Series 40

M46
Service Training
Sept. 2002
M46 - Series 40 Family member

Single Pumps

Tandem Pumps

Fixed Motors

Variable Motors
M46 Applications
 “Tech Manual”
M46 Product – Capabilities 46cc / 2.80 cu in, rev
Case Pressure Ratings
Continuous 1.7 bar - 25 psi
Maximum 5.2 bar - 75 psi
System Pressure Ratings
Continuous 210 bar - 3000 psi
Maximum 345 bar - 5000 psi
Inlet Vacuum
Continuous 0.8 bar absolute - ( 5 inches of mercury)
Maximum 0.7 bar absolute - (10 inches of mercury)
Speed Limits
Rated 4000 rpm (at max angle)
Maximum 4100 rpm (at max angle)
Minimum 500 rpm
Theoretical Maximum Flow (at rated speed)
166 lpm 43.6 gpm
M46 Displacement Controls
Four basic types of pump controls available:

• Manual Displacement Control (MDC)

– most economical control
– manual control handle acts as input
– customer supplies input cable or linkage
• Electrical Displacement Control (EDC)
– low current signal acts as input command.
• Hydraulic Displacement Control (HDC)
– hydraulic delta signal acts as input
• Forward - Neutral - Reverse (FNR)
– 12V or 24V solenoid powers 3-position 4-way valve
M46 Displacement Controls

• Integral servo for both pumps

and motors
– reduces operator control effort

• Positive neutral adjustment

– Pump designed to automatically return to
neutral with loss of operator input command
 M46 Controls (Cut away)

PCP

HDC

EDC

FNR

MDC
 “Tech Manual”

Manual Displacement Control (MDC)

 “Tech Manual”

Hydraulic Displacement Control (HDC)

Electric Displacement Control (EDC)
Control dead band
Pump Displ.
100%

Operator
Input

Neutral
Deadband

100%
Control Hysteresis
Operator Input

Narrow Deadband
Spool

Displacement
Pump
Normal Deadband
Spool
HYSTERESIS
“A lagging of an effect behind it’s cause.”
M46 Options - Narrow Deadband Spool

• M46 pumps have available a spool for improved

controllability (option “AS”)
– Metered control spool allows for tighter, small displacement
control, better feathering
– Service Bulletin SB-9740 discusses the improved wear
resistance on this spool
Series 40 Hydraulic Circuit -- Forward
M46 Rotary Control - Neutral

Optional Supply Orifice

(PCP) Control linkage

Pressure Control Pilot connected to spool

Sleeve
Optional Optional
Servo Orifice Servo Orifice

Optional Drain
Orifice (Sleeve)

Swash Plate

Servo Piston
M46 Rotary Control - Input

Optional Supply Orifice

Control linkage
(PCP)
direction of movement

Optional Optional
Servo Orifice Servo Orifice

Optional Drain
Orifice (Sleeve)

Servo Piston
M46 Rotary Control - Feedback

Optional Supply Orifice

(PCP) Due to normal operating force

changes, the swashplate tends
to drift from the position preset
Optional Optional by the machine operator.
Servo Orifice Servo Orifice Drift, sensed by the feedback
linkage system connecting
Optional Drain
the swashplate to the control
Orifice (Sleeve) valve, will activate the valve
and supply pressure to the
servo piston, maintaining the
Feedback pin swashplate in its preset position.

Servo Piston
Feedback link and sleeve

Direction of
servo piston
 Correct Spool Installation

The control spool must be

installed with the index notch
facing or closest to the servo piston.
 Orifice Locations and Passageways

sleeve orifice

servo orifice
supply orifice
Service Sleeve VS New Production Sleeve
The “service” control sleeve seal groove is in a different location to
accommodate wear in the housing bore. Saves cost of new housing.

Sealing ring groove

Service

New production
Servo Piston Assembly

Compression type spring

Servo screw (neutral adjustment)

is stationary.

As servo piston travels across

the housing bore it causes
the servo stop to bottom
against the spring guides
(Or depending on
configuration the servo
piston bottoms against
the external limiter screw)
Cross-Sectional View M46 PT

Question? If this is a CW rotating unit,

does it use CW valve plates?
M46 Port / Valve Locations
 M46 Port / Valve Locations
Case outlet Charge pump inlet

Servo pres test ports (4 plcs) Bypass valve

Charge pres relief valve

A, B, C, D test ports SCR valves

SCR valves Charge pres test port

A, B, C, D ports

Case outlet
M46 Identifier

M46
M46 Options - Neutral Start Switch

• The M46 MDC has an available integral neutral

start switch (option “AT” & “AU”= no lead )
– Design requires slightly wider neutral deadband on control
– Switch isolated from case pressure
NSS Control Assembly
 M P V
Model Code M46 Pump
A 0 4 6 Displacement

B C Type

C Swashplate Group

D Seal Group

E Input Shaft

F Rotation

G Charge Pump Displacement

H Charge Pres Relief Valve Setting

J Filtration

K Displacement Limiters

L Bypass Valve

M System Pres Protection + Port A + Port B

N Control

P Handle Position (MDC)

R Orifice 1 + 2

S Auxiliary Mounting Pad

T Special Hardware Features

 Model Code M46 Tandem
MP T
Pump
A 0 4 6 Displacement

B Type

E Input Shaft

F Rotation

G Charge Pump Displacement

H Charge Pres Relief Valve Setting

Front Rear
Filtration
Pump J Pump
C Swashplate Group Q Swashplate Group

D Seal Group Seal Group

D
K Displacement Limiters U Displacement Limiters

L Bypass Valve X Bypass Valve

System Pres Protection System Pres Protection
M + Port A + Port C V + Port B + Port D
N Control Y Control

P Handle Position (MDC) Handle Position (MDC)

Z
R Orifice 1 + 2 W Orifice 1 + 2

S Auxiliary Mounting Pad

T Special Hardware Features

Series 40 Pumps Model Code

Acrobat Document
Nameplate
M46 Options - Charge Pumps

Charge Pump Options

Charge Pump M46 M46
Size Variable Pump Tandem Pump
None Option (A) Option (A)

13.9 cm3/rev Option (B) Not Applicable

(0.85 in3/rev)
15.6 cm3/rev Not Applicable Option (B)
(0.95 in3/rev)
22.9 cm3/rev Not Applicable Option (C)
(1.40 in3/rev)
M46 Options - Valve Plates

• M46 quiet valve plate now considered standard (SB-9615)

– Today, new models are designed with the quiet plate
– Charge pressure requirements do increase slightly, option B is
the recommended minimum setting (275-300 psi)
M46 Options - Filtration Options

• Suction or remote pressure filtration for M46

pumps
– Bolt-on adapters are easily changed
– Non-bypass for remote filtration option
– No charge pump option

Filter Adapter and O-Rings Filter Adapters and Gaskets

Earlier Production Later Production
M46 Options - SCR Valves
• Dual function SCR valves
– Same valve segments across displacements
– Non-adjustable, but easily converted to pressures up to
5000 psid
– Related Service Bulletins
• 8704 - Advance Notice of 8724
• 8724 - SCR Valve Change
CORRECTION piece parts are individually available
• 9014 - Disregard
This change was never incorporated
• 9732 - Higher Force Check Spring
• 9739 - Customer Specific Plug Change
• 9810 - Possible Low Set Pressures
M46 Options - Bypass Valve
• Bypass valves are standard in M46
pumps
– The bypass valve is located opposite the system
pressure ports
– Three available no orifice, .031” orificed, .040”
– Service Bulletin SB-9122 introduces an
improvement to the bypass valve
M46 Options - Porting

• M46 tandem pump has a housing option wherein all

four main ports are placed together
– Can be beneficial in some installations
– Known as “same sided ports” or “mirror image”
M46 Pump Options - Through-Drive
Capabilities

Full complement of auxiliary drive pads

• Mounting of external auxiliary pumps
• SAE “A” ( 9T)
• SAE “A” (11T)
• SAE “B” (13T)

“A” “B”
3.25” pilot 4” pilot
 M46 Pumps- Complete line of product support
Technical Manuals
S40 Pumps (BLN-9989 April 1997 Rev. C)
Service Manual
M46 - Axial Piston Pumps and Motors Service Manual (BLN-9939 March
1993 Rev. E)
Repair Manual
M46 - Axial Piston Pumps and Motors Repair Manual (BLN-9987 March
1993 Rev. C)
Service Bulletins
Assorted
Parts Lists
M46-Axial Piston Pumps Service Parts Manual (BLN-2-41701 January
2000)
M46-Axial Piston Tandem Pumps Service Parts Manual (BLN-2-41702
January 2000)
Quick Reference Parts Lists
Variable Displacement Pump (BLN-2-41663 March, 2000)
Variable Displacement Tandem Pump (BLN-2-41666 March, 2000)
M46 Motors

 The M46 Motors provide complimentary features to

meet customer needs.
 Porting options include axial, radial, and radial twin ports - (radial twin
ports are standard)
 Fixed motor endcaps feature optional integral loop flushing valves in
all frame sizes - (First Quarter 1997)
 Variable motor housings are ductile iron - (Fourth Quarter 1998)
 Speed sensors available in each configuration - (housing needs to be
machined to accept the sensor)
M46 Motors

 MVs are normally mechanically biased to maximum

displacement although biased to minimum
displacement options do exist - (for example code C in
the displacement module)
 Swashplate command is stop-to-stop (not proportional)
 Shift pressure required is 11 bar (160 psi) min, 28 bar
(400 psi) maximum
 2-position 2-way valve normally required to command
shift
M46 Single & Two Line Motor
Control
M46 Variable Motors

• Shift response rate can be tailored with supply / drain

orifices (SB-9702)
• Two styles of variable motors
 SAE (introduced in 1989)
 Cartridge (introduced in 1994)
M46 Variable Motors min disp.stops
Various minimum displacement options exist
Servo Stop (4460445-xxxx)
Number of Minimum
-xxxx Grooves Swashplate Angle
0001 1 11
0002 2 9
0003 3 7
0004 4 6
M46 Cartridge Variable Motors

• Cartridge MV fits Fairfield CW12 & 18 and CT18, 26 &

35 gear boxes
– Introduced in 1994
– Integral loop flushing valve is standard

Single line control only

Series 40 Motors Model Code

Acrobat Document
 M46 Motors- Complete line of product support
Technical Manuals
S40 Motors (BLN-9990 July 1997 Rev. D)
Service Manual
M46 - Axial Piston Pumps and Motors Service Manual (BLN-9939 March 1993 Rev. E)
Repair Manual
M46 - Axial Piston Pumps and Motors Repair Manual (BLN-9987 March 1993 Rev. C)
Service Bulletins
Assorted
Parts Lists
M46-Axial Piston Motors Service Parts Manual (BLN-2-41698 December 1998)
Quick Reference Parts Lists
Fixed Displacement Motor (BLN-2-41664 March, 2000)
Variable Displacement Motor (BLN-2-41665 March, 2000)
 Any
Sauer – Questions?
Danfoss Series 40
Questions?
M46
Series 40 M46 Product Tear Down
Series
•M4640 M46 Product Tear Down
Series 40 M46 Product Tear Down
Series 40 M46 Product Tear Down
Series 40 M46 Product Tear Down
Series 40 M46 Product Tear Down
 Series 40

M46

Service
 Trouble Shooting

Basic Troubleshooting Questions

1.What is charge pressure when the problem occurs.
(Leakage with worn rotating group parts. Motor loop
flushing spool sticking. Charge pump damaged / worn.
Charge pressure relief valve stuck open.
2. Is the problem “Uni” or “Bi”-directional.
(what component(s) function in one direction and not the other)
(Identifies what part of the circuit the problem is in.)

3. Does the problem get worse as system temperature increases.

(As oil temp rises efficiency goes down. Wear in rotating group or the
control.)
 Trouble Shooting

Reporting the Problem

1. Well defined problem definition
2. Know the model number(s) of the unit(s) in the system
3. Know the serial number(s) of the unit(s) in the system
4. Who is the customer
5. What type of machine is this system on
6. Where did the problem occur
7. When did the problem occur (hour meter reading)
8. How many systems/machines are affected
9. What is the field population
10. Provide system schematics
11. What type of oil is used in the system
12. History of previous failures/problems,
including above information
 Neutral Difficult or Impossible to Find
Item Description Action
Input Control Signal Check input signal Repair or Replace
Linkage, Control Manual linkage
Pressure, Current

Servo Pressure Check if servo pressure Adjust control

differential is less than neutral
20 PSI

System Pressure Check if system pressure Adjust mechanical

differential is less than neutral
50 PSI
 Neutral Difficult or Impossible to Find
Item Description Action
Possible Other Problems to Check

Servo Piston Assembly Backlash Requires Adjustment

Worn Swashplate Slider Block Worn

Feedback pin and control orifice sleeve interface has too much
clearance
 Operates in One Direction Only
Item Description Action
Input Signal Check input signal Repair or Replace
that it is working the
same in both directions
Servo Pressure Check servo pressure in Adjust control
both directions, if one is neutral
higher than the other
Servo Pressure Check in both directions. Replace seal ring.
If one side will not reach
rated pressure. Inspect
sealing ring for damage.
Servo Pressure Pressure is good but pump Inspect and clean

S
Stroke is slow or not at all. Servo/drain orifice.
Servo/drain orifice plugged.
 Operates in One Direction Only
Item Description Action
SCR Valves Swap SCRs to see if Replace defective
problem switches direction SCR valve

Charge Pressure Check charge pressure, If applicable

if it drops lower in one Inspect motor loop
direction than the other flushing valve
Repair or Replace
Swashplate Inspect swashplate for Replace Swashplate
crack or damage

PCP Pressure Check PCP output pressure Replace PCP valve

C1 increases as C2 decreases
 System Will Not Operate in Either Direction
Item Description Action
Reservoir Oil Level Check the hydraulic oil Fill to the proper
level in the reservoir level

Input Signal Control Check input signal Repair or Replace

Signal Linkage, Manual linkage
Control Pressure, Hydraulic lines
Current Electrical connector

Control Inspect control for Repair or Replace

damage or binding
 System Will Not Operate in Either Direction
Item Description Action
By-pass Valve Check that the by-pass Close by-pass valve
valve is properly seated

SCR Valves Inspect poppet, seat, and Repair or Replace

verify that it moves freely
in the cap

Charge Pressure Check charge pressure, Inspect charge relief

if low in neutral and charge pump
Repair or Replace
If low in Stroke If applicable,
Inspect motor charge
relief and loop flushing
 System Will Not Operate in Either Direction
Item Description Action
Servo Pressure Inspect control orifice Clean or Replace

Filters Check suction filter Inspect filter and

inlet
Repair or Replace

Check pressure filter Inspect filter and

inlet
Repair or Replace
 System Response is Sluggish
Item Description Action
Oil Reservoir Check that the hydraulic Fill to the proper
oil level in reservoir level

Pump Control Inspect pump control Repair or Replace

By-pass Valve Check that the by-pass Close by-pass valve

valve is properly seated

SCR Valves Inspect poppet, seat, and Repair or Replace

that they move freely in
the cap
Check that conical springs
are in place
 System Response is Sluggish
Item Description
Filter Check suction filter
Check pressure filter
Action
Inspect filter and
inlet
Repair or Replace
Inspect filter and
inlet
Repair or Replace

Charge Pressure Check charge pressure, Inspect charge relief

if low in neutral and charge pump
Repair or Replace
If low in Stroke If applicable,
Inspect motor charge
relief and loop flushing
 System Response is Sluggish
Item Description Action
Servo Pressure Inspect control orifice Clean or Replace

Other Replace pump

and/or motor
 Transmission Operates Hot
Item Description Action
Oil Reservoir Check the hydraulic oil Fill to the proper
level in the reservoir level

Heat Exchanger Inspect heat exchanger Clean, Repair or

Replace

By-pass Valve Inspect that the by-pass Repair or Replace

valve is properly seated

Charge Pressure Check charge pressure Inspect charge

if low pressure
relief and
charge pump
Repair or Replace
 Transmission Operates Hot
Item Description Action
System Pressure Check system pressure Inspect SCR poppet
if low seat, verify
that it
moves freely in the
cap and that the
correct relief setting
is used
Repair or Replace

Filter Check suction filter Inspect filter and

inlet
Repair or Replace
Check pressure filter Inspect filter and
inlet
Repair or Replace
 Transmission Operates Hot
Item Description Action

Load Check that the load does Reduce load

not exceed the system
design parameters
Other causes –
High pressure static

Swashplate brg
application (accelerated
wear).
Swashplate and bearing
surfaces do not mate (erosion
of material).
Swashplate brg
 Any Series 40
Sauer - Danfoss

Questions?