inlet line for leaks and eliminate source of air ingression Check control spools Sticking control spools cause erratic operation Inspect spools for free movement in bore Clean or replace 520L0607 Rev Al Sep 2013 19 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Troubleshooting continued Pressure or Flow Instability continued System Pressure not Reaching PC Setting High Inlet Vacuum Caution High inlet vacuum causes cavitation which can damage internal pump components Item Check LS setting Description Low LS setting may cause instability Action Adjust L
30. ning the Required Hydraulic Fluid Cleanliness 520L0465 See Fluid and filter maintenance page 17 for recommended fluid and filter change intervals Hydraulic fluid viscosity must be maintained within the prescribed limits As measured at the hottest point in the system e g drain line 10 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Features Auxiliary Mounting Pads Input Shafts 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 an O ring must be used to seal the auxiliary pump mounting flange to the pad The drive coupling is lubricated by oil from the main pump case For details refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information 520L0676 Auxiliary pad options P104 361 Series 45 J frame pumps are available with a variety of splined straight keyed and tapered end shafts For information on shafts refer to Series 45 J Frame Axial Piston Open Circuit Pumps Technical Information 520L0676 520L0607 Rev Al Sep 2013 Dont Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Features continued Control Options The Series 45 Frames J have three possible general control options a Load Sensing LS control with Pressure Compensator PC
31. nsing function The PC spool has 3 plug priority over the LS spool PC adjusting Plug plug Through internal porting system pressure j Spool L Spring upstream of ECV is applied to the non spring P Spring rs PC heavy end of the LS spool and through hydraulic line guide BINOS connected at port X LS pressure downstream of ECV is applied to the spring end This arrangement allows the LS spool to act on the delta between system pressure and LS pressure The LS spring sets the threshold of operation LS setting LS spool shifts to port system pressure to servo piston Because the swashplate is biased to maximum angle the pump attempts to deliver full flow to the hydraulic system When the flow being delivered exceeds demand the pressure delta across the ECV is great enough to overcome spring force and shift the LS spool porting system pressure to the servo piston The pump de strokes reducing flow until the delta across the ECV becomes equal to the LS setting When flow being delivered is less than demand the delta across the ECV drops below the LS setting and the LS spring shifts the spool connecting the servo piston to pump case The pump strokes increasing flow until the delta across the ECV becomes equal to the LS setting When the external control valve is placed in neutral it connects the LS signal line to drain With no LS pressure acting on the non spring end of the LS spool the pump adjusts stroke to whatever po
32. ontamination Contamination may interfere with movement of the PC spool Clean PC control components take appropriate action to eliminate contamination Item Check fluid temperature Description Low temperature increases viscosity High fluid viscosity causes high inlet vacuum Action Allow system to warm up before operating Inspect inlet screen Blocked or restricted inlet screen causes high inlet vacuum Clean screen remove blockage Check inlet piping Hydraulic fluid viscosity above acceptable limits Too many fittings bends or long piping causes high inlet vacuum High fluid viscosity causes high inlet vacuum Eliminate fittings to make path more direct Select fluid with appropriate viscosity for expected operating temperature See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 20 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Adjustments PC Control A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection Relieve pressure in the system before removing hoses fittings gauges or components Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable di
33. p 2013 Zonen Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps 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 Using the appropriate snap ring pliers remove the retaining ring K010 from the housing Shaft seal and retaining ring 2 Remove the shaft seal K020 from the bore in the pump housing and discard 6 O Caution Don t damage the pump housing or shaft Remove second seal if pump is so equipped See illustration below 3 Puncture the face of the seal with a packing hook or use a slide hammer type puller to remove the seal E101 187 Installation 4 Inspect the pump housing and new seal for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary 5 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 installation Caution 6 Premature bearing failure can result if the shaft seal contacts the shaft bearing Press the seal into the housing only far enough to clear the retaining ring groove Keeping the seal perpendicular to the shaft press the new seal into
34. r system pressure during start up Follow recommendations in the vehicle machine operator s manual for prime mover start up procedures 7 While 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 established increase to full operating speed If system pressure is not maintained shut down the prime mover determine cause and take corrective action Refer to Troubleshooting page 18 8 Operate the hydraulic system for at least fifteen minutes under light load conditions 9 Checkand adjust control settings as necessary after installation Refer to Adjustments page 21 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M1 11 Check the fluid level in the reservoir add clean filtered fluid if necessary 12 The pump is now ready for operation 16 520L0607 Rev Al Sep 2013 Zonen Service Manual Series 45 J Frame 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 Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Water in the fluid may be noted by a cloudy
35. ration Auxiliary Mounting o e EE ETE ELLE 11 Input shafts Control options PC control LS control Electric Proportional Controls Electric On Off Controls Required tools Port locations and gauge installation ci oirlb Start up procedure Recommendations cete vertu to rant dnt iR a RU MEER AL RIETI P PS TEE ette eI UTE 17 Excessive noise and or vibration Actuator response is sluggish System operating hot Low pump output flow Pressure or flow instability Pressure or flow instability continued System pressure not reaching PC setting FAVA AL e leti er R 20 520L0607 Rev Al Sep 2013 3 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Contents continued Adjustments Minor repair PC GOhtfol eara nmt catenis ene dud Ee MEUM D IDE MEE IE 21 ESS to ere E E UT T m 22 Shattseal replacemebt xsceeececi retenti tan e I HEURE Ue UR ITE OeL eese E 23 Auxiliary pads 24 LS and PC Controls m25 LS and PC Controls continued 126 Electric Controls 227 Servo Control Orifice A Plug aind fitting sizes and tOrgUE S sssesscsscscscsussisccssccsusescssssncveuscontuesbanssscssasicdesocsssttetbsccasouasatbusebianesasaaasacdsidsusaecnusscveuseenses 30 520L0607 Rev Al Sep 2013 Deve Service Manual Series 45
36. sconnect the mechanism while servicing Q Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines PC setting is indicated in the pump model code Refer to the Series 45 J Frame Open Circuit Axial Piston Pumps Technical Information Manual 520L0676 for more information Before performing adjustments read page 15 Pressure measurement 1 Install a pressure gauge in port M1 to measure system pressure Install a pressure gauge in case drain port L1 or L2 to measure case pressure A 6 2 Start the prime mover and allow 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 adjusting plug until the desired setting is indicated on the pressure gauge at port M1 Clockwise rotation increases pressure counterclockwise rotation decreases approximate gain 42 bar 610 psi per turn If the pressure does not increase an external system 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 screw to 7 5 10 8 Nem 5 5 8 Ibf ft 5 Stop the prime mover remove the pressure gauges and return the system to its normal operatin
37. servoir Inspect heat exchanger Check air flow and input air temperature for the heat exchanger Insufficient air flow high input air temperature or undersized heat exchanges will not meet cooling demands of the system Clean repair or replace heat exchanger as required Verify proper size of heat exchanger Check external system relief valve setting Fluid passing through relief valve adds heat to system Adjust external system relief valve setting following manufacturer s recommendations External relief valve setting must be above PC setting for proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions Item Check fluid level in reservoir Description Insufficient hydraulic fluid will limit output flow and cause internal damage to pump Action Fill the reservoir 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 Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Check external system relief valve setting Check PC and LS control setting Check pump inlet pressure vacuum Eternal relief va
38. sition necessary to maintain system pressure at the LS setting The pump is now in standby mode Because of the series arrangement of the LS and PC spools the PC spool will override the LS spool 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 causing the pump to destroke 520L0607 Rev Al Sep 2013 13 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Features continued Control Options Electric Proportional Controls continued 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 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section gt COMPLIANT Electric Proportional Control Principle The Electric Proportional Control consists of a proportional solenoid integrated into a Remote Pressure Compensated control This control allows the 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 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 comp
39. t 4 Install the LS spool C112 spherical end first into the LS bore 5 Install plug C104 Torque the plug to 10 8 13 5 Nem 8 10 Ibf ft 6 Place the two LS springs C114 C115 onto the spring guide C113 and install into the LS bore Thread adjusting screw C118 into the LS bore until flush then make another full turn Install and torque the LS set screw C102 to 7 5 10 8 Nem 5 5 8 Ibf ft 7 Install the electric control manifold drain orifice C149 and torque to 2 3 4 Nem 18 30 inelb 8 Install the cartridge valve C150 into the electric control manifold C152 Torque to 25 8 28 5 Nem 19 21 Ibf ft DO NOT OVERTORQUE the cartridge valve 9 Install the electric solenoid C155 and solenoid coil nut C125 Torque to 6 8 9 5 Nem 5 7 Ibf ft 10 Install plug C153 Torque the plug to 10 8 13 5 Nem 8 10 Ibf 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 the manifold assembly onto the control housing using four screws C151 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque the screws in a criss cross pattern and re torque the first Screw to ensure proper torque retention 13 Using petroleum jelly to retain them install the four interface O rings C200 in the recesses on the control housing 14 Install the control assembly onto the endcap using the four screws C300 Torque the screws to 5
40. tional gear motor I 1 B Meese oS ee sew im L E System pressure ex Servo pressure Heat exchanger eae Filter Actuator pressure a Load sense pressure aaa eee Actuator return Suction case drain P104 366E system return 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 8 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Technical Specifications General Specifications Features and options Model Feature Unit J45B J51B J60B J65C J75C Maximum Displacement cm in 45 2 75 51 3 11 60 3 66 65 3 97 75 4 58 l min 126 0 S77 156 0 162 6 180 Flow at rated speed theoretical mesas 33 3 36 4 41 2 42 9 47 5 Input torque at maximum N m bar 0 716 0 811 0 956 1 035 1 193 displacement theoretical Ibf in 1000 psi 436 9 495 1 583 6 631 4 728 1 Mass moment of inertia of kg m 0 00455 0 00455 0 00455 0 00433 0 00433 internal rotating components slug ft 0 00336 0 00336 0 00336 0 00319 0 00319 Axial ports kg lb 23 13 51 Weight p g Ib 51 Radial ports 26 65 58 8 Rotation Clockwise Counterclockwise
41. uplings Improper inlet conditions cause erratic behavior and low output flow A loose or incorrect shaft coupling causes excessive noise and or vibration Correct pump inlet pressure vacuum conditions Refer to Hydraulic parameters page 10 Repair or replace coupling and ensure that correct coupling is used Check shaft alignment Misaligned shafts create excessive noise and or vibration Correct shaft misalignment Hydraulic fluid viscosity above acceptable limits Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operating or use fluid with the appropriate viscosity grade for expected operating temperatures See Hydraulic Fluids and Lubricants Technical Information Manual 520L0463 Item Check external system relief valve setting Description Low external relief valve setting slows down system Action Adjust external relief valve setting following manufacturer s recommendations External relief setting must be above PC setting to operate properly Check PC and LS control setting Low PC setting prevents the pump from achieving full stroke Low LS setting limits output flow Adjust PC and LS setting Refer to Adjustments page 21 Check LS control signal pressures Internal system leaks Hydraulic fluid viscosity above acceptable limits
42. y 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 while limiting the maximum pressure Therefore flow and pressure in the system are compensated to meet requirements oo JFrameSeries 45 Double acting cylinder z open circuit axial piston pump with load sensing control PVG 32 i multi section load sensing control Valve SZ f AG Zt 72 ELLA ELE Bi direc
43. y onto the endcap using the 4 screws C300 Torque the screws to 5 4 7 5 Nem 4 5 5 Ibf ft Torque screws in a criss cross pattern and re torque the first screw to ensure proper torque retention 20 Check and adjust the control setting See Adjustments page 21 26 520L0607 Rev Al Sep 2013 Service Manual Series 45 J Frame Open Circuit Axial Piston Pumps Minor Repair continued Electric Controls Disassembly 1 2 Remove set screws C102 PC adjusting Remove plug C103 Remove PC spool Remove plug G030 and orifice G020 Remove LS adjusting plug C118 springs Control assembly Remove four screws C300 Remove the control and discard the four O rings C200 plug C138 with O ring C138A springs C134 C135 and seat C133 Discard the O ring if it is damaged C132 Note orientation of the spool for reassembly C114 C115 and seat C113 Remove plug C104 and spool C112 Note the orientation of the spool for reassembly Remove four screws C151 Remove the CO csa manifold C152 and discard the two cs amp interface O rings C154 mI For electric proportional controls only Remove the electric control manifold drain orifice C149 10 Remove plug C153 Remove the cartridge valve nut C125 electric solenoid C155 and cartridge valve C150 from the electric control manifold Inspection j Inspect the adjusting plu
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