Series 40 M46 Variable Pumps Service Manual
Contents
1. i j j Bypass i i Z valve h V r H j KLAAI 1 ji Ne AL n i N Output O ams SJ shaft f ES Charge SS j pump Loop flushing 1 3E module N Input esa shaft Variable So displacement Check valves Eno nO pump w high pressure Bl Charge pressure relief valve E servo pressure Bl High pressure Case low P106 608E Pump schematic Pump schematic L r C i j j j S e re j j L o Q E f A mg JON o e LJ M1 M5 Q L2 M2 B i vas y y L1 S P100 587E Above schematic shows the function of a Series 40 M46 axial piston variable displacement pump 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Fluid 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 was exposed to excessive heat2. 24 HE EDC Control ina T UU anti e E ke Ve a W len K n 25 11026743 Rev BA June 2014 3 Service Manual Series 40 M46 Variable Pumps Contents Minor repair Torque chart Control Neutral Adjustment sense 25 Standard procedures removing the PUMP sccsssccsssscccssseccsnseccsseccssuseccssecsssuecessuecessusccesuseessueceesusecssneeessneeessueeessneesenuseesse 28 Displacement WAST RR 28 OO EE El 29 EI EL 30 Shaft seal roller bearing and shaft replacement nn 32 A HH 33 Charge pressure relief Valve inner 34 Bypass valve 6035 Manual displacement control E Electronic displacement control hydraulic displacement control 5 37 MDC Orlfic T Dal E M 38 EDC HDC orifice T pall s ottobre R A lar kinar AV aA nanere i ika a ara k rr d ed 39 HC EDC Control Repair 40 Fastener size and torque Charts 43 Plug size and torque El nent 43 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Introduction Overview Warranty General instructions This manual includes information for the installation maintenance and minor repair of the Series 40 M46 pump It includes a description of the unit and its individual components troubleshooting information and minor repair procedure
3. 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 had failed EDC 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 No power to controller Restore power to controller Erratic pump function Filter bypass indicator switch Electrical connection to pump is bad Filter switch may be bad Disconnect connection check wires reconnect wires Check replace filter switch Add gauge to filter bypass port to verify proper fluid flow and verify switch operation by measuring resistance open resistance gt 510 ohms closed resistance lt 122 ohms 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments Standard procedures inspections and adjustments Warranty Pump adjustment Charge pressure relief valve Before working on the pump clean all dirt and grime from the outside of the pump and surrounding area e Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when remo
4. 928 and sleeve 929 Use a 1 4 in hex wrench to hold neutral adjustment screw in place Use a 9 16 in hex wrench to remove hex nut 115 2 Use a flat screw driver to hold displacement limiter 911 in place Use a 9 16 in hex wrench to remove lock nut 927 3 Using a 3 8 in hex wrench remove five bolts 921 from servo cover 902 4 Unscrew servo cover 902 to remove it from neutral adjustment screw Remove and discard gasket 936 5 Turn displacement limiter 911 out of servo cover 902 28 11026743 Rev BA June 2014 Zonen Service Manual Series 40 M46 Variable Pumps Minor repair Inspection Inspect all parts for damage Inspect the mating surfaces of the servo cover 902 and pump housing for scratches grooves and other damage Inspect threads of screws and nuts for damage Replace any damaged parts Reassembly 1 Turn displacement limiter 911 into servo cover 902 Install new gasket 936 and turn servo cover 902 onto neutral adjustment screw 2 Using a 3 8 in hex wrench install five bolts 921 Torque to 15 Nem 11 Ibf ft 3 Adjust displacement limiter to position originally noted during disassembly Use a flat screw driver to hold displacement limiter Use a 9 16 in hex wrench to install seal nut 927 onto displacement limiter 911 Torque to 12 Nem 9 Ibf ft 4 Set neutral adjustment screw at the position noted during disassembly Use a 1 4 in hex wrench to hold neutral a
5. 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 We recommend first fluid change at 500 hours Caution High temperatures and pressures accelerate 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 you change the fluid 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 Sealed 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 11026743 Rev BA June 2014 Service Manual Series 40 M46 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 pum
6. Input control signal linkage current or pressure Displacement limiters may be improperly adjusted such that the servo piston is locked in place 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 displacement limiters are adjusted to the proper setting Verify that the input signal being received 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 one or both may result in a cross port leakage 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 in stroke Charge pressure may be insufficient to recharge the system loop There is low charge pressure resulting from internal leakage within the system 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 Repair or replace the component or components within the system causing the internal leakag
7. and pits If wear scratching or pitting is found replace the shaft and bearing Rotate bearing while feeling for roughness Replace bearing if it doesn t spin freely 32 11026743 Rev BA June 2014 Zonen Service Manual Series 40 M46 Variable Pumps Minor repair SCR valves Reassembly 1 Using a snap ring pliers install snap ring 133 Lubricate and press bearing 131 onto shaft Install second snap ring 133 2 Install shaft and bearing assembly into front cover Rotate shaft to align with block splines Ensure bearing is installed deep enough to clear snapring groove 3 Using a snap ring pliers install snapring 132 4 Cover shaft splines with an installation sleeve to protect lipseal during installation Lubricate and press new seal 301 into pump cover 5 Install second snap ring 132 Remove installation sleeve Shaft seal installation tool P106 652E The SCR valves are factory set and are not field adjustable Removal 1 Using a 1 1 4 in hex wrench remove relief valve plug 166 Remove and discard Oring 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 2 Lub
8. 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 4 Remove sleeve 1402 Remove and discard backup ring 1208 and O ring 302 Inspection Inspect all parts of control assembly Replace any damaged parts Inspect spool and sleeve 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 Install control spool 1207 with alignment slot facing servo piston 36 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Minor repair En Alignment slot Servo piston P107 958E 3 Install neutral return spring 1214 neutral return bracket 1216 handle 1215 and washer 1235 onto spool 1207 4 Using a 1 2 in hex wrench install lock nut 1213 Torque to 15 N m 11 Ibf ft 5 Lubricate and install spool 1207 into sleeve 1402 6 Using a 3 8 in hex wrench install scre
9. filter recommendations 10 Hazardous material Initial startup procedures ET EEN Start up procedure Required tools and pressure measurements Required TO E 12 Port locations and gauge installation nn 12 Troubleshooting eil NN 14 Safety lU e E 14 System noise or vibration srncnsrnenss 14 System operating Ano O A PU RE OOOO e eases ieena eiis 14 System will not operate in one direction 15 System will not operate in either direction 15 Neutral difficult or impossible to find 16 System response is sluggish 16 Electrical troubleshooting ENEE 17 Adjustments Standard procedures inspections and adjustments sens 18 War A D is 18 Pump adjustment 18 Charge pressure relief valve 18 Engaging the bypass functions a EEGENEN 19 System check relief SCR valves rene 20 Displacement limiter adjustment nn 21 Swashplate neutral adjustment nn 22 UEM eorr 22 A jen ekr 22 Manual Displacement Control Neutral Return Bracket Adjustment ns 23 OU e 23 diese t n 23 Electric Displacement Control Hydraulic Displacement Control Neutral Adjustment 24 M as red data 24 Procedure san
10. freely within its bore Clean repair or replace it as necessary Bypass valve A partially activated bypass valve causes 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 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 as necessary 16 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action Charge pressure in stroke Servo pressure There is low charge pressure resulting from internal leakage within the system There is insufficient pressure differential across the servo piston Repair or replace the component or components within the system causing the internal leakage 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 Charge pump
11. part use a new part c Apply locking compound Non removable item E Inspect for wear or damage gt Option either part may exist Clean area or part Superseded parts are not interchangeable Be careful not to scratch or damage T Measurement required 5 Note correct orientation Flatness specification Z Mark orientation for reinstallation Parallelism specification Torque specification External hex head I Press in press fit Internal hex head H pull out with tool press fit Torx head Cover splines with installation sleeve O ring boss port 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 Design Danfoss Series 40 M46 closed circuit axial piston pumps convert input torque into hydraulic power The input shaft transmits rotational force to the cylinder block Bearings at the front and rear of the pump support the input shaft Splines connect the cylinder block to the input shaft 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 A ball joint connects a br
12. postitions 22 11026743 Rev BA June 2014 Zonen Service Manual Series 40 M46 Variable Pumps Adjustments 6 Use a 1 4 hex wrench to hold the servo adjustment screw in place and a 9 16 hex wrench to tighten servo lock nut 115 Torque to 37 Nem 27 Ibf ft 7 Shut down prime mover and remove previously installed gauges and fittings Plug ports MA MB M4 and M5 Servo neutral adjustment Connect Ports M4 and M5 Qe O 0 0 115 P106 630E 11 16 in Manual Displacement Control Neutral Return Bracket 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 securely block the wheels to prevent movement Check swashplate mechanical neutral adjustment before adjusting control bracket Refer to previous topic Swashplate neutral adjustment on page 22 for instructions If swashplate neutral is properly adjusted and system is not in neutral adjust MDC bracket as described below Measured data Servo pressure at M4 Servo pressure at M5 Pressure differential between M4 and M5 optional Procedure 1 Attach 20 bar 300 psi gauge to each servo gage port M4 and M5 Run prime mover at normal operating speed 2 Using a 3 8 in hex wrench loosen screw 1210 allowing the neutral bracket to move but not freely 3 Start prime mov
13. swashplate 2 If you have a three position control use a 4 mm internal hex wrench to install screws 1226 Torque screws to 14 Nem 10 Ibf ft Install three posion control housing 1223 Using a 3 16 in internal hex wrench install screws 1203 and 1204 or 1224 Torque to 14 Nem 10 Ibf ft EDC HDC repair 1203 3 16i ZS YE di 3 16 in 1203 3 P106 640E A di 9 3 16 in 1224 9 3 16 in 3 Position Control MDC orifice repair Removal 1 Using a 3 16 in internal hex wrench remove pipe plug 1219 2 Using a 1 8 in internal hex wrench remove filter or orifice plug 1401 Inspection Clean orifice Replace if necessary Reassembly 1 Using a 1 8 in internal hex wrench install filter or orifice plug 1401 Torque to 3 Nem 2 Ibf ft 2 Using a 3 16 in internal hex wrench install pipe plug 1219 Torque to 22 Nem 16 Ibf ft 38 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Minor repair Install Pipe plug 1219 with thread lock Apply a few drops before installation MDC orifice repair e o 2 O 9 d 8 Bei O 401 SR l1 8 in N ey SS D ef m Sa 3 16 in E P106 654E EDC HDC orifice repair Removal 1 Remove servo covers See Displacement limiter on page 28 for servo cover rem
14. 46 Variable Pumps Required tools and pressure measurements Port locations MA L1 M5 M4 A a D L2 Til D TU P106 604E 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Troubleshooting Overview This section provides general steps to follow if undesirable system conditions occur Follow these steps until you solve the problem Some of the items are system specific For areas this manual covers we reference the section Always observe the safety precautions in ntroduction on page 5 and those related to your specific equipment Safety precautions Caution High inlet vacuum causes cavitation which can damage internal pump components Ensure charge pump supply plumbing is adequate Locating pump below the level of the reservoir when possible improves inlet conditions 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
15. Clean repair or replace the heat exchanger as necessary Heat exchanger bypass valve A partially activated heat exchanger 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 as necessary 14 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action SCR System Check Relief Valves A partially activated SCR valve or SCR valves with relief settings too low may generate heat 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 can result in the pump and or motor operating at speeds and pressures beyond system design limitations X 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 bindin
16. MAKING MODERN LIVING POSSIBLE Service Manual Variable Pumps powersolutions danfoss com Service Manual Series 40 M46 Variable Pumps Revision history Table of revisions Date Changed Rev June 2014 Danfoss layout add HC EDC Control BA October 2010 corrections to port location illustration AE March 2010 Fix Osaka address AD March 2009 added spool alignment illustration AC May 2008 Fixed the illustrations AB October 2007 First edition AA 2 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Contents Introduction nui feu 5 Warranty 5 General instructions 5 Remove the unit 5 Keep it clean 5 Replace all O rings and gaskets 5 Safety le CG 6 Unintended machine movement EEN 6 Flammable cleaning solvents 5 kes nude e Gina Ger l ay G k ye serr k MA Me kya dR 6 Fluid under de IST RR 6 AS rte itte tees ERES ERE EFE EM P HUPHNREUMAL RU n Ie EOE VEU atisi Taa Ei iinr Eii 6 Hazardous material titre ctii heec bere kade na e ke ear repe bel peto Ee 6 Symbols used in Danfoss literature Ni Bi me H 7 The system circuit 8 The basic closed Reie ll PR Hr ere 8 Case drain and heat A 8 Din REEL 9 Fluid and filter maintenance Fluid and
17. The basic closed circuit Hydraulic lines connect the main ports of the pump to the main ports of the motor Fluid flows in either direction from the pump to the motor and back in this closed circuit Either of the hydraulic lines can be under high pressure In pumping mode the angle of the pump swashplate determines which line is high pressure as well as the direction of fluid flow Case drain and heat exchanger The pump and motor require case drain lines to remove hot fluid from the system The pump and motor should be drained from their top most drain port to ensure the case remains full of fluid Flow from the motor case drain may route to the lower drain port on the pump housing and out the top most port or feed directly to the heat exchanger The system requires a heat exchanger with a bypass valve to cool the case drain fluid before it returns to the reservoir 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Introduction System circuit diagram Heat exchanger Reservoir j j j j j bypass n j Filter j i H i j E i Displacement Heat ee a CH a iren E ea Ci j j 1 Control handle o o i 7 und 1 Cylinder Variable E 0 ji block displacement lL i assembly motor Cylinder ED loc assembly Charge relief j t valve
18. ariable Pumps 46 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps 11026743 Rev BA June 2014 47 Products we offer 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 Bent Axis Motors excel in the harsh operating conditions of the mobile off highway market Building on our extensive Closed Circuit Axial Piston Pumps and Motors 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 Displays market faster Electrohydraulic Power Danfoss Your Strongest Partner in Mobile Hydraulics Steering Go to www powersolutions danfoss com for further product information Electrohydraulics Hydraulic Power Steering Wherever off highway vehicles are at work so is Danfoss Integrated Systems 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 Joysticks and Control Handles Microcontrollers and Please contact the Danfoss Power Solution representative nearest you Software Open Circuit Axial Piston Pumps Orbita
19. ass slipper to each piston A spring washer and the force of charge pressure holds the slippers to the swashplate 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 connects to low pressure and the other half to high pressure As each piston cycles in and out of its bore fluid displaces from inlet to outlet imparting hydraulic power into the system A small amount of fluid flows from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling The pump also uses excess flow from the charge pressure relief valve for cooling Case drain ports return this fluid to the reservoir A gerotor style charge pump provides this flow and maintains a minimum pressure in the system loop 11026743 Rev BA June 2014 7 Ponit Service Manual Series 40 M46 Variable Pumps Introduction The system circuit The angle of the swashplate controls the volume of fluid displaced into the system The servo piston sets swashplate angle The pump control modulates servo piston position by varying differential pressure across the piston Cross section view Gerotor Valve plate Piston Ball bearing Slipper TET Shaft Shaft Seal Journal Bearing Swashplate bearing pin Needle bearing Cylinder block Swashplate P d Manual displacement Control Servo piston Sleeve Bearing
20. cate and install new O ring 106 au fF W N Using a 1 1 4 in hex wrench install relief valve plug Torque to 176 N m 130 Ibf ft 20 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments Installing the SCRs 166 KOl1 1 4 in 176 Nm 130 ft lb 106 ie Ne MANE O O 9 Q G 3 0 O y O X 1103 N n 165 ES 4 e AN A 1 1 4 in S 176 Nm 130 ft Ib P106 635E 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 Using a flat screw driver to hold the displacement limiter loosen the locking nut 927 with a 9 16 hex wrench 3 Rotate the displacement limiter 911 to adjust maximum displacement Rotating the adjusting screw clockwise decreases the maximum displacement of the pump while rotating the adjusting screw counterclockwise increases the maximum displacement The displacement changes approximately 4 cm per revolution 4 After establishing the desired maximum displacement setting hold displacement limiter in place using a flat screw driver and tighten the locking nut with a 9 16 in hex wrench Torque to 12 Nem 9 Ibf ft Repeat if necessary to adjust ma
21. djustment screw and a 9 16 in hex wrench to install hex nut 115 Torque to 37 Nem 27 Ibf ft Install sleeve 929 and snap ring 928 Displacement limiter removal installation Servo neutral adjustment screw J gt 9 16 in P106 641E Pressure filtration adapter Removal 1 Using an 11 16 in hex wrench remove plug 810 Remove and discard O ring 810A 2 Using a 1 2 in hex wrench remove screws 806 3 Remove pressure filtration cover 801 Remove and discard seal adapter 805 Inspection Inspect the machined surface on the control If any nicks or scratches are found replace the damaged component Reassembly 1 Install new seal adapter 805 and filtration cover 801 11026743 Rev BA June 2014 29 ones Service Manual Series 40 M46 Variable Pumps Minor repair 2 Using a 1 2 hex wrench install three screws 806 Torque to 30 Nem 22 Ibf ft 3 Lubricate and install O ring 810A onto plug 810 Using an 11 16 in hex wrench install plug 810 Torque to 37 Nem 27 Ibf ft Pressure filtration adapter removal installation Q 0 810 O 810A L 806 P106 642E Charge pump Removal If a gear pump is attached to the auxiliary pad remove the gear pump and O ring or gasket 1 Using a 9 16 in hex wrench remove screws 1506 and c
22. e 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Troubleshooting Item Description Action Servo pressure Charge pump There is an insufficient pressure differential across the servo piston The charge pump is damaged or has been installed with the incorrect rotational orientation 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 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 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 With no input signal to the control a pressur
23. e pump is now ready for operation 11026743 Rev BA June 2014 11 Service Manual Series 40 M46 Variable Pumps Required tools and 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 information Port identifier Port size Wrench size Pressure obtained Gauge size bar psi L1 L2 1 1 16 12 SAE 9 16 internal hex Case drain 10 150 MA MB 9 16 18 SAE 11 16 hex System pressure 600 9 000 M3 9 16 18 UNF 11 16 hex Charge pressure 50 750 M4 M5 9 16 18 SAE 11 16 hex Servo pressure 50 750 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 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 S charge pressure inlet 1 5 16 12 SAE 12 11026743 Rev BA June 2014 Service Manual Series 40 M
24. e delta may exist between the two sides of the working loop Readjust pump neutral setting Refer to Swashplate neutral adjustment on page 22 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 Manual Displacement Control Neutral Return Bracket Adjustment on page 23 and Electric Displacement Control Hydraulic Displacement Control Neutral Adjustment on page 24 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 reservoir 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
25. e or disable disconnect the mechanism while servicing 1 Install a 50 bar 1000 psi gauge in each of the two servo gauge ports M4 and M5 Disconnect the external control input electrical connections from the control Start the prime mover and operate at normal speed 2 Use a 4mm internal hex wrench to hold the neutral adjusting screw D015 stationary while loosening the locknut D060 with a 13mm wrench 3 Observe pressure gauges lf necessary turn adjusting screw D015 to reduce pressure differential EDC adjustment is very sensitive Be sure to hold the hex wrench steady while loosening the locknut Total adjustment is less than 120 degrees 11026743 Rev BA June 2014 25 Service Manual Series 40 M46 Variable Pumps Adjustments Locknut 13mm Z 12 Nem 9 Ibf ft Adjusting screw 4mm 0 50 bar 0 1000 psi 9 3 16 in z 19 Nem 14 Ibf ft Servo pressure gauge port M4 amp 0 50 bar 0 1000 psi o 3 16 in 19 Nem 14 Ibfeft P108773 4 Rotate the neutral adjusting screw D015 clockwise until the pressure increases on the gauge Note the angular position of the wrench Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge Again note the angular position of the wrench 5 Rotate the neutral adjusting screw clockwise half the d
26. econds 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 8 Check the pressure gauge at M3 When charge pressure begins to build 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 o Caution Air entrapment in oil under high pressure may damage hydraulic components Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered 9 When the pump estabishes adequate charge pressure as shown in model code increase engine speed to normal operating rpm to further purge residual air from the system 10 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 11 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 12 Check that the reservoir is full Remove charge pressure gauge Re intall charge pressure plug Th
27. er and slowly accelerate to normal operating rpm 4 Using your hand press neutral bracket towards the pump housing and rotate it until one of the servo pressure gages indicates an increase in pressure Note position of bracket Rotate neutral bracket in opposite direction until the other servo pressure gage indicates an increase in pressure Note position of bracket Rotate neutral bracket half way between the two positions 5 Holding the neutral adjustment bracket in place use a 3 8 in hex wrench to tighten screw 1210 Torque to 14 Nem 10 Ibfeft 11026743 Rev BA June 2014 23 Ronin Service Manual Series 40 M46 Variable Pumps Adjustments 6 Shut down prime mover and remove previously installed gauges Plug ports M4 M5 Torque to 37 Nem 27 Ibf ft Manual displacement control bracket adjustment 00 1210 3 8 in Neutral bracket O P106 631E Electric Displacement Control Hydraulic Displacement Control Neutral Adjustment With the pump properly plumbed primed and mounted on a vehicle or test stand use this procedure to adjust the pump displacement control to neutral position If pump is on a vehicle block the wheels to prevent movement Measured data Servo pressure at M4 Servo pressure at M5 e Pressure differential between M4 and M5 optional Procedure 1 Attach 20 bar 300 psi gauge to each servo gage port 2 Use a 5 32in internal hex wrench to hold the ad
28. g 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 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 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 orifice is of the correct size and free of debris Clean or repair them as necessary 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 Displacement limiters
29. is a ttached to the auxiliary pad install a new O ring or gasket and gear pump 6 Install cover plate 1505 Using a 9 16 in hex wrench install capscrews 1506 Torque to 30 Nem 22 Ibf ft If a gear pump is attached seal 1504 cover 1505 and bolts 1506 are not used Replace O ring or gasket between gear pump and M46 pump 11026743 Rev BA June 2014 31 ones Service Manual Series 40 M46 Variable Pumps Minor repair Shaft seal roller bearing and shaft replacement The shaft assembly is serviceable without removing the front cover of the pump but the charge pump must be removed first Orient the pump on the work surface so the shaft is pointing up with the charge pump 603 and key 605 removed from shaft See Charge pump on page 30 Removal 1 Using a snap ring pliers remove snap ring 132 from pump cover Remove and discard seal 301 Remove second snap ring 132 2 Remove shaft assembly from pump cover e Caution Do not damage the housing bore shaft or bearing when removing the shaft and shaft seal 3 Using a snap ring pliers remove both snap rings 133 Press bearing 131 off of shaft o Caution Do not rotate or move pump after removing shaft Internal components may be dislodged making shaft replacement impossible without complete disassembly Shaft assembly P106 637E Inspection Inspect the shaft and bearing for wear scratching
30. istance between the wrench positions noted above The gauges should read the same pressure indicating that the control is in its neutral position 6 Hold the neutral adjusting screw stationary and tighten the locknut D060 Torque to 12 Nem 9 Ibf ft Do not over torque the nut 7 When the neutral position is set stop the prime mover remove the gauges and install the gauge port plugs Reconnect the external control input A small pressure differential of 1 5 bar 22 psi or less is acceptable Zero differential is usually not possible 26 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments Neutral Adjustment EDC bottom view Solenoid shaft Control spool Feedback pin Maximum adjustment less than 120 P106 046E up Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is re installed 11026743 Rev BA June 2014 27 Service Manual Series 40 M46 Variable Pumps Minor repair Standard procedures removing the pump Before working on the pump clean all dirt and grime from the outside If the pump has an auxiliary pump attached remove both pumps as a single unit Tag all hydraulic lines 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
31. justing screw in place and a 1 2 hex wrench loosen locknut 3 Start prime mover and slowly accelerate to normal opperating rpm 4 Rotate adjustment screw until one of the servo pressure gages indicates an increase in pressure Note position of screw Rotate adjustment screw in opposite direction until the other servo pressure gage indicates an increase in pressure Note position of screw Rotate adjustment screw halfway between the two positions 5 While holding the neutral adjustment screw in place tighten locknut Torque to 3 N m 27 Ibf in 6 Stop prime mover and remove previously installed gauges Plug ports M4 M5 Torque to 37 Nem 27 Ibfeft 24 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments EDC HDC control adjustment Adjustment screw 0 5 32 in Lock nut a C3 9 16 in P106 643 O O HC EDC Control Control Neutral Adjustment All functions of the Electric Displacement Control EDC are preset at the factory If necessary adjust the pump to neutral with the pump running on a test stand or on the vehicle machine with the prime mover operating If adjustment fails to give satisfactory results you may need to replace the control or coils See Minor repair for details A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machin
32. l Motors e PLUS GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Comatrol www comatrol com Schwarzm ller Inverter www schwarzmueller Local address 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 Danfoss Power Solutions US Company Power Solutions GmbH amp Co OHG 2800 East 13th Street Krokamp 35 Ames lA 50010 USA D 24539 Neum nster Germany Phone 1 515 239 6000 Phone 49 4321 8710 comprehensive global service for all of our components Power Solutions ApS Nordborgvej 81 DK 6430 Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions Shanghai Co Ltd Building 22 No 1000 Jin Hai Rd Jin Qiao Pudong New District 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 11026743 Rev BA June 2014 www danfoss com Danfoss A S 2014
33. level leads to cavitation Fill reservoir Aeration of the oil pump inlet vacuum Air in system decreases efficiency of units and controls Excessive noise foaming oil and heat may indicate air in system 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 Pump inlet vacuum Cold oil may be too viscous for proper function pump cavitates High inlet vacuum causes noise cavitation Allow the oil to warm up to it s normal operating temperature with engine at idle speed Check that inlet line is not restricted and is the proper size Check filter and bypass valve Shaft couplings A loose shaft coupling causes excessive noise Replace loose shaft coupling Replace pump shaft Shaft alignment Misaligned shafts creates noise Align 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 Cil 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
34. 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 using a clean solvent wash and air drying is usually adequate 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 Replace all O rings and gaskets EN M Danfoss reccommends you replace all O rings seals and gaskets during repair Lightly lubricate all O rings with clean petroleum jelly prior to assembly 11026743 Rev BA June 2014 5 ones Service Manual Series 40 M46 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 solven
35. on A Correct screen orientation P106 519E M 6 Install the control module and six cap screws D250 Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the control module when installing control 7 Using a 5 mm internal hex wrench torque the cap screws D250 to 13 5 N m 10 Ibf ft HC ECD Control D250 6X e P108776 11026743 Rev BA June 2014 41 Service Manual Series 40 M46 Variable Pumps Minor repair Torque sequence 42 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Torque chart Fastener size and torque chart Item Fastener Wrench size Torque 920 Servo piston cover screws 3 8 hex 15 Nem 11 Ibf ft 921 Servo piston cover screws 3 8 hex 15 Nem 11 Ibf ft 130 Front cover screw T50 Torx 58 Nem 43 Ibf ft 163 Front cover screws T55 Torx 91 Nem 67 Ibf ft 1506 Rear cover screws 9 16 hex 77 Nem 57 Ibf ft 806 Filtration cover screw 1 2 hex 30 Nem 22 Ibf ft 115 Lock seal nut 11 16 hex 37 Nem 27 Ibf ft 927 Displacement limiter lock seal nut 9 16 hex 12 N m 9 Ibf ft 1213 Control handle nut 1 2 hex 15 Nem 11 Ibf ft 1210 Screw 3 8 14 Nem 10 Ibf ft Plug size and torque chart Item O ring plug Wrench size Torque 102 3 4 16 UNF 1 inch hex 108 N m 80 Ibf f
36. oval and installation instructions 2 Using a 7 32 in internal hex wrench remove orifice plugs 1403 and 1404 Inspection Clean orifice Replace if necessary Reassembly 1 Using a 7 32 in internal hex wrench install orifice plugs 1403 and 1404 Torque to 3 Nem 2 Ibf ft 2 Install servo covers See Displacement limiter on page 28 for servo cover removal and installation instructions 11026743 Rev BA June 2014 39 Service Manual Series 40 M46 Variable Pumps Minor repair EDC HDC orifice repair 3 8 in P106 655E HC EDC Control Repair 1 Using a 5 mm internal hex wrench remove the six cap screws D250 2 Remove the control module and gasket D150 Discard the gasket 3 Inspect the machined surfaces on the control and top of the pump If you find any nicks or scratches replace the component 4 Install a new gasket D150 Ensure that you install the dowel pins D300 in the housing before installing the control 5 If you removed screen D084 install a new one Install with the mesh facing outward see drawing 40 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Minor repair Proper screen orientation D084 D084 CSS Be 2 gt muc Ee ES S gt ES d SS A i Ve Incorrect screen orientati
37. over plate 1505 Remove and discard seal 1504 Using a 9 16 in hex wrench remove screws 1502 Remove auxiliary pad 1503 Remove and discard O ring 141 and load ring 142 Remove gerotor cover 155 and gerotor 603 Remove pin 604 and key 605 Uu AUN 30 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Minor repair Charge pump removal installation 1506 O 9 16 in 30Nm 20 ftelb 1502 LE 9 16 in 43Nm 32 ft lb OX P T m TE Fn j P aa Pass 603 Do Fe P106 636E Inspection Inspect the gerotor 603 and gerotor cover 155 for wear scratches or pitting If any component shows signs of wear scratching or pitting relpace all components Inspect pin 604 and key 605 for damage and replace parts if necessary Replace O ring 141 load ring 142 and seal 1504 whenever charge pump is disassembled Reassembly Charge pump parts are available as a complete set Install key 605 Lubricate and install gerotor assembly 603 Install pin 604 and gerotor cover 155 Lubricate and install new O ring 141 and load ring 142 Install auxiliary pad 1503 Using a 9 16 in hex wrench install screws 1502 Torque to 43 Nem 32 lb ft Lubricate and press seal 1504 onto auxiliary pad 1503 U BF WM If a gear pump
38. p was removed Ensure pump is thoroughly tested on a test stand before installing 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 shipping damage 1 Ensure 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 M 4 Fillthe housing by adding filtered oil in the upper case drain port Replace plug 5 Fillthe 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 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 start up A Warning Damage to hydraulic components may occur if you fail to maintain the oil supply 7 Use a common method to disable the engine to prevent it from starting Crank the starter for several s
39. 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 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 Inspect 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 filtered 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 41701 for your model Displacement limiter Removal Only remove displacement limiter 911 if replacement is necessary Mark the location of displacement adjustment and neutral adjustment screws before disassembly This saves time during re assembly 1 Remove snap ring
40. rclockwise Do not rotate more than 3 revolutions additional rotation permits external leakage 2 To close the bypass valve rotate the bypass valve clockwise until seated Torque to 20 Nem 15 Ibf ft 3 Vehicle machine should move with bypass valve open Close valve for normal operation o Caution Bypass valve is not a tow valve Damage to pump and motor is possible when operating without charge pressure Limit speed of movement to 2096 of the vehicle machine s maximum for no longer than 3 minutes 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments Using the bypass function Bypass check valve 00 O 5 8 in P106 633E 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 is replaced or opened opperate the pump 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 Refer to the model code for pressure designation If you suspect SCR malfunction replace valve and test operation of pump This procedure explains how to replace the SCR valves 1 Shut down the system Using a 1 1 4 in hex wrench remove relief valve plug 166 Remove spring 165 and relief valve 1103 from pump housing Insert new relief valve and spring into pump housing Lubri
41. ricate and install new O ring 106 onto plug 166 Using a 1 1 4 in hex wrench install relief valve plug 166 Torque to 176 Nem 130 Ibf ft 11026743 Rev BA June 2014 33 Service Manual Series 40 M46 Variable Pumps Minor repair Charge pressure relief valve SCR valves 166 1 1 4 in 176 Nm 130 ftelb S 3 O o 0 O 0 0 166 1 1 4 in Z 176 Nm 130 ft lb P106 635E Replace the charge pressure relief valve components if they are damaged or if you suspect failure See Charge pressure relief valve on page 18 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 spring and shims 2 Lubricate and install O ring onto plug Using a 1 in hex wrench install plug Torque to 108 N m 80 Ibfeft 3 Operate pump at full range of controls to ensure proper machine operation 34 11026743 Rev BA June 2014 Ser
42. s 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 trains Global Service Partners and certifies their facilities on a regular basis You can locate your nearest Global Service Partner using the distributor locator at www powersolutions danfoss com 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 unit s front flange voids the warranty unless done by a Danfoss Global Service Partner Follow these general procedures when repairing Series 40 M46 variable displacement closed circuit pumps Remove the unit A Prior to performing 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 and plug ports after removal to prevent contamination Keepit clean Cleanliness is a primary
43. t 107 1 1 16 12 UNF 9 16 internal hex 115 N m 85 Ibf ft 110 9 16 18 UNF 11 16 hex 37 N m 27 Ibf ft 111 9 16 18 UNF 11 16 hex 37 N m 27 Ibf ft 158 7 16 20 UNF 9 16 hex 20 N m 15 Ibf ft 810 9 16 18 UNF 11 16 hex 37 N m 27 Ibf ft 1001 5 8 18 UNF 5 8 hex 20 N m 15 Ibf ft 1101 1 5 16 12 UNF 1 1 4 hex 176 N m 130 Ibf ft 1102 1 5 16 12 UNF 1 1 4 hex 176 Nem 130 Ibf ft 11026743 Rev BA June 2014 43 Service Manual Series 40 M46 Variable Pumps Torque chart Hardware locations DES 110 1213 163 f 2places j f 0 O 6 places a e 111 1506 806 810 2 places 3 places Rear 3 places e 2 places 1001 s 927 2 places Fm 2 i Co T 5 places S DI i J P106 604E we E107 Q 920 i 2 places O e 5 places RSS 158 Bottom 1101 In we js 102 Top 44 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps 11026743 Rev BA June 2014 45 Service Manual Series 40 M46 V
44. ts 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 contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Introduction Symbols used in Danfoss literature A WARNING may result in injury amp Tip helpful suggestion 9 CAUTION may result in damage to product or 4 Lubricate with hydraulic fluid property amp Reusable part Apply grease petroleum jelly Non reusable
45. ust charge pressure shut down system 3 Using a 1 inch hex wrench remove charge pressure relief plug 102 Add or remove shims 101 in relief valve Adding shims increases charge pressure while removing shims decreases charge pressure 4 Lubricate and install new O ring 103 5 Using a 1 inch hex wrench reinstall plug Torque to 108 N m 80 Ibf ft 6 Operate pump in neutral to verify proper charge setting Charge pressure is referenced to case pressure Subtract case pressure L1 L2 from charge pressure M3 to compute actual setting Repeat steps 1 5 if necessary 7 Remove gages and replace plugs M3 L1 L2 Using an 11 16 in hex wrench torque plug M3 to 37 Nem 27 Ibf ft Using a 9 16 in internal hex wrench torque plug L1 L2 to 115 Nem 85 Ibf ft 18 11026743 Rev BA June 2014 Service Manual Series 40 M46 Variable Pumps Adjustments Charge pressure adjustment SW O Tin E E S e 8 S 7 S IR O O lo M3 O 11 16 in 0 0 Charge pressure gage port P106 634E Engaging the bypass function Test the bypass function with the pump installed on the machine The bypass function is engaged by unscrewing the bypass valve Do not open the bypass valve when the machine is operating 1 To engage the bypass function use a 5 8 in hex wrench to unthread the bypass valve Rotate the bypass valve approximately three turns counte
46. vice Manual Series 40 M46 Variable Pumps Minor repair Charge pressure relief valve 102 9 9g 103 JT a Be 104 PM 105 SES Q O ASIS o 9 la A le 6 STE TI 0 0 P106 638E Bypass valve Removal 1 Using a 5 8 in hex wrench remove bypass valve 1001 2 Remove and discard O ring 1003 and backup ring 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 backup ring 1002 onto bypass valve 1001 2 Using a 5 8 in hex wrench install bypass valve 1001 Torque to 20 Nem 15 Ibf ft 3 Operate pump at full range of controls to ensure proper machine operation 11026743 Rev BA June 2014 35 Service Manual Series 40 M46 Variable Pumps Minor repair Bypass valve el O 5 8 in 20 Nm 15 ft lb 1002 M4 NE 1003 IM Ta ES S e 9 O G S 6 o N y D A 0 0 P106 653E Manual displacement control Removal 1 Using a 3 8 in hex wrench remove screw 1210 Remove manual control spool assembly from pump housing 2 Using a 1 2 in hex wrench remove lock nut 1213 Remove lock washer 1235 handle 1215 neutral return
47. ving and reinstalling system lines 1 If removing the pump tag each hydraulic line If you disconnect hydraulic lines plug each open port to ensure that dirt and contamination do not get into the pump 2 Inpect the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles 3 If there are signs of contamination in the hydraulic fluid replace all filters and drain and clean the hydraulic system Fill with the correct hydraulic fluid 4 Flush the lines before replacing the hydraulic fluid 5 Before re installing the pump test for leaks 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 unit s front flange voids the warranty unless done by a Danfoss Global Service Partner This section offers instruction on adjustment of pump components Read through the entire topic before beginning a service activity Refer to Port locations and gauge installation on page 12 for location of gauge ports and suggested gauge size This procedure explains how to check and adjust the charge pressure relief valve 1 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 L2 Operate the system with the pump in neutral zero displacement when measuring charge pressure 2 To adj
48. w 1210 Torque to 14 Nem 10 Ibf ft See Manual Displacement Control Neutral Return Bracket Adjustment on page 23 for adjustment procedure Manual displacement control 1208 Nos 3 1 j X 69 1210 Le P106 639E Electronic displacement control hydraulic displacement control Removal If you suspect control 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 in internal hex wrench remove screws 1203 and 1204 or 1224 If you have a three position controll remove screws 1226 using a 4 mm internal hex wrench 2 Remove control housing 1201 or manifold 1225 Remove and discard O rings 1220 and 304 or 1227 1228 and 12234 11026743 Rev BA June 2014 37 ones Service Manual Series 40 M46 Variable Pumps Minor repair Inspection Inspect control spool for scratches grooves and other damage If spool is damaged or you suspect control 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 for a three position control lubricate and install O rings 1227 and 1228 onto manifold 1225 and O rings 1229 onto control housing 1223 Install control housing 1201 or manifold 1225 onto pump housing align sleeve groove with spring pin on
49. ximum displacement in other direction 5 After adjustment verify proper maximum vehicle machine speed Readjust if necessary 11026743 Rev BA June 2014 21 Service Manual Series 40 M46 Variable Pumps Adjustments Displacement limiter adjustment Swashplate neutral adjustment With the pump properly plumbed primed and mounted on a vehicle or test stand use this procedure to adjust mechanical neutral If pump is on a vehicle securely block the wheels to prevent movement Measured data e System pressure at MA e System pressure at MB e Pressure differential between MA and MB optional Pump Setup 1 Attach 600 bar 10 000 psi gauge to system pressure gage ports MA and MB 2 Using a hydraulic line and fittings shunt the servo piston by connecting servo pressure ports M4 and M5 Connecting servo ports M4 and M5 defeats the affect of any control pressure on the servo piston 3 Run prime mover at normal operating speed 4 Use a 1 4 hex wrench to hold adjusting screw 908 in place and a 9 16 hex wrench to loosen servo lock nut 115 5 Turn neutral adjustment screw 908 until one system pressure gage begins to show an increase in pressure Note position of screw Turn the neutral adjustment screw 908 in the opposite direction until the other system pressure gage begins to show an increase in pressure Note position of screw Turn the neutral adjustment screw half way between the two
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