Series 42 4T Tandem Pumps Service Manual
Contents
1. 3 mm 2 2 4 Nem 1 5 3 Ibfeft E100026E Shafts Orient housing so shaft to be replaced is on top Do not move the pump until the shaft has been replace 32 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Minor repair Remove rear shaft 1 Remove retaining ring C012 Remove bearing C009 2 Pull shaft C006 from housing If necessary use a snap ring pliers to pull shaft 0 Caution Do not damage machined surfaces of pump when removing shaft Remove front shaft with seal carrier 1 Remove retaining ring F096 Remove shaft seal carrier C020 2 Remove shaft seal carrier C020 Remove and discard O ring C017 3 Press seal out of carrier and discard it 4 Remove shaft with bearing from housing e 5 If replacing bearing use a snap ring pliers to remove retaining ring C002 or C010 Remove roller bearing C003 or C008 Remove front shaft without seal carrier 1 Remove shaft with bearing from housing e 2 If replacing bearing use a snap ring pliers to remove retaining ring C010 Remove roller bearing C008 Inspect shafts Check to see that the shaft and its splines are straight and free of damage or heavy wear Inspect the shaft sealing surface Replace the shaft if a groove exists at the sealing land Clean the sealing area with a nonabrasive material Install rear shaft 1 Lubricate and install2. 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 Fluid and filter change intervals Sealed reservoir 2000 hours Breather reservoir 500 hours 11042614 Rev BA November 2014 15 Service Manual Series 42 4T Pumps Troubleshooting Overview This section provides general steps to follow if you observe certain undesirable system conditions Some of the items are system specific Always observe the safety precautions listed in the introduction of this manual If standard troubleshooting procedures do not remedy the problem contact a Danfoss Global Service Partner System operating hot Item Oil level in reservoir Description Insufficient hydraulic fluid will not meet the cooling demands of system Action Fill the reservoir to the proper level with clean hydraulic oil Heat exchanger if equipped The heat exchanger is not sufficiently cooling the system Check the air flow and input air temperature for the heat exchanger Clean repair or replace the heat exchanger as necessary Bypass valve A partially activated bypass valve may result in heat generation within the system Verify that the bypass valve is fully closed and that the valve is seating properly Repair or repl
3. November 2014 35 Service Manual Series 42 4T Pumps Port locations and torque chart Fastener plug and port locat ions and gauge installation The following table shows the fastener plug and port locations and gauge sizes needed Port information Port identifier Port size Wrench size Pressure obtained Gauge size bar psi L1 L2 15 16 12 UNF 2B 15 mm internal hex Case drain 10 100 M1 M2 9 16 18 UNF 7 mm internal hex System pressure 600 10 000 M4 M5 9 16 18 UNF 7 mm internal hex Servo pressure 50 1000 System ports Port identifier 110 Split flange boss thread M12 x 1 75 A 11 16 12 UN 2B B 11 16 12 UN 2B Fastener size and torque chart Item Fastener Wrench size Torque D081 EDC MDC kit screws not shown 1 2 inch 16 Nem 12 lbfeft B002 Side cover screws 13mm 16 Nem 12 Ibf ft D002 Control cover screws T30 Torx 16 Nem 12 Ibf ft L020 Displacement limiter adjustment screws 4mm N A MO005 Servo cover screws T30 Torx 16 N m 12 Ibf ft T060 Seal nut 13 mm 23 Nm 17 lbfeft Plug size and torque chart Item O ring plug Wrench size Torque D032 3 4 16 UNF 7 8 inch 65 Nem 48 Ibf ft D035 3 4 16 UNF 5 16 inch 82 Nm 60 Ibf ft F093 9 16 18 UNF 1 4 inch 35 Nem 26 Ibf ft L010 9 16 18 UNF 11 16 inch 35 Nem 26 Ibf ft K001 3 4 16 UNF 1 inch or 8 mm internal hex 82 Nm 60 Ibfeft F030 3 4 16 UNF 7 8 inch 65 N
4. while performing the procedure in order to prevent injury to the technician and bystanders 1 2 Disconnect the external control linkage for MDC or control signal input for EDC from the pump Install pressure gauges in the servo gauge ports M4 and M5 to measure pressure on the pump servo piston Start the prime mover and run at normal operating speed 4 Loosen the control neutral adjustment seal lock nut D015 6 7 Turn the adjustment screw D014 clockwise until one of the gauges registers an increase in pressure on the servo piston Mark the position of the adjustment screw Turn the screw counterclockwise until the other gauge registers an increase in pressure on the servo piston Mark the position of the adjustment screw Turn the adjustment screw clockwise so that it is midway between the marks Adjustment screw movement produces constant change for both directions so both the pressure gauges should indicate nearly equal pressures While holding the adjustment screw D014 in position torque the seal lock nut D015 to 31 50 Nem 23 37 Ibfeft Stop the prime mover and remove the pressure gauges Remove the plugs in the gauge ports 22 11042614 Rev BA November 2014 Dossi Service Manual Series 42 4T Pumps Adjustments 8 Connect the external control linkage for MDC or control signal input for EDC to the pump Reconnect the work function Control neutral adjustment screw
5. D014 MDC EDC neutral adjustment screw 5mm Yak A 2 Go MDC EDC neutral adjustment seal lock nut 17mm Ze 31 50 Nem 23 37 Ibf ft E100003E EDC Shown Equalization of pressure gauges using pump neutral adjustment screw M3 M4 O x P101 270E 11042614 Rev BA November 2014 23 Service Manual Series 42 4T Pumps Minor repair Standard procedures Remove the pump Prior to performing certain minor repairs on the Series 42 pump it may be necessary to remove the pump from the machine Chock wheels of vehicle to prohibit movement Be aware that hydraulic fluid may be under high pressure and may be hot Inspect the outside of the pump and fittings for damage Keep it clean Cleanliness is a primary means of assuring satisfactory pump life on either new or repaired units Clean the outside of the pump thoroughly before disassembly Take care to avoid contamination of the system ports Clean parts using a clean solvent wash and air dry As with any precision equipment keep all parts free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the pump with a protective layer of plastic Inspect for system contamination Inspect the pump for system contamination If you find contamination fu
6. Torque to 16 Nem 12 Ibf ft in the pattern shown Bolt torque pattern TORQUE BOLTS IN ORDER INDICATED Torque this screw first and last P10158 Use an 8 mm wrench to secure neutral adjusting screw Install a new seal lock nut T060 onto the neutral adjustment screw T015 Do not torque at this time Perform pump neutral adjustment and control neutral adjustment procedures Refer to Control neutral adjustment for MDC and EDC on page 22 Removal of the servo covers may change the position of optional displacement limiters readjust if necessary see Displacement limiter adjustment on page 19 Wrench size for locknut T060 and neutral adjust screw T015 Frame size cm 41 51 Control MDC EDC NFPE NFPH Lock nut T060 17mm 17mm Neutral adjust screw T015 7mm 7mm 11042614 Rev BA November 2014 31 Service Manual Series 42 4T Pumps Minor repair Servo piston covers 16 Nm 12 Ibf ft M005 T30 T30 4 i Loos 13 mm I 16 Nm 12 Ibf ft T30 16 Nm 12 Ibfeft ue b T015 Neutral adjust screw 16 Nm 12 Ibf ft P107 781E Removing NFPH orifirces single pumps shown E051 NFPH orifice 3 mm 2 24Nm 1 5 3 Ibfeft 2 E052 NFPHorifice
7. D032 6 mm ae lt 65 Nem 48 Ibfeft D015 017 mm 2 40 Nem 30 Ibfeft System Check Relief SCR valves lt 16 J 3 3 and 16 Nem 12 Ibfeft D081 4mm R Nem Be Q 2 gt a 40 Nem 30 Ibf ft D032 6mm 65 Nem 48 Ibfeft 65 Nem 48 Ibf ft P107 779E The System Check Relief valve assembly performs the charge check high pressure relief and loop bypass functions You may remove this assembly for cleaning and replacement of O rings Removal 1 Using a 1 inch wrench or an 8 mm internal hex remove the valve seat plugs K001 from the pump housing Remove and discard the O rings and backup rings K008 K009 and K010 28 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Minor repair 2 Remove the SCR valve assemblies H005 J005 If SCR valve does not have a bypass plunger skip steps 3 and 4 3 Use a snap ring pliers to remove retaining ring K005 4 Remove bypass plunger K002 and O rings K006 Discard O rings Inspection Inspect the valves and mating seats in the valve seat plugs K001 for damage or foreign material The SCR valves H005 J005 are not serviceable replace as a complete unit Replacement If SCR valve does not have a bypass plunger
8. address Danfoss Power Solutions Danfoss Danfoss Shanghai Co Ltd Power Solutions GmbH amp Co OHG Power Solutions ApS Building 22 No 1000 Jin Hai Rd Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District DK 6430 Nordborg Denmark Phone 45 7488 2222 Shanghai China 201206 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 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 11042614 Rev BA November 2014 www danfoss com Danfoss A S 2013
9. bearing C009 onto shaft U001 2 Install shaft with bearing into housing o Install retaining ring C012 Caution Do not damage machined surfaces of pump when removing shaft Install front shaft with seal carrier 1 Lubricate and install bearing C003 onto shaft 2 Use a snap ring pliers to install retaining ring C002 Install shaft with bearing into housing e 3 Lubricate and install seal C018 into seal carrier C020 Lubricate and install O ring C017 4 Install seal carrier into housing Install retaining ring F096 Install front shaft without seal carrier 1 Lubricate and install roller bearing C008 11042614 Rev BA November 2014 33 Service Manual Series 42 4T Pumps Minor repair 2 Replace shafts Rear shaft C006 a _ Install shaft with bearing into housing Install retaining ring C010 Front shafts D C010 D F096 020 a C005 P107 782E 34 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Minor repair Seal carrier assembly C017 5 S Seal carrier shown 77 DL with the inside facing up T _A VEDI hl Press seal to bottom of carrier P107 783E 11042614 Rev BA
10. displacement limiter adjustment screw results in approximate flow output changes per the table 5 Once you achieve the proper output flow torque the displacement limiter seal lock nut L025 to 20 26 Nem 15 19 Ibf ft while holding the position of the adjustment screw L020 11042614 Rev BA November 2014 19 Dose Service Manual Series 42 4T Pumps Adjustments 6 If required repeat this procedure using the opposite displacement limiter to set the output flow in the other direction Displacement limiters L025 Displacement L limiter seal lock nut uc Oe O 13mm ee Z 20 26 Nem ita 15 19 Ibfeft VO sani L001 Servo piston RIGHT SIDE VIEW M4 M020 Displacement M025 limiter Displacement limiter seal lock nut Q 13 mm lt 20 26 Nem 15 19 Ibfeft LEFT SIDE VIEW M5 Displacement limiter adjustment Size Displacement change per turn 41 cm 5 0 cm3 rev 31 in3 rev 20 11042614 Rev BA November 2014 Dos Service Manual Series 42 4T Pumps Adjustments Pump neutral adjustment Conversions Changes to the displacement limiter settings are conversions to the pump Change the nomenclature on the specification tag to reflect the alterations of the unit Refer to 520L0637 Series 42 Technical Information Manual Model Code Supplement or contact your Danfoss represen
11. of the pump the springs D91 are located Remove control spools washers and springs 5 Remove the seal nuts D015 and neutral adjustment screws D014 Note position of adjustment screws for reassembly 24 11042614 Rev BA November 2014 Dose Service Manual Series 42 4T Pumps Minor repair Installation 1 Install adjustment screws D014 to position previously noted Install lock nuts D015 Do not tighten the nuts After pump is installed on machine refer to Control neutral adjustment for MDC and EDC on page 22 for control neutral adjustment procedure 2 Lubricate and install spools D90 washers D92 and springs D91 noting proper orientation Install the two side bore plugs and torque to 65 Nem 48 lbf ft 3 Combine the center pin of the feedback links D012 with the mating bore of the neutral adjustment links D013 Insert the end of the feedback links into the servo piston slots Mate the neutral adjustment links with the control neutral adjustment screws D014 Insert the linkage pivot screws D010 and torque to 12 Nem 9 Ibf ft Install the summing links D011 It may be necessary to rotate the control spools so that the summing link forks engage the flats on the control spools 4 Install new gaskets E011 Install controls 11042614 Rev BA November 2014 25 Service Manual Series 42 4T Pumps Minor repair 5 Install screws D002 Torque to 16 Nm 12 lbfeft MDC EDC
12. spool and linkage T30 l rao D002 16 Nm 12 Ibf ft O til DALE amp D032A 17mm re lt P D032 P po 7 8inch D092 65 Nm B030 48 Ibf ft y Al ee P 7 BY F035 6 mm 65 Nm i 48 Ibf ft F035A F035 6 mm 65 Nm D 48 Ibf ft D090 x D092 N n DOI D132A p D d D014 ai z 65 Nm 7 8 inch 5 ae 48 Ibf ft D015 17mm P107 778E FNR controls FNR controls are non feedback type controls The FNR controls consist of external solenoid actuated spool valves mounted on the pump housing It may be necessary to remove the FNR controls to clean the ports and replace the O rings however the controls themselves are not serviceable 26 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Minor repair Removal of FNR modules 1 Clean the pump and control housings N Use a 4mm internal hex to remove screws D081 Remove the control modules from the pump housing Remove and discard the O rings FD01A from the control ports Examine the ports for cleanliness Use a 4 mm internal hex to remove screws D180 Remove plates D043 and D143 Remove and discard gaskets D044 If necessary remove plugs D032 and F035 Remove and discard O rings
13. 385 415 Hydraulic fluid parameters Fluid temperature range Minimum 40 C 40 F Intermittent cold start Maximum continuous 104 C 220 F Maximum 115 C 240 F Intermittent Fluid cleanliness level Required fluid cleanliness level ISO 4406 Class 22 18 13 Fluid viscosity Minimum 7 0 mm2 s cSt Intermittent Recommended operating range 12 60 mm s cSt Maximum 1600 mm s cSt Intermittent cold start 12 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Pressure measurement Required tools You can perform the service procedures in this manual using common mechanic s hand tools Calibrate gauges frequently to ensure accuracy Use snubbers to protect pressure gauges Port locations and pressure gauge installation On pumps with non feedback controls the positions of the case drains may vary Ports and pressure gauges Proper service and diagnosis may require pressure measurement at various points in the hydraulic circuit The Series 42 pump has several locations at which to take these measurements The following illustration shows the locations of the various gauge ports The table shows the recommended gauge size and the fitting size for each port Gauge ports Gauge port Pressure measured Recommended gauge size O ring boss 28 cc 41 51 cc M1 amp M2 System pressure fo
14. D035A and D032A a uu aUW The spools are solid other than plugging the bores they do not provide any function 7 Unless leaking fluid adjusting screws D014 and lock nuts D015 do not need to be removed Other than plugging the bores adjusting screws do not provide any function Installation of FNR modules 1 If previously removed install spools D090 Lubricate and install new O rings D032A and F035A Install plugs D032 and F035 Torque to 65 Nm 48 Ibf ft 2 If previously removed install adjusting screws D014 and locknuts D015 Torque locknuts to 40 Nm 30 Ibfft 3 Clean the sealing surfaces on the controls and housing 4 Install gaskets D044 Install plates D043 and D143 Use a 4 mm internal hex to install screws D180 Torque to 16 Nm 12 Ibf ft 5 Using petroleum jelly lubricate and install O rings FD01A to bottom of controls 11042614 Rev BA November 2014 27 Dose Service Manual Series 42 4T Pumps Minor repair 6 Install control modules Use a 4 mm internal hex install screws D081 Torque to 16 Nem 12 Ibf ft FNR Minor Repair D081 4mm lt 16 Nem 12 Ibfeft QQ O D180 7 4 mm j lt 16 Nem La 12 Ibfeft a D043 ou ere N Al e D044 FO35A F035 6 mm 2 65 Nem 48 Ibf ft D032A
15. DD a 31 Shaft 32 REMOVE MAIS I Veli caiicszsazstscsvnescsscasasa tessvcnaisautesscsusesavozsatenccsuspssasntentiesscnvestansssasiacsteaseuneoasnsa4scuasastnensna ives iasaosveusanssaesioasieerstestes 33 Remove front shaft With Seal Carrier cccscssssssssssssssssssssssssesssssssssssssssssesscssssssssesssssessessesssssssesssssssssssscsssssssssssssssssesseess 33 Remove front shaft without seal carrier Inspect shafts Install rear shaf 10 33 Install front shaft With Seal Catriet rerrerrerreereereereeree rie reeree rie ree rie ree see ree rie eee nie nee sierra see nie ere sreneeereceeseeeceeneenieneee 33 Install front shaft without seal Carriet eerrerreereereereeree rie ree rie reereeree rie ree nie nee nie nee scene riesi see ere nie nee nie neeneeeeeenene 33 Port locations and torque chart Fastener plug and port locations and gauge installation Fastener size and torque Chalt ssscssssecssssccsseccenssecesecsesees 136 Plug size and torque chart 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Introduction Overview Warranty General instructions This manual includes information for the installation maintenance and minor repair of Series 42 axial piston closed circuit pumps It includes a description of the unit and its individual components troubleshooting information and minor repair procedures P
16. Deviate Service Manual Closed Circuit Axial Piston Pumps Series 42 4T powersolutions danfoss com Service Manual Series 42 4T Pumps Revision history Table of revisions Date Changed Rev November 2014 Danfoss layout BA September 2010 New Back Page AC March 2010 Fix Osaka address AB July 2008 First edition AA 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Contents Introduction VSN VI OW PE DN E a E A ATA ii 5 VELE ARR RA IE 5 General instructions Remove the unit Keepiit clcancirica lr aaa 5 Replace all O rings and Gaskets sssssscssssccssssssssssecssecsssssecssneesssuseecsueeessnsesssusecssneessusecssneceesasecesasecssnsesesaseessneeeenseessneeesse 5 SE 020 CRCR RR ORO ERE RA 5 hayde el lo EKE PK KE GKmi r b RR ir 6 Unintended machine movementi ss rsseresesereeeenneeseneeenereeesAee AHH HERAN HHMA HHHH MH HA HAH HEMAHH HH MH HA HAH HHHAHHKHAHHKHAKKeR 6 Flammable cleaning SOIVENtS sccssscssssssesseccssseccsssesccssecsssuseccssecesssecessueecsssecesnsscessueceesuseccsneesssusesssuseessueecesueessneeessuecseuees 6 Fluid under pressure Personal safety Symbols used in Danfoss literature essccsssccssssccsseeeesssecsssesecsseccsusecssueeessncessuecsesueessuseeesuseessuseessuscsesnseessneesesueersneessueessaees 7 Ordering replacement parts and SELVICE secssssscssseescsseecesneccssse
17. L0589 Series 42 PV 41cc Service Parts Manual or 520L0590 Series 42 PV 28cc Service Parts Manual for listings of available service parts and service kits for Series 42 units 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps General description Basic design S42 Pumps are advanced hydrostatic units for medium power applications with maximum loads of 415 Bar 6020 psi 41 cm3 and 350 Bar 5075 psi 51 cm3 You can combine these pumps with a suitable Danfoss motor or other products in a system to transfer and control hydraulic power The Series 42 variable displacement pump is a compact high power density unit using the parallel axial piston slipper concept in conjunction with a tiltable swashplate to vary the pump s displacement Reversing the angle of the swashplate reverses the flow of fluid from the pump and reversing the direction of rotation of the motor output Series 42 pumps provide an infinitely variable speed range between zero and maximum in both forward and reverse Series 42 pumps use a cradle swashplate design with a hydraulic servo control cylinder Control is provided through a compact servo control system A variety of servo controls are available These include mechanically or electrically actuated feedback controls hydraulic or electric proportional controls and a three position electric control These controls feature low hysteresis and responsive performance 28 32 41 51 cm cro
18. RA Adjustments Overview Displacement limiter adjustment ela 42 i le ni PERAV SS WW YE PEL SI T aaa Pump neutral adjustment allineare Control neutral adjustment for MDC and EDC sesssssssssssssecssstescsnsecssssecesaseccsnsecssasecesssccsssseeecusecssneeesauecesssecesneeeesaneessaess 22 Minor repair Standard PrOCSCA UNOS sss N N iasa uatsagien dectedaisansq esdvsdgentecannaisnau usttescaundsionasqnanasnaphnuenstnnanecsinnae 24 Remove the pump Keep it clean Inspect for system contamination Replace the O rings and gaskets Lubricate all MOVING partSs 24 EDC Spool linkage and neutral adjustment screw Removal Installation 11042614 Rev BA November 2014 3 Service Manual Series 42 4T Pumps Contents FNR erol al el Se N N III ILE AL 26 Re moval of FNRIMOJU E St iiy ca n k ran y ile e k EW ANNE A y ke Va C LAV Va k SEE N eV R k Va Geriy d 27 Installation of FNR modules 27 System Check Relief SCR valves 28 Removal nnzz 28 Inspection 29 ReEPlaceMent sesscccsssccssesescsseeeesseeessseeeesseesssese 29 Servo piston covers and NFPH control OLIFICES essssescsssecssecsssecssecsssccsseesssccsnecsssccessesssscsssccssscessecsssccssecsssecsscssucseseesseesess 30 PI MN eeeOPDKDDFKECFPEKEFKEKErErFK Kw Kw wr DDDDDDK Mr rmn 30 PRS SORIA VP Da e a DD DD
19. ace it as necessary SCR System Check Relief Valves A partially activated SCR valve or SCR valves with relief settings too low may result in heat generation within the system Verify that the SCR valve is seating properly and is at the correct relief setting Repair or replace it as necessary Oil filters Clogged oil filters may result in an insufficient supply of cool oil to the system Inspect the oil filters and verify that they are still operable Replace them if necessary Machine load Excessive loads or extreme duty cycles could result in the pump and or motor operating at speeds and pressures beyond system design limitations Verify that the machine is operating within the parameters for which it was designed If necessary reduce the load on the machine System response is sluggish Item Description Action Reservoir oil level Input control signal linkage current or pressure There is an insufficient amount of hydraulic fluid resulting in an inadequate supply for the system loop The pump is receiving a faulty control signal MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Fill the reservoir to the proper level with clean hydraulic fluid Verify that the input signal is correct and identical in both directions Pump control A damaged pump control or control spool wil
20. cesnsecessseecsssecsesscessssecsssueeessuecesssecsssueeessueesesueeessneeessueeseautentes 7 General description Basic ESIC ERRE RR ROC ROC OA RR EE RR EE RE REA IRC ERA PETITE 8 System diagram no System SCHEMAIC sesccssssscsssescesseecssseccsssecsssuecssseceesuecessucessucsssuscessuecsssuseccsuecessuseessuecessuecsssusecssueesesuceesanecessueesssueecsasecssaueeceaneees 10 Technical specifications SystemispecificationSs iprrrrir RR 11 System arah l AS CTR 11 Fiydratilic fluid pafat t l iy EA 5ani n h nina WERA k na Kya ein e l s re e e ente ka 12 Pressure measurement Required tools Port locations and pressure gauge installation Ports ANA pressure GAUGE Sensuous Wik y iaia ir 13 Initial Start Up Procedure GOMES Tall sess cdscssssnncnsvssonnozassacacessoscsndvasssngensuveonstoassssncesususntbadegasienusuanctbasnsacedoasuenrdbadagasebnante E 14 Start Up Proce UNG siii Rie 14 Fluid and Filter Maintenance Recommendationsi sicralarin lara 15 Troubleshooting O SAY SAP ia ai Systemioperating h0ti arnie RE R RaraaRa REaVIRVrVERRDaMM MR esR X RX W RXeEeE mm System response is SlUg l 5h snna aiar H n ner k Wes n be eker NA System will not operate in either direction System will not operate in one direction Neutral difficult or impossible to find uueiihnerereeenneeeeerehneeeer k neren HHHH HNNHHHHHHANH HH HHHH HHHH HA
21. ect 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 in a 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 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Introduction Symbols used in Danfoss literature A p e el DD 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 specif
22. em 48 Ibf ft F035 3 4 16 UNF 6 mm internal hex 82 Nm 60 Ibf ft 36 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Port locations and torque chart Fastener plug and Port locations F093 L010 M2 D002 Koi M005 M4 L010 M5 T060 L020 J f L020 M T060 A it i UT dr B002 e di reza n K001 L2 L1 on other side M1 A C on other side P107 776E 11042614 Rev BA November 2014 37 Service Manual Series 42 4T Pumps 38 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps 40 11042614 Rev BA November 2014 Products we offer e Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics e Hydraulic Power Steering e Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors Steeri
23. ement limiters Option Input shaft options Splined Auxiliary mounting pad SAE A 9 tooth 11 tooth 13 tooth SAE pad per SAE J744 SAE B 13 tooth Control options MDC NFPH EDC FNR Loop flushing NONE System parameters Case pressure Continuous pressure bar psi 3 4 50 Maximum pressure cold start bar psi 10 3 150 Pressure limits Displacement cm rev 41 51 Rated pressure bar psi 350 5075 325 4713 Maximum pressure bar psi 415 6017 350 5075 Speed limits Displacement cm rev 41 51 Minimum speed min rpm 500 Rated speed at maximum displacement min rpm 3200 2900 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Technical specifications Speed limits continued Maximum speed at maximum displacement min rpm 3450 3400 Charge pump displacement and setting pressure Charge pump 41 51 Internal cm3 rev in3 rev none none Charge relief valve Standard 20 290 settings bar psi Optional 14 24 203 340 Theoretical flow Displacement cm3 rev 41 51 Theoretical flow at rated speed l min US gal min 131 34 6 148 39 1 Check high pressure relief valve Options No relief valve check only Relief valve check Settings bar psi 210 415 3045 6020 or by setting available 210 250 280 300 325 345 360
24. ents 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 0 Caution Incorrect shaft alignment may result in damage to drive shaft bearings or seal which can cause external oil leakage 2 Fill the reservoir with recommended hydraulic fluid Always filter fluid through a 10 micron absolute 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 To ensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at port M2 to monitor 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 at M2 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 the pump does not maintain system pressure shut down the prime mover determine cause and take correct
25. erforming minor repairs requires you remove the unit 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 Global Service Partners GSPs is available for major repairs Danfoss trains and certifies GSPs on a regular basis You can locate your nearest GSP using the distributor locator at www sauer danfoss com Click on the Sales and Service link Performing installation maintenance and minor repairs according to the procedures in this manual does not affect your warranty Major repairs requiring the removal of a unit s rear cover or front flange voids the warranty unless done by a Danfoss global service partner Follow these general procedures when repairing Series 42 variable displacement closed circuit pumps Remove the unit A Prior to performing minor repairs remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses after removal to prevent contamination Keep it clean Al Cleanliness is a primary means of assuring satisfact
26. fy that the displacement limiters are adjusted to the proper setting System will not operate in one direction Item Description Action Input control signal linkage current or pressure The pump is receiving a faulty control signal MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal is correct and identical in both directions Adjust clean repair or replace the control module as necessary SCR System Check Relief valves The SCR valves are malfunctioning or improperly set Verify that the SCR valves are operating properly Repair or replace them as necessary 11042614 Rev BA November 2014 Dorf Service Manual Series 42 4T Pumps Troubleshooting Item Description Action Pump control A damaged or biased pump control may be sending a signal commanding the pump to stroke only in one direction Verify that the pump s control is functioning properly Repair or replace it as necessary Servo pressure The drain or supply path to one side of the servo piston may be blocked Verify that the servo supply and drain paths are unobstructed and that any orifices are of the correct size and free of debris Clean or repair them as necessary Displacement limiters if equipped Neutral difficult or impossible to find The displacement lim
27. ication External hex head Internal hex head Torx head O ring boss port hi A iS a E QO l 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 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 appearance of the symbol itself denotes its meaning The legend above defines each symbol and explains its purpose Ordering replacement parts and service Danfoss provides a complete repair service for its products Contact any Danfoss Global Service Partner for details To ensure the best performance use genuine Danfoss replacement parts To order parts contact Danfoss Extended Customer Service ECS at 515 239 6078 fax 515 239 6230 or your nearest Global Service Partner Some service parts may be available only in kits while other parts may be available on an individual basis See publication 520
28. iters may be improperly adjusted such that the servo piston is prevented from moving in one direction Verify that the displacement limiters are adjusted properly Item Input control signal linkage current or pressure Description The pump is receiving a faulty control signal MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Action Verify that the input signal is correct and identical in both directions Adjust clean repair or replace control module as necessary System pressure With no input signal to the control a pressure delta may exist between the two sides of the working loop Readjust pump neutral setting Refer to Pump neutral adjustment on page 21 Servo pressure With no input signal to the control a pressure delta may exist across the servo piston Readjust the control neutral setting Refer to Control neutral adjustment for MDC and EDC on page 22 PCP pressure EDCs only With no input signal to the control a pressure difference may exist across the control spool Replace the EDC 18 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Adjustments Overview This section offers instruction on how to perform adjustments to the Series 42 pump Read through the entire procedure before beginning any service activity Refer to Port locations and
29. ive action Refer to Troubleshooting on page 16 8 Operate the hydraulic system for at least fifteen minutes under light load conditions 9 Check and adjust control settings as necessary after installation Refer to Adjustments on page 19 10 Shut down the prime mover and remove the pressure gauge Replace plug at port M2 11 Check the fluid level in the reservoir add clean filtered fluid if necessary The pump is now ready for operation 14 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Fluid and Filter Maintenance Recommendations To ensure optimum life of Series 42 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 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 vehicle machine manufacturer s recommendations or at these intervals 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
30. l not correctly transmit the control input signal to the pump Verify that the pump s control is operating properly and that the control spool is not damaged or worn and moves freely within its bore Clean repair or replace it as necessary Bypass valve A partially activated bypass valve will cause cross port leakage Verify that the bypass valve is closed and that the valve is seating properly Clean repair or replace it as necessary SCR system check relief valves One or both of the SCR valves may be binding within their bores Verify that the SCR valves operate freely Repair or replace them as necessary Charge pressure in neutral Low charge pressure resulting from a damaged charge pump or low charge pressure relief valve setting Charge pressure may be insufficient to recharge the system loop Inspect the charge pump for damage and verify the charge pressure relief valve setting Repair or replace it as necessary Charge pressure in stroke There is low charge pressure resulting from internal leakage within the system Repair or replace the component or components within the system causing the internal leakage 16 11042614 Rev BA November 2014 Dos Service Manual Series 42 4T Pumps Troubleshooting Item Description Action Servo pressure There is insufficient pressure differential across the servo piston Check servo pressures at po
31. lly disassemble clean and inspect all components of the pump Pump warranty will be voided unless disassembly and rebuild are performed by a Danfoss Global Service Provider Replace the O rings and gaskets Danfoss recommends you replace all O rings and gaskets Lightly lubricate O rings with clean petroleum jelly prior to assembly Lubricate all moving parts During reassembly coat all moving parts with a film of clean hydraulic oil This will help to lubricate these parts during start up For fluid quality requirements refer to bulletin 520L0463 Hydraulic Fluids and Lubricants Technical Information EDC Spool linkage and neutral adjustment screw It may be necessary to remove the control spool control linkage and control neutral adjustment screw for cleaning and to change the O rings or the seal lock nut Removal 1 Clean the external surface of the pump 2 Use a T30 Torx to remove the screws D002 Remove control modules from pump Remove and discard gaskets E011 Note control linkage assemblies and the way the summing links engage the control spool flats 3 Remove the summing links D011 by sliding them off the feedback link Using a 4mm internal hex wrench remove the summing link pivot pin D010 Slide the feedback link D012 towards the servo piston to disengage the neutral adjustment link D013 Remove all linkages 4 Remove plugs D032 Note the orientation of the control spools D90 and which side
32. m port pressure through ports M1 and M2 The pump has two case drains L1 and L2 to ensure there is lubricating fluid in the system This schematic includes a manual displacement control For other control schematics see the related control section 10 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Technical specifications System specifications General specifications Pump type In line axial piston positive displacement pumps including cradle swashplate and servo control Direction of input rotation Clockwise or counterclockwise Recommended installation position Pump installation recommended with control position on the top or side Consult Danfoss for non conformance guidelines The housing must always be filled with hydraulic fluid Other system requirements Independent braking system suitable reservoir and heat exchanger Hardware features Pump configuration Integrated Tandem Pump Displacement cm rev in3 rev 41 2 50 x2 51 3 11 x2 Weight kgf lbf MDC 76 168 NFPH 72 158 Mass moment of inertia 0 0072 0 0054 0 0076 0 0056 kg m lbf ft Type of front mounting flange SAE flange size per SAE J744 2 Bolt SAE C 4 additional bolt holes available Port connections SAE twin ports radial opposite side ports System pressure regulation 210 415 3045 6020 210 325 3045 4715 bar psi Displac
33. nd that the valves are seating properly Clean repair or replace them as necessary Charge pressure in neutral Charge pressure may be insufficient to recharge the system loop Inspect the charge pump for damage and verify that the charge pressure relief valve is at the proper setting Repair or replace it as necessary Charge pressure in stroke Low charge pressure resulting from internal leakage within the system Repair or replace the component or components within the system causing the internal leakage Servo pressure There is an insufficient pressure differential across the servo piston Check servo pressures to verify sufficient pressure delta Verify that the servo supply and drain paths are unobstructed and that any orifices are of the correct size and free of debris Clean repair or replace them as necessary Charge pump The charge pump is damaged or has been installed with the incorrect rotational orientation Verify that the charge pump is in good working order and that it is correctly installed Repair or replace it as necessary SCR system check relief valves The SCR valves are malfunctioning or improperly set Verify that the SCR valves are operating and properly set Repair or replace them as necessary Displacement limiters The displacement limiters may be improperly adjusted such that the servo piston is prevented from moving in one direction Veri
34. ng e Transit Mixer Drives Comatrol www comatrol com Schwarzmiiller Inverter www schwarzmueller inverter com Turolla www turollaocg com Valmova www valmova 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 D 24539 Neum nster Germany Phone 49 4321 871 0 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
35. ory pump life on either new or repaired units Clean the outside of the pump thoroughly before disassembly Take care to avoid contamination of the system ports Cleaning parts with a clean solvent wash and air drying is usually adequate As with any precision equipment you must keep all parts free of foreign material and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the pump with a protective layer of plastic Replace all O rings and gaskets Danfoss recommends replacing all O rings gaskets and seals when servicing Lightly lubricate all O rings with clean petroleum jelly prior to assembly Secure the unit 5 11042614 Rev BA November 2014 5 Dose Service Manual Series 42 4T Pumps Introduction Safety precautions For repair place the unit in a stable position with the shaft pointing downward It is necessary to secure the pump while removing and torquing end covers controls and valves Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system 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 disconn
36. pressure gauge installation on page 13 for location of gauge ports and suggested gauge size Displacement limiter adjustment You may adjust displacement limiters to achieve a desired maximum flow rate For Series 42 pumps displacement limiters are available on one or both sides of the servo piston Accurate adjustment of the displacement limiters requires the use of a test stand capable of measuring system flow output from both the A and B output ports 1 Mount the pump onto the test stand 2 Loosen the displacement limiter seal lock nut L025 but do not remove it 3 Start the prime mover and place the pump into full stroke in one direction Note the system output flow from either the A or B system port 4 Adjust the displacement limiter adjustment screw L020 until the desired output flow is reached Turning the displacement limiter adjustment screw clockwise decreases the maximum output flow setting Turning the displacement limiter adjustment screw counter clockwise increases the maximum output flow setting A Warning WARNING The seal nut lock nut must be retorqued after every adjustment and the limiter screw must have full thread engagement in the servo piston cover to prevent unexpected changes in operating conditions and to prevent external leakage during unit operation The pump achieves maximum flow when the displacement limiter does not contact the servo piston while the unit is in full stroke One full turn of the
37. que to 31 50 Nem 23 37 Ibf ft 7 Stop the prime mover and remove the hose between gauge ports M4 and M5 Remove the pressure gauges in gauge ports M1 and M2 Reinstall the plugs in the gauge ports 8 Proceed to the control neutral adjustment section on the next page Pump neutral adjustment screw T060 Pump mechanical neutral adjustment seal lock nut See table See table T015 Pump neutral adjustment screw See table See table E100002E MDC Shown 11042614 Rev BA November 2014 21 Service Manual Series 42 4T Pumps Adjustments Neutral adjustment gauge port readings M1 M2 M1 M2 OC O O sa r QEWA M1 M2 O O da P101259 Frame size cm 41 51 Control MDC EDC NFP Lock nut mm 17 17 Servo adjust screw mm in 7 7 Lock nut torque Nem Ibfeft 31 50 23 37 31 50 23 37 Control neutral adjustment for MDC and EDC Control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control setting provides a zero degree swashplate setting Perform this adjustment whenever you adjust or move any part of the control or swashplate mechanism or after you adjust the pump neutral setting A Warning The following procedure requires the vehicle machine to be disabled wheels raised off the ground work function disconnected etc
38. r ports A and B 600 bar 8700 psi 9 16 18 9 16 18 M4 amp M5 Servo pressure 60 bar 870 psi 9 16 18 9 16 18 Case pressure 35 bar 510 psi 1 1 16 12 1 5 16 12 4T gauge ports M2 M4 O O O M5 O o 9 N i B system pressure C D on other side Ni i 9 j EREZ wi ST sl TIP2 nu m2 L2 L1 on other side M1 A system pressure C on other side P107 818E 11042614 Rev BA November 2014 13 Service Manual Series 42 4T Pumps Initial Start Up Procedure General Start up procedure Follow this procedure when starting up a new Series 42 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 compon
39. rt M4 and M5 to verify sufficient pressure delta Verify that the servo supply and drain paths are unobstructed and that any orifices are of the correct size and free of debris Clean repair or replace as necessary Charge pump The charge pump has been damaged or installed with the incorrect rotational orientation Verify that the charge pump is in good working order and that it is correctly installed Repair or replace it as necessary System will not operate in either direction Item Description Action Oil level in reservoir There is an insufficient amount of hydraulic fluid resulting in an inadequate supply for the system loop Fill the reservoir to the proper level with clean hydraulic oil Input control signal linkage current or pressure The pump is receiving a faulty control signal MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal is correct and identical in both directions Adjust clean repair or replace the input device as necessary Oil filters Clogged oil filters may result in an insufficient supply of oil to the system Inspect the oil filters and verify that they are still serviceable Replace them as necessary Bypass valve A partially activated bypass valve may result in a cross port leakage Verify that the bypass valves are closed a
40. sket or to clean or replace the NFPH control orifices Disassembly 1 Use a 13 mm or 17 mm wrench to remove locknuts T060 30 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps Minor repair Using a T 30 Torx remove the servo cover screws L005 M005 A Warning Unintended vehicle movement hazard When you remove the right side servo piston cover adjust neutral and control neutral after reinstalling the pump Refer to Pump neutral adjustment on page 21 and Control neutral adjustment for MDC and EDC on page 22 Remove servo piston covers L001 M001 To remove the right side servo cover turn the neutral adjusting screws T015 clockwise until cover can be turned off without interference from housing 4 Remove gaskets F009 Clean gasket sealing surfaces If so equipped NFPH orifice plugs E051 and E052 are located beneath the servo covers If necessary use a 3 mm internal hex to remove the orifices and clean them Assembly 1 If previously removed replace the NFPH orifice plugs E051 E052 Torque to 2 4 Nm 1 5 3 lbfeft 2 Install new gaskets L002 M002 On the right side thread the servo piston cover L001 onto the neutral adjustment screw Then while holding the cover turn the neutral adjustment screw T015 counter clockwise to run the cover down the screw threads Using a T30 Torx driver install the servo piston cover screws L005 M005
41. skip steps 6 and 7 1 Lubricate and install O rings K006 onto bypass plunger 2 Install bypass plunger K002 Install snap ring K005 3 Install new outer O ring K008 backup ring K009 and inner O ring K010 on each valve seat plug 4 Verify that the conical springs are properly retained on the check poppets relief valves H005 J005 Install the check poppet relief valve assemblies into the pump housing Ensure that the valve assembly moves freely in its bore 11042614 Rev BA November 2014 29 Dose Service Manual Series 42 4T Pumps Minor repair 5 Using a 1 inch wrench or an 8 mm internal hex install the valve seat plugs or valve seat bypass plugs into the pump housing and torque to 82 Nem 60 Ibf ft System check relief valve components 2 82N m O K001 Q gt NY Koo2 K006 f Qo0 xoos a K009 Tj OL notes K008 N K009 x K010 x L J015 i O K001 N SI gt 7 8 mm SS lt 82 Nm e 4 60 Ibf ft Hoos S H015 lt 82 Nem 60 Ibfeft Ol koo1 Q Tinch N La or Koro gow KO009 j FN K008 e K006 K001 Q a koo2 ij 8mm Qe koro Koos P B K009 f lt 82 Nem Koog P107 780E 60 Ibf ft Servo piston covers and NFPH control orifices You can remove the servo piston covers to replace the ga
42. ss sectional view Slipper Swashplate Piston Cylinder block Roller bearing Charge pump Valve plate 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps General description System diagram Charge Pressure Control Pressure Suction Case Drain System Return EE System Pressure Em Low Loop Pressure Suction Heat Exchanger Bypass Check Charge Pump Screen Reservoir Control Handle Servo Control Cylinder Swash Plate Displacement Control Spool Cylinder Block Assembly Charge Pressure Relief Valve Valiable Displacement Pump Charge check HPRV valve Brake release control valve H H H Motor displacement control valve P106 147E Loop Loop Flushing Flushing Valve Valve Gear box Gear box 11042614 Rev BA November 2014 Service Manual Series 42 4T Pumps General description System schematic AT axial piston pump baia Gearbox Gearbox P107 820E The illustration above shows a schematic of a 4T axial piston pump System ports A C and B D connect to the high pressure work lines Return fluid is received from its inlet port and discharged through the outlet port Flow direction is determined by swashplate position You can read syste
43. tative for the appropriate nomenclature Zero output flow from the pump defines the neutral condition To attain zero output flow the pump must achieve both mechanical neutral and control neutral conditions Mechanical neutral is the condition when the swashplate is at zero angle without any signal input from the control Set mechanical neutral prior to setting control neutral A Warning To prevent injury disable the machine raise wheels off the ground or disconnect the mechanism 1 Disable the control input to the pump by equalizing the pressures on both ends of the pump servo piston To accomplish this connect an SAE 06 hose between servo gauge ports M4 and M5 2 Install pressure gauges in gauge ports M1 and M2 to measure system pressure 3 Start the prime mover and run at normal operating speed 4 Loosen the pump neutral adjustment seal lock nut T060 in the center of the servo cover on the right side of the pump 5 Turn the adjustment screw T015 clockwise until one of the gauges registers an increase in system pressure Mark the position of the adjustment screw Turn the screw counterclockwise until the other gauge registers an increase in system pressure Mark the position of the adjustment screw Turn the adjustment screw clockwise to a position halfway between the marks The system pressure gauges should indicate equal pressures 6 While holding the adjustment screw in position torque the seal lock nut T060 Tor
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