Series 90 Variable Pumps Service Manual - PV Global
MAKING MODERN LIVING POSSIBLEService ManualSeries 90 Pumpspowersolutions.danfoss.com
Service ManualSeries 90 PumpsRevision historyTable of revisions2DateChangedRevAugust 2015edits to Aux Pad minor repair0101December 2014Danfoss layoutBAJune 2012minor editsADDecember 2011minor editsACApril 2008page 70 correction to bolt torquesABOctober 2007First printingAA520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsContentsIntroductionOperationOperating parametersTechnical specificationsInitial start-up procedurePressure measurementTroubleshootingOverview.5Warranty. 5General instructions. 5Safety precautions.6Unintended machine movement.6Flammable cleaning solvents. 6Fluid under pressure. 6Personal safety. 6Symbols used in Danfoss literature.7Design.7The system circuit.8The basic closed circuit. 8Case drain and heat exchanger.9Charge pump.11Charge relief valve. 11Multi-function valves. 11Pressure limiter and high pressure relief valves. 12System check valves.12Bypass valves. 12Speed sensors.13Filtration options.13Pressure override (POR) – 180 frame size only. 13Manual displacement control (MDC).14Non-Linear MDC. 14Solenoid override valve for MDC.14Neutral start switch (NSS).14Hydraulic displacement control (HDC). 14Electric displacement control (EDC).15Automotive control (FBA II B). 153-Position (FNR) electric control. 15Overview. 16Input speed. 16System pressure. 16Charge pressure.16Charge inlet pressure.17Case pressure.17Temperature and viscosity. 17Fluid and filter recommendations. 17Overview. 19Features and options.19Operating parameters.19Fluid specifications.19General .21Start-up procedure. 21Required tools. 22Port locations and gauge installation.22Overview. 25Neutral difficult or impossible to find.25System operating hot.25520L0818 Rev 0101 August 20153
Service ManualSeries 90 PumpsContentsTransmission operates normally in one direction only. 25System will not operate in either direction. 26Low motor output torque.26Improper motor output speed.26System noise or vibration. 27System response is sluggish. 27AdjustmentsMinor repairTorque chart4Standard procedures, inspections, and adjustments. 28Adjustments.28Charge pressure relief valve adjustment.28Multi-function valve pressure adjustment.30Engaging the bypass function. 31Pressure override (POR) valve pressure adjustment (option for 180 frame size).32Displacement limiter adjustment. 33Standard manual displacement control (MDC) adjustment. 33Non-linear manual displacement control (MDC). 34MDC Neutral start switch (NSS) adjustments.35Checking switch continuity.38Hydraulic displacement control (HDC) and electric displacement control (EDC) adjustment.39Speed sensor adjustment. 40Standard procedures. 42Removing the pump.42Shaft seal and shaft replacement.42Multi-function valve cartridges.44Multi-function valve cartridges - pre 1988.46Pressure override valve (option for 180 frame size). 47Charge pressure relief valve.48Adding an Auxiliary pad to a pump previously without one.50Auxiliary pad. 51Charge pump.52Integral charge pressure filter replacement.55Pump control cover plate. 56Displacement control orifices.57Displacement control orifice check valve. 57Displacement control adapter plate (early production 130 pumps only).58Manual displacement control (MDC).59Solenoid override valve for MDC.60Solenoid override valve for MDC with pressure released brake. 61Hydraulic and electric displacement controls. 62Pressure control pilot (PCP) for electric displacement control (EDC).633-Position (FNR) electric control. 63Displacement control filter screens.65Speed sensor. 66Fastener size and torque chart.68Plug size and torque chart.69Fasteners and plugs. 70520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsIntroductionOverviewThis manual includes information for the installation, maintenance, and minor repair of Series 90 axialpiston closed circuit pumps. It includes a description of the unit and its individual components,troubleshooting information, and minor repair procedures.Performing minor repairs requires you remove the unit from the vehicle/machine. Thoroughly clean theunit before beginning maintenance or repair activities. Since dirt and contamination are the greatestenemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especiallyimportant when changing the system filter and when removing hoses or plumbing.A worldwide network of Danfoss Global Service Partners (GSPs) is available for major repairs. Danfosstrains GSPs and certifies their facilities on a regular basis. You can locate your nearest ASC using thedistributor locator at www.DanfossPower Solutions.com. Click on the Sales and Service link.WarrantyPerforming installation, maintenance, and minor repairs according to the procedures in this manual willnot affect your warranty. Major repairs requiring the removal of a unit’s rear or side cover voids thewarranty unless done by a Danfoss Authorized Service Center.General instructionsFollow these general procedures when repairing Series 90 variable displacement closed circuit pumps.Remove the unitPrior to performing major repairs, remove the unit from the vehicle/machine. Chock the wheels on thevehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid may be under highpressure and/or hot. Inspect the outside of the pump and fittings for damage. Cap hoses after removal toprevent contamination.Keep it cleanCleanliness is a primary means of assuring satisfactory pump life, on either new or repaired units. Cleanthe outside of the pump thoroughly before disassembly. Take care to avoid contamination of the systemports. 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 allexposed sealing surfaces and open cavities from damage and foreign material. If left unattended, coverthe pump with a protective layer of plastic.Replace all O-rings and gasketsUse new O-rings and gaskets during reassembly. Lightly lubricate all O-rings with clean petroleum jellyprior to assembly.Secure the unit520L0818 Rev 0101 August 20155
Service ManualSeries 90 PumpsIntroductionFor repair, place the unit in a stable position with the shaft pointing downward. It will be necessary tosecure the pump while removing and torquing end covers, controls, and valves.Safety precautionsAlways consider safety precautions before beginning a service procedure. Protect yourself and othersfrom injury. Take the following general precautions whenever servicing a hydraulic system.Unintended machine movementWWarningUnintended 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 mechanismwhile servicing.Flammable cleaning solventsWWarningSome cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an areawhere a source of ignition may be present.Fluid under pressureWWarningEscaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing seriousinjury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing withhydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, orcomponents. Never use your hand or any other body part to check for leaks in a pressurized line. Seekmedical attention immediately if you are cut by hydraulic fluid.Personal safetyWWarningProtect yourself from injury. Use proper safety equipment, including safety glasses, at all times.6520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsIntroductionSymbols used in Danfoss literatureWARNING may result in injuryTip, helpful suggestionCAUTION may result in damage to product orpropertyLubricate with hydraulic fluidReusable partApply grease / petroleum jellyNon-reusable part, use a new partApply locking compoundNon-removable itemInspect for wear or damageOption - either part may existClean area or partSuperseded - parts are not interchangeableBe careful not to scratch or damageMeasurement requiredNote correct orientationFlatness specificationMark orientation for reinstallationParallelism specificationTorque specificationExternal hex headPress in - press fitInternal hex headPull out with tool – press fitTorx headCover splines with installation sleeveO-ring boss portPressure measurement/gauge location orspecificationThe symbols above appear in the illustrations and text of this manual. They are intended to communicatehelpful information at the point where it is most useful to the reader. In most instances, the appearanceof the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.DesignDanfoss Series 90 closed circuit piston pumps convert input torque into hydraulic power. The input shafttransmits rotational force to the cylinder block. Bearings support the input shaft at the front and rear ofthe pump. The shaft is splined into the cylinder block. A lip-seal at the front end of the pump preventsleakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocatingpistons. A ball joint at one end connects each piston to a brass slipper. Fixed-clearance hold-downbrackets keep the slippers in contact with the swashplate. The reciprocating movement of the pistonsoccurs as the slippers slide against the inclined swashplate during rotation. The valve plate connects onehalf of the cylinder block to low pressure and the other half to high pressure. As each piston cycles in andout of its bore, fluid is drawn from the inlet and displaced to the outlet thereby imparting hydraulicpower into the system. A small amount of fluid flows from the cylinder block/valve plate and slipper/swashplate interfaces for lubrication and cooling. Case drain ports return this fluid to the reservoir.The angle of the swashplate controls the volume of fluid displaced into the system. The servo pistonforces the swashplate into an inclined position. The pump control, acting on input from the operator, bymodulating pressure balance across the servo piston, sets displacement in the system circuit.520L0818 Rev 0101 August 20157
Service ManualSeries 90 PumpsIntroductionCross sectionPistonSlider blockSlipperDisplacement controlServo armServo pistonFeedback linkageCradle bearingBushingCylinder blockRoller bearingShaftsealValve plateRearbushingInput shaftSwashplateCharge pumpCradle guideP106 648EThe system circuitThe basic closed circuitHydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid flows in eitherdirection from the pump to the motor then back to the pump in this closed circuit. Either of the hydrauliclines can be under high pressure. In pumping mode the position of the pump swashplate determineswhich line is high pressure as well as the direction of fluid flow.8520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsIntroductionBasic closed circuit diagramReservoirInputOutputMFPVFlow (Bi-directional)Case drain lineP104 120ECase drain and heat exchangerThe pump and motor require case drain lines to remove hot fluid from the system. The topmost portdrains the motor to ensure the case remains full of fluid. Fluid routes through the lower drain port on thepump and out the topmost port to the reservoir. A heat exchanger, with a bypass valve, cools the casedrain fluid before it returns to the reservoir.System circuit diagramControl handleDisplacement control valveHeat exchanger bypass valveReservoirOrificed checkvalveVacuum gaugeHeat exchangerCharge pressure relief valveReversiblevariabledisplacement pumpServo control cylinderPurge relief valveP102 000Fixed displacementmotorMulti-function valveTopumpcaseServopressurerelief valvesCharge pumpInput shaftOutput shaftMulti-function valvePump swashplateMotor swashplateLoop flushing valveServo control cylinderPumpWorking loop (high pressure)MotorWorking loop (low pressure)520L0818 Rev 0101 August 2015Suction lineControl fluidCase drain fluid9
Service ManualSeries 90 PumpsIntroductionPump schematicM3X5AM1M5M4M2BL1SL2P104 126E10520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsOperationCharge pumpThe charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in themain system loop, to provide pressure to operate the control system, and to make up for internal leakage.Charge pressure must be at its specified pressure under all conditions to prevent damage to thetransmission.The charge pump is a fixed-displacement, gerotor type pump driven off the main pump shaft. The chargerelief valve limits charge pressure.Pump charge systemCasedrainlineInputCharge relief valveSystemcheckvalvesPVPFChargepumpInlet filterTankP104 121ECharge relief valveThe charge relief valve on the pump maintains charge pressure at a designated level. A direct-actingpoppet valve relieves fluid when charge pressure reaches a certain level. This level is nominally setreferencing case pressure at 1500 rpm. This nominal setting assumes the pump is in neutral (zero flow). Inforward or reverse, charge pressure is lower. The pump model code specifies the charge relief valvesetting.Charge pressure relief valveCharge pressureP106 157EMulti-function valvesThe multi-function valve incorporates the system check valve, the pressure limiter valve, the highpressure relief valve, and the bypass valve in a replaceable cartridge. These functions are describedseparately. There are two multi-function valve cartridges in each Series 90 pump to handle functions ineither direction. See corresponding sections for adjustments and repairs.520L0818 Rev 0101 August 201511
Service ManualSeries 90 PumpsOperationMulti-function valveHigh pressurerelief / checkvalve poppetPressure limiter housingPressure limiterlock nutCheck valvepoppetPressure limiteradjustment screwBypassactuatorPressure limitervalve poppetBypassP104 122ESome multi-function valves do not include a pressure limiter valvePressure limiter and high pressure relief valvesSeries 90 pumps have a sequenced pressure limiting system and high pressure relief valves. When thesystem pressure reaches the preset, the pressure limiter system rapidly de-strokes the pump to limitsystem pressure. For unusually rapid load application, the high pressure relief valve immediately limitssystem pressure by cross-porting system flow. The pressure limiter valve acts as the pilot for the highpressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar(500 psi) above the level that initiates the pressure limiter valve.Circuit diagram showing pressure control mechanismTo controlMulti-function valveServo pistonBypassadjustmentPort "A"Servo Pres.Relief ValvePort "B"Chargepressurerelief valveServo pistonMulti-function valveP104 123EFor some applications, such as dual path vehicles, the pressure limiter function may be defeated so thatonly the high pressure relief valve function remains.System check valvesThe system check valves allow pressurized flow from the charge pump to enter the low pressure side ofthe loop. This is needed as the pump generally loses system pressure due to lubrication/cooling flow andother factors. Since the pump operates in either direction, the system uses two check valves to direct thecharge supply into the low pressure lines. The system check valves are part of the multi-function valveassembly.Bypass valvesYou can operate the bypass valves to move the vehicle or mechanical function when the pump is notrunning. Manually resetting the valve position opens the valve. The bypass valves are built into the multifunction valves.12520L0818 Rev 0101 August 2015
Service ManualSeries 90 PumpsOperationSpeed sensorsAn optional speed sensor can provide unit speed information. The sensor reads a magnetic ring on theunit’s cylinder block. See the corresponding section to locate, install, and adjust the speed sensor.Filtration optionsSeries 90 pumps may have either suction or charge pressure filtration to filter the fluid entering thecircuit.The suction filter is in the circuit between
forces the swashplate into an inclined position. The pump control, acting on input from the operator, by modulating pressure balance across the servo piston, sets displacement in the system circuit. Service Manual Series 90 Pumps Introduction 520L0818 Rev File Size: 3MBPage Count: 72Explore furtherSeries 90 Axial Piston Pumps Technical Information Manualwww.precisionfluidpower.comSeries 90 180cc Pump Parts Manual - PV Globalpvglobal.com.sgSeries 90 130cc Pump Parts Manual - PV Globalpvglobal.com.sgSeries 90 100 cc Axial Piston Pump Parts Manualwww.moorepumps.comSundstrand Series 90 Replacement Partsscrewmax.comRecommended to you b
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