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MAKING MODERN LIVING POSSIBLE

Service Manual

Series 90 Pumps

powersolutions.danfoss.com

Summary of Contents for Series 90

Page 1: ...MAKING MODERN LIVING POSSIBLE Service Manual Series 90 Pumps powersolutions danfoss com...

Page 2: ...edits to Aux Pad minor repair 0101 December 2014 Danfoss layout BA June 2012 minor edits AD December 2011 minor edits AC April 2008 page 70 correction to bolt torques AB October 2007 First printing A...

Page 3: ...lenoid override valve for MDC 14 Neutral start switch NSS 14 Hydraulic displacement control HDC 14 Electric displacement control EDC 15 Automotive control FBA II B 15 3 Position FNR electric control 1...

Page 4: ...42 Removing the pump 42 Shaft seal and shaft replacement 42 Multi function valve cartridges 44 Multi function valve cartridges pre 1988 46 Pressure override valve option for 180 frame size 47 Charge...

Page 5: ...de cover voids the warranty unless done by a Danfoss Authorized Service Center General instructions Follow these general procedures when repairing Series 90 variable displacement closed circuit pumps...

Page 6: ...ts W Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure W Warning Escaping hydra...

Page 7: ...ut shaft transmits rotational force to the cylinder block Bearings support the input shaft at the front and rear of the pump The shaft is splined into the cylinder block A lip seal at the front end of...

Page 8: ...e basic closed circuit Hydraulic lines connect the main ports of the pump to the main ports of the motor Fluid flows in either direction from the pump to the motor then back to the pump in this closed...

Page 9: ...tem circuit diagram Pump Motor Working loop low pressure Control fluid Suctionline Case drainfluid Working loop high pressure Motor sw ashplate Loop flush ing valve Displacem ent control valve Heat ex...

Page 10: ...Pump schematic P104 126E M4 M5 L2 S L1 X5 M1 M2 A B M3 Service Manual Series 90 Pumps Introduction 10 520L0818 Rev 0101 August 2015...

Page 11: ...at a designated level A direct acting poppet valve relieves fluid when charge pressure reaches a certain level This level is nominally set referencing case pressure at 1500 rpm This nominal setting as...

Page 12: ...uit diagram showing pressure control mechanism Servo Pres Relief Valve Charge pressure relief valve Multi function valve Multi function valve To control Servo piston Servo piston Port A Port B Bypass...

Page 13: ...he pump or remotely for ease of servicing You will typically find a 100 125 m mesh screen in the reservoir or the charge inlet This system requires a filter capable of withstanding charge pressure ref...

Page 14: ...the change in the angular position of the pump swashplate progressively increases as the control input shaft is rotated toward its maximum displacement position Solenoid override valve for MDC A sole...

Page 15: ...portional to the EDC input Automotive control FBA II B The automotive control allows the operator to drive a vehicle similar to an automobile with an automatic transmission The automotive control incl...

Page 16: ...expected life System pressure must remain at or below continuous pressure during normal operation to achieve expected life Continuous pressure is the average regularly occurring operating pressure Op...

Page 17: ...ffect 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...

Page 18: ...t becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater than the recommended maximum Dispose of used hydraulic fluid properly Never...

Page 19: ...ted bar psi 3 0 40 Maximum 5 0 75 Parameter Unit Frame size 042 055 075 100 130 180 250 Displacement maximum cm in 42 2 56 55 3 35 75 4 57 100 6 10 130 7 93 180 10 98 250 15 25 Minimum speed min 1 rpm...

Page 20: ...66 278 1600 7500 Temperature C F 40 40 104 220 115 240 Cleanliness ISO 4406 Class 22 18 13 or better Filtration efficiency suction filtration 35 44 75 10 2 charge filtration 15 20 75 10 10 Service Ma...

Page 21: ...y 7 Use a common method to disable the engine to prevent the engine from starting Crank the starter for several seconds Do not to exceed the engine manufacturer s recommendation Wait 30 seconds and th...

Page 22: ...d gauge sizes needed Port information Port identifier Pressure obtained Gauge size Port size M1 M2 System pressure 1000 bar 10 000 psi 9 16 18 M3 M6 Charge pressure 50 bar 1000 psi 9 16 18 M4 M5 Servo...

Page 23: ...sure gauge port M1 System pressure port A Case drain port L2 Carge pump inlet port S Charge inlet pressure vacuum Pump with twin port end cap and manual displacement control Servo displacement cylinde...

Page 24: ...ressure filtration Charge pressure gauge port M3 after the filter Charge pressure gauge port M6 before the filter Charge pressure gauge port M3 back side after the filter Port E from filter Port D to...

Page 25: ...let 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 settings are too low the...

Page 26: ...es are not secure control orifices are blocked Repair or replace control module as necessary System pressure Low system pressure will not provide power necessary to move load Measure system pressure C...

Page 27: ...nt Misaligned shafts cause noise Align shafts System response is sluggish Item Description Action Oil level in reservoir Insufficient hydraulic fluid causes sluggish response Fill reservoir to proper...

Page 28: ...ill with the correct filtered hydraulic fluid 7 Flush the lines before replacing the hydraulic fluid Adjustments This section offers instruction on inspection and adjustment of pump components Read th...

Page 29: ...25 8 30 7 bar 37 4 44 5 psi This is the actual charge pressure port gauge reading minus the case pressure port gauge reading 3 Earlier production Series 90 pumps have a shim adjustable charge pressure...

Page 30: ...0 1000 bar 0 10000 psi 9 16 18 23 N m 17 lbf ft Adjusting screw Lock nut smaller hex nut Lock nut torque t h I 1 Install two 1000 bar or 10 000 psi pressure gauges in the high pressure gauge ports M1...

Page 31: ...t down the prime mover remove the gauges and install the gauge port plugs Replace the plastic dust plugs if used Use the same procedure for setting the pressure limit of the other multi function valve...

Page 32: ...1 and M2 Install a 50 bar 1000 psi pressure gauge in the pump charge pressure gauge port M3 2 Start the prime mover and operate at normal speed 3 With the pump operating at approximately 20 displaceme...

Page 33: ...er adjustment I Adjusting screw Lock nut Lock nut torque P106 164E F212 F213 Frame size Lock nut wrench size and torque Adjusting screw size Approximate displacement change per revolution of adjusting...

Page 34: ...000 psi gauge in each of the two servo cylinder gauge ports M4 and M5 Disconnect the external control linkage from the control handle and make certain the control shaft is in its neutral position Star...

Page 35: ...ce check valve seat Neutral start switch Eccentric plug Switch pin Special lock nut for eccentric plug Switch lock nut A A Control shaft Switch cam P104 146E View A A Adjust the Neutral Start Switch t...

Page 36: ...e control deadband you must adjust the position of the NSS deadband to match it The switch pin is located in an eccentric plug which you turn to move the center of the NSS deadband Ensure the MDC is i...

Page 37: ...eutral position in the center of the control shaft free play area Locate the switch pin in the slot of the switch cam by turning the eccentric plug while checking the pin position depth in the plug Wh...

Page 38: ...lbf ft torque 6 With the continuity checker attached to the switch rotate the control handle or the control shaft in each direction to assure the switch opens when the control is not in the neutral po...

Page 39: ...ned at neutral 5 Slowly move the control handle in the opposite direction Again The switch must open before the gauge pressure increases more than 1 bar 14 5 psi from base pressure 6 Verify continuity...

Page 40: ...re increases in one of the pressure gauges Note the angular position of the wrench Rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gaug...

Page 41: ...contacts the speed ring 6 Hold sensor in position with a 1 2 inch hex wrench while tightening the lock nut to 13 N m 10 lbf ft Cross section view of speed sensor in variable pump Magnetic speed ring...

Page 42: ...ect hydraulic fluid 2 Flush the lines before replacing the hydraulic fluid Shaft seal and shaft replacement You can replace the shaft and seal without major disassembly of the unit Clean pump and surr...

Page 43: ...the shaft and bearing for rust wear or contamination Spin the bearing in your hand feeling for roughness Replace if necessary Reassembly 1 Using the arbor press press the new seal L40 into seal carrie...

Page 44: ...lve cartridges Older multifunction valves pre 1988 contain different components See multifunction valves Pre 1988 for disassembly instructions Multi function valve removal installation P2B1 P2A1 P06 P...

Page 45: ...8 P03 P04 P02 P01 Inspection Context for the current task Clean and inspect all disassembled parts Reassembly 1 Lubricate and install internal components P07 P08 P17 P16 P15 P14 P09 P11 and P12 2 Plac...

Page 46: ...cleaning Wrench size is 1 1 16 Multi function valves are sold as complete units only O rings may be purchased separately 4 To retain pressure setting do not disassemble bypass function P14 5 Remove re...

Page 47: ...ble below W Warning Do not overtorque the multi function valve cartridges Multi function valve torque Frame size Torque 030 100 89 N m 66 lbf ft 130 250 210 N m 155 lbf ft Pressure override valve opti...

Page 48: ...intain the original adjustment when assembling Remove the screw adjustable charge relief valve plug by loosening the lock nut with a hex wrench corresponding to the table Lock nut wrench size Frame si...

Page 49: ...ts lock nut aligning the marks made at disassembly and torque the lock nut to 52 N m 38 lbf ft Check the charge pressure and adjust if necessary Refer to Charge pressure adjustments Charge pressure re...

Page 50: ...e charge pump leave it in place If the pin comes out with the cover plate reinstall it in the geroter eccentric Ensure that a cover for left hand rotation is used See instructions included with the au...

Page 51: ...ndcap pilot 7 Install the auxiliary mounting pad J60 on the rear of the endcap 8 Install four large screws J80 through the mounting pad and endcap into the housing Torque per the table using a criss c...

Page 52: ...screws J80 and new washers J70 through the mounting pad and end cap into the housing Torque per the accompanying table Torque endcap screws in a criss cross pattern End cap screw torque Frame size To...

Page 53: ...spect all parts for abnormal wear or damage and replace if necessary If installing a different displacement charge pump the gerotor assembly gerotor outer eccentric ring and inner port plate early and...

Page 54: ...identifier groove is used in 75 cm pumps The front keyway closest to the internally splined end of the shaft is used in 100 cm pumps 8 Install the charge pump coupling The internally splined end of t...

Page 55: ...70 N m 52 lbf ft 055 130 1 5 8 inch 122 N m 90 lbf ft 180 250 1 5 8 inch 156 N m 115 lbf ft Inspection Inspect the filter head and lock nut sealing surfaces If you find any nicks or scratches replace...

Page 56: ...he six cover plate mounting screws M90 Remove the cover plate M1 and gasket M11 from housing Discard the gasket C Caution Protect exposed surfaces and cavities from damage and foreign material Reassem...

Page 57: ...them up with a 4mm internal hex wrench Note the location of each plug do not interchange plugs Clean reinstall and torque the orifice plugs to 3N m 2lbf ft 3 Assemble the control onto the pump Refer t...

Page 58: ...trol adapter plate early production 130 pumps only Do not remove the adapter plate unless leakage is evident The mounting screws with sealing compound are difficult to remove The screws fastening the...

Page 59: ...o the swashplate 3 With the control in position move control lever both directions to check proper engagement of control linkage pin If properly assembled lever will return to center If lever does not...

Page 60: ...solenoid valve M76 from the manifold M75 with a 7 8 inch hex wrench 3 Using a 5 mm internal hex wrench remove the two screws M78 and remove solenoid manifold M75 from housing Remove and discard the ga...

Page 61: ...screws M98 Remove the adapter plate and O rings M95 M96 and M97 from the control housing Discard the O rings Reassembly 1 Using petroleum jelly to retain them install new O rings M96 M96 M97 on the ad...

Page 62: ...and spring T are in their proper position in the control 2 Position the control on the housing Insert the control linkage pin into the swashplate link Hydraulic Electric displacement control P106 187...

Page 63: ...in PCP Housing Place PCP against EDC housing and install the screws M98 Torque to 5 4 N m 4 lbf ft Do not remove black plastic cover from the aluminum plate This is not a serviceable item and will vo...

Page 64: ...on Reassembly 1 Install a new gasket M11 on the housing Place the adapter plate into position and install the screws M90 Torque the screws to 16 N m 12 lbf ft C Caution Protect exposed surfaces and ca...

Page 65: ...bf ft Displacement control filter screens If the pump is equipped with control filter screens in the pump housing late production press them into position with the rounded edge of the filter screens f...

Page 66: ...lling the sensor 2 Reinstall the speed sensor with lock nut and O ring into the housing Adjust the gap between the sensor and the magnetic speed ring as instructed in Speed sensor adjustment page 46 a...

Page 67: ...Typical location of speed sensor E101 095E B83 O ring plug B83 B83A B83A 40 N m 30 lbf ft 40 N m 30 lbf ft Service Manual Series 90 Pumps Minor repair 520L0818 Rev 0101 August 2015 67...

Page 68: ...4 mm hex 298 N m 220 lbf ft 100 130 14 mm internal hex 298 N m 220 lbf ft 180 250 17 mm internal hex 580 N m 429 lbf ft K10 Charge pressure valve plug 030 250 1 2 in hex NA K90 Charge pressure lock nu...

Page 69: ...s or fittings Item O ring plug Wrench size Torque B70 B72 9 16 18 3 16 internal hex wrench 40 N m 30 lbf ft B71 9 16 18 3 16 internal hex wrench 12 N m 9 lbf ft B80 1 1 16 12 9 16 internal hex wrench...

Page 70: ...lug assembly G97End cap screw M90Control bolt H80Charge pump retaining screw J80Auxilliary pad end cap screw F111 F211Servo cylinder screw G90End cap screw E60Side cover screw K10Charge pressure relie...

Page 71: ...Service Manual Series 90 Pumps 520L0818 Rev 0101 August 2015 71...

Page 72: ...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...

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Danfoss Series 90, Service Manual

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