JA00055R01H

Parts-Service Gram 11/06/2020

See Models Below

TO: DEALER PRINCIPALS, BRANCH MANAGERS, SERVICE MANAGERS, PARTS

MANAGERS and TRAINERS

SUBJECT: Danfoss VDP Load Sense Pressure Test and Adjustment Process

MODELS AFFECTED: A/B/C238 (H360-36/48HD, XD), A/B/C236 (H400-450HD/HDS,

XD/XDS), D/E/F214 (H450-500HD-EC, H180-H230HD, XD- EC6/7, ECD8/9), G/H008
(H550-700HD/HDS, XD/XDS), J/K/L/N/P007 (H190-280HD/HDS, XD/XDS),
H/J/K/L/N019 (H300-360HD, XD)

DESCRIPTION: This Part-Service Gram replaces JA00055R00H to provide clarification

on the new VDP Pump adjustment process. Please discard all electronic and paper
copies of that previous Gram.

The new VDP Pump adjustment process that follows is now required due to the
following improvements on these pump models (see Figure 1). Use this process when
replacing a pump or LS controller, or if a defective LS controller is suspected. This
process is not intended to be a comprehensive test to determine proper pump operation
and performance.

Figure 1: Danfoss Pump Improvements

Please note that the LS Controller, part number 4080506, has been replaced by part
number 4265165 on all Big Truck models. This LS Controller update includes
improvements to provide resistance to LS bore wear. However as shown in Figure 2,
below, the previous access to Port P1 is not possible anymore due to the longer LS

This Parts-Service Gram is confidential and for use by Hyster-Yale Group employees and authorized Hyster® dealers only. Do not
copy or distribute to unauthorized parties. We reserve the right to change the design of our products without incurring an obligation
to modify previously manufactured products.
 JA00055R01H
Page 2 of 3
spool, and required additional travel adjacent to the P1 plug. For this reason, the
previous “Margin Pressure” adjustment process (P1-LS) is no longer applicable.

Figure 2: New LS Controller

New Adjustment Process: (See Figure 3 for detailed adjustment locations.)

Step 1: Remove LS lines from Pump 1 and Pump 2. Install plugs in each of the two LS
hydraulic lines. Caution: Do not cap the fittings on the pumps. No amount of oil
should flow from these fittings but capping these fittings could damage the
pump.

Step 2: Install a 1000 psi gage in port MP.

Step 3: Start the engine and monitor the LS fittings at each pump. Wait for a single drip
at each fitting to occur, then initiate a stopwatch to determine drip rate. The drip rate will
be an indication of the internal wear of the spool and the bore of the pump controller. If
the drip rate is faster than 1 drip per minute replace the pump controller with part
number 4265165 because the internal wear of the spool is therefore excessive.

Step 4: Reduce Pump 1 stand-by pressure by rotating the adjustment screw

counterclockwise until the pressure reading at MP stops dropping. Then rotate the
adjustment screw another 1/4 turn to ensure Pump 1 is below Pump 2 pressure.

Step 5: Adjust Pump 2 stand-by pressure by turning the adjustment screw until the
gage reads 30 Bar (435 psi). Lock the adjustment setscrew on this pump. Pump 2 is
now set to the correct setting of 30 Bar.

Step 6: Adjust Pump 1 stand-by pressure by turning the adjustment screw clockwise
until the gage on MP raises to 34 Bar (493 psi). Lock the adjustment setscrew on this
pump. Pump 1 is now set to the correct setting of 34 Bar.

This Parts-Service Gram is confidential and for use by Hyster-Yale Group employees and authorized Hyster® dealers only. Do not
copy or distribute to unauthorized parties. We reserve the right to change the design of our products without incurring an obligation
to modify previously manufactured products.
 JA00055R01H
Page 3 of 3

Step 7: Install LS lines previously removed from Pump 1 and Pump 2.

Note: A rise in pressure on gage at MP after installing LS lines of approximately

12 bar (174 psi) may be seen. This the normal spring rate of the priority valve in
the main manifold.

Figure 3: Adjustment and Port Locations

The following table lists the tools and fitting sizes for these adjustments, for reference only.

Table 1: Pump Control Valve, Port Thread Size and Allen Wrench Size
Test Port Function Pressure Gauge Port Thread Size/Allen Wrench
Range Size
Pump 0 to 400 bar (0 to 5000 #4 ORB Female (7/16-20 UN-
P1 Pressure psi) 2A) 3/16 inch Allen Wrench
Load Sense 0 to 400 bar (0 to 5000 #4 ORB Female (7/16-20 UN-
LS Pressure psi) 2A) 3/16 inch Allen Wrench
Margin Pressure Adjust the Pump Margin Pressure
Adjustment Plug 6 mm Allen Wrench
Locks the Pump Margin Pressure
Set Screw Adjustment Plug 4 mm Allen Wrench

WARRANTY REIMBURSEMENT: This Parts-Service Gram is for information purposes

only.

This Parts-Service Gram is confidential and for use by Hyster-Yale Group employees and authorized Hyster® dealers only. Do not
copy or distribute to unauthorized parties. We reserve the right to change the design of our products without incurring an obligation
to modify previously manufactured products.