Series 40 - M46

Tandem Variable
Pumps

Service Manual
 Series 40 M46 Tandem Variable Pumps
Service Manual
Revisions

History of Revisions Table of Revisions

Date Page Changed Rev.

March 2010 last Fix Osaka address AC

March 2009 37 added spool alignment illustration AB
June 2008 - First edition AA

© 2010 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and

other printed material. Sauer -Danfoss reserves the right to alter its products without
prior notice. This also applies to products already ordered, provided that such alterations
can be made without affecting agreed specifications. All trademarks in this material
are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype,
the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in
Motion™ are trademarks of the Sauer-Danfoss Group.

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Contents

Introduction Overview............................................................................................................................................................ 5
Warranty............................................................................................................................................................. 5
General instructions....................................................................................................................................... 5
Safety precautions.......................................................................................................................................... 6
Unintended machine movement........................................................................................................ 6
Flammable cleaning solvents................................................................................................................ 6
Fluid under pressure................................................................................................................................. 6
Personal safety............................................................................................................................................ 6
Hazardous material................................................................................................................................... 6
Symbols used in Sauer-Danfoss literature.............................................................................................. 7
Design................................................................................................................................................................. 8
The system circuit........................................................................................................................................... 9
Pump schematic............................................................................................................................................10

Fluid and filter Fluid and filter recommendations...........................................................................................................11

maintenance Hazardous material.................................................................................................................................11

Initial startup General . ...........................................................................................................................................................12

procedures Start-up procedure.......................................................................................................................................12

Pressure Required tools................................................................................................................................................14

measurements Port locations and gauge installation....................................................................................................14

Troubleshooting Overview..........................................................................................................................................................16
Safety precautions........................................................................................................................................16
System noise or vibration...........................................................................................................................16
System operating hot..................................................................................................................................17
System will not operate in one direction..............................................................................................17
System will not operate in either direction..........................................................................................18
Neutral difficult or impossible to find....................................................................................................18
System response is sluggish......................................................................................................................19
Electrical troubleshooting..........................................................................................................................19

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Service Manual
Contents

Inspections and Standard procedures, inspections, and adjustments.......................................................................20

adjustments Warranty...........................................................................................................................................................20
Pump adjustment.........................................................................................................................................21
Charge pressure relief valve......................................................................................................................21
Engaging the bypass function.................................................................................................................22
System check/relief (SCR) valves..............................................................................................................23
Displacement limiter adjustment............................................................................................................24
Displacement limiter adjustment data..................................................................................................24
Swashplate neutral adjustment...............................................................................................................25

Minor repair Standard procedures, removing the pump.........................................................................................28

Displacement limiter....................................................................................................................................29
Pressure filtration adapter..........................................................................................................................30
Charge pump..................................................................................................................................................31
Shaft seal..........................................................................................................................................................33
SCR valves........................................................................................................................................................34
Charge pressure relief valve......................................................................................................................35
Bypass valve....................................................................................................................................................36
Manual displacement control...................................................................................................................37

Torque chart MDC orifice repair.........................................................................................................................................39

EDC/HDC orifice repair................................................................................................................................39
Fastener size and torque chart.................................................................................................................40
Plug size and torque chart.........................................................................................................................40

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Introduction

Overview This manual includes information for the installation, maintenance, and minor repair of
the Series 40 M46 tandem 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 Sauer-Danfoss Global Service Partners is available for major

repairs. Sauer-Danfoss Global Service Partners are trained by the factory and certified on
a regular basis. You can locate your nearest Global Service Partner using the distributor
locator at www.sauer-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
rear cover or front flange voids the warranty unless done by a Sauer-Danfoss Global
Service Partner.

General instructions Follow these general procedures when repairing Series 40 M46 tandem variable
displacement closed circuit pumps.

w Remove the unit

Prior to performing major 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 after removal to prevent contamination.

e 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 by using a clean solvent wash
and air drying is usually adequate.

As with any precision equipment, all parts must be kept 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.

d Replace all O-rings and gaskets

Replace all O-rings, gaskets and seals. Lightly lubricate all O-rings with clean hydraulic
fluid or petroleum jelly prior to assembly.

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Introduction

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.

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.

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 Series 40 M46 Tandem Variable Pumps
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Introduction

Symbols used in  WARNING may result in injury

Sauer-Danfoss
literature  CAUTION may result in damage to
product or property

 Non-reusable part, use a new part

 Measurement required

 Flatness specification

 Parallelism specification

 External hex head

 Internal hex head

 Torx head

 Lubricate with hydraulic fluid

 Inspect for wear or damage

 Be careful not to scratch or damage

 Torque specification

R Note orientation for reassembly

p Pull

P Press

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.

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 Series 40 M46 Tandem Variable Pumps
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Introduction

Design Sauer-Danfoss Series 40 M46 closed circuit piston pumps convert input torque into
hydraulic power. Rotational force is transmitted through the input shaft to the cylinder
block. The input shaft is supported by bearings at the front and rear of the pump and is
splined into the cylinder block. 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. Each piston has a brass slipper connected at one end by a ball
joint. The slippers are held to the swashplate by a spring washer and charge pressure.
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
is connected to low pressure and the other half to high pressure. As each piston cycles
in and out of its bore, fluid is replenished by charge flow and displaced to the outlet
thereby imparting hydraulic power into the system. A small amount of fluid is allowed to
flow from the cylinder block/valve plate and slipper/swashplate interfaces for lubrication
and cooling. Excess flow across the charge pressure relief also flows through the case and
is used for cooling. Case drain ports return this fluid to the reservoir.

The volume of fluid displaced into the system is controlled by the angle of the
swashplate. The swashplate is forced into an inclined position (into stroke) by the servo
piston.

The pump control, by varying the pressure at the servo piston, controls the displacement
of fluid in the system circuit.

Cross section view

Ball bearing Slipper Gerotor

Piston Valve plate Valve plate Piston Ball bearing

Slipper
Shaft

Journal Journal
bearing bearing
Swashplate Swashplate
bearing pin bearing pin
Cylinder block
Servo piston
Swashplate
P106 665E
Servo piston Manual displacement Control

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Introduction

The system circuit The basic closed circuit

The main ports of the pump are connected by hydraulic lines to the main ports of the
motor. Fluid flows, in either direction, from the pump to the motor then back to the
A tandem circuit contains pump in this closed circuit. Either of the hydraulic lines can be under high pressure. In
two pumps and motors. pumping mode the position of the pump swashplate determines which line is high
Each pump and motor pressure as well as the direction of fluid flow.
circuit is similar to the one
shown. Case drain and heat exchanger
The pump and motor case drain lines 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. The motor case drain can be connected to the lower drain port on the pump
housing and out the top most port or feed into the case drain line coming from the
pump ahead of the heat exchanger. A heat exchanger, with a bypass valve, is required to
cool the case drain fluid before it returns to the reservoir.

System circuit diagram

Heat exchanger Reservoir

bypass
Control
handle
Filter

Displacement Heat
control exchanger
valve
Cylinder Variable
block displacement
assembly motor
Cylinder
block
assembly Charge relief
valve Bypass
valve

Output
shaft
Charge
pump Loop flushing
module
Input
shaft
Variable
displacement Suction flow
Check valves
pump w/ high pressure Charge pressure
relief valve
Servo pressure
High pressure
Case flow P106 608E

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Introduction

Pump schematic Pump schematic

BNA

E M3

M4 A

M1
M5

L2
M2

L1 S
P100 587E

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

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Fluid and filter maintenance

Fluid and filter To ensure optimum life, perform regular maintenance of the fluid and filter.
recommendations 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 has been exposed
to excessive heat. Change the fluid immediately if these conditions occur. Correct the
problem immediately.

Inspect vehicle for leaks daily.

Fluid and filter change interval
Change the fluid and filter per the Reservoir type Max. oil change interval
vehicle/machine manufacturer’s Sealed 2000 hours
recommendations or at these intervals: Breather 500 hours
First fluid change recommended at 500
hours.

CCaution
High temperatures and pressures will result in accelerated 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 the fluid is changed or when the filter indicator shows that it is
necessary to change the filter. Replace all fluid lost during filter change.

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.

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Initial startup procedures

General Follow this procedure when starting-up a new pump installation or when restarting an
installation in which the pump has been removed and re-installed on a machine. Ensure
pump has been thoroughly tested on a test stand before installing on a machine.

WWarning
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 damage that may have occurred during shipping.

Start-up procedure 1. Ensure that 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
M3.

4. Fill the housing by adding filtered oil in the upper case drain port.

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.

7. Re-install plug or fitting removed in step 4.

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 the
start-up.

WWarning
Damage to hydraulic components may occur if the oil supply is not maintained.

8. Use a common method to disable the engine to prevent the engine 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.

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 Series 40 M46 Tandem Variable Pumps
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Initial startup procedures

Startup procedure 9. When charge pressure begins to appear, enable and start engine. Let the engine
(continued) 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.

CCaution
Air entrapment in oil under high pressure may damage hydraulic components.

CCaution
Do not run at maximum pressure until system is free of air and fluid has been thoroughly
filtered.

10. When adequate charge pressure is established (as shown in model code), increase
engine speed to normal operating rpm to further purge residual air from the system.

11. 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.

12. 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.

13. Check that the reservoir is full. Remove charge pressure gauge. Re-install charge
pressure plug. The pump is now ready for operation.

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 Series 40 M46 Tandem Variable Pumps
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Pressure measurements

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 The following tables and drawing show the port locations and gauge sizes needed.
gauge installation

Port information
Port identifier Port size Wrench size Pressure obtained Gauge size, bar [psi]
L1, L2, L3 1-1/16 12 SAE 9/16 internal hex Case drain 10 [100]
MA, MB, MC, MD 9/16 18 SAE 11/16 hex System pressure 600 [10,000]
M3 9/16 18 UNF 11/16 hex Charge pressure 50 [1000]
M4, M5 9/16 18 SAE 11/16 hex Servo pressure 50 [1000]

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
RC C port pressure relief valve 1-5/16 12 UNF 1-1/4 hex
RD D 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
C system pressure port 1-5/16 12 SAE
D system pressure port 1-5/16 12 SAE
S (charge pressure inlet) 1-5/16 12 SAE

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Series 40 M46 Tandem Variable Pumps
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Troubleshooting

Port locations

L2 C

D S BP

M5
RD R
RA
M4

MD MA
M3

MC MB

PB
M5 RC RB
M4

L3 B
L1
A P106 663E

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Troubleshooting

Overview This section provides general steps to follow if undesirable system conditions are
observed. Follow the steps listed until the problem is solved. Some of the items will be
system specific. For areas covered in this manual, a section is referenced. Always observe
the safety precautions listed in the Introduction section, page 6, and related to your
specific equipment.

Safety precautions C Caution

High inlet vacuum causes cavitation which can damage internal pump components.

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 Item Description Action

vibration Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump inlet Air in system decreases efficiency of Find location where air is entering
vacuum units and controls. Air in system is into the system and repair leak.
indicated by excessive noise in pump, Check that inlet line is not
foaming in oil, and hot oil. restricted and is the proper size.
Cold oil If oil is under cold conditions, it may Allow the oil to warm up to it’s
be too viscous for proper function normal operating temperature
and pump cavitates with engine at idle speed.
Pump inlet vacuum High inlet vacuum causes noise/ Check that inlet line is not
cavitation. restricted and is the proper size.
Check filter and bypass valve.
Shaft couplings A loose shaft coupling will cause Replace loose shaft coupling.
excessive noise. Replace pump shaft.
Shaft alignment Misaligned shafts creates noise Align shafts.
Charge/system relief valves Unusual noise may indicate sticking Clean/replace valves and test
valves. Possible contamination. pump.
May be a normal condition.

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 Series 40 M46 Tandem Variable Pumps
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Troubleshooting

Item Description Action

System operating hot
Oil level in reservoir Insufficient hydraulic fluid will Fill the reservoir to the proper level
not meet the cooling demands of with clean hydraulic oil.
system.
Heat exchanger (if equipped) The heat exchanger is not Check the air flow and input air
sufficiently cooling the system. temperature for the heat exchanger.
Clean, repair, or replace the heat
exchanger as necessary.

Bypass valve A partially activated bypass valve Verify that the bypass valve is fully
may result in heat generation within closed and that the valve is seating
the system. properly. Repair or replace it as
necessary.
SCR (System Check / Relief ) A partially activated SCR valve or Verify that the SCR valve is seating
Valves SCR valves with relief settings too properly and is at the correct relief
low may result in heat generation setting. Repair or replace it as
within the system. necessary.
Oil filters Clogged oil filters may result in an Inspect the oil filters and verify that
insufficient supply of cool oil to the they are still operable. Replace them
system. if necessary.
Machine load Excessive loads or extreme duty Verify that the machine is operating
cycles could result in the pump and within the parameters for which it
/ or motor operating at speeds and was designed. If necessary, reduce
pressures beyond system design the load on the machine.
limitations. 

Item Description Action

System will not
operate in one Input control signal (linkage, A faulty control signal is being Verify that the input signal being
current, or pressure) received at the pump. (MDC received is correct and identical in
direction - binding or broken linkage, EDC - both directions. Adjust, clean, repair,
faulty or inadequate electrical signal, or replace the control module as
HDC - blocked or incorrectly orificed necessary.
control lines)
SCR (system check / relief ) The SCR valves are malfunctioning Verify that the SCR valves are
valves or improperly set. operating properly. Repair or replace
them as necessary.

Pump control A damaged or biased pump Verify that the pump’s control is
control may be sending a signal functioning properly. Repair or
commanding the pump to stroke replace it as necessary.
only in one direction.
Servo pressure The drain or supply path to one side Verify that the servo supply and
of the servo piston may be blocked. drain paths are unobstructed and
that each orifice is of the correct size
and free of debris. Clean or repair
them as necessary.
Displacement limiters (if The displacement limiters may be Verify that the displacement limiters
equipped) improperly adjusted such that the are adjusted properly.
servo piston is prevented from
moving in one direction.

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 Series 40 M46 Tandem Variable Pumps
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Troubleshooting

Item Description Action

System will not
operate in either Oil level in reservoir There is insufficient hydraulic fluid Fill the reservoir to the proper level
to supply the system loop. with clean hydraulic oil.
direction
Input control signal A faulty control signal being Verify that the input signal being
(linkage, current, or pressure) received at the pump. (MDC received is correct and identical
- binding or broken linkage, EDC - in both directions. Adjust, clean,
faulty or inadequate electrical signal, repair, or replace the input device as
HDC - blocked or incorrectly orificed necessary.
control lines)
Oil filters Clogged oil filters may result in Inspect the oil filters and verify that
an insufficient supply of oil to the they are still serviceable. Replace
system. them as necessary.
Bypass valve A partially activated bypass valve Verify that the bypass valves are
may result in a cross port leakage. closed and that the valves are
seating properly. Clean, repair, or
replace them as necessary.
Charge pressure Charge pressure may be insufficient Inspect the charge pump for
(in neutral) to recharge the system loop. damage and verify that the charge
pressure relief valve is at the proper
setting. Repair or replace it as
necessary.
Charge pressure There is low charge pressure Repair or replace the component
(in stroke) resulting from internal leakage or components within the system
within the system. causing the internal leakage.
Servo pressure There is an insufficient pressure Check servo pressures to verify
differential across the servo piston. 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.
Charge pump The charge pump is damaged or Verify that the charge pump is in
has been installed with the incorrect good working order and that it is
rotational orientation. correctly installed. Repair or replace
it as necessary.
SCR (system check / relief ) The SCR valves are malfunctioning Verify that the SCR valves are
valves or improperly set. operating and properly set. Repair or
replace them as necessary.
Displacement limiters Displacement limiters may be Verify that the displacement limiters
improperly adjusted such that the are adjusted to the proper setting.
servo piston is locked in place.

Item Description Action

Neutral difficult or
impossible to find Input control signal (linkage, A faulty control signal is being Verify that the input signal being
current, or pressure) received at the pump. (MDC received is correct and identical
- binding or broken linkage, EDC - in both directions. Adjust, clean,
faulty or inadequate electrical signal, repair, or replace control module as
HDC - blocked or incorrectly orificed necessary.
control lines)
System pressure With no input signal to the control, Readjust pump neutral setting. Refer
a pressure delta may exist between to adjustment procedure on page
the two sides of the working loop. 24.
Servo pressure With no input signal to the control, Readjust the control neutral setting.
a pressure delta may exist across the Refer to adjustment procedure on
servo piston. pages 25 and 26.
PCP pressure (EDCs only) With no input signal to the control, a Replace the EDC.
pressure difference may exist across
the control spool.

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 Series 40 M46 Tandem Variable Pumps
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Troubleshooting

Item Description Action

System response is
sluggish Reservoir oil level There is an insufficient amount Fill the reservoir to the proper level
of hydraulic fluid, resulting in an with clean hydraulic fluid.
inadequate supply for the system
loop.
Input control signal A faulty control signal is being Verify that the input signal being
(linkage, current, or pressure) received at the pump. (MDC received is correct and identical in
- binding or broken linkage; EDC - both directions.
faulty or inadequate electrical signal;
HDC - blocked or incorrectly orificed
control lines)
Pump control A damaged pump control or control Verify that the pump’s control is
spool will not correctly transmit the operating properly and that the
control input signal to the pump. control spool is not damaged or worn
and moves freely within its bore.
Clean, repair, or replace it as necessary.
Bypass valve A partially activated bypass valve Verify that the bypass valve is closed
will cause cross port leakage. and that the valve is seating properly.
Clean, repair, or replace it as necessary.
SCR (system check / relief ) One or both of the SCR valves may Verify that the SCR valves operate
valves be binding within their bores. freely. Repair or replace them as
necessary.
Charge pressure (in neutral) There is low charge pressure Inspect the charge pump for damage
resulting from a damaged charge and verify the charge pressure relief
pump or low charge pressure relief valve setting. Repair or replace it as
valve setting. necessary.
Charge pressure (in stroke) There is low charge pressure Repair or replace the component
resulting from internal leakage or components within the system
within the system. causing the internal leakage.
Servo pressure There is insufficient pressure Check servo pressures at port M4 and
differential across the servo piston. M5 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 as
necessary.
Charge pump The charge pump has been Verify that the charge pump is in
damaged or installed with the good working order and that it is
incorrect rotational orientation. correctly installed. Repair or replace it
as necessary.

Electrical
Item Description Action
troubleshooting
Control operates pump in one Control coil failure Measure resistance at coil pins.
direction only Resistance should be 14.20 ohms
(24V) or 3.66 ohms (12V) at 20°C
[70°F]. Replace coil
No pump function No power to controller Restore power to controller
Erratic pump function Electrical connection to pump is bad Disconnect connection, check wires,
reconnect wires
Filter bypass indicator switch Filter switch may be bad Check/replace filter switch. Add
gauge to filter bypass port to verify
proper fluid flow and verify switch
operation by measuring resistance.
open resistance=510 ohms, closed
resistance=122 ohms

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Standard C Caution
procedures, Contamination can damage internal components and void the manufacturer’s warranty.
inspections, and Take precautions to ensure system cleanliness when removing and reinstalling system
adjustments lines

1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the
pump.

2. If removing the pump, tag each hydraulic line connected to the pump. If hydraulic
lines are disconnected, plug each open port, to ensure that dirt and contamination
do not get into the pump.

3. Ensure the surrounding areas are clean and free of contaminants such as dirt and
grime.

4. Inspect the system for contamination.

5. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam
in the oil, sludge, or small metal particles.

6. Drain and flush the hydraulic system and replace all filters.

7. Before re-installing the pump, perform a leakage test per Sauer-Danfoss leakage test
HPP 112.

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
rear cover or front flange, voids the warranty unless done by a Sauer-Danfoss Global
Service Partner.

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 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Pump adjustment This section offers instruction on inspection and adjustment of pump components.
Read through the entire topic before beginning a service activity. Refer to Pressure
measurements page 14, for location of gauge ports and suggested gauge size.

Charge pressure The following procedure explains how to check and adjust the charge pressure relief
relief valve valve.

1. Shut down prime mover.

Measure charge pressure at 2. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a
1775 RPM. Charge pressure 10 bar [100 psi] gauge in one of the case pressure ports L1 or L2. Operate the system
is found by subtracting case with the pump in neutral (zero displacement) to measure charge pressure.
pressure from the pressure
measured at the charge 3. To adjust charge pressure, shut down prime mover.
pressure gage port M3.
4. Using a 1 inch hex wrench, remove charge pressure relief plug (102). Add or remove
shims (101) in relief valve. Adding shims (101) increases charge pressure, while
removing shims decreases charge pressure. Refer to pump model code for the unit’s
proper charge pressure setting.

5. Lubricate and install new O-ring O-ring (103).

6. Using a 1 inch hex wrench, reinstall plug (102). Torque to 108 Nm [80 ft•lb].

7. Operate pump in neutral to verify proper operation.

8. Remove gages. Operate pump and check for leaks.

Charge pressure adjustment

103

102
1 in. 101
104
105

M3
11/16 in
Charge pressure
gage port
P106 666E

11029852 • Rev AC • March 2010 21

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Engaging the bypass Test bypass function with pump installed on machine. The bypass function is engaged by
function unscrewing the bypass valve. Do not open the bypass valve when machine is operating.

1. To engage the bypass function, use a 5/8 hex wrench to unscrew the bypass valve.
Rotate the bypass valve approximately three turns counterclockwise. Do not rotate
more than 3 revolutions, as additional rotation will permit external leakage.

2. To close the bypass valve, rotate the bypass valve clockwise until seated. Torque to 20
N•m [15 lbf•ft].

3. If machine is towable with bypass valve opened three turns, and if wheels are locked
(not towable) with bypass valve closed, bypass function is working correctly.

C Caution
Avoid excessive speeds and extended load/vehicle movement. Do not move the load or
vehicle more than 20 % of maximum speed or for more than 3 minutes. Damage to drive
motor(s) is possible.

Using the bypass function

Bypass valve
5/8 in

Bypass valve
5/8 in P106 667E

22 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

System check/relief The SCR valve is a high pressure relief valve and a system check valve in combination.
(SCR) valves Whenever an SCR valve has been replaced or opened, the pump should be operated
in its full range of functions to ensure proper machine operation. The SCR valves are
pre-set at the factory, no adjustment is possible. Pressure code is marked on the valve
To adjust max. system (1103). Refer to the model code for pressure designation. If SCR malfunction is suspected,
pressure, replace SCR replace valve and test operation of pump.
valve with one set for the
desired pressure setting. The following procedure explains how to replace the SCR valves.

1. Shut down the system.

2. Using a 1-1/4 hex wrench, remove relief valve plug (166).

3. Remove spring (165) and relief valve (1103) from pump housing.

4. Insert new relief valve (1103) and spring (165) into pump housing.

5. Replace O-ring (106). Lubricate new O-ring before installation.

6. Using a 1-1/4 hex wrench install relief valve plug (166). Torque to 174 Nm [128 ft•lb].

Adjusting the HPRV’s

166
1-1/4 in
174 Nm [128 ft•lb]

106
165

1103

1103

165

106 166
1-1/4 in
174 Nm [128 ft•lb]

P106 668E

11029852 • Rev AC • March 2010 23

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Displacement limiter Pump may have a displacement limiter on each side of the servo. Each limiter may be
adjustment adjusted to a different setting.

1. Remove snap ring (928) and sleeve (929).

2. Hold the adjusting screw (913) in place using a flat screw driver. Use a 9/16 hex
wrench to loosen the locking nut (927).

3. Rotate the displacement limiter (913) based on the table below.
Rotating the adjusting screw clockwise decreases the maximum displacement of the
pump while rotating the adjusting screw counterclockwise increases the maximum
displacement.

4. After establishing the desired maximum displacement setting, hold displacement

limiter in place using a flat screw driver and tighten the locking nut using a 9/16 hex
wrench. Torque locking nut to 12 N•m [9 lbf•ft].

5. One full turn of the adjusting screw will change the maximum displacement
approximately as shown in the table below.

Displacement limiter adjustment

929

928

927
9/16 in

913

P106 672E

Displacement limiter Displacement limiter adjustment data

adjustment data Displacement Locknut wrench size and Adjusting screw Approximate displacement change
torque size per revolution of adjusting screw
46 9/16 12 Nm [9 lbf•ft] Flat screw driver 4.1 cc / turn

24 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Swashplate neutral With the pump properly plumbed, primed and mounted on a vehicle or test stand,
adjustment use the following procedure to adjust the pump to mechanical neutral. If pump is on a
vehicle, block the wheels to prevent movement.

Measured data:
• System pressure at MA or MC
• System pressure at MB or MC
• Pressure differential between MA and MB or MC and MD (optional)

Pump Setup
1. Attach 600 bar [10,000 psi] gauge to system pressure gage ports MA and MB or MC
and MD

2. Using a hydraulic line and fittings, connect servo pressure ports (M4 and M5).

Connecting servo ports M4 and M5 removes the effects of any control pressure on the
servo piston by creating zero pressure differential between the two sides of the servo.

3. Using a 1/4 hex wrench and a 9/16 hex wrench, loosen servo lock nut (2115).

4. Using a 1/4 hex wrench, turn neutral adjustment screw (908) until one system
pressure gage begins to show an increase in pressure. Turn the neutral adjustment
screw (908) in the opposite direction until the other system pressure gage begins to
show an increase in pressure. Turn the neutral adjustment screw half way between
the two positions.

5. Using a 1/4 hex wrench to hold the servo adjustment screw in place, and a 9/16 hex
wrench, tighten servo lock nut (2115). Torque to 37 Nm [27 ft•lb].

Servo neutral adjustment

M4 M5
MD MA

MB
MC
M5 908
M4
1/4 in
Servo pressure port

2115
9/16 in
P106 669E

11029852 • Rev AC • March 2010 25

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Manual displacement With the pump properly plumbed, primed and mounted on a vehicle or test stand, use
control bracket the following procedure to adjust the pump displacement control to neutral position. If
neutral adjustment pump is on a vehicle, block the wheels to prevent movement. Check swashplate neutral
adjustment before adjusting control bracket. If swashplate neutral is properly adjusted
and system is not in neutral, adjust MDC bracket as described below.

Verify swashplate neutral adjustment (see page 25) before performing control neutral
adjustment.

Measured data:
• Servo pressure at M4
• Servo pressure at M5
• Pressure differential between M4 and M5 (optional)

Procedure
1. Attach 20 bar [300 psi] gauge to each servo gage port.

2. Using a 3/8 hex wrench, loosen screw (1210) to allow the neutral adjustment bracket
to move, but not freely.

3. Start prime mover and slowly accelerate to normal operating RPM.

4. Using your hand, press neutral adjustment bracket towards the pump housing,
and rotate adjustment bracket until both servo gages read equal pressures. Rotate
adjustment bracket until one of the servo pressure gages indicates an increase in
pressure. Rotate adjustment bracket in opposite direction until the other servo
pressure gage indicates an increase in pressure. Rotate neutral bracket until it is half
way between the two positions.

5. While holding the neutral adjustment bracket in place, use a 3/8 hex wrench to
tighten screw (1210). Torque to 14 Nm [10 ft•lb].

Manual displacement control bracket adjustment

1210
M4 3/8 in M5

M5 Neutral bracket M4
P106 670E

26 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Adjustments

Electronic With the pump properly plumbed, primed and mounted on a vehicle or test stand, use
displacement the following procedure to adjust the pump displacement control to neutral position. If
control/hydraulic pump is on a vehicle, block the wheels to prevent movement.
displacement
control neutral Verify swashplate neutral adjustment (see page 25) before performing control neutral
adjustment adjustment.

Measured data:
• Servo pressure at M4 (refer to port and gage locations page 15)
• Servo pressure at M5 (refer to port and gage locations page 15)
• Pressure differential between M4 and M5 (optional)

Procedure
1. Attach 20 bar [300 psi] gauge to each servo gage port.

2. Use a 5/32 internal hex wrench to hold the adjusting screw in place.

3. Using a 1/2 hex wrench, loosen locknut.

4. Start prime mover and slowly accelerate to normal operating RPM.

5. Rotate adjustment screw until both servo gages read equal pressures. Rotate
adjustment screw until one of the servo pressure gages indicates an increase in
pressure. Rotate adjustment screw in opposite direction until the other servo
pressure gage indicates an increase in pressure. Rotate adjustment screw until it is
half way between the two positions.

6. While holding the neutral adjustment screw in place, tighten locknut. Torque to 3 Nm
[27 in•lb].

EDC / HDC control adjustment

Adjustment screw
5/32 in

Lock nut
1/2 in

P106 643

11029852 • Rev AC • March 2010 27

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Standard Before working on the pump, clean all dirt and grime from the outside of the pump.
procedures, If the pump has an auxiliary pump attached, remove all pumps as a single unit.Tag all
removing the pump hydraulic lines as they are disconnected and plug all open ports, to ensure that dirt and
contamination do not get into the pump.

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.

Removal
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the
pump.

2. Tag and disconnect each hydraulic line connected to the pump. As hydraulic lines
are disconnected, plug each open port, to ensure that dirt and contamination do not
get into the pump.
C Caution
Be careful not to damage 3. Remove the tandem pump and its auxiliary pump (if applicable) as a single unit. C
solenoids and electrical
connections when using Inspection
straps or chains to remove 4. Ensure the work surface and surrounding area are clean and free of contaminants
pump from machine. such as dirt and grime.

5. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam
in the oil, sludge, or small metal particles.

Reassembly
6. Before replacing the pump on the machine, replace all filters and drain the hydraulic
system. Fill the system with the correct hydraulic fluid.

7. Flush the lines before replacing the hydraulic fluid.

For repair part information, see Sauer-Danfoss publication Series 40 M46 Variable Pump
Parts Manual BLN-2-41702 for your model.

28 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Displacement limiter Removal

1. Remove snap ring (928) and sleeve (929). Use a 1/4 hex wrench to hold neutral
adjustment screw in place. Use a 9/16 hex wrench to remove hex nut (2115).

Mark the location of 2. Use a flat screw driver to hold displacement limiter in place. Use a 9/16 hex wrench
displacement adjustment to remove lock nut (927).
and neutral adjustment
screws before disassembly. 3. Using a 3/8 hex wrench, remove five bolts (921) from servo cover (902).
This will save time during
re-assembly. 4. Turn servo cover (902) counter clockwise to remove it from neutral adjustment
screw. Remove and discard gasket (2161).

5. Turn displacement limiter (913) out of servo cover (902).

Inspection
6. Inspect all parts for damage. Inspect the mating surfaces of the servo cover (902) and
motor housing for scratches, grooves, and other damage. Inspect threads of screws
and nuts for damage. Replace any damaged parts.

Reassembly
7. Turn displacement limiter (913) into servo cover (902). Install new gasket (936) and
turn servo cover (902) onto neutral adjustment screw.

8. Using a 3/8 hex wrench, install five bolts (921). Torque to 15 Nm [11 lb•ft].

9. Use a flat screw driver to hold displacement limiter. Use a 9/16 hex wrench to
install seal nut (927) onto displacement limiter (913) at the position noted during
disassembly. Torque to 12 Nm [9 lb•ft]. Install sleeve (929) and snap ring (928).

10. Using a 1/4 hex wrench to hold neutral adjustment screw and a 9/16 hex wrench,
install hex nut (2115) onto neutral adjustment screw at the position noted during
disassembly. Torque to 37 Nm [27 ft•lb].

Displacement limiter removal/installation

927 929
9/16 in
928

Servo neutral 921

adjustment screw 3/8 in

913

2115
9/16 in

2161

902

P106 671E

11029852 • Rev AC • March 2010 29

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Pressure filtration Removal

adapter 1. Using a 11/16 hex wrench, remove plug (810). Remove and discard O-ring (810A).

2. Using a 1/2 in hex wrench, remove bolts (806).

3. Remove pressure filtration cover (801). Remove and discard gasket (805).

Inspection
4. Inspect the machined surface on the control. If any nicks or scratches are found,
replace the damaged component.

Reassembly
5. Install new gasket (805) and filtration cover (801).

6. Using a 1/2 hex wrench, install three bolts (806). Torque to 30 Nm [22 ft•lb].

7. Lubricate and install O-ring (810A) onto plug (810). Using a 11/16 hex wrench, install
plug (810). Torque to 37 Nm [27 ft•lb].

Pressure filtration adapter removal/installation

810
11/16 in 805

801
P106 673E
810A
806
1/2 in

30 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Charge pump If the pump has an auxiliary pump attached, remove the auxiliary pump and connecting
shaft before removing the auxiliary pad.

Removal
1. Using a 3/4 hex wrench remove nut (2144). Remove bracket (2146).

2. Using a 1/2 12 point hex wrench, remove bolts (2147). Pull to separate front and rear
pump housings.

3. Unthread tie rod (2145).

4. Remove and discard O-rings (2407, 2408, and 2150).

Note the location of pin
(2404) for reassembly. It 5. Remove gerotor cover (2304) and gerotor (2403).
can be assembled for right
hand or left hand pump 6. Remove pin (2404), coupling (2142), and pin (2405).
rotation.

Charge pump removal/installation

2407
2408

2304

2404 2403
2144
3/4 in
102 Nm 2150
[75 ft•lb] 2142
2147
2146 1/2 in
2145 102 Nm
[75 ft•lb]

2405

P106 674E

11029852 • Rev AC • March 2010 31

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Charge pump Inspection

(continued) 6. Inspect the gerotor (2403) and gerotor cover (2304) for wear, scratches or
pitting. If any component shows signs of wear, scratching, or pitting, replace all
damaged components. Inspect pin (2404) and key (2405) for damage, and replace
parts if necessary. Replace O-ring (2407, 2408, 2150) whenever charge pump is
disassembled.

Reassembly
7. Install pin (2405) into coupling (2142). Install coupling (2142) into gerotor (2403) with
pin (2405) aligned in groove.

8. Install coupling onto shaft of front pump.

9. Install pin (2404) into front pump housing and gerotor cover (2304) onto gerotor
(2403).

10. Lubricate and install O-rings (2407, 2408, and 2150).

11. Thread tie rod (2145) into front pump housing.

12. Mate two pumps together to install rear pump shaft into coupling (2124). Using a
pipe wrench or pliers, rotate front pump shaft to align coupling with rear pump shaft
and then push two pump housings together. Use a rubber mallet if necessary.

Position the pumps vertically with the front housing on top of the rear housing to make
alignment easier.

13. Using a 1/2 12 point hex wrench, install bolts (2147). Torque to 102 Nm [75 ft•lb].

14. Install bracket (2146). Using a 3/4 hex wrench install nut (2144). Torque to 102 Nm
[75 ft•lb].

32 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Shaft seal The shaft assembly is serviceable without removing the front cover of the pump. Orient
the pump on the work surface so the shaft is pointing up.

Removal Shaft assembly

1. Using a snap-ring pliers, remove
snap-ring (2132) from pump cover. 301
2132
2. Using a sharp instrament (like a
C Caution
P106 675E
screw driver)or a slide hammer type
Do not damage the puller remove the shaft seal (301).
housing bore, shaft or
bearing when removing
the shaft seal. Inspection
3. Inspect the shaft and bearing for
wear, scratching and pits. If wear,
scratching or pitting is found, replace
the shaft and bearing.

Shaft seal installation tool

Reassembly
4. Press new seal (301) into pump cover.

5. Install Snap-ring (2132) using a snap-

ring pliers.
7 in

2.75 in
0.750 in

0.370 in
1.24 in

1.5 in

2.45 in

3 in P106 652E

11029852 • Rev AC • March 2010 33

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

SCR valves The SCR valves are factory set and are not field adjustable.

Removal
1. Using a 1-1/4 hex wrench, remove relief valve plug (166). Remove and discard O-ring
(106).

2. Remove spring (165) and relief valve (1103) from pump housing.

Inspection
3. Inspect the sealing surfaces of the pump for nicks or scratches. Inspect the relief
valve (1103) sealing surface for nicks or scratches. If the relief valve (1103) is
damaged, replace it.

Reassembly
4. Lubricate and insert relief valve (1103) and spring (165) into pump housing.

5. Lubricate and install new O-ring (106) onto plug (166). Using a 1-1/4 hex wrench
install relief valve plug (166). Torque to 174 Nm [128 ft•lb].

High pressure relief valves

166
1-1/4 in
174 Nm [128 ft•lb]

106
165

1103

1103

165

106 166
1-1/4 in
174 Nm [128 ft•lb]

P106 668E

34 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Charge pressure Replace the charge pressure relief valve components if they are damaged or otherwise
relief valve suspected of failure. See Charge pressure relief valve adjustment page 21, for adjustment
instructions.

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
3. Inspect the sealing surfaces of the pump for nicks or scratches. Inspect the relief
valve (105) sealing surface for nicks or scratches. If the relief valve (105) is damaged,
replace it.

Reassembly
4. Install charge pressure relief valve (105), spring (104), and shims (101).

5. Lubricate and install O-ring (103) onto plug (102). Using a 1 inch hex wrench, install
plug (102). Torque to 108 Nm [80 ft•lb].

6. Operate pump at full range of controls to ensure proper machine operation.

Charge pressure relief valve

103

102
1 in
101
104
105

P106 676E

11029852 • Rev AC • March 2010 35

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Bypass valve Removal

1. Using a 5/8 hex wrench, remove bypass valve (1001).

2. Remove and discard O-ring (1003) and seal (1002).

Inspection
3. 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
4. Lubricate and install new O-ring (1003) and seal (1002) onto bypass valve (1001).

5. Using a 5/8 hex wrench, install bypass valve (1001). Torque to 20 Nm [15 ft•lb].

6. Operate pump at full range of controls to ensure proper machine operation.

Bypass valve
1001
5/8 in
1002 20 Nm [15 ft•lb]

1003

1003

1001
5/8 in 1002
20 Nm
P106 677E
[15 ft•lb]

36 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Manual displacement Removal

control 1. Using a 3/8 hex wrench, remove screw (1210). Remove manual control spool
assembly from pump housing.

Mark the location of neutral 2. Using a 1/2 hex wrench, remove lock nut (1213). Remove tooth lock washer (1235),
return bracket (1216) handle (1215), neutral return bracket (1216), and spring (1214) from spool (1207).
before disassembly.
3. Remove and discard backup ring (1209) and O-ring (303) from spool (1207).

4. Remove sleeve (1402). Remove and discard backup ring (1208) and O-ring (302).

Inspection
5. Inspect all parts of control assembly. Replace any damaged parts. Inspect spools for
grooves, scratches, and other damage. If spools are damaged, replace them. Inspect
sleeve bore in housing for damage.

Reassembly
When installing sleeve 6. Lubricate and install O-ring (302) and backup ring (1208) onto sleeve (1402).
(1402), ensure that sleeve Lubricate and install sleeve (1402) into motor housing.
groove engages spring pin
on swashplate 7. Lubricate and install O-ring (303) and backup ring (1209) onto spool (1207).

8. Install neutral return spring (1214), neutral return bracket (1216), handle (1215), and
washer (1235) onto spool (1207).
Install control spool (1207)
with alignment slot facing 9. Using a 1/2 hex wrench, install lock nut (1213). Torque to 15 Nm [11 ft•lb].
servo piston.
10. Lubricate and install spool (1207) into sleeve (1402).
Alignment slot
11. Using a 3/8 hex wrench, install screw (1210). Torque to 14 Nm [10 ft•lb]. See MDC
Servo piston bracket adjustment, page 26, for adjustment procedure.

Manual displacement control

302

P107 958E
1208

1402

1210 1209
3/8 in 1207
15 Nm
303
[11 ft•lb]
1214
1235
1216
1213 1215
1/2 in
P106 678E
15 Nm [11 ft•lb]

11029852 • Rev AC • March 2010 37

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

Electronic Removal
displacement 1 Using a 3/16 internal hex wrench, remove screws (1203 and 1204) or (1226 and
control/hydraulic 1224).
displacement
control 2. Remove control housing (1201) or control housing (1223) and manifold (1225).
Remove and discard O-rings (1220 and 304) or (1227, 1228, and 1229).

If control is suspected of Inspection

failure, replace control 3. Inspect control spool for scratches, grooves, and other damage. If spool is damaged,
and test pump for proper or control is otherwise suspected of malfunction replace entire control unit. Inspect
operation. When installing sleeve bore in housing for damage.
control, ensure that sleeve
groove engages spring pin Reassembly
on swashplate 4. Lubricate and install O-rings (1220 and 304) onto control housing (1201) or lubricate
and install O-rings (1227 and 1228) onto manifold (1225) and O-rings (1223A) onto
control housing (1223). Lubricate and install control housing (1201) or manifold
(1225) onto pump housing aligning sleeve groove with spring pin on swashplate.

5. Using a 3/16 internal hex wrench, install screws (1203 and 1204) or (1226). Torque
to 14 Nm [10 ft•lb]. If necessary, install control housing (1223). Using a 4 mm internal
hex wrench, install screws (1224). Torque to 14 Nm [10 ft•lb].

EDC / HDC repair

1220

1201

1203
3/16 in 304

1220 1220

1201
EDC

304
1204 1203
3/16 in 3/16 in 1220
1228
HDC 1227

1204
1225
3/16 in
1223

1224 1226 P106 679E

4 mm 3/16 in
1223A

3-Position Control

38 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Minor repair

MDC orifice repair Removal MDC orifice repair

1. Using a 3/16 internal hex wrench,
remove pipe plug (1219). Using a 1/8
internal hex wrench, remove filter or
orifice plug (1401).

Inspection
2. Inspect orifice for damage,
contamination, and correct size.
Replace orifice if necessary. 1401
1/8 in

Pipe plug (1219) needs to Reassembly

be installed with thread 3. Using a 1/8 internal hex wrench, 1219
lock. Apply a few drops install filter or orifice plug (1401). 3/16 in P106 680E

of thread lock before Torque to 3 Nm [2 lb•ft].

installation.
4. Using a 3/16 internal hex wrench,
install pipe plug (1219). Torque to 22 EDC/HDC orifice repair
Nm [16 lb•ft].
934 920
3/8 in
EDC/HDC orifice repair Removal 901
1. Remove servo covers. See
displacement limiter repair, page 2161
29, for servo cover removal and
installation instructions.
1403
2. Using a 7/32 internal hex wrench,
remove orifice plugs (1403 and
1404).

Inspection
3. Inspect orifice for damage,
contamination, and correct size.
Replace orifice if necessary.

Reassembly
4. Using a 7/32 internal hex wrench,
install orifice plugs (1403 and 1404). 1404
Torque to 3 Nm [2 ft•lb]. P106 681E

5. Install servo covers.

936

902

921
115
3/8 in
9/16 in

11029852 • Rev AC • March 2010 39

 Series 40 M46 Tandem Variable Pumps
Service Manual
Torque chart

Fastener size and Item Fastener Wrench size Torque

torque chart 920 Servo piston cover screws 3/8 hex 15 Nm [11 ft•lb]
921 Servo piston cover screws 3/8 hex 15 Nm [11 ft•lb]
4115 Front and rear cover screw T50 Torx 58 Nm [43 ft•lb]
4135 Front and rear cover screws T55 Torx 91 Nm [67 ft•lb]
2504 Aux cover screws 3/4 hex 43 Nm [32 ft•lb]
806 Filtration cover screw 1/2 hex 30 Nm [22 ft•lb]
927 Displacement limiter lock nut 9/16 hex 12 Nm [9 ft•lb]
1213 Control handle nut 1/2 hex 15 Nm [11 ft•lb]
1210 Screw 3/8 14 Nm [10 ft•lb]
2147 Screw 1/2 12 point 102 Nm [75 ft•lb]
2144 Nut 3/4 hex 102 Nm [75 ft•lb]
2115 Servo lock nut 9/16 hex 37 Nm [27 ft•lb]

Plug size and torque Item O-ring plug Wrench size Torque
chart 102 3/4 16 UNF 1 inch hex 108 Nm [80 ft•lb]
2107 1-1/16 12 UNF 9/16 internal hex 115 Nm [85 ft•lb
2148 9/16 18 UNF 11/16 hex 37 Nm [27 ft•lb]
2110 9/16 18 UNF 11/16 hex 37 Nm [27 ft•lb]
2111 9/16 18 UNF 11/16 hex 37 Nm [27 ft•lb]
2155 7/16 20 UNF 9/16 hex 20 Nm [15 ft•lb]
810 9/16 18 UNF 11/16 hex 37 Nm [27 ft•lb]
1001 5/8 18 UNF 5/8 hex 20 Nm [15 ft•lb]
166 1-5/16 12 UNF 1-1/4 hex 176 Nm [130 ft•lb]

40 11029852 • Rev AC • March 2010

 Series 40 M46 Tandem Variable Pumps
Service Manual
Torque chart

Hardware locations
2107 2147
2155
4115
1001

4135
4135 (3X)
(3X)

927

927 921
920 2111
166 102
166
2111 1210
2504
2144 2148 2110 1213

810

1210 2148 2110

1213 806
(3X)
1001
921 2111 166 166
2111 920
2115
2115
927

927 4135
4135 (3X)
(3X)

2107
2107 4115
P106 664E
2147

11029852 • Rev AC • March 2010 41

 Series 40 M46 Tandem Variable Pumps
Service Manual
Notes

42 11029852 • Rev AC • March 2010

Series 40 M46 Tandem Variable Pumps
Service Manual
Notes

11029852 • Rev AC • March 2010 43

Our Products Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Open circuit axial piston pumps
Sauer-Danfoss is a comprehensive supplier providing complete
Gear pumps and motors ­systems to the global mobile market.
Fan drive systems
Sauer-Danfoss serves markets such as agriculture, construction, road
Closed circuit axial piston pumps building, material handling, municipal, forestry, turf care, and many
and motors others.
Bent axis motors
We offer our customers optimum solutions for their needs and
Hydrostatic transmissions develop new products and systems in close cooperation and
partner­ship with them.
Transit mixer drives
Hydrostatic transaxles Sauer-Danfoss specializes in integrating a full range of system
­components to provide vehicle designers with the most advanced
Electrohydraulics
total system design.
Integrated systems
Sauer-Danfoss provides comprehensive worldwide service for its
Microcontrollers and software
products through an extensive network of Global Service Partners
PLUS+1™ GUIDE strategically located in all parts of the world.
Displays
Joysticks and control handles Local address:

Sensors
Orbital motors
Inverters
Electrohydraulic power steering
Hydraulic power steering
Hydraulic integrated circuits (HIC) Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Cartridge valves Ames, IA 50010, USA Phone: +45 7488 4444
Phone: +1 515 239-6000 Fax: +45 7488 4400
Directional spool valves
Fax: +1 515 239-6618
Proportional valves Sauer-Danfoss-Daikin LTD
Sauer-Danfoss GmbH & Co. OHG Shin-Osaka TERASAKI 3rd Bldg.6F
Postfach 2460, D-24531 Neumünster 1-5-28 Nishimiyahara, Yodogawa-ku,
Krokamp 35, D-24539 Neumünster, Germany Osaka 532-0004, Japan
Phone: +49 4321 871-0 Phone: +81 6 6395 6066
Fax: +49 4321 871 122 Fax: +81 6 6395 8585

www.sauer-danfoss.com
520L0958 • Rev AC • March 2010