Series 40 M46 Tandem Pumps Service Manual
Contents
1. um T B COO E 9 SEN 5 8 in P106667 ass valve System check relief SCR valves The SCR valve is a high pressure relief valve and a system check valve in combination Whenever an SCR valve has been replaced or opened the pump should be operated in its full range of functions to ensure proper machine operation The SCR valves are pre set at the factory no adjustment is possible Pressure code is marked on the valve 1103 Refer to the model code for pressure designation If SCR malfunction is suspected replace valve and test operation of pump To adjust max system pressure replace SCR valve with one set for the desired pressure setting The following procedure explains how to replace the SCR valves 1 Shut down the system 2 Using a 1 1 4 hex wrench remove relief valve plug 166 3 Remove spring 165 and relief valve 1103 from pump housing 4 Insert new relief valve 1103 and spring 165 into pump housing 5 Repla2. 11029852 Rev BA November 2014 41 Service Manual Series 40 M46 Tandem Variable Pumps 42 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps 44 11029852 Rev BA November 2014 Products we offer Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics Hydraulic Power Steering Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Comatrol www comatrol com Schwarzm ller 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 8710 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 f
3. Inspection Inspect all parts of control assembly Replace any damaged parts Inspect spools for grooves scratches and other damage If spools are damaged replace them Inspect sleeve bore in housing for damage Reassembly 1 Lubricate and install O ring 302 and backup ring 1208 onto sleeve 1402 Lubricate and install sleeve 1402 into motor housing When installing sleeve 1402 ensure that sleeve groove engages spring pin on swashplate 2 Lubricate and install O ring 303 and backup ring 1209 onto spool 1207 11029852 Rev BA November 2014 35 ones Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 3 Install neutral return spring 1214 neutral return bracket 1216 handle 1215 and washer 1235 onto spool 1207 Install control spool 1207 with alignment slot facing servo piston Fs Alignment slot Servo piston H P107 958E 4 Using a 1 2 hex wrench install lock nut 1213 Torque to 15 Nm 11 ftelb 5 Lubricate and install spool 1207 into sleeve 1402 6 Using a 3 8 hex wrench install screw 1210 Torque to 14 Nm 10 ft lb See Manual Displacement Control Bracket Neutral Adjustment on page 24 for adjustment procedure Manudl displacement control C3 o LENS S SEH a 2 lt O AN Ps gt 2 lt Q 302 U
4. If the pump has an auxiliary pump attached remove the auxiliary pump and connecting shaft before removing the auxiliary pad Removal Using a 3 4 hex wrench remove nut 2144 Remove bracket 2146 Using a 1 2 12 point hex wrench remove bolts 2147 Pull to separate front and rear pump housings Unthread tie rod 2145 Remove and discard O rings 2407 2408 and 2150 Remove gerotor cover 2304 and gerotor 2403 Remove pin 2404 coupling 2142 and pin 2405 O Uu P WM Note the location of pin 2404 for reassembly It can be assembled for right hand or left hand pump rotation 11029852 Rev BA November 2014 29 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair Charge pump removal installation 2 Z7 9 Le 2 5 Ze 102 Nm C2 BN bora 75 ft lb n 2 nk ES N N SE 2147 ENX Q 1 2 in 2145 a M 102 Nm CH Cee 75 ft Ib 2405 S Q g SSC N P106674 Q D Inspection Inspect the gerotor 2403 and gerotor cover 2304 for wear scratches or pitting If any component shows signs of wear scratching or pitting replace all damaged components Inspect pin 2404 and key 2405 for damage and replace parts if necessary Replace O ring 2407 2
5. 1219 Ei 3 16 in P106 680E aim EDC HDC orifice repair Removal 1 Remove servo covers See Displacement limiter on page 27 for servo cover removal and installation instructions 2 Using a 7 32 internal hex wrench remove orifice plugs 1403 and 1404 Inspection Inspect orifice for damage contamination and correct size Replace orifice if necessary Reassembly 1 Using a 7 32 internal hex wrench install orifice plugs 1403 and 1404 Torque to 3 Nm 2 ft lb 38 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 2 Install servo covers EDC HDC orifice repair 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Torque chart Fastener size and torque chart Item Fastener Wrench size Torque 920 Servo piston cover screws 3 8 hex 15 Nm 11 ft Ib 921 Servo piston cover screws 3 8 hex 15 Nm 11 ft lb 4115 Front and rear cover screw T50 Torx 58 Nm 43 ft Ib 4135 Front and rear cover screws T55 Torx 91 Nm 67 ft lb 2504 Aux cover screws 3 4 hex 43 Nm 32 ft Ib 806 Filtration cover screw 1 2 hex 30 Nm 22 ftelb 927 Displacement limiter lock nut 9 16 hex 12 Nm 9 ft Ib 1213 Control handle nut 1 2 hex 15 Nm 11 ft lb 1210 Screw 3 8 14 Nm 10
6. 1003 and seal 1002 Inspection Inspect the sealing surfaces of the pump for nicks or scratches Inspect the bypass valve 1001 sealing surface for nicks or scratches Replace any damaged parts Reassembly 1 Lubricate and install new O ring 1003 and seal 1002 onto bypass valve 1001 2 Using a 5 8 hex wrench install bypass valve 1001 Torque to 20 Nm 15 ft lb 34 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 3 Operate pump at full range of controls to ensure proper machine operation Bypass valve nm 5 8in 1002 lt j 20 Nm 15 ft lb AN BA NE 771003 C 1 CC S ES D 7 oO US C3 Q 2 gt 6 o C 1003 MIA i e 1001 L A O de JG 20Nm le 15 ftelb P106677 Manual displacement control Removal 1 Using a 3 8 hex wrench remove screw 1210 Remove manual control spool assembly from pump housing 2 Using a 1 2 hex wrench remove lock nut 1213 Remove tooth lock washer 1235 handle 1215 neutral return bracket 1216 and spring 1214 from spool 1207 Mark the location of neutral return bracket 1216 before disassembly 3 Remove and discard backup ring 1209 and O ring 303 from spool 1207 4 Remove sleeve 1402 Remove and discard backup ring 1208 and O ring 302
7. Attach 20 bar 300 psi gauge to each servo gage port 2 Using a 3 8 hex wrench loosen screw 1210 to allow the neutral adjustment bracket to move but not freely 3 Start prime mover and slowly accelerate to normal operating RPM 4 Using your hand press neutral adjustment bracket towards the pump housing and rotate adjustment bracket until both servo gages read equal pressures Rotate adjustment bracket until one of the servo pressure gages indicates an increase in pressure Rotate adjustment bracket in opposite direction until the other servo pressure gage indicates an increase in pressure Rotate neutral bracket until it is half way between the two positions 5 While holding the neutral adjustment bracket in place use a 3 8 hex wrench to tighten screw 1210 Torque to 14 Nm 10 ft lb Manudl displacement control bracket adjustment e 1210 Ma N Ms Neutral bracket P106 670E Electronic Displacement Control Hydraulic Displacement Control Neutral Adjustment With the pump properly plumbed primed and mounted on a vehicle or test stand use the following procedure to adjust the pump displacement control to neutral position If pump is on a vehicle block the wheels to prevent movement Verify swashplate neutral adjustment see Swashplate neutral adjustment on page 23 before performing control neutral adjustment 11029852 Rev BA November 2014 25 Service Manual Seri
8. High pressure relief valves 166 1 1 4 in 174 Nm 128 ft lb 174 Nm 128 ft Ib P106 668E Charge pressure relief valve Replace the charge pressure relief valve components if they are damaged or otherwise suspected of failure See Charge pressure relief valve on page 19 for adjustment instructions Removal 1 Using a 1 inch hex wrench remove charge pressure relief plug 102 Remove and discard O ring 103 2 Remove shims 101 spring 104 and charge pressure relief valve 105 Inspection Inspect the sealing surfaces of the pump for nicks or scratches Inspect the relief valve 105 sealing surface for nicks or scratches If the relief valve 105 is damaged replace it Reassembly 1 Install charge pressure relief valve 105 spring 104 and shims 101 2 Lubricate and install O ring 103 onto plug 102 Using a 1 inch hex wrench install plug 102 Torque to 108 Nm 80 ft lb 11029852 Rev BA November 2014 33 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 3 Operate pump at full range of controls to ensure proper machine operation Charge pressure relief valve P106676 Bypass valve Removal 1 Using a 5 8 hex wrench remove bypass valve 1001 2 Remove and discard O ring
9. Install sleeve 929 and snap ring 928 4 Using a 1 4 hex wrench to hold neutral adjustment screw and a 9 16 hex wrench install hex nut 2115 onto neutral adjustment screw at the position noted during disassembly Torque to 37 Nm 27 ft lb Displacement limiter removal installation 927 929 g O 9 16 in j een Servo neutral Oe adjustment screw 3 gt 2115 9 16 in P106671 Pressure filtration adapter Removal 1 Using a 11 16 hex wrench remove plug 810 Remove and discard O ring 810A 2 Using a 1 2 in hex wrench remove bolts 806 3 Remove pressure filtration cover 801 Remove and discard gasket 805 28 11029852 Rev BA November 2014 ouf Service Manual Series 40 M46 Tandem Variable Pumps Minor repair Inspection Inspect the machined surface on the control If any nicks or scratches are found replace the damaged component Reassembly 1 Install new gasket 805 and filtration cover 801 2 Using a 1 2 hex wrench install three bolts 806 Torque to 30 Nm 22 ft lb 3 Lubricate and install O ring 810A onto plug 810 Using a 11 16 hex wrench install plug 810 Torque to 37 Nm 27 ft lb Pressure filtration adapter removal installation 810 Le V e SE i P106 673E 810A X gt 806 D Charge pump
10. The volume of fluid displaced into the system is controlled by the angle of the swashplate The swashplate is forced into an inclined position into stroke by the servo piston 11029852 Rev BA November 2014 7 ones Service Manual Series 40 M46 Tandem Variable Pumps Introduction The pump control by varying the pressure at the servo piston controls the displacement of fluid in the system circuit Cross section view Ball bearing Slipper Gerotor Piston Piston Ball bearing Valve plate Valve plate Slipper Shaft Journal Journal bearing bearing Swashplate bearing pin Swashplate bearing pin Cylinder block Servo piston Swashplate P106665 Servo piston Manual displacement Control The system circuit The basic closed circuit The main ports of the pump are connected by hydraulic lines to the main ports of the motor Fluid flows in either direction from the pump to the motor then back to the pump in this closed circuit Either of the hydraulic lines can be under high pressure In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow A tandem circuit contains two pumps and motors Each pump and motor circuit is similar to the one shown Case drain and heat exchanger The pump and motor case drain lines remove hot fluid from the system The pump and motor should be drained from their t
11. established as shown in model code increase engine speed to normal operating rpm to further purge residual air from the system 11 Shut off engine Connect pump control signal Start engine checking to be certain pump remains in neutral Run engine at normal operating speed and carefully check for forward and reverse control operation 12 Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop Normal charge pressure fluctuation may occur during forward and reverse operation 11029852 Rev BA November 2014 11 Ronin Service Manual Series 40 M46 Tandem Variable Pumps Initial startup procedures 13 Check that the reservoir is full Remove charge pressure gauge Re install charge pressure plug The pump is now ready for operation 12 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Pressure measurements Required tools The service procedures described in this manual can be performed using common mechanic s hand tools Special tools if required are shown When testing system pressures calibrate pressure gauges frequently to ensure accuracy Use snubbers to protect gauges Port locations and gauge installation The following tables and drawing show the port locations and gauge sizes needed Port inf
12. not damage the housing bore shaft or bearing when removing the shaft seal Shaft assembly 301 li P106675 Inspection Inspect the shaft and bearing for wear scratching and pits If wear scratching or pitting is found replace the shaft and bearing Reassembly 1 Press new seal 301 into pump cover 11029852 Rev BA November 2014 31 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 2 Install Snap ring 2132 using a snapring pliers Shaft seal installation tool H D i re 0 370 in 124in 1 5 in 2 45 in 3in P106652 Leg SCR valves The SCR valves are factory set and are not field adjustable Removal 1 Using a 1 1 4 hex wrench remove relief valve plug 166 Remove and discard O ring 106 2 Remove spring 165 and relief valve 1103 from pump housing Inspection Inspect the sealing surfaces of the pump for nicks or scratches Inspect the relief valve 1103 sealing surface for nicks or scratches If the relief valve 1103 is damaged replace it Reassembly 1 Lubricate and insert relief valve 1103 and spring 165 into pump housing 32 11029852 Rev BA November 2014 Zones Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 2 Lubricate and install new O ring 106 onto plug 166 Using a 1 1 4 hex wrench install relief valve plug 166 Torque to 174 Nm 128 ft Ib
13. section is referenced Always observe the safety precautions listed in Introduction on page 5 and related to your specific equipment Safety precautions Caution High inlet vacuum causes cavitation which can damage internal pump components Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines System noise or vibration Item Description Action Reservoir oil level Low oil level leads to cavitation Fill reservoir Aeration of the oil pump inlet vacuum Air in system decreases efficiency of units and controls Air in system is indicated by excessive noise in pump foaming in oil and hot oil Find location where air is entering into the system and repair leak Check that inlet line is not restricted and is the proper size Cold oil If oil is under cold conditions it may be too viscous for proper function and pump cavitates Allow the oil to warm up to it s normal operating temperature with engine at idle speed Pump inlet vacuum High inlet vacuum causes noise cavitation Check that inlet line is not restricted and is the proper size Check filter and bypass valve Shaft couplings Shaft alignment A loose shaft coupling will cause excessive noise Misaligned shafts creates noise Replace loose shaft coupling Replace pump shaft Al
14. swashplate 2 Using a 3 16 internal hex wrench install screws 1203 and 1204 or 1226 Torque to 14 Nm 10 ft lb If necessary install control housing 1223 Using a 4 mm internal hex wrench install screws 1224 Torque to 14 Nm 10 ft Ib EDC HDC Repair 53 16 in P106679 3 Position Control 11029852 Rev BA November 2014 37 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair MDC orifice repair Removal Using a 3 16 internal hex wrench remove pipe plug 1219 Using a 1 8 internal hex wrench remove filter or orifice plug 1401 Inspection Inspect orifice for damage contamination and correct size Replace orifice if necessary Reassembly 1 Using a 1 8 internal hex wrench install filter or orifice plug 1401 Torque to 3 Nm 2 Ib ft 2 Using a 3 16 internal hex wrench install pipe plug 1219 Torque to 22 Nm 16 Ib ft Pipe plug 1219 needs to be installed with thread lock Apply a few drops of thread lock before installation MDC orifice repair C3 ES N 7 co O N Q Ki EN N e A 401 E o 2 Oisin N gt 7
15. 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 Design Danfoss Series 40 M46 closed circuit piston pumps convert input torque into hydraulic power Rotational force is transmitted through the input shaft to the cylinder block The input shaft is supported by 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 seven reciprocating pistons Each piston has a brass slipper connected at one end by a ball joint The slippers are held to the swashplate by a spring washer and charge pressure 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 low pressure and the other half to high pressure As each piston cycles in and out of its bore fluid is replenished by charge flow and displaced to the outlet thereby imparting hydraulic power into the system A small amount of fluid is allowed to flow from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling Excess flow across the charge pressure relief also flows through the case and is used for cooling Case drain ports return this fluid to the reservoir
16. within the system Repair or replace the component or components within the system causing the internal leakage Servo pressure There is insufficient pressure differential across the servo piston Check servo pressures at port M4 and M5 to verify sufficient pressure delta Verify that the servo supply and drain paths are unobstructed and that each orifice is of the correct size and free of debris Clean repair or replace as necessary 11029852 Rev BA November 2014 ZDonfsi Service Manual Series 40 M46 Tandem Variable Pumps Troubleshooting Item Description Action 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 Electrical troubleshooting Item Description Action Control operates pump in one direction only Control coil failure Measure resistance at coil pins Resistance should be 14 20 ohms 24V or 3 66 ohms 12V at 20 C 70 F Replace coil No pump function Erratic pump function No power to controller Electrical connection to pump is bad Restore power to controller Disconnect connection check wires reconnect wires Filter bypass indicator switch Filter switch may be bad Check replace filter switch Add gauge to filter bypass por
17. 1029852 Rev BA November 2014 3 Service Manual Series 40 M46 Tandem Variable Pumps Contents Torque chart EDC HDC Grifice repaire rrr 38 Fastener size and torque chatt 40 Plug size and torque chart 40 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Introduction Overview Warranty General instructions This manual includes information for the installation maintenance and minor repair of the Series 40 M46 tandem pump It includes a description of the unit and its individual components troubleshooting information and minor repair procedures 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 Global Service Partners is available for major repairs Danfoss Global Service Partners are trained by the factory and certified on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www sauer danfoss com Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring th
18. 408 2150 whenever charge pump is disassembled Reassembly 1 Install pin 2405 into coupling 2142 Install coupling 2142 into gerotor 2403 with pin 2405 aligned in groove 2 Install coupling onto shaft of front pump 3 Install pin 2404 into front pump housing and gerotor cover 2304 onto gerotor 2403 4 Lubricate and install O rings 2407 2408 and 2150 5 Thread tie rod 2145 into front pump housing 6 Mate two pumps together to install rear pump shaft into coupling 2124 Using a pipe wrench or pliers rotate front pump shaft to align coupling with rear pump shaft and then push two pump housings together Use a rubber mallet if necessary Position the pumps vertically with the front housing on top of the rear housing to make alignment easier 7 Using a 1 2 12 point hex wrench install bolts 2147 Torque to 102 Nm 75 ft Ib 30 11029852 Rev BA November 2014 Zonen Service Manual Series 40 M46 Tandem Variable Pumps Minor repair 8 Install bracket 2146 Using a 3 4 hex wrench install nut 2144 Torque to 102 Nm 75 ft Ib Shaft seal The shaft assembly is serviceable without removing the front cover of the pump Orient the pump on the work surface so the shaft is pointing up Removal 1 Using a snap ring pliers remove snap ring 2132 from pump cover 2 Using a sharp instrament like a screw driver or a slide hammer type puller remove the shaft seal 301 o Caution Do
19. M 9 08 SIDA KE TI pa M o O 1208 gt gt xem liu AN ue nl 1402 1209 SE O 3 8 in j BS b 1207 15 Nm Se 303 11 ft lb SITE YA UE 1235 d a 1213 1215 1 2 in P106678 15 Nm 11 ftelb 36 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair Electronic Displacement Control Hydraulic Displacement Control Removal If control is suspected of failure replace control and test pump for proper operation When installing control ensure that sleeve groove engages spring pin on swashplate 1 Using a 3 16 internal hex wrench remove screws 1203 and 1204 or 1226 and 1224 2 Remove control housing 1201 or control housing 1223 and manifold 1225 Remove and discard O rings 1220 and 304 or 1227 1228 and 1229 Inspection Inspect control spool for scratches grooves and other damage If spool is damaged or control is otherwise suspected of malfunction replace entire control unit Inspect sleeve bore in housing for damage Reassembly 1 Lubricate and install O rings 1220 and 304 onto control housing 1201 or lubricate and install O rings 1227 and 1228 onto manifold 1225 and O rings 1223A onto control housing 1223 Lubricate and install control housing 1201 or manifold 1225 onto pump housing aligning sleeve groove with spring pin on
20. MAKING MODERN LIVING POSSIBLE Service Manual Series 40 M46 Tandem powersolutions danfoss com Service Manual Series 40 M46 Tandem Variable Pumps Revision history Table of revisions Date Changed Rev November 2014 Danfoss layout BA September 2010 New Back Page AD March 2010 Fix Osaka address AC March 2009 added spool alignment illustration AB June 2008 First edition AA 2 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Contents Introduction Fluid and filter maintenance Initial startup procedures Pressure measurements Troubleshooting Adjustments Minor repair nui e n 5 Warranty 5 General instructions 5 Safety precautione 6 Unintended machine movement 6 Flammable cleaning solvents 6 Faid under DEES ENEE ereechen Ee 6 apa l E 6 Hazardousinatelial s RR 6 Symbols used in Danfoss literature 7 DISA e sya ayn 7 The system CU CUI ee M 8 Pump E El 9 Fluid and filter recommendations nn 10 EE 11 Start UD Eelere TO 11 Required to01s 13 Port locations and gauge installation nn 13 OV GIV Ee 15 Safety precautione 15 System
21. Tandem Variable Pumps Introduction Safety precautions 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 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 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 Hazardous material A Warning Hydraulic fluid contains hazardous material Avoid prolonged c
22. aled 2000 hours Breather 500 hours Hazardous material A Warning Hydraulic fluid contains hazardous material Avoid contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 10 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Initial startup procedures General Start up procedure Follow this procedure when starting up a new pump installation or when restarting an installation in which the pump has been removed and re installed on a machine Ensure pump has been thoroughly tested on a test stand before installing on a machine 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 that may have occurred during shipping 1 Ensure that the machine hydraulic oil and system components reservoir hoses valves fittings and heat exchanger are clean and free of any foreign material 2 Install new system filter element s if necessary Check that inlet line fittings are properly tightened and there are no air leaks 3 Install the pump Install a 50 bar 1000 psi gauge in the charge pressure gauge port M3 4 Fill the housing by adding filtered oil in the upper case drain por
23. and filter maintenance Fluid and filter recommendations To ensure optimum life 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 Fluid contaminated by water may appear cloudy or milky or free water may settle 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 Inspect vehicle for leaks daily Change the fluid and filter per the vehicle machine manufacturer s recommendations or at these intervals First fluid change recommended at 500 hours o Caution High temperatures and pressures will result in accelerated fluid aging More frequent fluid changes may be required 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 than 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 Fluid and filter change interval Reservoir type Max oil change interval Se
24. ce O ring 106 Lubricate new O ring before installation 11029852 Rev BA November 2014 21 ones Service Manual Series 40 M46 Tandem Variable Pumps Adjustments 6 Using a 1 1 4 hex wrench install relief valve plug 166 Torque to 174 Nm 128 ft lb Adjusting the HPRV s 166 1 1 4 in 174 Nm 128 ft lb 1 1 4 in 174 Nm 128 ft lb P106668 Displacement limiter adjustment Pump may have a displacement limiter on each side of the servo Each limiter may be adjusted to a different setting 1 Remove snap ring 928 and sleeve 929 2 Hold the adjusting screw 913 in place using a flat screw driver Use a 9 16 hex wrench to loosen the locking nut 927 3 Rotate the displacement limiter 913 based on the table below Rotating the adjusting screw clockwise decreases the maximum displacement of the pump while rotating the adjusting screw counterclockwise increases the maximum displacement 4 After establishing the desired maximum displacement setting hold displacement limiter in place using a flat screw driver and tighten the locking nut using a 9 16 hex wrench Torque locking nut to 12 Nem 9 Ibf ft 22 11029852 Rev BA November 2014 ones Service Manual Series 40 M46 Tandem Variable Pumps Adjustments 5 One full turn of the ad
25. charge 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 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 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 each orifice is 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 16 11029852 Rev BA November 2014 Zonen Service Manual Series 40 M46 Tandem Variable Pumps Troubleshooting Item Description Action SCR system check relief valves set The SCR valves are malfunctioning or improperly Verify that the SCR valves are operating and properly set Repair or replace them as necessary Displacement limiters such that the servo piston is locked in place Displacement limiters may be improperly adjusted Veri
26. d 11029852 Rev BA November 2014 www danfoss com Danfoss A S 2014
27. e 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 40 M46 tandem variable displacement closed circuit pumps Remove the unit A Prior to performing major 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 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 Cleaning parts by using a clean solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept 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 Replace all O rings and gaskets ESS M Replace all O rings gaskets and seals Lightly lubricate all O rings with clean hydraulic fluid or petroleum jelly prior to assembly 11029852 Rev BA November 2014 5 ones Service Manual Series 40 M46
28. emove snap ring 928 and sleeve 929 Use a 1 4 hex wrench to hold neutral adjustment screw in place Use a 9 16 hex wrench to remove hex nut 2115 2 Use a flat screw driver to hold displacement limiter in place Use a 9 16 hex wrench to remove lock nut 927 Mark the location of displacement adjustment and neutral adjustment screws before disassembly This will save time during re assembly 3 Using a 3 8 hex wrench remove five bolts 921 from servo cover 902 4 Turn servo cover 902 counter clockwise to remove it from neutral adjustment screw Remove and discard gasket 2161 5 Turn displacement limiter 913 out of servo cover 902 11029852 Rev BA November 2014 27 ones Service Manual Series 40 M46 Tandem Variable Pumps Minor repair Inspection Inspect all parts for damage Inspect the mating surfaces of the servo cover 902 and motor housing for scratches grooves and other damage Inspect threads of screws and nuts for damage Replace any damaged parts Reassembly 1 Turn displacement limiter 913 into servo cover 902 Install new gasket 936 and turn servo cover 902 onto neutral adjustment screw k step 2 Using a 3 8 hex wrench install five bolts 921 Torque to 15 Nm 11 Ib ft 3 Use a flat screw driver to hold displacement limiter Use a 9 16 hex wrench to install seal nut 927 onto displacement limiter 913 at the position noted during disassembly Torque to 12 Nm 9 Ib ft
29. es 40 M46 Tandem Variable Pumps Adjustments 8 Remove gages Operate pump and check for leaks Charge pressure adjustment 11 16 in Charge pressure gage port P106 666E Engaging the bypass function Test bypass function with pump installed on machine The bypass function is engaged by unscrewing the bypass valve Do not open the bypass valve when machine is operating 1 To engage the bypass function use a 5 8 hex wrench to unscrew the bypass valve Rotate the bypass valve approximately three turns counterclockwise Do not rotate more than 3 revolutions as additional rotation will permit external leakage 2 To close the bypass valve rotate the bypass valve clockwise until seated Torque to 20 Nem 15 Ibf ft 3 If machine is towable with bypass valve opened three turns and if wheels are locked not towable with bypass valve closed bypass function is working correctly e Caution Avoid excessive speeds and extended load vehicle movement Do not move the load or vehicle more than 20 96 of maximum speed or for more than 3 minutes Damage to drive motor s is possible 20 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Adjustments Using the bypass function Bypass valve bi
30. es 40 M46 Tandem Variable Pumps Adjustments Measured data Servo pressure at M4 refer to Port locations and gauge installation on page 13 Servo pressure at M5 refer to Port locations and gauge installation on page 13 e Pressure differential between M4 and M5 optional Procedure Attach 20 bar 300 psi gauge to each servo gage port Use a 5 32 internal hex wrench to hold the adjusting screw in place Using a 1 2 hex wrench loosen locknut Start prime mover and slowly accelerate to normal operating RPM U A WM Rotate adjustment screw until both servo gages read equal pressures Rotate adjustment screw until one of the servo pressure gages indicates an increase in pressure Rotate adjustment screw in opposite direction until the other servo pressure gage indicates an increase in pressure Rotate adjustment screw until it is half way between the two positions 6 While holding the neutral adjustment screw in place tighten locknut Torque to 3 Nm 27 inelb EDC HDC control adjustment Adjustment screw 0 5 32 in Lock nut LL QO Sat 26 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Minor repair Standard procedures removing the pump Before working on the pump clean all dirt and grime from the outside of the pump If the pump has an auxiliary pump attached remove all pumps as a single unit Tag all hydraulic line
31. fice is of the correct size and free of debris Clean or repair them as necessary Displacement limiters if equipped The displacement limiters may be improperly adjusted such that the servo piston is prevented from moving in one direction Verify that the displacement limiters are adjusted properly System will not operate in either direction Item Description Action Oil level in reservoir There is insufficient hydraulic fluid to supply the system loop Fill the reservoir to the proper level with clean hydraulic oil Input control signal linkage current or pressure A faulty control signal being received at the pump MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal being received is correct and identical in both directions Adjust clean repair or replace the input device as necessary Cil filters Bypass valve Clogged oil filters may result in an insufficient supply of oil to the system A partially activated bypass valve may result in a cross port leakage Inspect the oil filters and verify that they are still serviceable Replace them as necessary Verify that the bypass valves are closed and that the valves are seating properly Clean repair or replace them as necessary Charge pressure in neutral Charge pressure may be insufficient to re
32. ft lb 2147 Screw 1 2 12 point 102 Nm 75 ftelb 2144 Nut 3 4 hex 102 Nm 75 ft Ib 2115 Servo lock nut 9 16 hex 37 Nm 27 ftelb Plug size and torque chart Item O ring plug Wrench size Torque 102 3 4 16 UNF 1 inch hex 108 Nm 80 ft Ib 2107 1 1 16 12 UNF 9 16 internal hex 115 Nm 85 ft lb 2148 9 16 18 UNF 11 16 hex 37 Nm 27 ft lb 2110 9 16 18 UNF 11 16 hex 37 Nm 27 ft lb 2111 9 16 18 UNF 11 16 hex 37 Nm 27 ft lb 2155 7 16 20 UNF 9 16 hex 20 Nm 15 ft lb 810 9 16 18 UNF 11 16 hex 37 Nm 27 ft lb 1001 5 8 18 UNF 5 8 hex 20 Nm 15 ft lb 166 1 5 16 12 UNF 1 1 4 hex 176 Nm 130 ft lb 40 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Torque chart Hardware locations 1001 166 T TI T 920 p 2115 _ 927 O 2107 4115 2147 P106664
33. fy that the displacement limiters are adjusted to the proper setting Neutral difficult or impossible to find Item Description Action Input control signal linkage current or pressure A faulty control signal is being received at the pump MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal being received is correct and identical in both directions Adjust Clean repair or replace control module as necessary System pressure may exist between the two sides of the working loop With no input signal to the control a pressure delta Readjust pump neutral setting Refer to Swashplate neutral adjustment on page 23 Servo pressure may exist across the servo piston With no input signal to the control a pressure delta Readjust the control neutral setting Refer to Manual Displacement Control Bracket Neutral Adjustment on page 24 and Electronic Displacement Control Hydraulic Displacement Control Neutral Adjustment on page 25 PCP pressure EDCs only With no input signal to the control a pressure Replace the EDC difference may exist across the control spool System response is sluggish Item Description Action Reservoir oil level There is an insufficient amount of hydraulic fluid resulting in an inadequate supply for the system loop Fill the reservoi
34. ign shafts Charge system relief valves Unusual noise may indicate sticking valves Possible contamination Clean replace valves and test pump May be a normal condition System operating hot Item Description Action Oil level in reservoir Insufficient hydraulic fluid will not meet the cooling demands of system 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 replace 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 11029852 Rev BA November 2014 ZZ avfi Service Manual Series 40 M46 Tandem Variable Pumps Troubleshooting Item Description Action Oil filters Clogged oil filters may result in an insufficient supply of cool oil to the system Inspect the
35. justing screw will change the maximum displacement approximately as shown in the table below Displacement limiter adjustment 9 16 in 913 P106 672E Displacement limiter adjustment data Displacement limiter adjustment data Displacement Locknut wrench size and torque Adjusting screw size Approximate displacement change per revolution of adjusting screw 46 9 16 12 Nm 9 Ibf ft Flat screw driver 4 1 cc turn Swashplate neutral adjustment With the pump properly plumbed primed and mounted on a vehicle or test stand use the following procedure to adjust the pump to mechanical neutral If pump is on a vehicle block the wheels to prevent movement 11029852 Rev BA November 2014 23 Service Manual Series 40 M46 Tandem Variable Pumps Adjustments Servo neutral adjustment Measured data e System pressure at MA or MC e System pressure at MB or MC Pressure differential between MA and MB or MC and MD optional Pump Setup 1 Attach 600 bar 10 000 psi gauge to system pressure gage ports MA and MB or MC and MD 2 Using a hydraulic line and fittings connect servo pressure ports M4 and M5 Connecting servo ports M4 and M5 removes the effects of any control pressure on the servo piston by creating zero pressure differential between the two sides of the servo 3 Using a 1 4 hex wrench and a 9 16 hex wrench loosen servo lock nut 2115 4 Using a 1 4 he
36. nit s rear cover or front flange voids the warranty unless done by a Danfoss Global Service Partner This section offers instruction on inspection and adjustment of pump components Read through the entire topic before beginning a service activity Refer to Pressure measurements on page 13 for location of gauge ports and suggested gauge size The following procedure explains how to check and adjust the charge pressure relief valve 1 2 Shut down prime mover Install a 50 bar 1000 psi pressure gauge in charge pressure gauge port M3 Install a 10 bar 100 psi gauge in one of the case pressure ports L1 or L Operate the system with the pump in neutral zero displacement to measure charge pressure Measure charge pressure at 1775 RPM Charge pressure is found by subtracting case pressure from the pressure measured at the charge pressure gage port M3 To adjust charge pressure shut down prime mover 4 Using a 1 inch hex wrench remove charge pressure relief plug 102 Add or remove shims 101 in relief valve Adding shims 101 increases charge pressure while removing shims decreases charge pressure Refer to pump model code for the unit s proper charge pressure setting Lubricate and install new O ring O ring 103 6 Using a 1 inch hex wrench reinstall plug 102 Torque to 108 Nm 80 ft lb Operate pump in neutral to verify proper operation 11029852 Rev BA November 2014 19 Service Manual Seri
37. noise or vibration SE System operating hot a15 System will not operate in one direction System will not operate in either direction 16 Neutral difficult or impossible to find sen 17 System response Eet S T sn nayn ad DP Kendi kenl k pk krye kk ke eW N k E k Erne AR a 17 Electrical troubleshooting sn 18 Standard procedures inspections and adjustments seen 19 W ali LS EE 19 Pump BT d En 19 Charge pressure relief Valve ire 19 Engaging th bypass FUMCKION e 20 System check relief SCR valves rennes 21 Displacement limiter adjustment sn 22 Displacement limiter adjustment data 23 Swashplate neutral adjustment m KK Manual Displacement Control Bracket Neutral Adjustment 24 Electronic Displacement Control Hydraulic Displacement Control Neutral Adjustment 25 Standard procedures removing the pUMpP rennes 27 Displacement limiter 27 Pressure filtration adapter 28 Charge pump j 29 Shaft seal 21 Mea cuc ONEN A A YE M M 32 Charge pressure relief Waly 3n nuna a nnn l n l l anak cad kan dlde ay N n Wik n ke ka kar n dake 33 Ie ECRIRE 34 Manual displacement control nee 35 Electronic Displacement Control Hydraulic Displacement Control 37 liegen TE 38 1
38. 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 will not operate in one direction Item Description Action Input control signal linkage current or pressure A faulty control signal is being received at the pump MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal being received 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 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 each ori
39. ontact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Introduction Symbols used in Danfoss literature A WARNING may result in injury 2 Tip helpful suggestion CAUTION may result in damage to product or F Lubricate with hydraulic fluid property A Reusable part Apply grease petroleum jelly rm Non reusable part use a new part EX Apply locking compound a Non removable item z Inspect for wear or damage w Option either part may exist A Clean area or part Superseded parts are not interchangeable E Be careful not to scratch or damage Tf Measurement required g Note correct orientation j Flatness specification Z Mark orientation for reinstallation 7 Parallelism specification lt Torque specification O External hex head 5 Press in press fit Internal hex head Eg Pull out with tool press fit e Torx head Cover splines with installation sleeve O ring boss port Pressure measurement gauge location or Q l specification The symbols above appear in the illustrations and text of this manual They are intended to communicate helpful information at the point
40. op most drain port to ensure the case remains full of fluid The motor case drain can be connected to the lower drain port on the pump housing and out the top most port or feed into the case drain line coming from the pump ahead of the heat exchanger A heat exchanger with a bypass valve is required to cool the case drain fluid before it returns to the reservoir 8 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Introduction System circuit diagram Reservoir Heat exchanger Control bypass handle SS Filter Displacement control valve Tl Heat exchanger N Cylinder block assembly Variable displacement motor Cylinder block assembly Charge relief valve Bypass et ht 2 valve SN NN Kl a 7 17 7 zera Output O shaft Charge pump Loop flushing module Variable Siem displacement Check valves uction flow pump w high pressure Charge pressure relief valve E servo pressure High pressure d P106608 Pump schematic Pump schematic 2 Lo J P100 587E Above schematic shows the function of a Series 40 M46 axial piston variable displacement pump 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Fluid
41. or 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 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 reserve
42. ormation Port identifier Port size Wrench size Pressure obtained Gauge size bar psi L1 L2 L3 1 1 16 12 SAE 9 16 internal hex Case drain 10 100 MA MB MC MD 9 16 18 SAE 11 16 hex System pressure 600 10 000 M3 9 16 18 UNF 11 16 hex Charge pressure 50 1000 M4 M5 9 16 18 SAE 11 16 hex Servo pressure 50 1000 System valves Port identifier Relief Port size Wrench size RA A port pressure relief valve 1 5 16 12 UNF 1 1 4 hex RB B port pressure relief valve 1 5 16 12 UNF 1 1 4 hex RC C port pressure relief valve 1 5 16 12 UNF 1 1 4 hex RD D port pressure relief valve 1 5 16 12 UNF 1 1 4 hex R Charge pressure relief valve 3 4 16 UNF 7 8 hex BP Bypass valve 5 8 18 UNF 1 inch hex System ports Port identifier Port size A system pressure port 1 5 16 12 SAE B system pressure port 1 5 16 12 SAE C system pressure port 1 5 16 12 SAE D system pressure port 1 5 16 12 SAE S charge pressure inlet 1 5 16 12 SAE 11029852 Rev BA November 2014 13 Service Manual Series 40 M46 Tandem Variable Pumps Pressure measurements Port locations A P106663 14 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Troubleshooting Overview This section provides general steps to follow if undesirable system conditions are observed Follow the steps listed until the problem is solved Some of the items will be system specific For areas covered in this manual a
43. r to the proper level with clean hydraulic fluid Input control signal linkage current or pressure A faulty control signal is being received at the pump MDC binding or broken linkage EDC faulty or inadequate electrical signal HDC blocked or incorrectly orificed control lines Verify that the input signal being received is correct and identical in both directions Pump control A damaged pump control or control spool will 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 SCR system check relief valves A partially activated bypass valve will cause cross port leakage One or both of the SCR valves may be binding within their bores Verify that the bypass valve is closed and that the valve is seating properly Clean repair or replace it as necessary Verify that the SCR valves operate freely Repair or replace them as necessary Charge pressure in neutral There is low charge pressure resulting from a damaged charge pump or low charge pressure relief valve setting 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
44. s as they are disconnected and plug all open ports to ensure that dirt and contamination do not get into the pump o Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines Removal 1 With the prime mover off thoroughly clean all dirt and grime from the outside of the pump 2 Tag and disconnect each hydraulic line connected to the pump As hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not get into the pump 3 Remove the tandem pump and its auxiliary pump if applicable as a single unit e Caution Be careful not to damage solenoids and electrical connections when using straps or chains to remove pump from machine Inspection 1 Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and grime 2 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles Reassembly 1 Before replacing the pump on the machine replace all filters and drain the hydraulic system Fill the system with the correct hydraulic fluid 2 Flush the lines before replacing the hydraulic fluid For repair part information see Danfoss publication Series 40 M46 Variable Pump Parts Manual BLN 2 41702 for your model Displacement limiter Removal 1 R
45. t 5 Fill the reservoir with hydraulic fluid of the recommended type and viscosity Use a 10 micron reservoir filler filter Ensure inlet line from reservoir to pump is filled 6 Disconnect the pump from all control input signals 7 Re install plug or fitting removed in step 4 After start up the oil level in the reservoir may drop due to filling of the system components Check the level in the reservoir to maintain a full oil level throughout the start up A Warning Damage to hydraulic components may occur if the oil supply is not maintained 8 Use acommon method to disable the engine to prevent the engine from starting Crank the starter for several seconds Do not to exceed the engine manufacturer s recommendation Wait 30 seconds and then crank the engine a second time as stated above This operation helps remove air from the system lines Refill the reservoir to recommended full oil level 9 When charge pressure begins to appear enable and start engine Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the system Check for leaks at all line connections and listen for cavitation Check for proper fluid level in reservoir eo Caution Air entrapment in oil under high pressure may damage hydraulic components o Caution Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered 10 When adequate charge pressure is
46. t to verify proper fluid flow and verify switch operation by measuring resistance open resistance 510 ohms closed resistance 122 ohms 18 11029852 Rev BA November 2014 Service Manual Series 40 M46 Tandem Variable Pumps Adjustments Standard procedures inspections and adjustments Warranty Pump adjustment Charge pressure relief valve o Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 1 With the prime mover off thoroughly clean all dirt and grime from the outside of the pump If removing the pump tag each hydraulic line connected to the pump If hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not get into the pump Ensure the surrounding areas are clean and free of contaminants such as dirt and grime 4 Inspect the system for contamination Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles 6 Drain and flush the hydraulic system and replace all filters Before re installing the pump perform a leakage test per Sauer Danfoss leakage test HPP 112 Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring the removal of a u
47. x wrench turn neutral adjustment screw 908 until one system pressure gage begins to show an increase in pressure Turn the neutral adjustment screw 908 in the opposite direction until the other system pressure gage begins to show an increase in pressure Turn the neutral adjustment screw half way between the two positions 5 Using a 1 4 hex wrench to hold the servo adjustment screw in place and a 9 16 hex wrench tighten servo lock nut 2115 Torque to 37 Nm 27 ft lb Pis cde mee 908 1 4 in Servo pressure port O ei 2115 O 9 16 in P106669 Manual Displacement Control Bracket Neutral Adjustment With the pump properly plumbed primed and mounted on a vehicle or test stand use the following procedure to adjust the pump displacement control to neutral position If pump is on a vehicle block the wheels to prevent movement Check swashplate neutral adjustment before adjusting control bracket If swashplate neutral is properly adjusted and system is not in neutral adjust MDC bracket as described below 24 11029852 Rev BA November 2014 Denpi Service Manual Series 40 M46 Tandem Variable Pumps Adjustments Verify swashplate neutral adjustment see Swashplate neutral adjustment on page 23 before performing control neutral adjustment Measured data Servo pressure at M4 Servo pressure at M5 e Pressure differential between M4 and M5 optional Procedure 1
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