Service Manual

K and L Frame
Variable Motors, Cartridge Mountwww.danfoss.com

Service Manual
K and L Frame Variable Motors, Cartridge Mount

Revision history

2 | © Danfoss | November 2023

Table of revisions
Date

ChangedRev

November 2023

Changed document number from 'AX00000042' and '520L0631' to 'AX152886481620'

0504

December 2018

Corrected technical data

0501

July 2017

Updated to Engineering Tomorrow

0402

April 2014

Danfoss layout

DA

July 2013

add anti-cavitation valve

CB

October 2010

new back page

CA

November 2006

Added loop flushing valve

B

July 2004

First edition

A

AX152886481620en-000504

Service Manual
K and L Frame Variable Motors, Cartridge Mount
Contents
Introduction
Overview..............................................................................................................................................................................................4
Safety precautions............................................................................................................................................................................4
Symbols used in Danfoss literature............................................................................................................................................4
Design...................................................................................................................................................................................................6
The System circuit............................................................................................................................................................................ 6
Technical specifications
Overview..............................................................................................................................................................................................8
Features and options...................................................................................................................................................................... 8Specifications..................................................................................................................................................................................... 8
Operating Parameters.....................................................................................................................................................................8
Fluid specifications.......................................................................................................................................................................... 8
Features
Output shafts...................................................................................................................................................................................10Controls............................................................................................................................................................................................. 10
Control orificing........................................................................................................................................................................ 10
Brake release port.......................................................................................................................................................................... 10
Pressure measurements
Required tools................................................................................................................................................................................. 11Port locations and gauge installation.....................................................................................................................................11
Initial start-up procedures
General ..............................................................................................................................................................................................12Start-up procedure........................................................................................................................................................................ 12
Fluid and filter maintenance
Recommendations........................................................................................................................................................................ 13
Troubleshooting
Excessive noise and/or vibration..............................................................................................................................................14
System operating hot...................................................................................................................................................................14
Motor shifting irregularities....................................................................................................................................................... 14
Minor repair
Shaft seal replacement.................................................................................................................................................................15
Remove the shaft seal............................................................................................................................................................. 15
Inspect the components........................................................................................................................................................ 15
Install the new shaft seal........................................................................................................................................................15
Loop flushing valve....................................................................................................................................................................... 16
Remove the loop flushing valve..........................................................................................................................................16
Inspect the components........................................................................................................................................................ 16
Install the loop flushing valve.............................................................................................................................................. 16
Anti-Cavitation Valve.................................................................................................................................................................... 16
Remove the anti-cavitation valve....................................................................................................................................... 16
Inspect the components........................................................................................................................................................ 17
Install the anti-cavitation valve............................................................................................................................................17© Danfoss | November 2023

AX152886481620en-000504 | 3

Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Overview
This manual includes information for the installation, maintenance, and minor repair of the K and L Frame
Cartridge Mount Variable Motors. The manual includes a description of the units and their individualcomponents, troubleshooting information, and minor repair procedures. Performing installation,
maintenance, and minor repair of K and L Frame Variable Motors according to the procedures in thismanual 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.powersolutions.danfoss.com.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and othersfrom injury. Take the following general precautions whenever servicing a hydraulic system.

W Warning
Unintended machine movement
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.

W Warning
Flammable cleaning solvents
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.

W Warning
Fluid under pressure
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 withhydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, orcomponents. Never use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.

W Warning
Personal safety
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.

Symbols used in Danfoss literature
WARNING may result in injury
CAUTION may result in damage to product or property
Reusable part4 | © Danfoss | November 2023

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Non-reusable part, use a new partNon-removable item
Option – either part may exist
Superseded – parts are not interchangeable
Measurement required
Flatness specification
Parallelism specification
External hex headInternal hex head
Torx headO-ring boss port
Tip, helpful suggestion
Lubricate with hydraulic fluid
Apply grease / petroleum jelly
Apply locking compound
Inspect for wear or damage
Clean area or partBe 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© Danfoss | November 2023

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
Pressure measurement / gauge location or specification
The symbols above appear in the illustrations and text of this manual. They are intended to communicate
helpful information at the point where it is most useful to the reader. In most instances, the appearanceof the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.
DesignK and L Frame Variable Motors (KC/LC) are low to medium power, two-position axial piston motors
incorporating an integral servo piston. They are designed for operation in both open and closed circuit
applications. KC/LC motors have a cartridge style mounting configuration. The standard control is a direct
acting single line hydraulic control. The integral servo piston controls motor displacement.
The motor is spring biased to maximum displacement and hydraulically shifted to minimum
displacement. Minimum and maximum displacement can be set with fixed internal stops. The large
diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing.
The motor is ideally configured for installations requiring compact packaging and optimized plumbing,such as wheel ends. One face of the motor contains all hydraulic porting.
KC/LC cross section
Servo piston
Bias spring

Swashplate

Outputshaft
Cylinder
block

Shaft
seal
EndcapBearing
Valve plate

PistonSlipper

The System circuit
The circuit below shows the KC/LC motor in a simple closed-loop hydrostatic propel application. The
motor is driven by a Series 42 medium power axial piston pump with manual displacement control.
Control pressure applied through an external control valve shifts the motor to minimum displacement;
spring force returns the motor to maximum displacement in the absence of control input.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Introduction
System circuit diagram
High loop pressure
Case pressure
Charge/low loop pressure
Control pressure
Inlet pressureServo
pistonReserviorMotordisplacement
control valve

Displacement
control spool

Pump control handle
and feedback linkage

Servo piston

Swashplate
Input
shaft

Charge relief valve
Outputshaft
Chargepump

Check valves
w/high pressure
relief valves andbypass plunger
FilterPump
swashplate

Cylinderblockassembly

Slipper

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Technical specifications
Overview
Specifications and operating parameters for KC/LC motors are given here for reference.
Features and options
Mount

SAE-B (LV/KV)

Cartridge (LC/KC)

Motor type

Inline, axial piston, positive displacement, two-speed variable motors

Displacement

L: 25, 30, or 35 cm3 [1.50, 1.83, or 2.14 in3] K: 38 or 45 cm3 [2.32 or 2.75 in3]

Rotation

Bidirectional

Installation position

Discretionary: Housing must always be filled with hydraulic fluid

Porting

SAE O-ring boss, axial or twin radial

SAE O-ring boss, twin radial

Output shafts

Splined 13 or 15 tooth 16/32 pitch, 0.875 in. straight
keyed, and 1:8 taper

Splined 13 or 15 tooth 16/32 pitch

Control options

Single or dual line hydraulic control

Single line hydraulic control

Displacement limiter

Fixed maximum and minimum displacement limiters available

Speed sensor

Available on L Frame SAE-B motors, in development* on K frame and cartridge motors

Loop Flushing Valve

Available

Specifications
Specifications
Parameter

Unit

L25

L30

L35

K38

K45

Displacement (maximum)

cm3 [in3]

25 [1.50]

30 [1.83]

35 [2.14]

38 [2.32]

45 [2.75]

Weight (cartridge and SAE-B)

kg [lb]15.4 [34]Mass moment of inertia of rotating componentskg•m2[slug•ft2] 0.0017 [0.0012] 0.0016 [0.0012] 0.0015 [0.0011] 0.0023 [0.0017] 0.0023 [0.0017]

Theoretical torqueN•m/bar0.40 [244][lbf•in/1000psi]

0.48 [293]0.56 [347]0.60 [366]0.72 [439]Operating Parameters
Operating parameters
Parameter

Unit

System pressure

maximum working

bar [psi]

maximum
Speed limit (at max. disp.)

rated

min-1 (rpm)

L25

L30

L35

K38

K45

400 [5800]

350 [5075]

300 [4350]

350 [5075]

300 [4350]

420 [6090]

375 [5440]

325 [4715]

415 [6020]

350 [5075]

3400

3500

3600

3600

3500

maximum

3950

4150

4300

4000

3900

Speed limit (at min. disp., including
Zero degrees)

rated

4400

4450

4500

4650

4500

5000

5150

5300

5200

5050

Case pressure

maximum working

maximum
maximumbar [psi]

2 [29]
6 [87]

Fluid specifications
Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing
oxidation, rust, and foam inhibitors.
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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Technical specifications
Parameter

Unit

Minimum

Continuous

Maximum

Viscosity

mm2/sec (cSt) [SUS]

7
[47]

12-60
[70-278]1600[7500]

Temperature°C [°F]-40 [-40]

82 [180]

104 [220]

Cleanliness
Filtration efficiency© Danfoss | November 2023

ISO 4406 Class 18/13 or better
suction filtration

β35-44=75 (β10≥1.5)

charge filtration

β15-20=75 (β10≥10)AX152886481620en-000504 | 9

Service Manual
K and L Frame Variable Motors, Cartridge Mount
Features
Output shafts
KC/LC motors may have a 13 or 15 tooth shaft, 16/32 pitch, and ANSI B92.1 1970-Class 5. For dimensions,refer to L and K Frame Variable Motors Technical Information, BC161386484850.
Controls
KC/LC motors are designed to operate in two positions: maximum and minimum displacement. The
motors are spring biased to maximum displacement and hydraulically shifted to minimum displacement.
KC/LC motors can operate with a single line control only. Pressure applied at port X1 shifts the motor tominimum displacement. Refer to the table above for control input pressure range.
Control input pressure limits
KC/LC with single line control

14 to 69 bar[200 to 1000 psi]

Control orificing
KC/LC motors can have optional, internal, supply and drain orifices installed to regulate control response
times.
KC/LC motors rely on external valving and orificing to regulate shift speeds. You can achieve quick
acceleration (shift to min) and slow deceleration (shift to max) simply by installing an orifice in the tankline of the external control valve.
Brake release port
KC/LC motors are equipped with a brake release port to allow access to the brake-release feature of thegear box from the rear of the motor. This consists of a simple passage through the motor housing with arear-facing 7/16 in. SAE O-ring boss port. Applications using this brake release port require an O-ring toseal the passage against the gear box.
While all motors will have the brake release port, not all gearboxes are compatible with this motorfeature. Consult your gearbox manufacturer for suitability and compatibility. If your gearbox is notcompatible with this feature, simply leave the port plugged.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Pressure measurements
Required tools
The service procedures described in this manual can be performed using common mechanic's handtools. Special tools, if required are shown. Calibrate pressure gauges frequently to ensure accuracy. Use
snubbers to protect gauges.
Port locations and gauge installation
For economical reasons, the cartridge motor does not contain any designated gauge installation ports.
All pressure measurements can be obtained by installing tee fittings to the connections at the locations
listed in the table / drawing below. Recommended gauge sizes are also listed.
Port information
Port identifier

Size

Pressure obtained

Gauge size, bar [psi]X1[0.5625]-18 UNF-2B

Control signal

600 [10 000]

Case drain port

[0.750]-16 PER SAE

Case drain

10 [100]

A[1.0625]-12 PER SAE

System pressure

600 [10 000]B

[1.0625]-12 PER SAE

System pressure

600 [10 000]

Brake release port

[0.4375]-20 PER SAE

N/A

N/A

Twin radial port locations
Control port (X1)
Brake release port

Case drain port
System port (B)System port (A)P104 249E© Danfoss | November 2023

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Initial start-up procedures
GeneralFollow this procedure when starting-up a new motor installation or when restarting an installation inwhich the motor has been removed.

W Warning
Unintended vehicle or machine movement hazard
When using the RDM in combination with S45 open circuit pumps with LS or EPC be aware that there will
likely be motor movement as long as the engine is turning. Due to the LS-setting of the pump, a standby
pressure will remain in the system even if the normally closed control is fully energized. Lowest standby
pressures to the motor, 15-18 bar or above, may be enough to turn the RDM and has the potential tocause injury or damage.
Prior to installing the motor, inspect for damage incurred during shipping. Make certain all systemcomponents (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.
Start-up procedure
1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter
when pouring into the reservoir. Never reuse hydraulic fluid.
2. 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.
3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper
most case drain port.
4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most casedrain ports.
5. Install a 0 to 35 bar [0 to 500 psi] gauge in the charge pressure gauge port of the pump to monitor
system pressure during start up.
Follow recommendations in the vehicle / machine operator's manual for prime mover start up
procedures.
6. While watching the pressure gauge, 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 isestablished, increase to full operating speed. If system pressure is not maintained, shut down theprime mover, determine cause, and take corrective action. Refer to Troubleshooting on page 14.
7. Operate the hydraulic system for at least fifteen minutes under light load conditions.
8. Check and adjust pump control settings as necessary after installation.
9. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressuregauge port.
10. Check the fluid level in the reservoir; add clean filtered fluid if necessary.
The motor is now ready for operation.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Fluid and filter maintenance
Recommendations
To ensure optimum life of these motors, perform regular maintenance of the fluid and filter.
Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness whenservicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid
contaminated by water may appear cloudy or milky or free water may settle in the bottom of thereservoir. 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 vehicle / machine manufacturer's recommendations or at theseintervals:
Fluid and filter change interval
Reservoir typeMax oil change interval

Sealed2000 hours

Breather

500 hours

Change the fluid more frequently if it becomes 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 tochange the filter. Replace all fluid lost during filter change.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Troubleshooting
Excessive noise and/or vibration
Item

Description

ActionCheck oil level in reservoir
and oil supply to the motor.

Insufficient hydraulic fluid could lead to cavitation thatwould cause system noise.

Fill the reservoir to the proper level and ensure that oil
supply to the motor is adequate and the lines areunobstructed.

Check for air in the system.

Air trapped within the system lines, or the motor itself,
could result in cavitation that would cause system noise.

Ensure that all of the system lines and components arepurged of air.

Inspect the output shaft
couplings.

A loose or incorrect shaft coupling will produce vibrations
that could result in system noise.

Ensure that the correct coupling is used and that it fitsproperly onto the shaft.

Inspect the output shaftalignment.

Misaligned shafts create excessive frictional vibration that
could result in system noise.

Ensure that the shafts are properly aligned.

Hydraulic oil viscosity above Viscosity above acceptable limits will result in cavitation
limits.
that would lead to system noise.

Replace hydraulic oil with appropriate fluid for operating
conditions. Refer to publication 5200L0463 for information
on fluid selection.

System operating hot
Item

Description

ActionCheck oil level in reservoir
and oil supply to the pump.

Insufficient amount of hydraulic fluid will not meet thecooling demands of the system.

Fill the reservoir to the proper level.

Inspect the heat exchanger,(if so equipped).

If the heat exchanger fails, or becomes obstructed, it may
not meet the cooling demands of the system.

Ensure that heat exchanger is receiving adequate air flow
and that the heat exchanger is in good operating
condition. Repair or replace as necessary.

Check the system relief
valves.

If a system relief valve becomes unseated for an extended
period of time or fails for any other reason, the system
could become overheated.

Repair or replace any malfunctioning relief valves asapplicable and verify that the loads on the machine are notexcessive.

Motor shifting irregularities
Item

Description

ActionCheck the electricalconnection and electricalsignal to the shifting valve
coil.

Electrical signal is needed to energize the valve coil. Theenergized coil is shifting the motor.

Ensure that the electrical connection between controller
valve coil is alright. Check wires and connectors. Checkelectric signal. Valve coil can be energized with 12V PWMsignal or directly with 12V.

Check valve coil

The energized valve coil is moving the valve spool. Thatleads to motor shifting.

Measure valve coil resistance. Value needs to be 5,3ohms+-5%. Replace valve if resistance is differing.

Check shifting pressure.

Shifting pressure moves servo piston. Obstruction could
result in slow or no shift conditions.

Shifting pressure at full energized valve coil (1500mA)
needs to be at 20-32bar [290-464psi] or system input
pressure, whichever is lower. Replace shifting valve whenmeasured pressure is differing.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Minor repair
Shaft seal replacement
Remove the shaft seal
1. Remove the snap ring (B002) retaining the shaft seal and support washer.
2. Remove the support washer (M004).
3. Carefully pry out the shaft seal (M003).
To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide
hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal.
4. Discard the seal.
Inspect the components
Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear,
and contamination. Polish the shaft and clean the housing if necessary.
Replacing the shaft seal
B002

M004

M003

P104 251

Install the new shaft seal
1. Cover the shaft splines with an installation sleeve to protect the shaft seal during installation.
2. Install a new shaft seal (M003) with the cupped side facing the motor. Press seal into housing until itbottoms out. Press evenly to avoid binding and damaging the seal.
3. Install seal support washer (M004).
4. Install snap ring (B002).
5. Remove the installation sleeve.

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Service Manual
K and L Frame Variable Motors, Cartridge Mount
Minor repair
Loop flushing valve
Remove the loop flushing valve
1. Using a 11/16 in internal hex wrench remove plug (E020) and (E010).
2. Using a 1/4 in hex wrench remove plug (E042).
3. Remove O-rings (E020B, E042A, and E010B).
4. Using pliers, remove centering springs (E041, E020C, and E010C).
5. Remove spring retaining washers (E020D and E010D).
6. Remove shift spool (E030). Remove orifice poppet (E040).
Loop flushing valve
E010B
E010C
E010D
E010
11/16 in
37 N·m[27 lbf·ft]

E020D
E020C
E020B

E030

E020
11/16 in
37 N·m[27 lbf·ft]
E042A

E040
P106 508E

E041
E042

5/8 in27 N·m[20 lbf·ft]

Inspect the components
Inspect sealing area for rust, wear, or contamination. Also check springs and poppet for wear.
Install the loop flushing valve
1. Install orifice poppet (E040). Install shift spool (E030).
2. Install spring retaining washers onto springs (E020D and E010D).
3. Carefully install centering springs (E041, E020C, and E010C).
4. Install new O-rings (E010B, E020B, and E042A).
5. Using a 1/4 in hex wrench torque plug (E042) to 27 N•m [20 lbf•ft].
6. Using a 11/16 in internal hex, torque plugs (E010 and E020) to 37 N•m [27 lbf•ft].
Anti-Cavitation Valve
Remove the anti-cavitation valve
The anti-cavitation valve is installed into the high pressure port. The high pressure port depends on
motor rotation. If rotation is counterclockwise, the high pressure port is A. If rotation is clockwise, thehigh pressure port is B.
1. Using a 5/16 in internal hex wrench remove valve plug (E061). Remove and discard O-ring (E063).
2. Remove spring (E012) and relief valve (E011) from end cap.
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K and L Frame Variable Motors, Cartridge Mount
Minor repair
3. Using a 5/16 in internal hex wrench remove plug (E020). Remove and discard O-ring (E020A).
Anti-cavitation valve

E020
E020A

Counter-Clockwise rotation shown.
Anti-cavitation valve is installedin port A.

E011
E012
E063
E061

P108 720E

Inspect the components
Inspect sealing area for rust, wear, or contamination. Check spring and relief valve for wear anddamage. Relief valve is non-serviceable, replace as complete unit if damaged.
Install the anti-cavitation valve
1. Lubricate and insert relief valve (E011) and spring (E012) in original location.
2. Lubricate and install new O-ring (E063) on valve plug (E061).
3. If needed lubricate and install new O-ring (E020A) on plug (E020).
4. Using a 5/16 inch internal hex wrench to install valve plug (E061) into port with relief valve (E011).
Torque to 80 N•m [59 lbf•ft].
5. If needed using a 5/16 inch internal hex wrench to install plug (E020) into port without relief valve(E011). Torque to 80 N•m [59 lbf•ft].

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© Danfoss | November 2023

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