MCV105C3023 | Danfoss EDC Pilot Valve 225psi 650psi

Product Overview

The MCV105C3023 and MCV116A3204 are core electro-hydraulic control valve components from the Danfoss / Sauer-Danfoss MCV series, widely used for displacement control of Danfoss medium duty pumps and Series 90 variable displacement pumps.

MCV105C3023:

The MCV105C3023 is a Danfoss MCV105C series Electric Displacement Control (EDC) module—a two-stage electrohydraulic pump stroke control device. The first stage is an MCV116A Pressure Control Pilot (PCP)—a torque motor-actuated double-nozzle flapper valve that produces a differential output pressure proportional to the applied electrical signal. The second stage uses this differential pressure to drive a linear motion piston, which actuates a rotary spool through a cam and ports oil to the pump servo piston. The MCV105C EDC uses mechanical feedback to establish closed-loop control of the swashplate angle of Danfoss 46 cc medium duty pumps.

The MCV105C3023 directly replaces the MCV105B series. All MCV105C models are factory-shipped with O-rings installed. The product features environmentally resistant design: silicone oil-filled torque motor prevents moisture condensation, environmentally sealed first/second stage interface, and full environmental testing.

MCV116A3204:

The MCV116A3204 is a Danfoss MCV116 series Pressure Control Pilot (PCP) valve—a torque motor-actuated double-nozzle flapper valve. As a self-contained closed-loop pressure control valve, the pilot stage utilizes internal hydraulic pressure feedback to achieve closed-loop regulation. Mounted directly on the pump housing, this valve converts 4-20 mA electrical signals into proportional pilot differential pressure to adjust the pump swashplate angle and regulate pump displacement and output flow. The MCV116A3204 is widely used for original assembly, equipment overhaul, and spare parts replacement of Danfoss Series 90 variable displacement piston pumps (90R/90L).

As original Danfoss / Sauer-Danfoss control valve components, the MCV105C3023 and MCV116A3204 offer complete interchangeability within their respective series, requiring no modifications to mounting interfaces or hydraulic piping layouts.

Technical Specifications 

MCV105C3023 Specifications:

• Model: MCV105C3023

• Brand: DANFOSS / SAUER-DANFOSS

• Material Number: 11164081

• Series: MCV105C Series

• Function: Electric Displacement Control (EDC)

• Valve Type: Two-stage electrohydraulic pump stroke control, torque motor-actuated double-nozzle flapper valve

• Compatible Pumps: Danfoss 46 cc Medium Duty Pumps

• Supply Pressure: 225 psi (Approx. 15.5 bar)

• Load Pressure: 650 psi (Approx. 44.8 bar)

• Maximum Hysteresis: 3 mA (single coil, 23Ω) / 15 mA (single coil, 643Ω) / 18 mA (dual coil)

• Symmetry: Input current required to reach rated output in each direction must be equal within 10%

• Linearity: 10% maximum of swashplate angle change (except within 5% of threshold current)

• Neutral Leakage: 0.65 gpm maximum at 200 psi (oil at 38°C/100°F, viscosity 145-160 SUS)

• Polarity: Positive voltage applied to terminal B (single coil) or terminals B/D (dual coil) causes pressure rise at C2 port

• Environmental Shock: 50 G’s for 11 milliseconds

• Humidity Test: 95% ± humidity at 49°C (120°F) for 10 days

• Connector Types: MS connector (4-pin, only pins A and B used for single coil) or Packard connector

• Weight: Approx. 1.8–2.0 kg

• Mounting: Direct plate mounting on pump head

MCV116A3204 Specifications:

• Model: MCV116A3204

• Brand: DANFOSS / SAUER-DANFOSS

• Series: MCV116 Series

• Function: Pressure Control Pilot (PCP)

• Valve Type: Torque motor-actuated double-nozzle flapper valve

• Control Type: Electro-hydraulic proportional control, closed-loop pressure regulation

• Input Control Signal: 4-20 mA DC

• Power Supply: 24 VDC

• Maximum Operating Pressure: 350 bar

• Maximum Flow: 60 L/min

• Compatible Pumps: Danfoss Series 90 Variable Displacement Piston Pumps (90R/90L)

• Body Material: High-strength aluminum alloy

• Working Medium: Anti-wear mineral hydraulic oil

• Working Temperature: -20°C to +80°C

• Weight: Approx. 1.8–2.0 kg

• Installation: Direct plate mounting on pump head

• Structural Features: Torque motor-nozzle flapper closed-loop structure, good control linearity, strong anti-vibration and anti-contamination performance

Key Technical Advantages

1. Two-Stage Electrohydraulic Control Architecture
The MCV105C3023 employs a two-stage electrohydraulic control architecture: the first stage is an MCV116A torque motor-actuated double-nozzle flapper pilot valve that produces differential pressure proportional to the input signal; the second stage uses this differential pressure to drive a linear motion piston, which actuates a rotary spool through a cam mechanism. This two-stage separation allows the MCV105C EDC to achieve both the null deadband required for safety and excellent dynamic response characteristics.

2. High-Precision Torque Motor Control
The torque motor-actuated double-nozzle flapper valve configuration delivers superior dynamic response frequency and lower hysteresis compared to conventional solenoid designs. The torque motor consists of an armature mounted on a torsion pivot suspended in the air gap of a magnetic field, precisely regulating output torque through control current. Internal hydraulic pressure feedback makes the pilot stage a self-contained closed-loop pressure control valve.

3. Superior Environmental Durability
The torque motor features silicone oil filling to prevent moisture condensation. The first/second stage interface is environmentally sealed, and the product has passed comprehensive environmental testing including 50 G shock testing, 95% humidity (49°C/10 days) testing, and mobile equipment vibration testing.

4. Flexible Coil Configurations and Serviceability
The MCV105C3023 supports both single and dual coil configurations. Dual coil configurations allow two command sources to be compared at the torque motor, with the resulting signal being the algebraic sum of the two. Pilot supply screens are in series, with the upstream screen externally serviceable. Both first and second stages can be individually replaced in the field.

5. High-Pressure High-Flow Control Capability
The MCV116A3204 delivers 350 bar pressure control capability with 60 L/min flow capacity. This performance places it at the forefront of pressure control pilot valves in its class, making it suitable for precise displacement control of demanding high-pressure, high-flow variable pump systems.

6. Modular Integrated Design
The MCV116A3204 mounts directly on the pump head, converting 4-20 mA electrical signals into proportional pilot differential pressure to adjust pump swashplate angle. The compact modular layout reduces external piping and fitting requirements, minimizing system leakage risk and installation space requirements.

Application Areas

• Construction Machinery Hydraulics — Electric displacement control of variable pumps in excavators, loaders, and mobile equipment

• Danfoss Series 90 Pump Control — Precise displacement control for 90R/90L series pumps

• Danfoss 46 cc Medium Duty Pump Control — MCV105C3023 EDC control for 46 cc medium duty pumps

• Road Construction and Mining Equipment — Hydraulic systems for road rollers, pavers, and mobile mining equipment

• Injection Molding Machinery — Displacement proportional regulation in pump-controlled systems

• Die-Casting Machines — Pressure and flow closed-loop control in variable pump systems

• Marine and Port Machinery — Variable pump control for steering gears and winch hydraulic systems

Expert Maintenance Tips

1. Installation Guidelines

• Thoroughly clean the mounting surface and ports before installation to prevent foreign particles from entering the pilot valve and causing nozzle blockage or flapper sticking.

• For MCV105C3023 mounting directly on the pump head, pay special attention to alignment with locating pins to prevent spool sticking due to misalignment.

• All MCV105C models are factory-shipped with O-rings installed. Verify O-rings are intact before installation.

2. Hydraulic Fluid Cleanliness

• MCV series pilot valves incorporate precision nozzle-flapper mechanisms that are highly sensitive to fluid cleanliness.

• Recommended fluid cleanliness: ISO 4406 19/17/14 or better.

• Install a return line filter with minimum 10 μm filtration rating. Pilot supply screens are in series—the upstream screen should be regularly inspected and replaced.

3. Electrical Connection Specifications

• MCV105C3023 is current-driven—use a compatible current control amplifier; do not connect directly to a voltage source.

• Coil resistance varies with temperature—consider temperature effects on resistance during use.

• For PWM (pulse width modulated) current input, do not exceed 110 mA for single coil devices or 150 mA for dual coil devices (algebraic sum of currents in coil A and B). Avoid PWM frequencies between 300 and 500 Hz, which approach the pilot’s resonant frequency of 400 Hz.

• MS connector has four pins—only pins A and B are used for single coil devices. Positive voltage on the Red wire (Pin B) will cause pressure rise at the C2 port.

4. Pilot Pressure Supply Configuration

• MCV series pilot valves require a stable, clean pilot oil supply. Pilot supply pressure must not fall below 225 psi (approx. 15.5 bar).

• Install a pilot filter with minimum 10 μm filtration rating in the pilot supply line.

5. Periodic Maintenance Inspection

• Inspect the valve body for external oil leakage every 2,000 operating hours or at least annually.

• Check electrical connectors for looseness, oxidation, or moisture ingress.

• If response lag or reduced control precision is observed, first check system fluid cleanliness and pilot screens for blockage—nozzle-flapper mechanism contamination is the most common cause of performance degradation.

• The torque motor assembly must not be disassembled by end users; any repairs should be performed by qualified hydraulic service professionals.