Danfoss MP1 Service Manual

Date Changed Rev April 2019 Updated for new control types 0201 October 2018 Corred sort strings on MDC and additional options to MDC illustration 0107 January 2018 update control current table 0106 November 2017 Add NFPE 0105 October 2017 Remove HDC 0104 July 2017 update ports and plugs 0103 April 2017 Add HDC 0102 August 2016 First edition 0101 Service Manual MP1 2 | © Danfoss | April 2019 AX00000244en-000201

General instructions........................................................................................................................................................................ 6 Remove the unit..........................................................................................................................................................................6 Lubricate moving parts.............................................................................................................................................................6 Replace all O-rings and gaskets............................................................................................................................................. 6 Safety Precautions............................................................................................................................................................................7 Unintended Machine Movement..........................................................................................................................................7 Flammable Cleaning Solvents................................................................................................................................................7 Fluid Under Pressure..................................................................................................................................................................7 Personal Safety.............................................................................................................................................................................7 Symbols used in Danfoss literature............................................................................................................................................7 Technical specifications MP1 design specifications.............................................................................................................................................................9 MP1 technical data...........................................................................................................................................................................9 MP1 operating parameters.........................................................................................................................................................10 MP1 fluid specifications...............................................................................................................................................................10 Operation MP1 high pressure relief valve (HPRV) and charge check...............................................................................................11 Bypass Function..............................................................................................................................................................................11 MP1 charge pressure relief valve (CPRV) function.............................................................................................................12 Loop flushing valve.......................................................................................................................................................................13 Electrical displacement control (EDC).................................................................................................................................... 14 EDC principle..............................................................................................................................................................................14 EDC operation............................................................................................................................................................................14 Control Signal Requirements, EDC ....................................................................................................................................15 EDC Solenoid Data................................................................................................................................................................... 15 Control Response......................................................................................................................................................................16 MP1 EDC response time....................................................................................................................................................16 Manual Over Ride (MOR)........................................................................................................................................................16 Swash Plate Angle Sensor for EDC Controls.........................................................................................................................18 Swash Plate Angle Sensor Parameters (EDC)..................................................................................................................18 Swash Plate Angle Sensor Connector............................................................................................................................... 19 Interface with ECU (EDC)........................................................................................................................................................19 Manual displacement control....................................................................................................................................................19 MDC principle............................................................................................................................................................................ 19 MDC Operation..........................................................................................................................................................................21 MDC Shaft Rotation................................................................................................................................................................. 21 Control Response......................................................................................................................................................................22 MP1 MDC response time..................................................................................................................................................22 Neutral Start Switch (NSS)..................................................................................................................................................... 22 Case gauge port M14.............................................................................................................................................................. 23 Lever..............................................................................................................................................................................................24 Forward-neutral-reverse (FNR) electic control....................................................................................................................24 FNR principle..............................................................................................................................................................................24 Control Response......................................................................................................................................................................26 Response time, FNR............................................................................................................................................................27 Non Feedback Proportional Electric Control (NFPE).........................................................................................................27 Control Signal Requirements............................................................................................................................................... 28 Control Response......................................................................................................................................................................28 Response Time..................................................................................................................................................................... 29 Non-Feedback, Proportional Hydraulic (NFPH) Control.................................................................................................. 29 Control Response......................................................................................................................................................................30 Response Time..................................................................................................................................................................... 31 Control-Cut-Off valve (CCO valve)........................................................................................................................................... 32 CCO Solenoid Data...................................................................................................................................................................33 Brake gauge port with MDC................................................................................................................................................. 34 Displacement limiter.....................................................................................................................................................................34 Service Manual MP1 Contents © Danfoss | April 2019 AX00000244en-000201 | 3

Operating parameters Input Speed......................................................................................................................................................................................35 System Pressure..............................................................................................................................................................................35 Charge Pressure..............................................................................................................................................................................36 Charge Pump Inlet Pressure.......................................................................................................................................................36 Case Pressure...................................................................................................................................................................................36 Temperature....................................................................................................................................................................................36 Viscosity.............................................................................................................................................................................................37 Fluid and filter maintenance Filtration System ............................................................................................................................................................................38 Pressures measurements MP1 port locations and gauge installation...........................................................................................................................39 Initial startup procedure General ..............................................................................................................................................................................................41 MP1 start-up procedure...............................................................................................................................................................41 Troubleshooting Overview........................................................................................................................................................................................... 43 Safety precautions.........................................................................................................................................................................43 Electrical troubleshooting.......................................................................................................................................................... 43 System Operating Hot..................................................................................................................................................................44 Transmission Operates Normally in One Direction Only.................................................................................................44 System Does Not Operate in Either Direction..................................................................................................................... 44 System noise or vibration........................................................................................................................................................... 45 Neutral Difficult or Impossible to Find................................................................................................................................... 45 Sluggish System Response.........................................................................................................................................................45 Adjustments Pump adjustment..........................................................................................................................................................................46 Standard Procedures.................................................................................................................................................................... 46 Charge Pressure Relief Valve......................................................................................................................................................46 Displacement Limiter................................................................................................................................................................... 47 Control Neutral Adjustment.......................................................................................................................................................48 Mechanical/Hydraulic Neutral Adjustment..........................................................................................................................49 Servo Adjustment.....................................................................................................................................................................49 Verify neutral setting...............................................................................................................................................................50 Servo Adjustment Side M4....................................................................................................................................................50 Minor repair MP1 standard procedures and pump removal...................................................................................................................52 EDC Control......................................................................................................................................................................................52 MP1 EDC control removal......................................................................................................................................................52 Controls inspection..................................................................................................................................................................53 MP1 EDC control assembly................................................................................................................................................... 53 MP1 control solenoids/actuator housing replacement...................................................................................................54 MDC Control.................................................................................................................................................................................... 55 MP1 MDC control removal....................................................................................................................................................55 MDC Illustration...................................................................................................................................................................56 MDC Legend......................................................................................................................................................................... 56 Controls inspection..................................................................................................................................................................57 MDC Control Assembly...........................................................................................................................................................57 Charge Pump...................................................................................................................................................................................57 MP1 charge pump removal.................................................................................................................................................. 57 MP1 charge pump inspection..............................................................................................................................................58 MP1 charge pump assembly................................................................................................................................................58 High Pressure Releif Valve (HPRV)............................................................................................................................................58 MP1 HPRV valve removal.......................................................................................................................................................59 Service Manual MP1 Contents 4 | © Danfoss | April 2019 AX00000244en-000201

HPRV Valve Reassembly......................................................................................................................................................... 59 Charge Pressure Relief Valve (CPRV)....................................................................................................................................... 59 MP1 CPRV removal...................................................................................................................................................................59 CPRV inspection........................................................................................................................................................................60 MP1 CPRV assembly.................................................................................................................................................................60 MP1 loop flushing removal (28/32).........................................................................................................................................61 MP1 loop flushing spool inspection.................................................................................................................................. 62 Reassembly.................................................................................................................................................................................62 Shaft Removal................................................................................................................................................................................. 62 Inspection....................................................................................................................................................................................63 Shaft Reassembly......................................................................................................................................................................63 Fastener size and torque chart Fastener size and torque.............................................................................................................................................................64 MP1 plug size and torque...........................................................................................................................................................65 Service Manual MP1 Contents © Danfoss | April 2019 AX00000244en-000201 | 5

This manual includes information on installation, maintenance, and minor repair of these pumps. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures. Performing minor repairs may require 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 and certifies Global Service Partners on a regular basis. You can locate your nearest Global Service Partner using the distributor locator at http://www.danfoss.com. Attention Major repairs requiring the removal of a unit’s center section, servo sleeves, or front flange voids the warranty unless a Danfoss Authorized Service Center performs them. General instructions Remove the unit If necessary, 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. 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, 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. Lubricate moving parts During assembly, coat all moving parts with clean hydraulic fluid. This assures that these parts are lubricated during start-up. Replace all O-rings and gaskets Danfoss recommends that you replace all O-rings, seals and gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Secure the unit Service Manual MP1 Introduction 6 | © Danfoss | April 2019 AX00000244en-000201

secure the pump while removing and torquing end covers, controls, and valves. 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 Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Secure the machine or disable/disconnect the mechanism while servicing to protect against unintended movement. Flammable Cleaning Solvents Some cleaning solvents are flammable. Do not use cleaning solvents in an area where a source of ignition may be present to avoid possible fire. Fluid Under Pressure 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. 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. Use caution when dealing with hydraulic fluid under pressure. Seek medical attention immediately if you are cut by hydraulic fluid. Personal Safety Protect yourself from injury whenever servicing a hydraulic system. Use proper safety equipment, including safety glasses, at all times. Hazardous Material 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 Superseded - parts are not interchangeable Be careful not to scratch or damage Measurement required Note correct orientation Service Manual MP1 Introduction © Danfoss | April 2019 AX00000244en-000201 | 7

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. Service Manual MP1 Introduction 8 | © Danfoss | April 2019 AX00000244en-000201

Features MP1 Design Axial piston pump with variable displacement using compact servo piston control. Direction of input rotation Clockwise or counterclockwise Recommended installation position Pump installation position is discretionary, however the recommended control position is on the top or at the side with the top position preferred. If the pump is installed with the control at the bottom, flushing flow must be provided through port M14 located on the EDC, FNR, NFPE, NFPH and MDC control. Vertical input shaft installation is acceptable. The housing must always be filled with hydraulic fluid. Recommended mounting for a multiple pump stack is to arrange the highest power flow towards the input source. Consult Danfoss for non-conformance to these guidelines. Filtration configuration Suction or charge pressure filtration MP1 technical data Feature 28 32 38 45 Displacement (cm3/rev [in3/rev]) 28.0 [1.71] 31.8 [1.94] 38.0 [2.32] 45.1 [2.75] Flow at rated (continuous) speed (l/min [US gal/min]) 95.3 [25.2] 108.1 [28.5] 125.3 [33.1] 149.5 [39.5] Torque at maximum displacement (N•m/bar [lbf•in/1000psi]) 0.45 [272.0] 0.51 [308.9] 0.60 [369.1] 0.72 [438.1] Mass moment of inertia of rotating components (kg•m2 [slug•ft2]) 0.0020 [0.0015] 0.0030 [0.0022] Mass (kg [lb]) 29.6 [65.3] 38 [83.8] Oil volume (liter [US gal]) 1.5 [0.40] 2.0 [0.53] Mounting flange ISO 3019-1 flange 101-2 (SAE B) Input shaft outer diameter, splines and tapered shafts ISO 3019-1, outer Ø22mm - 4 (SAE B, 13 teeth) ISO 3019-1, outer Ø25mm - 4 (SAE B-B, 15 teeth) ISO 3019-1, outer Ø22mm - 1 (Straight Key) ISO 3019-1, outer Ø31mm - 4 (19 teeth) ISO 3019-1, outer Ø25mm - 4 (Straight Key) ISO 3019-1, outer Ø25mm -3 (Conical keyed, taper 1:8) Auxiliary mounting flange with metric fasteners, shaft outer diameter and splines ISO 3019-1, flange 82-2, outer Ø16mm - 4 (SAE A, 9 teeth) ISO 3019-1, flange 82-2, outer Ø19mm - 4 (SAE A, 11 teeth) ISO 3019-1, flange 101-2, outer Ø22mm - 4 (SAE B, 13 teeth) ISO 3019-1, flange 101-2, outer Ø25mm - 4 (SAE B-B, 15 teeth) Main port configuration A, B ISO 11926-1 - 1 1/16 - 12 (Inch O-ring boss) ISO 11926-1 - 1 5/16 - 12 (Inch O-ring boss) ISO 6149-1, M27x2 (Metric o-ring boss) ISO 6162, Ø19mm, (Split flange boss, M10x1.5) ISO 6149-1 - M33x2 (Metric O-ring boss) Case drain ports L1, L2 ISO 11926-1, 1 1/16 -12 (Inch O-ring boss) ISO 6149-1, M27x2 (Metric O-ring boss) Suction ports S ISO 11926-1 - 1 1/16-12 (Inch O-ring boss) ISO 6149-1 - M27x2 (Metric O-ring boss) ISO 11926-1 - 1 5/16-12 (Inch O-ring boss) ISO 6149-1 - M33x2 (Metric O-ring boss) Other ports ISO 11926-1, (Inch O-ring boss) ISO 6149 -1, (Metric O-ring boss) Customer interface threads Metric fasteners Service Manual MP1 Technical specifications © Danfoss | April 2019 AX00000244en-000201 | 9

Features Units 28/32 38/45 Input speed Minimum1 min-1 (rpm) 500 500 Rated 3400 3300 Maximum 4000 3900 System pressure Maximum working pressure bar [psi] 350 [5000] 350 [5000] Maximum pressure 380 [5429] 380 [5429] Minimum low loop (above case) 10 [143] 10 [143] Charge pressure (minimum) bar [psi] 16 [232] 16 [232] Charge pump inlet pressure Minimum (continuous) bar (absolute) [in Hg vacuum] 0.8 [6] 0.8 [6] Minimum (cold start) 0.2 [24] 0.2 [24] Maximum 2.0 2.0 Case pressure Rated bar [psi] 3 [43] 3 [43] Maximum 5 [71] 5 [71] 1 No load condition. Refer to System Design Parameters/Charge Pump for details. MP1 fluid specifications Features Units 28/32/38/45 Viscosity Intermittent1 mm2/sec. [ SUS] 5 [42] Minimum 7 [49] Recommended range 12 - 80 [66 - 370] Maximum (cold start)2 1600 [7500] Temperature range3 Minimum (cold start) °C [°F] -40 [-40] Recommended range 60 - 85 [140 - 185] Maximum continuous 104 [220] Maximum intermittent 115 [240] Filtration (recommended minimum) Cleanliness per ISO 4406 22/18/13 Efficiency (charge pressure filtration) β-ratio β15-20=75(β10≥10) Efficiency (suction filtration) β35-45=75(β10≥2) Recommended inlet screen mesh size µm 100 - 125 1 Intermittent=Short term t <1 min per incident and not exceeding 2 % of duty cycle based load-life. 2 Cold start = Short term t < 3 min, p < 50 bar [725 psi], n < 1000 min-1 (rpm) 3 At the hottest point, normally case drain port. Service Manual MP1 Technical specifications 10 | © Danfoss | April 2019 AX00000244en-000201

All pumps are equipped with a combination high pressure relief and charge check valve. The high- pressure relief function is a dissipative (with heat generation) pressure control valve for the purpose of limiting excessive system pressures. The charge check function acts to replenish the low-pressure side of the working loop with charge oil. Each side of the transmission loop has a dedicated HPRV valve that is non-adjustable with a factory set pressure. When system pressure exceeds the factory setting of the valve, oil is passed from the high pressure system loop, into the charge gallery, and into the low pressure system loop via the charge check. The pump order code allows for different pressure settings to be used at each system port. The system pressure order code for pumps with only HPRV is a reflection of the HPRV setting. HPRV´s are factory set at a low flow condition. Any application or operating condition which leads to elevated HPRV flow will cause a pressure rise with flow above a valve setting. Consult factory for application review. Excessive operation of the HPRV will generate heat in the closed loop and may cause damage to the internal components of the pump. P400353 High Pressure Low Pressure Bypass Function The bypass function allows a machine or load to be moved without rotating the pump shaft or prime mover. The single pump HPRV valve also provides a loop bypass function when each of the two HPRV hex plugs are mechanically backed out three full turns. Engaging the bypass function mechanically connects both A & B sides of the working loop to the common charge gallery. Possible damage to drive motor(s). Excessive speeds and extended load/vehicle movement must be avoided. The load or vehicle should be moved not more than 20% of maximum speed and for a duration not exceeding 3 minutes. When the bypass function is no longer needed, care should be taken to re-seat the HPRV hex plugs to the normal operating position. Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 11

An internal charge pressure relief valve (CPRV) regulates charge pressure within the hydraulic circuit. The CPRV is a direct acting poppet valve that regulates charge pressure at a designated level above case pressure. The charge pressure relief valve setting is specified within the model code of the pump. pumps with charge pump have the CPRV set at 1800 rpm while MP1 pumps without charge pump have the CPRV set with 18.9 l/min [5.0 US gal/min] of external supply flow. The charge pressure rise rate, with flow, is approximately 1 bar/10 liter [5.4 psi/US gal]. Charge Pressure Case Drain P400341 Service Manual MP1 Operation 12 | © Danfoss | April 2019 AX00000244en-000201

pumps are available with an optional integral loop flushing. A loop flushing valve will remove heat and contaminants from the main loop at a rate faster than otherwise possible. The loop flushing design is a simple spring centered shuttle spool with an orifice plug. The shuttle shifts at approximately 3.9 bar [55.7 psi]. The flushing flow is a function of the low loop system pressure (charge) and the size of the plug. Working Loop (Low Pressure) Working Loop (High Pressure) Shuttle Spool Orifice Plug P400342 Loop flushing performance 25 20 35 40 45 30 15 10 5 0 0 4 8 10 12 14 Charge pressure [d bar] Flow [lpm] Ø1.6 (standard) Ø1.9 (optional) Oil Temp = 50°C (~30 mm2/S) 2 6 P400352 When a pump is used with an external loop flushing shuttle valve, ensure that the charge setting of the pump matches the setting of the loop flushing shuttle valve. Contact your Danfoss representative for the availability of additional charge relief settings. Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 13

EDC principle An EDC is a displacement (flow) control. Pump swashplate position is proportional to the input command and therefore vehicle or load speed (excluding influence of efficiency), is dependent only on the prime mover speed or motor displacement. The Electrical Displacement Control (EDC) consists of a pair of proportional solenoids on each side of a three-position, four-way porting spool. The proportional solenoid applies a force input to the spool, which ports hydraulic pressure to either side of a double acting servo piston. Differential pressure across the servo piston rotates the swashplate, changing the pump‘s displacement from full displacement in one direction to full displacement in the opposite direction. Under some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. A 170 μm screen is located in the supply line immediately before the control porting spool. EDC control P003 191 EDC schematic Feedback from Swash plate P T F00B M14 C1 C2 F00A P003 478E EDC operation EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal. Pulse width modulation allows more precise control of current to the solenoids. The PWM signal causes the solenoid pin to push against the porting spool, which pressurizes one end of the servo piston, while draining the other. Pressure differential across the servo piston moves the swashplate. A swashplate feedback link, opposing control links, and a linear spring provide swashplate position force feedback to the solenoid. The control system reaches equilibrium when the position of the swashplate spring feedback force exactly balances the input command solenoid force from the operator. As hydraulic pressures in the operating loop change with load, the control assembly and servo/swashplate system work constantly to maintain the commanded position of the swashplate. Service Manual MP1 Operation 14 | © Danfoss | April 2019 AX00000244en-000201

the servo piston assembly, and the linear control spring. Once the neutral threshold current is reached, the swashplate is positioned directly proportional to the control current. To minimize the effect of the control neutral deadband, we recommend the transmission controller or operator input device incorporate a jump up current to offset a portion of the neutral deadband. The neutral position of the control spool does provide a positive preload pressure to each end of the servo piston assembly. When the control input signal is either lost or removed, or if there is a loss of charge pressure, the spring- loaded servo piston will automatically return the pump to the neutral position. Control Signal Requirements, EDC Pump displacement vs. control current "0" -b -a b a 100 % 100 % Displacement Current mA EDC control current Voltage 12 VDC 24 VDC Minimum current to stroke pump a* 640 mA 330 mA b 1640 mA 820 mA Pin connections any order * Factory test current, for vehicle movement or application actuation expect higher or lower value. EDC Solenoid Data Description 12 V 24 V Maximum current 1800 mA 920 mA Nominal coil resistance @ 20 °C [68 °F] 3.66 Ω 14.20 Ω @ 80 °C [176 °F] 4.52 Ω 17.52 Ω Inductance 33 mH 140 mH PWM signal frequency Range 70 – 200 Hz Recommended* 100 Hz IP Rating IEC 60 529 IP 67 DIN 40 050, part 9 IP 69K with mating connector Connector color Black * PWM signal required for optimum control performance. Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 15

Shaft rotation CW CCW Coil energized* C1 C2 C1 C2 Port A out in in out Port B in out out in Servo port pressurized M4 M5 M4 M5 * For coil location see Installation drawings. Control Response H1controls are available with optional control passage orifices to assist in matching the rate of swash- plate response to the application requirements. The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a net function of spool porting, orifices, and charge pressure. H1 pumps are limited in mechanical orifice combinations. Mechanical servo orifices are to be used only for fail-safe return to neutral in a case of an electrical failure. A swash-plate response times table is available for each frame size. Testing should be conducted to verify the proper orifice selection for the desired response. Typical response times at the following conditions: Δ p = 250 bar [3626 psi] Charge pressure = 20 bar [290 psi] Viscosity and temperature = 30 mm²/s [141 SUS] and 50 °C [122 °F] Speed = 1800 min-1 (rpm) MP1 EDC response time Stroking direction 0.8 mm [0.03 in] orifice 1.0 mm [0.04 in] orifice 1.3 mm [0.05 in] orifice No orifice 28/32 38/45 28/32 38/45 28/32 38/45 28/32 38/45 Neutral to full flow 1.3 s 2.1 s 0.9 s 1.3 s 0.6 s 0.9 s 0.4 s 0.6 s Full flow to neutral 1.0 s 1.5 s 0.7 s 0.9 s 0.4 s 0.6 s 0.2 s 0.3 s Manual Over Ride (MOR) Electro-hydraulic controls are available with a Manual Over Ride (MOR) either standard or as an option for temporary actuation of the control to aid in diagnostics. Initial actuation of the o-ring seal MOR plunger will require a force of 45 N. Additional actuations typically require less force to engage the MOR plunger. Proportional control of the pump via the MOR is not intended. The MOR plunger has a 4 mm diameter and must be manually depressed to be engaged. Depressing the plunger mechanically moves the control spool which allows the pump to go on stroke. Unintended MOR operation can cause the pump to go into stroke. The vehicle or device must always be in a safe condition (example: vehicle lifted off the ground) when using the MOR function. The MOR should be engaged anticipating a full stroke response from the pump. Refer to control flow table for the relationship of solenoid to direction of flow. Service Manual MP1 Operation 16 | © Danfoss | April 2019 AX00000244en-000201

P003 204 Feedback from Swash plate P T F00B M14 C2 C1 F00A P003 205E Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 17

The angle sensor detects the swash plate position with an accuracy dependent upon the calibration effort done for the application and direction of rotation from the neutral position. At minimum the sensor can be used for forward, neutral and reverse (FNR) detection. The sensor works on the hall-effect technology. The implemented technology is based on a measurement of the magnetic field direction in parallel to the chip surface. This field direction is converted to a voltage signal at the output. Enhanced calibration of the non-linear behavior leads to more exact calculation of the pump swash plate angle. The 4-pin DEUTSCH connector is part of the sensor housing. The swash plate angle sensor is available for all EDC controls for 12 V and 24 V. Swash plate angle vs. output of supply voltage -18° -13° -8° 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Swashplate angle Sensor output, % of supply voltage -3° 0° 2° 7° 12° 17° Strong magnetic fields in the proximity of the sensor can influence the sensor signal and must be avoided. Contact your Danfoss representative in case the angle sensor will be used for safety functions. Swash Plate Angle Sensor Parameters (EDC) Parameter Minimum Typical Maximum Supply voltage range 4.5 VDC 5 VDC 5.5 VDC Supply protection – – 18 VDC Pump neutral output (% of supply voltage) – 50% – Working range (swash plate angle) –18° – 18° Required supply current – – 30 mA Output current signal – 9 mA 11 mA Working temperature –40°C 80°C 115°C Protection Class IP rating IEC 60 529 IP 67 IP rating DIN 40050, part 9 IP 69K with mating connector EMC Immunity (ISO 11452-2) 100 V/m Service Manual MP1 Operation 18 | © Danfoss | April 2019 AX00000244en-000201

software (±0.5°) are vehicle dependent and must consider different conditions, example: system temperature, system pressure and/or shaft speed. For safety function: If the sensor fails (invalid signal <10% or >90% of supply voltage), it must be sure that the ECU will go into a diagnostic mode and shift into limited mode in order for the driver to take the full control or the mechanical breaks should be activated. Strong magnetic fields in the proximity of the sensor can influence the sensor signal and must be avoided. Swash Plate Angle Sensor Connector Connector DEUTSCH, 4-pin 2 3 4 1 Pin assignment: 1. Ground (GND) 2. Not connected 3. Output signal 1 (SIG 1) 4. Supply (V+) Connector order numbers Description Quantity Order number Mating connector DTM06-4S-E004 1 11105824 Wedge lock WM-4S 1 not available Socket contact 0462-201-2031 3 Interface with ECU (EDC) Interface with ECU diagram ECU Supply Signal GND GND OUT VCC 100 nF 20 kΩ 100 nF Manual displacement control MDC principle An MDC is a Manual proportional Displacement Control (MDC). The MDC consists of a handle on top of a rotary input shaft. The shaft provides an eccentric connection to a feedback link. This link is connected on its one end with a porting spool. On its other end the link is connected the pumps swashplate. This design provides a travel feedback without spring. When turning the shaft the spool moves thus providing hydraulic pressure to either side of a double acting servo piston of the pump. Differential pressure across the servo piston rotates the swash plate, changing the pump’s displacement. Simultaneously the swashplate movement is fed back to the control spool providing proportionality between shaft rotation on the control and swashplate rotation. Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 19

some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. A 170 μm screen is located in the supply line immediately before the control porting spool. The MDC is sealed by means of a static O-ring between the actuation system and the control block. Its shaft is sealed by means of a special O-ring which is applied for low friction. The special O-ring is protected from dust, water and aggressive liquids or gases by means of a special lip seal. Manual Displacement Control P301 749 Pump displacement vs. control lever rotation "0" Lever rotation "A" Displacement 100 % a -a 100 % "B" -b -d b c d -c P301 752 MDC schematic diagram P005 701 M14 M5 M4 M3 Where: Deadband on B side – a = 3° ±1° Maximum pump stroke – b = 30° +2/-1° Service Manual MP1 Operation 20 | © Danfoss | April 2019 AX00000244en-000201

Internal end stop – d = 40° MDC torque Torque required to move handle to maximum displacement 1.4 N•m [12.39 lbf•in ] Torque required to hold handle at given displacement 0.6 N•m [5.31 lbf•in] Maximum allowable input torque 20 N•m [177 lbf•in] MDC Operation The MDC provides a mechanical deadband required to overcome the tolerances in the mechanical actuation. The MDC contains an internal end stop to prevent turning the handle into any inappropriate position. The MDC provides a permanent restoring moment appropriate for turning the MDC input shaft back to neutral position only. This is required to take the backlash out of the mechanical connections between the Bowden cable and the control. High case pressure may cause excessive wear and the NSS to indicate that the control is not in neutral position. In addition, if the case pressure exceeds 5 bar there is a risk of an insufficient restoring moment. The MDC is designed for a maximum case pressure of 5 bar and a rated case pressure of 3 bar. • Customers must install some support to limit the setting range of their Bowden cable to avoid an overload of the MDC. • Customers can apply their own handle design but they must care about a robust clamping connection between their handle and the control shaft and avoid overload of the shaft. • Customers can connect two MDC’s on a tandem unit in such a way that the actuation force will be transferred from the pilot control to the second control. The kinematic of the linkages must ensure that either control shaft is protected from torque overload. C Caution Using the internal spring force on the input shaft is not an appropriate way to return the customer connection linkage to neutral, or to force a Bowden cable or a joystick back to neutral position. It is not applicable for any limitation of the Bowden cable stroke, except the applied torque to the shaft will never exceed 20 Nm. MDC Shaft Rotation CCW CW Pump shaft rotation* Clock Wise (CW) Counter Clock Wise (CCW) MDC shaft rotation CW CCW CW CCW Port A in (low) out (high) out (high) in (low) Port B out (high) in (low) in (low) out (high) Servo port high pressure M5 M4 M5 M4 * As seen from shaft side. Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 21

plate response to the application requirements. The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a net function of spool porting, orifices, and charge pressure. H1 pumps are limited in mechanical orifice combinations. Mechanical servo orifices are to be used only for fail-safe return to neutral in a case of an electrical failure. A swash-plate response times table is available for each frame size. Testing should be conducted to verify the proper orifice selection for the desired response. Typical response times at the following conditions: Δ p = 250 bar [3626 psi] Charge pressure = 20 bar [290 psi] Viscosity and temperature = 30 mm²/s [141 SUS] and 50 °C [122 °F] Speed = 1800 min-1 (rpm) MP1 MDC response time Code Orifice description (mm) Stroking direction (sec) P A B Tank (A +B) Neutral to full flow Full flow to neutral 28/32 38/45 28/32 38/45 C3 – – – – 0.3 0.3 0.3 0.3 C6 – – – 1.0 0.5 1.0 0.5 0.7 C7 – – – 1.3 0.4 0.7 0.5 0.5 C8 0.8 – – 0.6 1.5 2.6 1.4 1.9 C9 1.0 – – 0.6 1.3 2.4 1.1 1.8 D1 1.0 – – 0.8 0.9 1.6 0.8 1.1 D2 1.3 – – 0.8 0.8 1.5 0.7 1.1 D3 1.3 – – 1.0 0.6 1.1 0.6 0.8 D4 1.3 1.3 1.3 1.0 0.8 1.3 0.7 0.9 D5 0.6 0.8 0.8 0.6 3.2 4.0 2.0 2.9 Neutral Start Switch (NSS) The Neutral Start Switch (NSS) contains an electrical switch that provides a signal of whether the control is in neutral. The signal in neutral is Normally Closed (NC). Service Manual MP1 Operation 22 | © Danfoss | April 2019 AX00000244en-000201

P005 702 M14 M5 M4 M3 Neutral Start Switch data Max. continuous current with switching 8.4 A Max. continuous current without switching 20 A Max. voltage 36 VDC Electrical protection class IP67 / IP69K with mating connector Case gauge port M14 The drain port should be used when the control is mounted on the unit’s bottom side to flush residual contamination out of the control. MDC w/h drain port shown P400344 Case gauge port M14 Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 23

P005 701 M14 M5 M4 M3 Lever MDC controls are available with optional lever/handle. Align with Settings: Y module in the model code. Standard orientation 90° from input shaft P301 749 Forward-neutral-reverse (FNR) electic control FNR principle The 3-position FNR control uses an electric input signal to switch the pump to a full stroke position. Under some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. A 170 μm screen is located in the supply line immediately before the control porting spool. Service Manual MP1 Operation 24 | © Danfoss | April 2019 AX00000244en-000201

P003 193 FNR hydraulic schematic P003 189 C2 C1 F00A M14 T P F00B Pump displacement vs. electrical signal P003 190E 100 % “0“ 100 % Voltage VDC Displacement Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 25

Pin connections 12 V 750 mA any order 24 V 380 mA DEUTSCH connector, 2-pin 1 2 P003 480 Connector ordering data Description Quantity Ordering data Mating connector 1 DEUTSCH DT06-2S Wedge lock 1 DEUTSCH W2S Socket contact (16 and 18 AWG) 2 DEUTSCH 0462-201-16141 Danfoss mating connector kit 1 K29657 Solenoid data Voltage 12 V 24 V Minimum supply voltage 9.5 VDC 19 VDC Maximum supply voltage (continuous) 14.6 VDC 29 VDC Maximum current 1050 mA 500 mA Nominal coil resistance @ 20 °C [70 °F] 8.4 Ω 34.5 Ω PWM Range 70-200 Hz PWM Frequency (preferred)* 100 Hz IP Rating (IEC 60 529) + DIN 40 050, part 9 IP 67 / IP 69K (part 9 with mating connector) Bi-directional diode cut off voltage 28 VDC 53 VDC * PWM signal required for optimum control performance. Pump output flow direction vs. control signal Shaft rotation CW CCW Coil energized* C1 C2 C1 C2 Port A in out out in Port B out in in out Servo port pressurized M5 M4 M5 M4 * For coil location see Installation Drawings. Control Response H1controls are available with optional control passage orifices to assist in matching the rate of swash- plate response to the application requirements. The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a net function of spool porting, orifices, and charge pressure. Service Manual MP1 Operation 26 | © Danfoss | April 2019 AX00000244en-000201

for fail-safe return to neutral in a case of an electrical failure. A swash-plate response times table is available for each frame size. Testing should be conducted to verify the proper orifice selection for the desired response. Typical response times at the following conditions: Δ p = 250 bar [3626 psi] Charge pressure = 20 bar [290 psi] Viscosity and temperature = 30 mm²/s [141 SUS] and 50 °C [122 °F] Speed = 1800 min-1 (rpm) Response time, FNR Stroking direction 0.8 mm [0.03 in] orifice 1.0 mm [0.04 in] orifice 1.3 mm [0.05 in] orifice No orifice 28/32 38/45 28/32 38/45 28/32 38/45 28/32 38/45 Neutral to full flow 2.1 s 2.6 s 1.1 s 1.6 s 0.8 s 1.1 s 0.7 s 0.7 s Full flow to neutral 1.1 s 1.8 s 0.9 s 1.0 s 0.6 s 0.7 s 0.3 s 0.3 s Non Feedback Proportional Electric Control (NFPE) The Non Feedback Proportional Electric (NFPE) control is an electrical automotive control in which an electrical input signal activates one of two proportional solenoids that port charge pressure to either side of the pump servo cylinder. The NFPE control has no mechanical feedback mechanism. A 170 μm screen is located in the supply line immediately before the control porting spool. Under some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. Non Feedback Proportional Electric Control P003 192 NFPE schematic P003 188 C2 C1 F00A M14 T P F00B Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 27

Control current Voltage a* b c Pin connections 12 V 600 mA 1080 mA 1360 mA any order 24 V 300 mA 540 mA 680 mA * Factory test current, for vehicle movement or application actuation expect higher or lower value. DEUTSCH connector, 2-pin 1 2 P003 480 Connector ordering data Description Quantity Ordering data Mating connector 1 DEUTSCH DT06-2S Wedge lock 1 DEUTSCH W2S Socket contact (16 and 18 AWG) 2 DEUTSCH 0462-201-16141 Danfoss mating connector kit 1 K29657 Description 12 V 24 V Maximum current 1800 mA 920 mA Nominal coil resistance @ 20 °C [68 °F] 3.66 Ω 14.20 Ω @ 80 °C [176 °F] 4.52 Ω 17.52 Ω Inductance 33 mH 140 mH PWM signal frequency Range 70 – 200 Hz Recommended* 100 Hz IP Rating IEC 60 529 IP 67 DIN 40 050, part 9 IP 69K with mating connector Connector color Black * PWM signal required for optimum control performance. Pump output flow direction vs. control signal Shaft rotation CW CCW Coil energized* C1 C2 C1 C2 Port A in out out in Port B out in in out Servo port pressurized M5 M4 M5 M4 * For coil location see Installation drawings. Control Response MP1 controls are available with optional control passage orifices to assist in matching the rate of swashplate response to the application requirements (e.g. in the event of electrical failure). The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a net function of spool porting, orifices, and charge pressure. A swashplate response Service Manual MP1 Operation 28 | © Danfoss | April 2019 AX00000244en-000201

conducted to verify the proper orifice selection for the desired response. Typical response times at the following conditions: ∆p 250 bar [3626 psi] Viscosity and temperature 30 mm2/s [141 SUS] and 50°C [122 °F] Charge pressure 24 bar [348 psi] Speed 1800 min-1 (rpm) Response Time Stroking direction 0.8 mm [0.03] orifice 1.0 mm [0.04] orifice 1.3 mm [0.05] orifice 28/32 38/45 28/45 38/45 28/45 38/45 Neutral to full flow 1.5 s 2.2 s 0.9 s 1.4 s 0.6 s 0.8 s Full flow to neutral 0.9 s 1.1 s 0.6 s 0.7 s 0.4 s 0.5 s Non-Feedback, Proportional Hydraulic (NFPH) Control The Non-Feedback Proportional Hydraulic (NFPH) control is a hydraulic proportional control in which an input pressure signal directly controls the pump servo piston to achieve pump displacement. pumps with NFPH control have a special servo cylinder capable of providing proportional control with a hydraulic input. Swashplate position is proportional to the differential signal pressure at ports X1 and X2, but displacement is also dependent on pump speed and system pressure. This characteristic of non-feedback controls provides a natural power limiting function by reducing the pump swashplate angle as system pressure increases. The accompanying graph shows typical operating characteristics. The system may require tuning through the pump orifice combinations, control pressure supply line sizing, actuation device output pressure and flow adjustments to achieve proper vehicle performance characteristics. Non-feedback proportional hydraulic control schematic M4 M5 L2 X2 X1 Pump Flow Direction with NFPH control Input Shaft Rotation CW CCW High pressure at port: X2 X1 X2 X1 Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 29

Port A flow Out In In Out Port B flow In Out Out In High servo gauge port M4 M5 M4 M5 NFPH pump displacement to Input signal "0" Signal Current mA(DC) a b c a b c Displacement 100 % 100 % NFPE control ∆p = 300 bar ∆p = 300 bar ∆p = 0 bar ∆p = 0 bar P003 187E NFPH input signal pressure (bar) Frame size a b c 28/32 5.5 13.7 17 38/45 5 12.75 16 The values provided in the table above are approximations at 1800 RPM and system delta pressures as indicated in the graph provided. The values are dependent on input speed and delta pressure operating conditions. Control Response MP1 controls are available with optional control passage orifices to assist in matching the rate of swashplate response to the application requirements (e.g. in the event of electrical failure). The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a net function of spool porting, orifices, and charge pressure. A swashplate response table is available for each frame indicating available swashplate response times. Testing should be conducted to verify the proper orifice selection for the desired response. Typical response times at the following conditions: ∆p 250 bar [3626 psi] Viscosity and temperature 30 mm2/s [141 SUS] and 50°C [122 °F] Charge pressure 24 bar [348 psi] Speed 1800 min-1 (rpm) Service Manual MP1 Operation 30 | © Danfoss | April 2019 AX00000244en-000201

1.0 mm [0.04] orifice 1.3 mm [0.05] orifice 28/32 38/45 28/45 38/45 28/45 38/45 Neutral to full flow 1.5 s 2.2 s 0.9 s 1.4 s 0.6 s 0.8 s Full flow to neutral 0.9 s 1.1 s 0.6 s 0.7 s 0.4 s 0.5 s Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 31

The pump offers an optional control cut off valve integrated into the control. This valve will block charge pressure to the control, allowing the servo springs to de-stroke the pump regardless of the pump´s primary control input. There is also a hydraulic logic port, X7, which can be used to control other machine functions, such as spring applied pressure release brakes. The pressure at X7 is controlled by the control cut off solenoid. The X7 port would remain plugged if not needed. In the normal (de-energized) state of the solenoid charge flow is prevented from reaching the controls. At the same time the control passages and the X7 logic port are connected and drained to the pump case. The pump will remain in neutral, or return to neutral, independent of the control input signal. Return to neutral time will be dependent on oil viscosity, pump speed, swashplate angle, and system pressure. When the solenoid is energized, charge flow and pressure is allowed to reach the pump control. The X7 logic port will also be connected to charge pressure and flow. The solenoid control is intended to be independent of the primary pump control making the control cut off an override control feature. It is however recommended that the control logic of the CCO valve be maintained such that the primary pump control signal is also disabled whenever the CCO valve is de- energized. Other control logic conditions may also be considered. All EDC and MDC controls are available with a CCO valve. The response time of the unit depends on the control type and the control orifices used. The CCO-valve is available with 12 V or 24 V solenoid. EDC with CCO Control Hydraulic logic Port X7 P400346 Schematic X7 M14 C2 C1 P400349 Service Manual MP1 Operation 32 | © Danfoss | April 2019 AX00000244en-000201

Control X7 Schematic P005 703 M14 M5 M4 M3 X7 1 2 CCO Solenoid Data Nominal supply voltage 12 V 24 V Supply voltage Maximum 14.6 V 29 V Minimum 9.5 V 19 V Nominal coil resistance at 20°C 10.7 Ω 41.7 Ω Supply current Maximum 850 mA 430 mA Minimum 580 mA 300 mA PWM frequency Range 50-200 Hz 50-200 Hz Preferred 100 Hz 100 Hz Electrical protection class IP67 / IP69K with mating connector Bi-directional diode cut off voltage 28 V 53 V Service Manual MP1 Operation © Danfoss | April 2019 AX00000244en-000201 | 33

consideration of a wide range of environmental temperature common for known hydraulic applications. Closed loop PWM current supply can be also applied and is helpful in case that the voltage range is exceeded, or ambient temperature could rise in an unusual manner. Brake gauge port with MDC C Caution It is not recommended to use brake port for any external flow consumption to avoid malfunction of CCO function. Displacement limiter All pumps are designed with optional mechanical displacement (stroke) limiters factory set to max. displacement. The maximum displacement of the pump can be set independently for forward and reverse using the two adjustment screws to mechanically limit the travel of the servo piston. Adjustment procedures are found in the Service Manual. Adjustments under operating conditions may cause leakage. The adjustment screw can be completely removed from the threaded bore if backed out to far. Displacement limiter Servo piston Displacement limiter Servo cylinder P400347 Displacement change (approximate) Parameter 28 32 38 45 1 Turn of displacement limiter screw 2.9 cm3 [0.18 in3] 3.3 cm3 [0.20 in3] 3.56 cm3 [0.22 in3] 4.22 cm3 [0.26 in3] Internal wrench size 4 mm External wrench size 13 mm Torque for external hex seal lock nut 23 N•m [204 lbf•in] Service Manual MP1 Operation 34 | © Danfoss | April 2019 AX00000244en-000201

minimum speed limits pump’s ability to maintain adequate flow for lubrication and power transmission. Rated speed is the highest input speed recommended at full power condition. Operating at or below this speed should yield satisfactory product life. Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed limit under any operating conditions. Operating conditions between Rated speed and Maximum speed should be restricted to less than full power and to limited periods of time. For most drive systems, maximum unit speed occurs during downhill braking or negative power conditions. During hydraulic braking and downhill conditions, the prime mover must be capable of providing sufficient braking torque in order to avoid pump over speed. This is especially important to consider for turbocharged and Tier 4 engines. W Warning Unintended vehicle or machine movement hazard. Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss. System Pressure System pressure is the differential pressure between system ports A and B. It is the dominant operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted average, pressure that can only be determined from a duty cycle analysis. Application pressure is the high pressure relief setting normally defined within the order code of the pump. This is the applied system pressure at which the driveline generates the maximum calculated pull or torque in the application. Maximum working pressure is the highest recommended Application pressure. Maximum working pressure is not intended to be a continuous pressure. Propel systems with Application pressures at, or below, this pressure should yield satisfactory unit life given proper component sizing. Maximum pressure is the highest allowable Application pressure under any circumstance. Application pressures above Maximum Working Pressure will only be considered with duty cycle analysis and factory approval. Pressure spikes are normal and must be considered when reviewing maximum working pressure. All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop pressure from gauge readings to compute the differential. Minimum low loop pressure (above case pressure) is the lowest pressure allowed to maintain a safe working condition in the low side of the loop. Service Manual MP1 Operating parameters © Danfoss | April 2019 AX00000244en-000201 | 35

in the low side of the transmission loop. The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the pump in neutral, operating at 1800 min-1 [rpm], and with a fluid viscosity of 32 mm2/s [150 SUS]. Pumps configured with no charge pump (external charge supply) are set with a charge flow of 15.0 l/min [4.0 US gal/min] and a fluid viscosity of 32 mm2/s [150 SUS]. The charge pressure setting is referenced to case pressure. Charge Pump Inlet Pressure At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure (vacuum). Minimum charge inlet pressure is only allowed at cold start conditions. In some applications it is recommended to warm up the fluid (e.g. in the tank) before starting the engine and then run the engine at limited speed until the fluid warms up. Maximum charge pump inlet pressure may be applied continuously. Case Pressure Under normal operating conditions, the rated case pressure must not be exceeded. During cold start case pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly. C Caution Possible component damage or leakage Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings, causing external leakage. Performance may also be affected since charge and system pressure are additive to case pressure. Temperature The high temperature limits apply at the hottest point in the transmission, which is normally the motor case drain. The system should generally be run at or below the rated temperature. The maximum intermittent temperature is based on material properties and should never be exceeded. Cold oil will not affect the durability of the transmission components, but it may affect the ability of oil to flow and transmit power; therefore temperatures should remain 16 °C [30 °F] above the pour point of the hydraulic fluid. The minimum temperature relates to the physical properties of component materials. Size heat exchangers to keep the fluid within these limits. Danfoss recommends testing to verify that these temperature limits are not exceeded. Ensure fluid temperature and viscosity limits are concurrently satisfied. Service Manual MP1 Operating parameters 36 | © Danfoss | April 2019 AX00000244en-000201

recommended range. The minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation. The maximum viscosity should be encountered only at cold start. Service Manual MP1 Operating parameters © Danfoss | April 2019 AX00000244en-000201 | 37

filter capable of controlling the fluid cleanliness to ISO 4406, class 22/18/13 (SAE J1165) or better, under normal operating conditions, is recommended.These cleanliness levels cannot be applied for hydraulic fluid residing in the component housing/case or any other cavity after transport. Filtration strategies include suction or pressure filtration. The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. Filters are selected to meet the above requirements using rating parameters of efficiency and capacity. Filter efficiency can be measured with a Beta ratio (βX). For simple suction-filtered closed circuit transmissions and open circuit transmissions with return line filtration, a filter with a β-ratio within the range of β35-45 = 75 (β10 ≥ 2) or better has been found to be satisfactory. For some open circuit systems, and closed circuits with cylinders being supplied from the same reservoir, a higher filter efficiency is recommended. This also applies to systems with gears or clutches using a common reservoir. For these systems, a charge pressure or return filtration system with a filter β-ratio in the range of β15-20 = 75 (β10 ≥ 10) or better is typically required. Because each system is unique, only a thorough testing and evaluation program can fully validate the filtration system. Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information, 520L0467 for more information. Cleanliness level and βx-ratio1 Filtration (recommended minimum) Cleanliness per ISO 4406 22/18/13 Efficiency (charge pressure filtration) β-ratio β15-20 = 75 (β10 ≥ 10) Efficiency (suction and return line filtration) β35-45 = 75 (β10 ≥ 2) Recommended inlet screen mesh size µm 100 – 125 1 Filter βx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given diameter (“x” in microns) upstream of the filter to the number of these particles downstream of the filter. Service Manual MP1 Fluid and filter maintenance 38 | © Danfoss | April 2019 AX00000244en-000201

The following table and drawing show the port locations and gauge sizes needed. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges. Port description Port Pressure obtained Gauge Size Inch/Metric Size Port Wrench size AM3 Alternative Charge Gauge 50 bar [1000 psi] inch 9/16-18 1/4 internal hex metric M14x1.5 6 mm E/F Filtration Inlet/Outlet inch 9/16-18 1/4 internal hex metric M14x1.5 6 mm L1/L2 Case Drain 10 bar [100 psi] inch 1 1/16-12 9/16 internal hex metric M27x2 12 mm MA/MB (28/32) System Gauge 600 bar [10,000 psi] inch 9/16-18 11/16 inch metric M14x1.5 19 mm MA/MB (38/45) System Gauge 600 bar [10,000 psi] inch ¾-16 7/8 inch metric M18x1.5 24 mm M3 Charge Gauge 50 bar [1000 psi] inch 9/16-18 1/4 internal hex metric M14x1.5 6 mm M4/M5 (28/32) Servo Gauge 50 bar [1000 psi] inch 7/16-20 3/16 internal hex metric M12x1.5 6 mm M4/M5 (38/45) Servo Gauge 50 bar [1000 psi] inch 9/16-18 1/4 internal hex metric M14x1.5 6 mm M14 Case drain 10 bar [100 psi] inch 7/16-20 1/4 internal hex metric M12x1.5 6 mm internal hex S Charge Pump Inlet - inch 1 1/16-12 9/16 internal hex metric M27x2 12 mm internal hex Service Manual MP1 Pressures measurements © Danfoss | April 2019 AX00000244en-000201 | 39

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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. 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 damage that may have occurred during shipping. MP1 start-up procedure 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. Prior to installing the pump on a machine, inspect for damage and ensure pump has been thoroughly tested on a test stand before installing on a machine. Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Ensure the machine is secured or disable/disconnect the mechanism while servicing. 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. If the control is installed on top, open the construction plug in the top of the control to assist in air bleed. 5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler filter. Fill inlet line from reservoir to pump. Ensure construction plug in control is closed after filling. 6. Disconnect the pump from all control input signals. 7. Close construction plug removed in step 4. C Caution After start-up the fluid level in the reservoir may drop due to system components filling. Damage to hydraulic components may occur if the fluid supply runs out. Ensure reservoir remains full of fluid during start-up. Air entrapment in oil under high pressure may damage hydraulic components. Check carefully for inlet line leaks. Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered. 8. Use a common method to disable the engine to prevent it from starting. Crank the starter for several seconds. Do not 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. 9. When the gauge begins to register charge pressure, 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. 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. Service Manual MP1 Initial startup procedure © Danfoss | April 2019 AX00000244en-000201 | 41

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. The pump is now ready for operation. Service Manual MP1 Initial startup procedure 42 | © Danfoss | April 2019 AX00000244en-000201

steps listed until you solve the problem. Some of the items are system specific. We reference the section in this manual of more information is available. Always observe the safety precautions listed in the Introduction section and any precautions related to your specific equipment. Safety precautions C Caution High inlet vacuum causes cavitation which can damage internal pump components. W Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. Relieve pressure in the system before removing hoses, fittings, gauges, or components. 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. 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 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. Electrical troubleshooting Item Description Action Control operates pump in one direction only Control coil failure Measure resistance at coil pins. 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 Service Manual MP1 Troubleshooting © Danfoss | April 2019 AX00000244en-000201 | 43

Item Description Action Oil level in reservoir. Insufficient hydraulic fluid will not meet cooling demands of system. Fill reservoir to proper level. Heat exchanger. Heat exchanger is not sufficiently cooling the system. Check air flow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger. Charge pressure. Low charge pressure will overwork system. Measure charge pressure. Inspect and adjust or replace charge relief valve. Inspect charge pump. Repair or replace charge pump. Charge pump inlet vacuum. High inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow. Check charge inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions. System relief pressure settings If the system relief valves are worn, contaminated, or valve settings are too low, the relief valves will be overworked. Verify settings of high pressure relief valves and replace valves as necessary. System pressure. Frequent or long term operation over system relief setting will create heat in system. Measure system pressure. If pressure is too high, reduce loads. Transmission Operates Normally in One Direction Only Item Description Action Open bypass valves. Open bypass causes one or both directions to be inoperative. Close/repair bypass function. Input to pump control. Input to control module is operating improperly. Check control input and repair or replace as necessary. Control orifices Control orifice(s) are blocked. Clean control orifices. High pressure relief valves (HPRV) Malfunctioning HPRV can affect one direction while the other functions normally. Exchange HPRVs. If the problem changes direction, replace the valve that does not operate correctly. Remember to return HPRVs to their original position afterward. Settings may be different for forward/reverse. Servo pressure Servo pressure low or decaying. Check for torn/missing servo seals. Replace and retest. Refer to AX00000303 MP1 Repair Instructions for seal locations. Only a Danfoss Global Service Partner may remove the servo piston without voiding the warranty. System Does Not Operate in Either Direction Item Description Action Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level. Pump control orifices Control orifices are blocked. Clean control orifices. Open bypass valve If bypass valves are open, the system loop becomes depressurized. Close bypass valves. Replace high pressure relief valve if defective. Charge pressure with pump in neutral Low charge pressure insufficient to recharge system loop Measure charge pressure with the pump in neutral. If pressure is low, go to next step. Pump charge relief valve A pump charge relief valve that is leaky, or contaminated, or set too low depressurizes the system. Adjust or replace pump charge relief valve as necessary. Charge pressure with pump in stroke Low charge pressure, resulting from elevated loop leakage, is insufficient control pressure to hold pump in stroke. Isolate pump from motor. With pump in partial stroke and engaged for only a few seconds, check pump charge pressure. Low charge pressure indicates a malfunctioning pump. Good charge pressure indicates a malfunctioning motor or other system component. Check motor charge relief operation (if present). Charge pump inlet filter A clogged filter under supplies system loop. Inspect filter and replace if necessary. Charge pump A malfunctioning charge pump provides insufficient charge flow. Repair or replace the charge pump. Service Manual MP1 Troubleshooting 44 | © Danfoss | April 2019 AX00000244en-000201

move load. Measure system pressure. Continue to next step. System relief valves Defective high pressure relief valves cause slow system pressure. Repair or replace high pressure relief valves. Input to control Input is operating improperly. Repair/replace control. 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. Air in system is indicated by excessive noise in pump, foaming in oil, and hot oil. 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 If oil is under cold conditions, it may be too viscous for proper function and 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 will cause 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. Neutral Difficult or Impossible to Find Item Description Action Input to pump control Input to control module is operating improperly. Disconnect input and check to see if pump comes back to neutral. If Yes, input fault, replace/repair external controller. If No, go to next step. Pump control neutral Neutral set improperly. Shunt servo gauge ports M4 and M5 together with external hose and see if pump comes back to neutral. If Yes: control neutral improperly set. If no: balance theswashplate (see Mechanical/hydraulic neutral adjustment). If you still cannot set neutral, replace the control. Sluggish System Response Item Description Action Oil level in reservoir Low oil level causes sluggish response. Fill reservoir. High pressure relief valves/ pressure limiter settings Incorrect pressure settings affects system reaction time. Adjust or replace high pressure relief valves. Low prime mover speed Low engine speed reduces system performance Adjust engine speed. Charge pressure Incorrect pressure affects system performance Measure and adjust charge pressure relief or replace charge pump. Air in system Air in system produces sluggish system response Fill tank to proper level. Cycle system slowly for several minutes to remove air from system. Contaminated control orifices Control orifices are plugged. Clean control orifices. Pump inlet vacuum Inlet vacuum is too high resulting in reduced system pressure. Measure charge inlet vacuum. Inspect line for proper sizing. Replace filter. Confirm proper bypass operation. Service Manual MP1 Troubleshooting © Danfoss | April 2019 AX00000244en-000201 | 45

entire topic before beginning a service activity. Refer to Pressure measurements, for location of gauge ports and suggested gauge size. Standard Procedures C Caution Contamination can damage internal components and void your warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines 1. With the prime mover off, thoroughly clean the outside of the pump. 2. If removing the pump, tag each hydraulic line. When you disconnect hydraulic lines, cap them and plug each open port to prevent contamination. 3. Ensure the surrounding area is clean and free of contaminants like dirt and grime. 4. Inspect the system for contamination. 5. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil, sludge, or metal particles. 6. If there are signs of contamination in the hydraulic fluid, replace all filters and drain the hydraulic system. Flush the lines and refill the reservoir with the correct filtered hydraulic fluid. 7. Before re-installing the pump, test for leaks. Charge Pressure Relief Valve This procedure explains how to check and adjust the charge pressure relief valve. Refer to model code located on serial number plate for charge relief setting. 1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3. Install a 10 bar [100 psi] gauge at case pressure port L1, L2. Operate the system with the pump in neutral (zero displacement) when measuring charge pressure. Listed pressures assume a pump speed of 1800 min-1 (rpm) and charge flow of 26.5 l/min [7 US gal/ min]. At higher pump speeds or higher charge flows the charge pressure will rise over the rated setting. Service Manual MP1 Adjustments 46 | © Danfoss | April 2019 AX00000244en-000201

3. Remove the gauges and plug the open ports. Displacement Limiter If your pump has displacement limiters, you will find them on either servo cover. You can limit forward and reverse displacement independently. C Caution Before adjusting the displacement limiter, mark the position of the servo cylinder. Be sure the servo cylinder does not turn when setting the displacement limiter locknut. 1. Loosen the lockingnut. 2. Rotate the adjusting screw to achieve the desired displacement. 3. After establishing the desired maximum displacement setting, hold the adjusting screw while torquing the locknut to the value shown. P108965 Locknut Adjusting screw Service Manual MP1 Adjustments © Danfoss | April 2019 AX00000244en-000201 | 47

Displacement Locknut wrench size and torque Adjusting screw size Approximate displacement change per revolution of adjusting screw 28 13 mm 23 N•m [17 lbf•ft] 4 mm internal hex 2.9 cm3 [0.18 in3] 32 13 mm 23 N•m [17 lbf•ft] 4 mm internal hex 3.3 cm3 [0.20 in3] 38 13 mm 23 N•m [17 lbf•ft] 4 mm internal hex 3.56 cm3 [0.22 in3] 45 13 mm 23 N•m [17 lbf•ft] 4 mm internal hex 4.22 cm3 [0.26 in3] Control Neutral Adjustment All functions of the control are preset at the factory. Adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to replace the control or coils. See Minor repair for details. 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. 1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5). Disconnect the external control input (electrical/hydraulic connections) from the control. Start the prime mover and operate at normal speed. 2. Use a 4mm internal hex wrench to hold the neutral adjusting screw stationary while loosening the locknut with a 13mm wrench. 3. Observe pressure gauges. If necessary, turn adjusting screw to reduce any pressure differential. A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Achieving zero differential is usually not possible. Adjustment of the EDC is very sensitive. Be sure to hold the hex wrench steady while loosening the locknut. Total adjustment is less than 120 degrees. Control adjustment P109037 Locknut Adjusting screw Servo gauge port M4 Servo gauge port M5 4. Rotate the neutral adjusting screw clockwise until the pressure increases on the gauge. Note the angular position of the wrench. Then rotate the neutral adjusting screw counter clockwise until the Service Manual MP1 Adjustments 48 | © Danfoss | April 2019 AX00000244en-000201

wrench. The illustration shows how the cam on the adjusting pin rotates to adjust for neutral position after the pump is re-installed. Neutral adjustment (EDC bottom view) P109514 1 5 6 2 4 3 1. Control spool 2. Adjusting screw (cam) 3. Feedback pin 4. Maximum adjustment less than 120 deg. 5. Adjusting screw 6. Lock nut 5. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted above. The gauges should read the same pressure, indicating that the control is in its neutral position. 6. Hold the neutral adjusting screw stationary and tighten the lock nut. Torque to 10 Nm [7 lbf•ft]. Do not over torque the nut. 7. When the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control input. A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Achieving zero differential is usually not possible. Mechanical/Hydraulic Neutral Adjustment Servo Adjustment 1. Run prime mover at 1800 min-1(rpm). 2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges. Ensure the differential between M4 and M5 is less than 1.5 bar [22 psi]. Service Manual MP1 Adjustments © Danfoss | April 2019 AX00000244en-000201 | 49

the servo cylinders have no contact with the servo piston. 4. Stroke the pump by turning the adjusting screw (or supplying current to solenoid C1) until the servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than at port M5 and the system pressure gauges indicate displacement. Pressure should be greater at port MA for clockwise rotation, or MB for counter clockwise rotation. This also indicates the servo piston is in contact with the servo cylinder on side M5. A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Achieving zero differential is usually not possible. 5. Slowly thread the servo cylinder on the M5 side in until the system pressure differential starts to decrease. Maintain servo pressure differential between 1-2 bar [14-29 psi] during this step. Continue turning the servo cylinder in until the system pressure differential (between ports MA/MB) is less than 1.5 bar [22 psi]. This procedure sets the servo and swashplate to mechanical neutral on the M5 side. 6. To complete setting neutral, repeat steps 1-5 but stroke the pump in the opposite direction by turning the adjusting screw in the opposite direction, or by supplying current/hydraulic pressure to solenoid C2. Reverse gauge locations (M4 for M5, MB for MA) from those stated above since the pump is now stroking the other direction. 7. Remove all gauges and replace gauge port plugs. Servo adjustment P108967 Servo cylinder locking bolt Servo cylinder locking plate Verify neutral setting 1. If using a PWM signal to set mechanical neutral, check that servo pressure differential is less than 1.5 bar [22 psi]. Refer to TS-422 or Control neutral adjustment. 2. To verify mechanical neutral, provide current to solenoid C1, or turn neutral adjusting screw, until the servo pressure differential is 3 bar [43 psi]. The system pressure differential must be below 1.5 bar [22 psi]. Repeat test on solenoid C2 side. 3. The current required to set the servo pressure differential to 3 bar [43 psi] should be the same for each solenoid. Refer to TS-422. 4. If using neutral adjusting screw to set mechanical neutral, reset control neutral. Servo Adjustment Side M4 1. Run prime mover at 1800 rpm. 2. If using a PWM signal to set mechanical neutral, start with the electronic control testing tool off (no current/hydraulic pressure to either solenoid). Check to be sure the servo pressure differential is less Service Manual MP1 Adjustments 50 | © Danfoss | April 2019 AX00000244en-000201

instructions. 3. Turn neutral adjusting screw (or supply current/hydraulic pressure to solenoid C2) until the servo pressure at port M5 is less than 1.5 bar [22 psi] greater than at port M4. 4. The system pressure differential must be greater than zero and the pressure at port A (B for clockwise rotation) must be greater than the pressure at port B (A for clockwise rotation). This step ensures the servo is in contact with the servo cylinder on side M4. 5. Slowly turn in the servo cylinder on the M4 side until the system pressure differential starts to decrease. The servo pressure differential must be less than 1.5 bar [22 psi] during this step. Continue turning in the servo cylinder until the system pressure differential is less than 1.5 bar [22 psi]. This procedure sets the servo and swashplate to mechanical neutral. Service Manual MP1 Adjustments © Danfoss | April 2019 AX00000244en-000201 | 51

Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached, remove both pumps as a single unit. Tag and cap all hydraulic lines as they are disconnected, and plug all open ports to ensure that dirt and contamination do not get into the system. Contamination can damage internal components and void the manufacturer's warranty. Take precautions to ensure system cleanliness when removing and installing system lines. 1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump. 2. Tag, disconnect, and cap 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. 3. Remove the pump and its auxiliary pump (if applicable) as a single unit. Be careful, do not damage solenoids and electrical connections when using straps or chains to support the pump. 4. Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and grime. 5. Inspect the system for contamination. 6. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge, or metal particles. 7. Before replacing the pump, replace all filters and drain the hydraulic system. Flush the system lines and fill the reservoir with the correct, filtered hydraulic fluid. 8. Fill the pump with clean, filtered hydraulic fluid. 9. Attach the pump to the prime mover. Torque mounting screws according to the manufacturers recommendation. 10. Replace all hydraulic lines. Ensure the charge inlet line is filled with fluid. EDC Control MP1 EDC control removal Follow the instructions for safe removal of the EDC control. 1. Using a 5 mm internal hex wrench, remove the six cap screws (D250). 2. Remove the control module and gasket (D150). Discard the gasket. 3. If necessary, remove orifices (F00A and F00B) using a 3 mm internal hex wrench. Tag and number them for re-installation. If dowel pins (D300) are removed, ensure they are replaced before re-installing the control. Service Manual MP1 Minor repair 52 | © Danfoss | April 2019 AX00000244en-000201

D150 D250 D300 (2x) F00B F00A Item Description Wrench size Torque D150 Control gasket - - D300 Dowel pins - - D250 Cap screw 5 mm internal hex 13 Nm [9.8 lbf•ft] F00B Servo orifice 3 mm internal hex 7.9 Nm [5.8 lbf•ft] F00A Servo orifice 3 mm internal hex 7.9 Nm [5.8 lbf•ft] Controls inspection Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component. MP1 EDC control assembly Ensure you install dowel pins (D300) in the housing before installing the control. 1. Install a new gasket (D150). 2. Install dowel pins (D300) in the housing. W Warning If the feedback pin comes off during operation, the pump will lose control and cause a potentially hazardous situation. Ensure feedback pin is properly torqued before continuing with reassembly. Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 53

Torque sequence 2 3 4 5 6 1 4. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 Nm [9.8 lbf ft]. MP1 control solenoids/actuator housing replacement 1. Disconnect electrical/hydraulic connection and remove the three cap screws (D050) using a 4 mm internal hex wrench. 2. Remove the solenoid/actuator housing (D025/QD77) and O-ring (D025A/QD26). Discard the O-ring. Individual coils may be replaced. Use a 12 point 26 mm socket. Torque the coil nut to 5 N•m [3.7 lbf•ft]. 3. Inspect the machined surface on the control. If you find any nicks or scratches, replace the component. 4. Lubricate new O-ring (D025A/QD26) using petroleum jelly and install. 5. Install solenoid/actuator housing with three cap screws (D050) using a 4 mm internal hex wrench. Torque screws to 5 N•m [4 lbf•ft]. 6. Reconnect electrical/hydraulic connections and test the pump for proper operation. MP1 control solenoid identification Control solenoid removal D025A D050 (3X) D025 D025A D050 (3X) D025 EDC Service Manual MP1 Minor repair 54 | © Danfoss | April 2019 AX00000244en-000201

Item Description Wrench size Torque D025 Solenoid - - D025A O-ring - - D050 Cap screw 4 mm internal hex 5 Nm [4 lbf•ft] QD26 O-ring - - QD77 Actuator housing - - QD72 Actuator pin - - MDC Control MP1 MDC control removal Follow the steps to safely remove the MDC control. 1. Use a 5 mm internal hex wrench to remove the six cap screws (D250). 2. Remove the control module and gasket (D150) and discard the gasket. 3. Optional: If necessary, remove servo orifices (F00A, F00B), supply orifice (F00P), and tank orifices (F00T) using a 3 mm internal hex wrench. It is recommended to tag the orifices for an easier re-installation process. The functionality of the control and the neutral position of the pump may be lost if the control is disassembled. Do not disassemble the control module. Before removing the control, note the position of the control lever for reassembly. Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 55

MDC with neutral start switch MDC with neutral start switch and CCO QD75 D065 D250 QD81 QD70 QD75 D065 D250 QD81 QD70 D250 D065 QD75 QD751 QD751 MDC Legend Wrench size and torque Item Description Wrench size Torque D065 O-ring plug 3/16 internal hex 12 N•m [9 lbf•ft] D200 feedback pin 5 mm internal hex 13.3 Nm [9.8 lbf•ft] D250 cap screw 5 mm internal hex 13.3 Nm [9.8 lbf•ft] QD70 solenoid - - QD81 O-ring - - QD75 neutral start switch assembly - - QD751 O-ring - - QD73 plug 3/4 inch F00A servo orifice 7/16 inch hex 7.9 Nm [5.8 lbf•ft] F00B servo orifice 7/16 inch hex 7.9 Nm [5.8 lbf•ft] F00P supply orifice 1/4 inch hex 14 Nm [10.8 lbf•ft] F00T tank orifice 3 mm internal hex 2.5 Nm [1.8 lbf•ft] Y020 cap screw 5 mm internal hex 13.3 Nm [9.8 lbf•ft] Service Manual MP1 Minor repair 56 | © Danfoss | April 2019 AX00000244en-000201

replace the component. MDC Control Assembly Ensure you install dowel pins (D300) in housing before installing control. The pump will lose control, causing a potentially hazardous situation. If a feedback pin comes off during operation, ensure the feedback pin is properly torqued before continuing with reassembly. 1. Install a new gasket (D150). 2. If previously removed, install orifices using a 3 mm internal hex wrench and torque to 2.5 N•m [1.8 lbf•ft]. 3. Install the control module and six cap screws (D250). 4. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft]. Torque sequence 2 3 4 5 6 1 Charge Pump If the pump has an auxiliary pump attached, remove the auxiliary pump and connecting shaft before removing the auxiliary pad. MP1 charge pump removal 1. Position pump so end cover or auxiliary pad (K100) is on top. 2. Remove end cover/auxiliary pad screws (K300) using an 8 mm internal hex wrench. 3. Remove and discard O-ring (K200). 4. Remove coupling (K500). Use a small hook if necessary. 5. Remove the charge pump (K400). Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 57

Charge pump removal (38/45 shown) P108949 K100 K300 K500 K400 K200 Identification and torque Item Wrench size Torque Screw (K300) 8 mm internal hex 111 N•m [81.9 lbf•ft] MP1 charge pump inspection Inspect the components for wear, scratches or pitting. Scratches on these components will cause a loss of charge pressure. If any component shows signs of wear, scratching or pitting, replace it. MP1 charge pump assembly 1. Lubricate and install charge pump (K400). 2. Install coupling (K500). 3. Lubricate and install a new O-ring (K200). 4. Install cover/aux pad (K100). 5. Install screws (K300). Torque screws per table. High Pressure Releif Valve (HPRV) Service Manual MP1 Minor repair 58 | © Danfoss | April 2019 AX00000244en-000201

Follow these steps to safely remove the high pressure relief valves. 1. Using a 5/16 inch internal hex, remove the HPRV's (N100/M100). 2. Remove and discard the O-rings (M023) and backup rings (M022). MP1 HPRV torque information HPRV valves removal P108950 N100 M022 M023 M100 M022 M023 N100 M022 M023 M100 M022 M023 38/45 28/32 Identification and torque Item Wrench size Torque HPRV Valve (N100/M100) 5/16 inch internal hex 81.0 N•m [59.7 lbf•ft] HPRV valve inspection Inspect the sealing surfaces in the pump for nicks or scratches. Check the high pressure relief valves for damage. Replace any damaged components. HPRV Valve Reassembly 1. Lubricate and install new O-rings (M022) and backup rings (M023). 2. Install the HPRV valves. Torque to the value shown in the table. 3. Operate the vehicle/machine through its full range of control to ensure proper operation. Check for leaks. Charge Pressure Relief Valve (CPRV) MP1 CPRV removal Follow these steps to safely remove the charge pressure relief valves. 1. Using a 1 inch wrench, remove the charge pressure relief valve (V100). 2. Remove and discard O-ring (QV110). 3. Use a small hook or magnet to remove washer(s) (V200), spring (V300), and seat (V400). Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 59

CPRV valve removal (38/45 shown) V100 QV110 V200 V300 V400 P108951 Identification and torque Item Wrench size Torque CPRV Valve (V100) 1 inch 78.6 N•m [58.0 lbf•ft] CPRV inspection Inspect washer, spring, and seat. Replace charge pressure relief valve if damage is found. Inspect the sealing surfaces of the pump for nicks or scratches. MP1 CPRV assembly 1. Install seat (V400), spring (V300), and washer (V200) into the housing. 2. Install new O-ring (QV110) onto the valve nut (V100). 3. Install valve nut in housing. Torque per table. Service Manual MP1 Minor repair 60 | © Danfoss | April 2019 AX00000244en-000201

1. Using an 11/16 inch wrench, remove plug (L150). 2. Using a ¼ inch internal hex, remove plug (G115). 3. Remove and discard O-ring (9Q50A). 4. Remove loop flushing spool (L100) 5. Using a 3 mm internal hex, remove orifice (L200). MP1 loop flushing torque information Loop flushing removal L150 L100 L200 G115 P109066 9Q50A Identification and torque Item Wrench size Torque Plug (L150) 11/16 inch 45 N•m [33 lbf•ft] Orifice (L200) 3 mm internal hex 2.5 N•m [1.8 lbf•ft] Plug (G115) 1/4 inch 40 N•m [30 lbf•ft] Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 61

Inspect loop flushing spool and spring. If damage or wear is found, replace spool and spring. P109067 Reassembly 1. Lubricate and install loop flushing spool (L100). 2. Lubricate and install new O-ring (9Q50A). 3. Using a 11/16 inch wrench, torque plug (L150) to 45 N•m [33 lbf•ft]. 4. Using a 3 mm internal hex, torque orifice (L200) to 2.5 N•m [1.8 lbf•ft]. 5. Using a ¼ inch internal hex, torque plug (G115) to 40 N•m [30 lbf•ft]. Shaft Removal The shaft assembly is serviceable without disassembling the pump. 1. Position the pump with the shaft pointing up. 2. Remove the first spring clip (J300). 3. Carefully remove and discard the shaft seal (J250) C Caution Do not damage the housing bore, shaft or bearing when removing the shaft and shaft seal. 4. Remove the second spring clip (J300). 5. Pull the shaft and bearing out of the housing. 6. Remove the retaining ring (J200). Press the bearing (J150) off the shaft (J100). Shaft removal (38/45 shown) P109063 J200 J300 J300 J150 J100 J150 J250 Service Manual MP1 Minor repair 62 | © Danfoss | April 2019 AX00000244en-000201

damaged. Rotate the bearing, if it does not rotate smoothly, replace it. Shaft Reassembly 1. Press the bearing (J150) onto the shaft (J100) and replace the retaining ring (J200). 2. Install the shaft/bearing assembly into the pump. 3. Install first spring clip (J300). 4. Cover the shaft with a protective sleeve while installing the seal. Lubricate and install the seal. 5. Install the second spring clip (J300). Service Manual MP1 Minor repair © Danfoss | April 2019 AX00000244en-000201 | 63

G060 G020 G025 G065 G070 G075 G010 G030 G040 G035 K300 D250 G045 G015 E085 E090 N100 M100 V100 H130 H130 H130 G060 G010 G020 G015 G025 G070 G075 G010 G035 G030 G040 G065 38/45 28/32 Service Manual MP1 Fastener size and torque chart 64 | © Danfoss | April 2019 AX00000244en-000201

5 mm internal hex 13 N•m [10 lbf•ft] E085 Displacement limiter screw 4 mm internal hex NA E090 Displacement limiter sealnut 13 mm 23 N•m [17 lbf•ft] H130 Front cover bolt 8 mm internal hex 28/32 cc - 50 N•m [37 lbf•ft] 38/45 cc - 64 N•m [47 lbf•ft] K300 Rear cover/aux pad mounting bolt 8 mm internal hex 111 N•m [82 lbf•ft] MP1 plug size and torque Item O-ring plug Wrench size Torque G010/G035 Charge pressure gauge 6 mm or 1/4 inch internal hex 40 N•m [29.5 Ft-lbs] for 9/16 35.3 N•m [26 Ft-lbs] for M14 G030/G040 Filtration inlet/outlet 6 mm or 1/4 inch internal hex 40 N•m [29.5 Ft-lbs] for 9/16 35.3 N•m [26 Ft-lbs] for M14 G020/G025 Servo gauge (28/32) 6 mm or 3/16 inch internal hex 25 N•m [18.4 Ft-lbs] for 7/16 25 N•m [18.4 Ft-lbs] for M12 G020/G025 Servo gauge (38/45) 6 mm or 1/4 inch internal hex 40 N•m [29.5 Ft-lbs] for 9/16 35.3 N•m [26 Ft-lbs] for M14 G060/065 Case drain 12 mm or 9/16 in internal hex 48 N•m [36 Ft-lbs] G070/075 System gauge (28/32) 19 mm or 11/16 inch wrench 38 N•m [28 Ft-lbs] for 9/16 24 N•m [17.7 lbf-ft] for M14 System gauge (38/45) 24 mm or 7/8 inch wrench 81 N•m [59.7 Ft-lbs] for 3/4 67 N•m [49.4 lbf-ft] for M18 M100/N100 High pressure relief 5/16 inch internal hex 81.0 N•m [59.7 Ft-lbs] V100 Charge pressure relief 1 inch 78.6 N•m [58 Ft-lbs] Service Manual MP1 Fastener size and torque chart © Danfoss | April 2019 AX00000244en-000201 | 65

electric components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market as well as the marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster. Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile electrification. Go to www.danfoss.com for further product information. We offer you expert worldwide support for ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide you with comprehensive global service for all of our components. Local address: Danfoss Power Solutions GmbH & Co. OHG Krokamp 35 D-24539 Neumünster, Germany Phone: +49 4321 871 0 Danfoss Power Solutions ApS Nordborgvej 81 DK-6430 Nordborg, Denmark Phone: +45 7488 2222 Danfoss Power Solutions (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239 6000 Danfoss Power Solutions Trading (Shanghai) Co., Ltd. Building #22, No. 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved. © Danfoss | April 2019 AX00000244en-000201 Products we offer: • DCV directional control valves • Electric converters • Electric machines • Electric motors • Hydrostatic motors • Hydrostatic pumps • Orbital motors • PLUS+1® controllers • PLUS+1® displays • PLUS+1® joysticks and pedals • PLUS+1® operator interfaces • PLUS+1® sensors • PLUS+1® software • PLUS+1® software services, support and training • Position controls and sensors • PVG proportional valves • Steering components and systems • Telematics Comatrol www.comatrol.com Turolla www.turollaocg.com Hydro-Gear www.hydro-gear.com Daikin-Sauer-Danfoss www.daikin-sauer-danfoss.com