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Danfoss Series 40 M46 Tandem, Service Manual, Page: 9 / 48

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Danfoss Series 40 M46 Tandem Service Manual Download Page 9

System circuit diagram

Input

shaft

Suction flow

Servo pressure

High pressure

Case flow

Charge pressure

Output

shaft

Cylinder
block

assembly

Filter

Charge

pump

Reservoir

Cylinder

block

assembly

Heat

exchanger

Check valves

w/ high pressure
relief valve

Variable
displacement

pump

Heat exchanger

bypass

Charge relief

valve

Displacement

control
valve

Control

handle

Bypass

valve

Loop flushing

module

P106 608E

Variable 
displacement 
motor

Pump schematic

Pump schematic

B

M2

M1

A

E

L1

L2

M5

M4

S

M3

B N A

P100 587E

Above schematic shows the function of a Series 40 M46 axial piston variable displacement pump.

Service Manual

Series 40 M46 Variable Pumps

Introduction

 

©

 Danfoss | September 2017

11026743 | AX00000027en-US0202 | 9

Summary of Contents for Series 40 M46 Tandem

Page 1: ...Service Manual Series 40 M46 Variable Pumps powersolutions danfoss com...

Page 2: ...ayout 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...

Page 3: ...operate in either direction 15 Neutral difficult or impossible to find 16 System response is sluggish 16 Electrical troubleshooting 17 Adjustments Standard procedures inspections and adjustments 18 W...

Page 4: ...cement control 36 Electronic displacement control hydraulic displacement control 37 MDC orifice repair 39 EDC HDC orifice repair 40 HC EDC Control Repair 41 Torque chart Fastener size and torque chart...

Page 5: ...eries 40 M46 variable displacement closed circuit pumps Remove the unit Prior to performing repairs remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to in...

Page 6: ...ponents 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 W Warning Protect yours...

Page 7: ...where the shaft exits the pump housing The spinning cylinder block contains seven reciprocating pistons A ball joint connects a brass slipper to each piston A spring washer and the force of charge pre...

Page 8: ...he 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 fl...

Page 9: ...le displacement pump Heat exchanger bypass Charge relief valve Displacement control valve Control handle Bypass valve Loop flushing module P106 608E Variable displacement motor Pump schematic Pump sch...

Page 10: ...gh 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 o...

Page 11: ...to disable the engine to prevent it 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 tim...

Page 12: ...se 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 Re...

Page 13: ...ort locations P106 604E M4 M5 L1 L2 B A MA MB M3 RA RB R S BP Service Manual Series 40 M46 Variable Pumps Required tools and pressure measurements Danfoss September 2017 11026743 AX00000027en US0202 1...

Page 14: ...t 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 A loose shaft coup...

Page 15: ...r 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...

Page 16: ...cription 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...

Page 17: ...ctrical 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...

Page 18: ...a Danfoss Global Service Partner Pump adjustment This section offers instruction on adjustment of pump components Read through the entire topic before beginning a service activity Refer to Port locat...

Page 19: ...unction use a 5 8 in hex wrench to unthread the bypass valve Rotate the bypass valve approximately three turns counterclockwise Do not rotate more than 3 revolutions additional rotation permits extern...

Page 20: ...ossible 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 rep...

Page 21: ...rench 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 coun...

Page 22: ...lock the wheels to prevent movement Measured data System pressure at MA System pressure at MB Pressure differential between MA and MB optional Pump Setup 1 Attach 600 bar 10 000 psi gauge to system pr...

Page 23: ...ed 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 swashp...

Page 24: ...pump is on a vehicle block the wheels to prevent movement Measured data Servo pressure at M4 Servo pressure at M5 Pressure differential between M4 and M5 optional Procedure 1 Attach 20 bar 300 psi gau...

Page 25: ...ntrol or coils See Minor repair for details W Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the...

Page 26: ...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 distance...

Page 27: ...am P106 046E Maximum adjustment less than 120 Control spool Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is re installed Service Manual Series 40 M46 V...

Page 28: ...me 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 f...

Page 29: ...ng disassembly Use a 1 4 in hex wrench to hold neutral adjustment screw and a 9 16 in hex wrench to install hex nut 115 Torque to 37 N m 27 lbf ft Install sleeve 929 and snap ring 928 Displacement lim...

Page 30: ...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 cover plate 1505 Remove and discard seal 1504 2 Using a 9 16 in hex wren...

Page 31: ...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 av...

Page 32: ...rst 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 ri...

Page 33: ...ing 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 7 in 2 75 in 0 370 in 0 750 in 3 in 2...

Page 34: ...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 seali...

Page 35: ...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 an...

Page 36: ...ve 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 da...

Page 37: ...nual Displacement Control Neutral Return Bracket Adjustment on page 23 for adjustment procedure Manual displacement control P106 639E 1213 1 2 in 1210 3 8 in 302 1214 1216 1215 1208 1235 1207 303 1209...

Page 38: ...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 fo...

Page 39: ...ntrol 1229 O rings 1229 are supplied as part of 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 ori...

Page 40: ...d 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 inst...

Page 41: ...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 scr...

Page 42: ...n orientation Correct screen orientation 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 o...

Page 43: ...the cap screws D250 to 13 5 N m 10 lbf ft HC ECD Control P108776 D250 6X 5 mm D150 D200 D300 2X D084 Torque sequence 2 3 4 5 6 1 Service Manual Series 40 M46 Variable Pumps Minor repair Danfoss Septe...

Page 44: ...14 lbf ft 1213 Control handle nut 1 2 hex 15 N m 11 lbf ft 1210 Screw 3 8 14 N m 10 lbf 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 lbf ft 10...

Page 45: ...102 102 1001 158 806 3 places 1506 3 places 163 6 places 130 115 2 places 927 2 places 921 5 places 1210 920 5 places 107 2 places Front Rear Bottom Top Side Service Manual Series 40 M46 Variable Pump...

Page 46: ...Service Manual Series 40 M46 Variable Pumps 46 Danfoss September 2017 11026743 AX00000027en US0202...

Page 47: ...Service Manual Series 40 M46 Variable Pumps Danfoss September 2017 11026743 AX00000027en US0202 47...

Page 48: ...tions ApS Nordborgvej 81 DK 6430 Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Sha...

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