Danfoss Series 40 M46 Service Manual
Service Manual
Series 40 M46
Variable Pumps
powersolutions.danfoss.com
Revision history Table of revisions
Date Changed Rev
September 2017 minor edit - displacement limiter torque 0202
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
Service Manual
Series 40 M46 Variable Pumps
2 | © Danfoss | September 2017 11026743 | AX00000027en-US0202
Introduction
Overview..............................................................................................................................................................................................5
Warranty.............................................................................................................................................................................................. 5
General instructions........................................................................................................................................................................ 5
Remove the unit.......................................................................................................................................................................... 5
Keep it clean..................................................................................................................................................................................5
Replace all O-rings and gaskets............................................................................................................................................. 5
Safety precautions............................................................................................................................................................................5
Symbols used in Danfoss literature............................................................................................................................................6
Design...................................................................................................................................................................................................7
The system circuit.............................................................................................................................................................................8
The basic closed circuit............................................................................................................................................................. 8
Case drain and heat exchanger..............................................................................................................................................8
Pump schematic............................................................................................................................................................................... 9
Fluid and filter maintenance
Fluid and filter recommendations........................................................................................................................................... 10
Hazardous material..................................................................................................................................................................10
Initial startup procedures
General ..............................................................................................................................................................................................11
Start-up procedure........................................................................................................................................................................11
Required tools and pressure measurements
Required tools.................................................................................................................................................................................12
Port locations and gauge installation.....................................................................................................................................12
Troubleshooting
Overview........................................................................................................................................................................................... 14
Safety precautions.........................................................................................................................................................................14
System noise or vibration........................................................................................................................................................... 14
System operating hot...................................................................................................................................................................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.......................................................................................................................................................... 17
Adjustments
Standard procedures, inspections, and adjustments....................................................................................................... 18
Warranty............................................................................................................................................................................................18
Pump adjustment.......................................................................................................................................................................... 18
Charge pressure relief valve.......................................................................................................................................................18
Engaging the bypass function.................................................................................................................................................. 19
System check/relief (SCR) valves.............................................................................................................................................. 20
Displacement limiter adjustment............................................................................................................................................ 21
Swashplate neutral adjustment................................................................................................................................................22
Measured data...........................................................................................................................................................................22
Pump Setup................................................................................................................................................................................22
Manual Displacement Control Neutral-Return Bracket Adjustment...........................................................................23
Measured data...........................................................................................................................................................................23
Procedure.................................................................................................................................................................................... 23
Electric Displacement Control/Hydraulic Displacement Control Neutral Adjustment........................................ 24
Measured data...........................................................................................................................................................................24
Procedure.................................................................................................................................................................................... 24
HC EDC Control...............................................................................................................................................................................25
Control neutral adjustment.................................................................................................................................................. 25
Minor repair
Standard procedures, removing the pump..........................................................................................................................28
Displacement limiter.....................................................................................................................................................................28
Pressure filtration adapter.......................................................................................................................................................... 29
Service Manual
Series 40 M46 Variable Pumps
Contents
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Charge pump...................................................................................................................................................................................30
Shaft seal, roller bearing and shaft replacement................................................................................................................32
SCR valves.........................................................................................................................................................................................33
Charge pressure relief valve.......................................................................................................................................................34
Bypass valve.....................................................................................................................................................................................35
Manual displacement 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..................................................................................................................................................44
Plug size and torque chart..........................................................................................................................................................44
Service Manual
Series 40 M46 Variable Pumps
Contents
4 | © Danfoss | September 2017 11026743 | AX00000027en-US0202
Overview
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 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 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.
Warranty
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.
General instructions
Follow these general procedures when repairing Series 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 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.
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 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
Danfoss reccommends you replace all O-rings, seals, and gaskets during repair. Lightly lubricate all Orings with clean petroleum jelly prior to assembly.
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.
Service Manual
Series 40 M46 Variable Pumps
Introduction
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Unintended machine movement
W
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
W
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
W
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
W
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous material
W
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.
Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or
property
Lubricate with hydraulic fluid
Reusable part Apply grease / petroleum jelly
Non-reusable part, use a new part Apply locking compound
Non-removable item Inspect for wear or damage
Option - either part may exist Clean area or part
Service Manual
Series 40 M46 Variable Pumps
Introduction
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Superseded - parts are not interchangeable Be careful not to scratch or damage
Measurement required Note correct orientation
Flatness specification Mark orientation for reinstallation
Parallelism specification Torque specification
External hex head Press in - press fit
Internal hex head 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 brass 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.
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.
Service Manual
Series 40 M46 Variable Pumps
Introduction
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Cross section view
Piston
Slipper
Valve plate
Ball bearing
Shaft
Journal Bearing
Swashplate bearing pin
Servo piston
Swashplate
Cylinder block
Sleeve Bearing
Needle bearing
Manual displacement Control
Gerotor
Shaft Seal
The system circuit
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.
Service Manual
Series 40 M46 Variable Pumps
Introduction
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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
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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 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:
We recommend first fluid change at 500 hours.
C
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
W
Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used
hydraulic fluid according to state, and federal environmental regulations.
Service Manual
Series 40 M46 Variable Pumps
Fluid and filter maintenance
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General
Follow this procedure when starting-up a new pump installation or when restarting an installation in
which the pump was removed. Ensure pump is thoroughly tested on a test stand before installing.
W
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.
Start-up procedure
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. Fill the housing by adding filtered oil in the upper case drain port. Replace plug.
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.
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.
W
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
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.
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.
C
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. The
pump is now ready for operation.
Service Manual
Series 40 M46 Variable Pumps
Initial startup procedures
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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
Service Manual
Series 40 M46 Variable Pumps
Required tools and pressure measurements
12 | © Danfoss | September 2017 11026743 | AX00000027en-US0202
Port 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
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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 Introduction on page 5 and those related
to your specific equipment.
Safety precautions
C
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.
C
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. 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 Cold oil may be too viscous for proper function:
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 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
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.
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.
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.
Service Manual
Series 40 M46 Variable Pumps
Troubleshooting
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Item Description Action
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.
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.
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 Displacement limiters may be improperly adjusted
such that the servo piston is locked in place.
Verify that the displacement limiters are adjusted
to the proper setting.
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.
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 may be insufficient to recharge
the system loop.
Inspect the charge pump for damage and verify
that the charge pressure relief valve is at the proper
setting. Repair or replace it as necessary.
Charge pressure
(in stroke)
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.
Service Manual
Series 40 M46 Variable Pumps
Troubleshooting
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