MAKING
MODERN LIVING
POSSIBLE
Service
Manual
Series
42
Property of American Airlines
powersol
utions.da
nfoss.com
I r'jll
ir5l/l
Service
Initial
General
Manual
Start-Up Procedure
Series 42
Follow
this
which
the
,.S
Warninq
Axial Piston
procedure
pump
has
been
when
Closed
starting-up
removed.
Circuit Pumps
a new
Series 42 installation
or when restarting
installation
an
in
Start-up
Unintended
protect
To
mcvement
against
of
the rnachine
unintended
or mechanism
movement,
secure the
may
cause injury
machine or
to the
technician
disable/disconnect
or bystanders.
the mechanism
while servicinq.
Prior
to installing
components
the
(reservoir,
pump,
hoses,
inspect
for
damage
valves, fittings,
incurred
heat
during shipping.
exchanger,
etc.)
are clean
Make
prior
certain
to filling
all system
with fluid.
procedure
1.
Connect
prime
the
r&
Incorrect
external oil
Fill
2.
the reservoir with
filter
3. Fill
the main
case
4. Fill
the
fittings
To
5.
ensure
6.
Install
Follow recommendations
procedures.
7. While
until
established,
down
8.
Operate
9. Check
10.
Shut
11.
Check
Property of American Airlines
The
pump
pump
the
mover.
fautior.r
sltaft alignment may
leakage.
pouring
into the reservoir.
pump
port.
drain
inlet
line leading
and
be certain it is free
pump
the
gauge
a
watching
system
the
pressure
increase
prime
port
at
the
mover,
the hydraulic
and
adjust
control settings
the
is now
prime
level in
readyfor
down
the fluid
prime
to the
result
recommended
Never
housing
pressure
with
from
the
of
stays filled with
M2
monitor
to
in
the vehicle/machine
gauge
builds
to full
system for
mover
normal
to
operating
determine
and remove
the reservoir
operation.
mover.
Ensure
in
damage
hydraulic
reuse
hydmulic fluid.
clean hydraulic
pump
to
oil, install
system
at M2,
levels
speed.
cause,
the
jog
and
restrictions
at least fifteen
as necessary
the
add
clean
pump
that
to drive
fluid. Always
fluid.
reservoir.
and
air
shaft is
shaft, bearings,
Pour
filtered
Check the inlet line
leak.
the case drain line
pressure
(minimum
lf the
pressure
during start
operator's
prime
the
take corrective
minutes
after installation.
pump
gauge.
mover
1
1 bar
does
under
filtered fluid if
properly
filter
fluid through
oil
in
the upper most
up.
manualfor
run
or
psil).
tl60
not maintain
action.
light
Refer
Replace
necessary.
aligned with
or
seal which
directly into
for
prime
at
the
Once system
system
Refer
to
load
conditions.
Adjustments.
to
plug
at
the shaft of
can
a 10 micron
the upper most
properfy
mover
lowest
Troubleshooting.
port
tightened
case drain
start
possible
pressure
pressure,
M2.
caLtse
absolute
port.
up
speed
is
shut
52010638
.
Rev
0300
.
July 20'15
Service Manual
Adjustments
Series 42
Frame
Axial Piston Closed
size cm3
Control
Lock
nut mm
Servo adjust
Lock nut torque
screw
N.m
mm
[in]
flbf.ft ]
Circuit Pumps
28132
MDC/EDC/HC-EDC
13
5
231171 40
NFP
17
7
[30]
4v51
MDC/EDC/HC-EDC
t7
7
40
[30]
NFP
17
7
40
[30]
Control n€ullal
adjustment for MDC and EDC/HC-EDC
Control neutral adjustment
contfolsetting
or move any
wurn,no
,A
The following
functiotr
and
llvstanders.
1. Disconnect
the
2.
Install
provides
part
of the control or swashplate mechanlsm
proceciure
discannected,
the externalcontrol
pump,
pressure
gauges
piston.
3.
Startthe
4. Loosen
5. Turn
on the servo
Turn
piston.
Turn
movement
indicate
6. While holding
prime
mover and run at
the control
adjustment
the
piston.
the screw
Mark
the
counterclockwise
position
the adjustment
produces
nearly
equal
the adjustment
neutral
tbf.ft].
7.
Stop
8.
Connect the external
pump.
prime
the
Reconnect
mover
the work
aligns the
a zero degree swashplate
requires
r,nrhile performing
etc.)
in the
pump
swashplate andthe
the vehicle/nrachine
(for
linkage
gauge ports
servo
normaloperating
screw
Mark
adjustment
(D014)
position
the
seal
clockwise untilone
of the
until the other
of the adjustment
screw
clockwise so that it is midway
constant
pressures.
and remove
control linkage
change for both directions,
(D014)
screw
pressure
the
(for
MDC)
function.
controlspoolso that a zeto angle
setting. Perform this adjustment wheneveryou
the
6rrocedure
MDC) or
lock nut
or afEr
to
be cjisabled
in
order to
controlsignalinput
M4 and
M5 to measure
speed.
(D015).
gauges
of
the
you
adJust
(wheels
prevent
registers
pump
the
raised
off the
injury
to
(for
EDC and HC-EDC)from
pressure
on
increase in
an
adjustment screw.
screw.
position,
in
gauges.
or
gauge
registers
between the marks.
so both the
torque the seal lock
Remove the
control
signal
an increase
pressure
plugs
(for
input
pressure
in
Adjustment
gauges
(D015)
nut
in
the
EDC
and
gauge ports.
HC-EDC)
adjust
neutral settlng.
the
the
ground,
pump
on
work
technician
servo
pressure
the servo
screw
should
N.m
to 04
to the
[30
Property of American Airlines
520L0638
.
Rev
0300
'July
201
5
Service
Adjustments
Manual
Series 42
Axial
Piston
Closed
Circuit Pumps
Control n e utral
Equalization
M3/M4
Ffl l7r'\l
tr--zl
l\Jl
/-\
a
pressure
of
dj
u st m ent s
crew
D014
D01
5
gouges
using
P108
pump
neutral
M3/M4
g@
/^\\
080E
adjustment
screw
M3/M4
ra rRr
tvt t.vt
Pl0r
fr
270E
Property of American Airlines
34
520L0638
.
Rev
0300.
July 201
5
Service
Manual
Troubleshooting
Overyiew
System opelating hot
Series 42 Axial Piston
This section
provides generalsteps
ofthe items are system
manual.
Service Panner.
lf5tandard troubleshooting
Closed
speclflc.
Circuit Pumps
to follow if
Always
observe the safety
procedures
you
observe certain
precautlons
do not remedythe
undesirable system conditlons,
listed in the introduction
problem,
contact a Danfoss
Some
of this
Global
System response
Item'
Oil level
Heat
exchanger
Bypass
(System
SCR
Oilfilters
Machine
in
reservoir
(if
equipped)
valve
Check/ Reliefl Valves
load
Description
Insufficient hydraulic
meet
the cooling demands
The heat
cooling
A
result
system.
A
valves
result
system.
Clogged
insufficient
system.
Excessive
could result
operating at speeds and
beyond system
exchanger is
the system.
partially
activated
in heat
partially
activated SCR valve
with
in heat
oil
loads or extreme
relief
filters may
supply
fl uid will not
bypass
generation
settings too
generation
of cool oilto the
pump
in the
design limitations.
of
not
sufficiently
within the
within
result in
duty
and/ or
pressures
system.
valve
or SCR
low may
the
an
Action
Fill
the
with
clean hydraulic
Check
temperature
Clean, repair, or
exchanger
Verify
may
closed and
properly.
necessary.
Verifli
properly
setting. Repair or replace
necessary.
Inspect
they are still
necessary.
Veriff
rycles
within
motor
designed. lf necessary,
on
the machine.
reservoir
to the
flow
the air
that the bypass
and input
for
the heat exchanger.
replace the heat
necessary.
as
that the valve
Repair
or
that the
SCR
and is at the
filters
the oil
operable. Replace
that
the machine
parameters
the
proper
oil.
valve is fully
is seating
replace
valve is
seating
correct relief
it as
verify
and
is operating
which
for
reduce
air
it
as
level
that
them if
was
it
the load
is sluggish
Item
Reservoir oil level
Input control
current, or
pressure)
signal
(linkage,
Property of American Airlines
Pump
control
Bypass
valve
(system
SCR
check
reliefl
/
valves
Description
There is an
hydraulic
inadequate
The
signal:
linkage;
electrical signal; HDC'
incorrectly orificed
A damaged
spoolwill not
control input
partially
A
cause
One or
binding within
fluid, resulting
pump
is
(MDC
EDC
activated
cross
both of
insufficient
supply for
receiving
-
binding
-
faulty or inadequate
control
pump
control
correctly transmit
signalto
port
leakage.
SCR valves
the
their bores.
amount of
in an
the
faulty
a
or broken
blocked
the
bypass
system
control
or
lines).
or control
the
pump.
valve will
may
Action
Fill the reservoir
with
loop.
Veriff
and identical
Verify
operating
controlspool is not
and moves freely
repair,
Veriff
and
Clean, repair,
Veriff
be
freely.
necessary.
to
in both
pump's
properly
the
and
clean hydraulic
that the input
that the
within
or replace it
that
that the valve
as necessary.
the bypass valve is
is
replace
or
that the SCR valves
Repair
or
replace
proper
level
fluid.
is
signal
correct
directions.
control is
that the
damaged orworn
its
bore. Clean,
closed
properly.
seating
it
necessary.
as
operate
them as
520L0638
.
Rev
0300
.
July 201 5
Service Manual
Troubleshooting
Series 42 Axial Piston
Closed Circuit Pumps
System will
not operate in
Property of American Airlines
Item
pressure
Charge
pressure
Charge
pressure
Servo
pump
Charge
either direction
Item
Oillevelin reservoir
Input controlsignal
(linkage,
current, or
Oilfilters
Bypass valve
pressure
Charge
neutral)
{in
pressure
Charge
(in
stroke)
pressure
Servo
pump
Charge
(in
neutral)
(in
stroke) There is
pressure)
Descfiption
The is low charge
from a damaged
pressure
charge
low charge'pressure resulting
pressure
charge
relief valve
from internalleakage
system.
There
insufficient
is
differential
The
or installed
rotational
charge
across the
pump
has
with
the
orientation.
Description
There is insufficient
supply
the system loop.
pump
The
signal:
linkage; EDC
electrical signal; HDC
incorrectly
Clogged oilfilters
insufficient
A
result
Charge
recharge
There
from internal
system.
There is
differential
The
been
rotational
(MDC
partially
in a cross
pressure
the system loop.
is low charge
an insufficient
charge
installed with
is receiving
-
binding
-
faulty
orificed
may result in
supply of oil to the
activated
port
may
leakage
across the servo
pump
is
orientation.
resulting
pump
or low
setting.
within
the
pressure
piston.
servo
been
damaged
incorrect
hydraulic
faulty
a
fluid
control
or broken
or inadequate
-
blocked
or
control lines).
an
system.
valve may
bypass
leakage.
be insufficient to
pressure
resulting
within
the
pressure
piston.
damaged or has
the incorrect
a
Action
Inspect the
and verifiTthe
valve
setting. Repair
necessary.
Repair
or replacethe
components
internal
the
Check servo
M5 to veriff sufficient
Veriff that
paths
are
orifices
of debris.
necessary.
Verifo that the charge
working
installed.
necessary.
Actioh
to
Fill the reservoir
with
clean hydraulic
Veriry
that
and identical
clean,
repair,
device
as necessary.
Inspect the
they are
necessary.
as
Verifi7
that the
and that the
properly.
as necessary.
Inspect
verifi7
and
rralve
relief
Repair
or replace it
Repair or replace
componenls within
the internalleakage.
Check servo
sufficient
servo supply
unobstructed
the
of
correct
Clean, repair,
necessary.
Veriff that
working
installed. Repair
necessary.
pump
charge
charge
pressure
replace
or
for
component or
within
the system causing
leakage.
pressures
port
at
pressure
the servo supply
unobstructed
are of the
Clean, repair,
and that any
correct size and free
or replace as
pump
order
and
it is
Repair
still serviceable.
Clean, repair, or replace
the charge
pressure
order and
that
replace
or
to the
oil.
input
the
that
is at the
the
signal
in both directions.
or replace
oil filters
and
bypass valves
valves
are seating
pump
the charge
proper
as necessary.
the
component or
the system causing
pressures
and drain
to verifi7
delta.
and that
any orifices
size and free
or
replace
pump
charge
that it is correctly
or replace
it as
proper
is
the input
verifi7
Replace
for
pressure
setting.
Verifi7 that
paths
of debris.
them
it as
damage
relief
it
as
M4 and
delta.
and drain
good
is in
correctly
level
correct
Adjust,
that
them
are closed
them
damage
are
as
good
is in
the
are
520L0638
.
Rev
0300
.
July
201
5
Service
Manual
Troubleshooting
series 42
Axial
Piston
closed
circuit Pumps
System
will not
operate in
Item
(system
SCR
Displacement
one direction
Item
Input control
current,
or
(System
SCR
Pump
control
pressure
Servo
Displacement
equipped)
check/
limiters
signal
pressure)
Check/Relie0
limiters
reliefl valves
(linkage,
valves
(if
Description
The SCR valves
improperly
Displacement
improperly
servo
piston
set.
limiters may
adjusted
is locked in
Description
pump
The
signah
linkage; EDC
electricalsignal;
incorrectly
The
improperly
A
may
the
direction.
The
the servo
The
improperly
servo
in
is receiving
(MDC
-
binding
-
faulty
orificed control
valves
SCR
set.
damaged
one direction.
or biased
be sending
pump
to stroke
drain or supply
piston
displacement limiters
adjusted
piston
prevented
is
are malfunctioning
be
such
that the
place.
a faulty
control
or broken
or inadequate
-
HDC
blocked
or
lines).
malfunctioning
are
pump
a signal
may
control
commanding
in
only
one
path
to one side
be bfocked.
may
such that the
from
be
moving
or
or
of
Action
Verify
that
properly
and
them
as necessary.
Veri[t
that the
are adjusted
Action
Verifu
that
and identical
clean,
repair, or replace
module
as necessary.
Veriff
that the
properly.
necessary.
Veri$r
Repair
that the
functioning
it
necessary.
as
Veriff
that the
paths
are
are of
debris.
that
adjusted
unobstructed
Clean
orifices
of
necessary.
Verifu
are
the SCR valves
set.
Repair or replace
displacement
proper
to the
the input signal
in
both dlrections.
the control
valves
SCR
or replace
pump's
properly.
the displacement
properly.
control is
Repair
servo
supply and
and
the correct
or repair them
size
are operating
limiters
setting.
is
correct
Adjust,
are operating
them as
or replace
drain
that any
free
and
as
limiters
Neutral
difficult
or impossible
Property of American Airlines
to find
Item:
Input
control signal
current,
System
pressure
Servo
pressure
PCP
52010638
pressure)
or
pressure
(EDCs
.
Rev 0300
(linkage,
only)
.
July 201 5
Description
pump
The
signal:
linkage; EDC
electricalsignah
incorrectly
With
pressure
two
With
pressure
seruo
is receiving
(MDC
-
-faulty
orifi
no input
delta may
sides of the working
input
no
delta may
piston.
Wth no input
pressure
difference
the
controlspool.
binding
or inadequate
-
HDC
ced control
signal
to the
exist
signalto
exist
signalto
may
a faulty
control
or
broken
blocked
or
lines).
control, a
between the
loop.
the control,
across
the
the control,
exist across
a
a
Action
Veriff
that
identical
and
clean,
repair,
necessary.
as
pump
Readjust
adjustment
Readjust
the controf neutral
Refer
to adjustment
Replace
the EDC.
the input
in
both directions.
or replace
neutral
procedure.
signal is correct
procedure.
Adjust,
control
module
setting. Refer
setting.
to
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