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Series 90 Variable Pumps Service Manual

1. Adjusting screw Lock nut smaller hex nut Lock nut torque See appropriate table System pressure gauge port M2 0 1000 bar 0 10000 psi 9 16 18 Z 23 Nem 17 Ibfft System pressure gauge port M1 C 0 1000 bar 0 10000 psi 9 16 18 23 Nem 17 Ibf ft P106 168E 1 Install two 1000 bar or 10 000 psi pressure gauges in the high pressure gauge ports M1 and M2 Install a 50 bar or 1000 psi pressure gauge in the pump charge pressure gauge port M3 2 Start the prime mover and operate at normal speed 3 Loosen locking nut 4 Insert an internal hex wrench into the pressure adjusting screw A plastic dust plug is installed in the adjusting screw 5 The model code shows the factory preset pressure limiter setting It is referenced to charge pressure so the pressure limiter setting is the difference between the high and low pressure sides of the system loop Activate or move the control input so that pressure increases in the high pressure side of the closed circuit to the pressure limiter pressure setting The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level as shown on the gauges 30 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Adjustments 6 Return the pump to its neutral zero flow position and
2. System pressure High system pressure will overheat system Measure system pressure If pressure is high reduce loads Transmission operates normally in one direction only Item Description Action Input to pump control Input to control module is operating improperly Check control input and repair or replace as necessary Pump displacement control Control linkages are not secure control orifices are blocked Repair or replace control module as necessary System pressure limiters high pressure relief valves or system check valves Interchanging the multi function valves will show if the problem is related to the valve functions contained in the multi function valves Interchange multi function valves If the problem changes direction repair or replace the valve on the side that does not operate Charge pressure If charge pressure decays in one direction the loop flushing valve may be sticking in one direction Measure charge pressure in forward and reverse If pressure decays in one direction inspect and repair the motor loop flushing valve 520L0818 Rev 0101 s August 2015 25 Service Manual Series 90 Pumps Troubleshooting System will not operate in either direction Item Description Action Oil level in reservoir Insufficient hydraulic fluid to supply system loop Fill reservoir to proper level Input
3. 520L0818 s Rev 0101 s August 2015 55 Service Manual Series 90 Pumps Minor repair Integral charge pressure filter N20 Filter manifold lock nut Lock nut torque N36 LL Se O Bei E oo gt Zz w CO 11 16 in 37 Nem 27 Ibfeft 11 16in 37 Nem 27 lbf ft P106 182E Pump control cover plate Removal 1 Thoroughly clean external surfaces prior to removal of cover plate 2 Using a5 mm internal hex wrench remove the six cover plate mounting screws M90 Remove the cover plate M1 and gasket M11 from housing Discard the gasket Caution Protect exposed surfaces and cavities from damage and foreign material Reassembly Install a new gasket on the housing Install the cover plate and install the screws Torque the screws to 16 Nem 12 Ibf ftl Install a sealing washer under the head of any mounting screws that are installed into through holes in the housing 56 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Pump controls cover plate 16 Nem 12 Ibfeft MI Seal washer location 42 180 250 cc Displacement control orifices 1 Remove the control assembly as described in the instructions for the specific displacement control 2 Orifice plugs may be located
4. Variable motor displacement control If variable motor displacement control is not functioning correctly variable motor swashplate may be in wrong position See if variable motor displacement control is responding If not repair or replace control Internal leakage Internal leakage will reduce system pressure Check for leaking O rings gaskets and other fittings Repair unit as required or replace leaky unit 26 520L0818 Rev 0101 s August 2015 Service Manual Series 90 Pumps Troubleshooting System noise or vibration Item Description Action Oil in reservoir Insufficient hydraulic fluid will lead to cavitation Fill reservoir to proper level Air in system Air bubbles will lead to cavitation Look for foam in reservoir Check for leaks on inlet side system loop and repair Afterwards let reservoir settle until foam dissipates Run system at low speed to move system fluid to reservoir Repeat Pump inlet vacuum High inlet vacuum causes noise A dirty filter will increase the inlet vacuum Inspect and replace filter as necessary Check for proper suction line size Shaft couplings A loose shaft coupling will cause excessive noise Replace loose shaft coupling or replace pump or motor Shaft alignment Misaligned shafts cause noise Align shafts System response is sluggish Item Description Action Oil level
5. 5mm Seal washer location 42 180 250 cc P106 185E Solenoid override valve for MDC Removal 1 Thoroughly clean external surfaces prior to removal of valve 2 Remove the solenoid from the valve by removing the nut with a 3 4 inch hex wrench Remove the solenoid valve M76 from the manifold M75 with a 7 8 inch hex wrench 3 Using a5 mm internal hex wrench remove the two screws M78 and remove solenoid manifold M75 from housing Remove and discard the gasket M77 Reassembly 1 Torque valve M76 to 24 Nem 17 7 lbf ft Torque solenoid nut to 6 Nem 5 lbf ft Do not overtorque the solenoid nut 2 Install a new gasket on the control housing Install the manifold onto the control housing align the gasket and install the screws Torque the screws to 13 5 Nem 10 lbf ft 60 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Solenoid override valve removal installation M90 x6 O 5 mm M77 16Nem 12 Ibf ft N M76A 7 Mier Dee Bi M78 x2 O 5 mm 13 5 Nem 10 Ibf ft P106 186E Solenoid override valve for MDC with pressure released brake Removal 1 Thoroughly clean external surfaces prior to removal of valve 2 Using a 4 mm internal hex wrench remove the four solenoid valve mounting screws M92 Remove the soleno
6. Multi function valve wrench size Frame size Wrench size 030 100 1 1 4 inch 130 250 1 5 8 inch 2 Remove and discard O rings P03 and P06 It is not necessary to remove the bypass function P14 except for cleaning Wrench size is 1 1 16 w Multi function valves are sold as complete units only O rings may be purchased separately To retain pressure setting do not disassemble bypass function P14 Remove retaining ring P22 with a snap ring pliers Remove poppet seat P12 Remove internal parts P21 P15 P14 P09 and P11 N OF Mi P Inspection Clean and inspect all disassembled parts Multi function valve pre 1988 P14 P19 QO x42 O fie KR p14 P09 c SE PHI Ten EIS P22 ec P1 E101 532E Reassembly 1 Lubricate and install internal components P01 P11 P09 P14 P15 and P21 46 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Install poppet seat P1 Install retaining ring P22 If previously removed lubricate and install O ring P19 If previously removed reassemble and install bypass actuator P14 Torque to 40 Nem 30 Ibfeft Lubricate and install new O rings P06 P13 au P WN Caution lf pressure limiter was removed from bypass actuator P14 adjust pressure limiter to model code specifications 7 Install cartridges and torque as shown in the table be
7. Reassembly 1 Install a new O ring before reinstalling 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 and torque the sensor lock nut to 13 Nem 10 lbf ft 3 If a speed sensor is not installed use a 1 4 in internal hex wrench to torque the housing plug B83 to 40 Nem 30 Ibf ft 66 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Typical location of speed sensor B83 1 1 16 in Z 40 Nem 30 Ibfeft B83 O ring plug SE B83A Zo ae 1 4 in 40 Nem 30 Ibfeft E101 095E 520L0818 s Rev 0101 s August 2015 67 Service Manual Series 90 Pumps Torque chart Fastener size and torque chart Item Fastener Frame size Wrench size Torque B83 Speed sensor lock nut 030 250 1 1 16 in hex 13 5 Nem 10 lbf ft E60 Side cover screw 030 042 10 mm hex 13 5 Nem 10 Ibfeft Bling holgs 055 100 13 mm hex 32 Nem 24 Ibf ft 130 250 17 mm hex 64 Nem 37 lbf ft E60 Side cover screw 030 042 10 mm hex 10 4 Nem 7 7 lbf ft Wl 055 100 13 mm hex 32 Nem 24 lbfeft 130 250 17 mm hex 32 Nem 47 lbf ft F111 Servo cylinder screw 030 055 8mm hex 13 5 Nem 10 l
8. N10 Filter reducer assembly 030 042 1 1 4 in hex 70 Nem 52 Ibfeft 055 130 1 1 2 in hex 122 Nem 90 lbf ft 180 250 1 1 2 in hex 156 Nem 115 Ibf ft N37 Filter plug assembly 030 250 1 4 in internal hex 27 Nem 20 Ibfeft 68 520L0818 s Rev 0101 s August 2015 Denpi Service Manual Series 90 Pumps Torque chart Plug size and torque chart Item Fastener Frame size Wrench size Torque P2B1 Multi function valve 030 100 1 1 4 in hex 89 N m 66 lbf ft P2A1 130 250 1 5 8 in hex 210 Nem 155 lbf ft If any plugs or fittings are removed from the pump during servicing install and torque as indicated in the accompanying table Caution Torque plugs or fittings installed into aluminum housings to the lower values specified for internal hex plugs of the same size Always install new O rings before reinstalling the plugs or fittings Item O ring plug Wrench size Torque B70 B72 9 16 18 3 16 internal hex wrench 40 Nem 30 lbf ft B71 9 16 18 3 16 internal hex wrench 12 Nem 9 lbf ft B80 1 1 16 12 9 16 internal hex wrench 115 Nem 85 Ibfeft B82 B83 9 16 18 1 4 internal hex wrench 40 Nem 30 lbf ft G18 7 16 20 3 16 internal hex wrench 12 Nem 9 lbf ft G45 G50 9 16 18 11 16 inch hex wrench 40 Nem 30 lbf ft G52 G54 9 16 18 1 4 internal hex wrench 23 Nem 17 lbf ft H90 not shown 1 5 16 12 5 8 internal hex wrench 70 Nem 52 Ibfeft
9. Displacement control 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 control adapter plate to the housing have sealing compound on the threads You may remove them with a 6 mm internal hex wrench if necessary Remove and discard the O rings and seals When installing the adapter plate replace screws with sealing compound and ensure the new O rings and seal are in the proper position Torque the screws to 32 Nem 24 Ibfeft Displacement control adapter plate early production 130 cm pumps only Adapter plate screws th gt O 6 mm ek Z 16 Nem 12 Ibf ft Gs cal ec H Adapter plate Seal E101 087E 58 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Manual displacement control MDC Removal 1 Thoroughly clean external surfaces prior to removal of control 2 Using a 5 mm internal hex wrench remove the six control mounting screws M90 Remove the control M1 with orifice check valve T40 and spring T30 and control gasket M11 from the housing Discard the gasket If necessary remove the control handle M70 by removing the locking nut M72 and washer M71 Caution Protect exposed surfaces and cavities from damag
10. If an auxiliary pad is installed an O ring is not used on the cover 11 Carefully remove the alignment pin from the charge pump parts Install the pin in its hole in the charge pump cover J15 see previous page for correct orientation and retain with petroleum jelly Install the cover with alignment pin into the end cap and aligned charge pump parts Take care not to damage the cover O ring if used Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port Refer to the section Auxiliary Pad Installation for details 54 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Minor repair 12 Install the charge pump cover retainer H70 and the six internal hex screws H80 Torque the screws per the table at the right Retainer screw torque Frame size Torque 030 100 16 Nem 11 85 Ibfeft 130 250 32 5 Nem 24 lbf ft 13 For pumps with auxiliary mounting pads install the O ring and auxiliary mounting pad adaptor onto the end cap Refer to the corresponding section for instructions on auxiliary pad installation Integral charge pressure filter replacement Removal 1 Remove the filter canister N40 from the filter head N10 as described on the canister 2 Hold the filter head in place and
11. case pressure below maximum intermittent case pressure 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 loop which is normally the motor case drain Maintain system temperature below the quoted rated temperature Never exceed the maximum intermittent temperature Cold oil will generally 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 Test heat exchangers to verify that these temperature limits are not exceeded Viscosity For maximum efficiency and bearing life ensure the fluid viscosity remains in the recommended range Minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation Maximum viscosity should be encountered only at cold start Fluid and filter recommendations To ensure optimum pump life perform regular maintenance of the flui
12. displacement port L1 cylinder pressure gauge port M4 Servo displacement System pressure cylinder pressure port B gauge port M5 E External control pressure Speed sensor System pressure portA Case drain port L2 E supply port X3 Charge pressure gauge port M3 P106 158E Pump with twin port end cap and manual displacement control Case drain port L1 Servo displacement cylinder pressure gauge port M4 Servo displacement cylinder pressure gauge port M5 System pressure gauge port M2 System pressure port B Charge pump inlet port S System pressure System pressure gauge port M1 port A Ba Get oF uT C ase drain port L2 P106 160E 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Pressure measurem
13. force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Introduction Symbols used in Danfoss literature A WARNING may result in injury A Tip helpful suggestion e CAUTION may result in damage to product or 5 Lubricate with hydraulic fluid property A Reusable part Apply grease petroleum jelly fi Non reusable part use a new part Apply locking compound a Non removable item Cl Inspect for wear or damage amp Option either part may exist A Clean area or part Superseded parts are not interchangeable A Be careful not to scratch or damage T Measurement required g Note correct orientation 7 Flatness specification 2 Mark orientation for reinstallation Paralle
14. housing and install the screws M98 Torque to 5 4 Nem 4 lbf ft Do not remove black plastic cover from the aluminum plate This is not a serviceable item and will void the product warranty PCP removal installation M90 x6 5 mm Z 16 Nem 12 Ibfeft Seal washer location e 42 180 250 cc M98 x4 S 4mm T 5 4 Nem 4 lbf ft P106 194E 3 Position FNR electric control Removal 1 Thoroughly clean external surfaces prior to removal of control 2 Using a 4 mm internal hex wrench remove the four solenoid valve mounting screws W702 Remove the solenoid valve W701 with O rings W701A and orifice from the adapter plate 520L0818 s Rev 0101 s August 2015 63 Devt Service Manual Series 90 Pumps Minor repair 3 Using a 5 mm internal hex wrench remove the six adapter plate mounting screws M90 Remove the adapter plate and gasket M11 from the housing Discard the gasket Caution Protect exposed surfaces and cavities from damage and foreign material Inspection Inspect the orifice installed between the valve and adapter plate This orifice must be installed in the case drain passage for proper pressure limiter operation 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 Nem 12 lbf
15. in the control assembly at the pump housing face Remove the orifice plugs one at a time to avoid mixing 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 to the instructions for the specific control Underside of an HDC EDC module showing orifice locations A g Ze D EN Ee 8 of iS 8 Q 8 E B Orifice plugs D JN orifice check valve E101 085E Displacement control orifice check valve 1 Remove the control assembly as described in the instructions for the specific displacement control 520L0818 s Rev 0101 s August 2015 57 Devt Service Manual Series 90 Pumps Minor repair 2 The orifice check valve is located in the control assembly at the surface of the pump housing face Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve 3 Clean and install the orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position 4 Assemble the control onto the pump Refer to the instructions for the specific control Underside of an MDC module showing orifice locations p Oe oo B Ti PA TB 4b Ei e B e Orifice plugs S 9 ES E 8 Orifice check valve E101 086E
16. other functions are preset at the factory Perform neutral adjustment on a test stand or on the vehicle machine with the prime mover operating A 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 MDC neutral adjustment Servo pressure gauge port M5 0 50 bar 0 1000 psi Servo pressure gauge port M4 9 16 18 12 Nem 9 Ibfeft 0 50 bar 0 1000 psi 9 16 18 12 Nem 9 Ibf ft 13mm 13 Nem 10 Ibfeft P106 165E 1 Install a 50 bar 1000 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 Start the prime mover and operate at normal speed 2 Loosen the lock nut M90 on the neutral adjusting screw M72 with a 13 mm hex wrench 3 Using a 4 mm internal hex wrench rotate the neutral adjusting screw clockwise until the pressure increases on one of the pressure gauges Note the angular position of the wrench Then rotate the adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge Note the angular position of the wrench 4 Rotate the adjusting screw clockwise half the distance between the lo
17. require the vehicle machine to be disabled wheels raised off the ground work function disconnected etc while performing the procedure in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle machine HDC and EDC neutral adjustment Servo pressure gauge port M5 C 0 50 bar 0 1000 psi 9 16 20 12 Nem 9 lbf ft Servo pressure gauge port M4 C 0 50 bar 0 1000 psi 9 16 20 12 Nem 9 Ibf ft M90 O 10 or 13 mm T 7 Nem 5 Ibf ft or 13 Nem 10 lbf ft P106 167E 1 Install a 50 bar 1000 psi gauge in each of the two displacement control cylinder gauge ports M4 and M5 Disconnect the external control input hydraulic or electronic from the control Start the prime mover and operate at normal speed 2 Loosen the lock nut M90 with a 10 mm or 13 mm hex wrench 3 Using a3 mm or 4 mm internal hex wrench rotate the adjusting screw M72 clockwise until the pressure 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 gauge Again note the angular position of the wrench 4 Rotate the adjusting screw clockwise half the distance between the locations noted above The gauges should read the same pressure case pressure indicati
18. switch A Warning Do not start the prime mover while the neutral start switch is removed from the control Case pressure will force the pin out of the eccentric plug causing oil loss 2 Note the slots on the eccentric plug for the adjustment tool Hold the eccentric plug in place with the adjustment tool and loosen the lock nut with a 1 1 8 inch wrench 3 Position the eccentric plug so the switch pin is offset toward the control mounting surface This will provide the best contact between the pin and the cam on the control shaft 4 Hold the control shaft in its neutral 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 When the pin engages the cam slot the pin will be at its maximum depth in the plug Hand tighten the plug lock nut to hold the eccentric plug in position 5 Turn the control shaft an equal amount in either direction from neutral The switch pin should move out of the eccentric plug an equal distance when the control shaft is turned Turn the eccentric plug to center the switch pin with the cam slot Only a small amount of adjustment in either direction is needed to center the pin 6 While holding the eccentric plug in place tighten the eccentric plug lock nut to 27 Nem 20 lbf ft Reinstall and adjust the switch as outlined in the previous section The ec
19. to limit system pressure For unusually rapid load application the high pressure relief valve immediately limits system pressure by cross porting system flow The pressure limiter valve acts as the pilot for the high pressure 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 mechanism To control Multi function valve Servo piston i Ze Port A j Bypass adjustment Port B _J Servo piston Charge pressure relief valve k Multi function valve P104 123E For some applications such as dual path vehicles the pressure limiter function may be defeated so that only the high pressure relief valve function remains The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop This is needed as the pump generally loses system pressure due to lubrication cooling flow and other factors Since the pump operates in either direction the system uses two check valves to direct the charge supply into the low pressure lines The system check valves are part of the multi function valve assembly Bypass valves You can operate the bypass valves to move the vehicle or mechanical function when the pump is not running M
20. to pump control Input to control module is operating improperly Check control input and repair replace as necessary Pump displacement control Control linkage is not secure control orifices are blocked etc Repair or replace control module as necessary Bypass valve s open If bypass valve s are open the system loop will be depressurized Close bypass valves Replace multi function valve if defective Charge pressure with pump in neutral Low charge pressure is insufficient to recharge system loop Measure charge pressure with the pump in neutral If pressure is low go to Pump charge relief valve otherwise continue with Charge pressure with pump in stroke Charge pressure with pump in stroke Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set Measure charge pressure with pump in stroke If pressure is low adjust or replace motor charge relief valve otherwise go to Charge pumps Pump charge relief valve A pump charge relief valve that is leaky or set too low will depressurize the system Adjust or replace pump charge relief valve as necessary Charge pump inlet filter A clogged filter will under supply system loop Inspect filter and replace if necessary Charge pumps A malfunctioning charge pump will provide insufficient charge flow Repair or replace the charge pump Pump dis
21. units only You may purchase O rings separately 5 The poppet seat section is pressed over a lip Place the cartridge in a vise and pry the poppet seat P12 off with an appropriate tool Maintain sufficient control to prevent the internal components from flying loose Do not damage parts during disassembly 6 Remove internal parts P07 P08 P17 P16 P15 P14 P09 and P11 Multi function valve E101 531E 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 Place the cartridge in a vise and press on the poppet seat P12 3 Lubricate and install new O rings P02 P06 P13 4 Install bypass actuator P03 with pressure limiter valve P01 Torque to 40 Nem 30 lbf ft Er Caution lf pressure limiter P01 was removed from bypass actuator P03 adjust pressure limiter to model code specifications 5 Install cartridges and torque as shown in the table Caution Do not overtorque the multi function valve cartridges 520L0818 Rev 0101 s August 2015 45 Service Manual Series 90 Pumps Minor repair Multi function valve torque Frame size Torque 030 100 89 N m 66 lbf ft 130 250 210 Nem 155 Ibfeft Multi function valve cartridges pre 1988 Removal 1 Remove multi function valves using hex wrench listed in table
22. 0 1 5 8 inch Unscrew the plug using a large screwdriver or 1 2 inch hex wrench Remove and discard the O ring K50 2 Remove the spring K70 and relief valve poppet K80 Inspection Inspect the poppet K80 and mating seat in the endcap for damage or foreign material When inspecting shim adjustable valves do not alter the shims or interchange parts 48 520L0818 s Rev 0101 s August 2015 Danfoss Service Manual Series 90 Pumps Minor repair Reassembly Install the poppet K80 and spring K70 For shim adjustable valves install the shims and plug torque to 68 N m 50 lbf ft For screw adjustable valves install the plug with its lock nut aligning the marks made at disassembly and torque the lock nut to 52 Nem 38 lbf ft Check the charge pressure and adjust if necessary Refer to Charge pressure adjustments Charge pressure relief valve K90 Lock nut Lock nut torque K10 O 1 2 in P106 169E 520L0818 s Rev 0101 s August 2015 49 2z Service Manual Series 90 Pumps Minor repair Adding an Auxiliary pad to a pump previously without one 1 Remove the six retaining screws H80 and remove the retaining plate H70 and cover plate J15 Remove the cover plate P108928 2 Observe the alignment pin H40 If the pin remains in the charge pump leave it in place If the pin comes out
23. 1 rpm 4200 3900 3600 3300 3100 2600 2300 Maximum speed min 1 rpm 4600 4250 3950 3650 3400 2850 2500 Maximum attainable speed at min 1 rpm 5000 4700 4300 4000 3700 3150 3750 maximum displacement Theoretical torque at maximum N m bar 0 67 0 88 1 19 1 59 2 07 2 87 3 97 displacement Ibf in 1000 380 530 730 870 1260 1750 2433 psi Weight base unit only kg 34 40 49 68 88 136 154 Ib 75 88 108 150 195 300 340 Fluid specifications Ratings and data are based on operation with premium petroleum based hydraulic fluids containing oxidation and foam inhibitors 520L0818 Rev 0101 s August 2015 19 Service Manual Series 90 Pumps Technical specifications Parameter Unit Minimum Continuous Maximum Viscosity mm sec cSt 7 12 60 1600 SUS 47 66 278 7500 Temperature C F 40 40 104 220 115 240 Cleanliness ISO 4406 Class 22 18 13 or better Filtration efficiency suction filtration B35 44 75 B1022 charge filtration 615 20 75 810210 20 520L0818 Rev 0101 s August 2015 Service Manual Series 90 Pumps Initial start up procedure General Start up procedure Follow this procedure when starting up a new pump installation or when restarting an installation in which the pump was removed A Warning Unintended movement of the machine or mechanism may cause injury to th
24. MAKING MODERN LIVING POSSIBLE Service Manual Series 90 Pumps powersolutions danfoss com Service Manual Series 90 Pumps Revision history Table of revisions Date Changed Rev August 2015 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 AA 520L0818 Rev 0101 s August 2015 Service Manual Series 90 Pumps Contents Introduction Operation Operating parameters Technical specifications Initial start up procedure Pressure measurement Troubleshooting ENGEM ee 5 Warranty 5 General instructions 5 Safety precautions 6 Unintended machine movement 6 Flammable cleaning solvents 6 It Ee e EE 6 Prsonal SafLW EE 6 Symbols used in Danfoss literature esscssssccssssccsssescsssecsssescessecssusecssuseessnscessuecsesuseessnseessaseessuseessuscessnsecssneecesuseersnceessueeessuees 7 DGS Le Lu DEE 7 The systeffI CUCU Sci ccs sassesscnvspacstsccanivsscnaieseraseayonsonsnwesicostgucesverdosnanssaassesnsetecuuacchnqsvcnvoqacuasaigonssvonaissetasevssnusertaqsuaosugscasvedabastnsstaasecnsaie 8 TH pasic closed CirCUitisscisacsncessdsesndsisscstwesedessnssacsdbvsvscessnuteesetstocednnsussbesSvnassGetsnssaedeesatisdessasstesbroavie escaussasionataisadtaibeediata
25. N35 N36 not shown 9 16 18 11 16 inch hex wrench 37 Nem 27 lbf ft N37 9 16 18 1 4 internal hex wrench 40 Nem 30 lbf ft 520L0818 Rev 0101 s August 2015 69 Service Manual Series 90 Pumps Torque chart Fasteners and plugs Fastener and plug locations B70 B72 O ring plug 9 16 18 380 Auxilliary pad M90Control bolt end cap screw G90End cap screw H80 Charge pump retaining screw L70Shaft seal retaining screw G53 G540 ring plug 9 16 18 K10Charge pressure relief valve plug M88 Neutral start switch lock nut M85 Eccentric plug K90Charge pressure lock nut relief valve lock nut B80O ring plu Ce P2B1 Multi function valve G97 End cap screw B710 ring plug m 9 16 18 Bgam co 1 1 i B83 Speed sensor G500 ring plug LV O ring plug x 9 16 18 9 16 18 Py S D _ O G49O ring plug 9 16 18 G48O ring plug goro 9 16 18 N H i l L Bi D H i LO O EU REESEN to EC LET EX N37Filter plug assembly F111 F211Servo cylinder screw E60Side cover screw N10Filter re
26. This operation helps remove air from the system lines Refill the reservoir to recommended full fluid level 8 When charge pressure reaches 3 5 bar 50 psi 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 Caution Air entrapment in fluid under high pressure may damage hydraulic components Do not run at maximum pressure until system is free of air and fluid has been thoroughly filtered 9 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 10 Shut off the engine Connect the pump control signal Start the engine checking to be certain the pump remains in neutral Run the engine at normal operating speed and carefully check for forward and reverse control operation 11 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 12 Check that the reservoir is full Remove charge pressure gauge The pump is now ready for operation 520L0818 Rev 0101 s August 2015 21 Service Manual Series 90 Pumps Pressure measurement Required tools You can perform
27. adjust the pressure limiter setting by rotating the pressure adjusting screw with an internal hex wrench Clockwise rotation of the pressure adjustment screw increases the pressure setting and counterclockwise rotation decreases the pressure setting Each complete rotation of the pressure adjusting screw changes the pressure as shown in the following table Pressure limiter adjustment data Frame size Lock nut wrench size and torque Adjusting Approximate pressure change per screw size revolution of adjusting screw early 042 100 10 mm 3 Nem 26 lbf in 3mm 80 bar 1157 psi 030 100 19 mm 20 Nem 15 bt 5mm 90 bar 1300 psi early 130 13 mm 20 Nem 15 lbf ft 4mm 80 bar 1157 psi 130 250 24 mm 40 Nem 30 lbf ft 8mm 80 bar 1157 psi 7 To verify the actual pressure setting actuate or move the control input so that the pump again develops pressure in the high pressure circuit to the newly adjusted pressure limiter pressure setting then read the high pressure gauge Allow the pump to return to its neutral position The pressure in the high pressure circuit should return to the charge pressure setting 8 While holding the pressure adjusting screw stationary tighten the pressure adjusting screw lock nut Torque as shown in the table Do not overtorque 9 Shut down the prime mover remove the gauges and install the gauge port plugs Replace the plastic dust plugs if used Use the same procedure fo
28. alve _ Bypass adjustment J Shute valve t Port B Multi function valve Charge pressure relief valve P104 124E Manual displacement control MDC Non Linear MDC The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring centered four way servo valve This valve ports hydraulic pressure to either side of a dual acting servo piston The servo piston rotates the cradle swashplate through an angular rotation of 17 varying the pump s displacement from full in one direction to full in the opposite direction The angular position of the pump swashplate is proportional to the rotation of the control input shaft The non linear manual displacement control operates in the same manner except that it is designed so 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 Neutral start switch NSS A solenoid override valve option is available for the MDC This safety feature returns the swashplate to zero displacement It is available in normally open activate to allow or normally closed activate to disallow options The neutral start switch is an optional feature available with the MDC When connected properly with the vehicle
29. anually resetting the valve position opens the valve The bypass valves are built into the multi function valves 12 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Operation Speed sensors An optional speed sensor can provide unit speed information The sensor reads a magnetic ring on the unit s cylinder block See the corresponding section to locate install and adjust the speed sensor Filtration options Series 90 pumps may have either suction or charge pressure filtration to filter the fluid entering the circuit The suction filter is in the circuit between the reservoir and the inlet to the charge pump as shown below The use of a filter contamination monitor is recommended Suction filtration Hydraulic fluid reservoi Manometer n Charge pump Filter Adjustable charge pressure relief valve To low loopand control L To pump case P102 003E Suction filtration option S The suction filter is in the circuit between the reservoir and the inlet to the charge pump as shown below The use of a filter contamination monitor is recommended Charge pressure filtration option R T P and L The pressure filter can be mounted on the pump or remotely for ease of servicing You will typically find a 100 125 um mesh screen in the reservoir or the charge inlet This system requires a filter capable of withstanding charge pressure reference
30. bf ft SH 075 250 10 mm hex 32 5 Nem 24 Ibfeft G90 G9 End cap screw 030 042 5 mm internal hex 13 5 Nem 10 lbf ft 7 055 100 6 mm internal hex 32 4 Nem 24 lbf ft 130 10 mm hex 38 Nem 28 lbf ft 180 250 10 mm hex 110 Nem 81 Ibf ft H80 Charge pump retaining screw 030 100 10 mm hex 16 Nem 11 85 bt 130 250 13 mm hex 32 Nem 24 lbf ft J80 End cap screw 030 8 mm internal hex 58 Nem 43 lbf ft early 042 8 mm internal hex 75 Nem 55 Ibfeft late 042 10 mm internal hex 75 Nem 55 lbf ft 055 19 mm hex 122 Nem 90 lbf ft 075 100 24 mm hex 298 Nem 220 Ibfeft 100 130 14 mm internal hex 298 Nem 220 Ibfeft 180 250 17 mm internal hex 580 Nem 429 Ibfeft K10 Charge pressure valve plug 030 250 1 2 in hex NA K90 Charge pressure lock nut 030 100 1 1 16 in hex 52 Nem 38 Ibfeft 130 250 1 5 8 in hex 52 Nem 38 lbf ft L70 Shaft retaining screw 030 042 10 mm hex 12 Nem 9 lbf ft 055 100 5 mm internal hex 16 Nem 12 lbfeft 130 250 6 mm internal hex 32 Nem 24 lbf ft M72 MDC handle nut 030 250 8mm 13 5 Nem 10 lbf ft M78 De stroke valve manifold screw 030 250 5 mm internal hex 13 5 Nem 10 Ibfeft M85 Eccentric plug lock nut 030 250 1 1 8 in hex 27 Nem 20 lbf ft M88 Neutral start switch lock nut 030 250 1 1 8 in hex 27 Nem 20 lbf ft M90 Control mounting screw 030 250 5 mm internal hex 16 Nem 12 lbfeft M92 Solenoid valve mounting screw 030 250 4 mm internal hex 5 4 Nem 4 lbf ft M98 PCP mounting screw 030 250 4 mm internal hex 5 4 Nem 4 lbf ft
31. bly outer ring N Install the alignment pin H40 to properly orient the port plates and outer eccentric ring for corresponding pump rotation Prior to installation lubricate the I D O D and side faces of the gerotor assembly Install the gerotor assembly H05 Install the outer port plate early production and intermediate production pumps only Install the spacer plate if present intermediate production pumps N Qu P WwW Install the charge pump drive key H60 into the charge pump coupling H50 and retain with petroleum jelly Intermediate production 75 cm and 100 cm pumps use the same charge pump coupling Two keyways are provided in the coupling for the charge pumps used in these units The rear keyway with 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 the coupling must engage the main pump shaft The outside diameter of the internally splined end of some early production charge pump couplings were chamfered Early production end caps may not be machined to accept a non chamfered coupling Always use a chamfered charge pump coupling in pumps with the early endcap For pumps with an auxiliary mounting pad install the auxiliary drive coupling 10 For pumps with no auxiliary pad install a new O ring J40 onto charge pump cover
32. cations noted above The gauges should read the same pressure indicating that the control is in its neutral position 5 Hold the adjusting screw stationary and tighten the lock nut to 13 5 Nem 10 lbf ft Do not overtorque the nut 6 Once the neutral position is set stop the prime mover remove the gauges and install the gauge port plugs Reconnect the external control linkage 34 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Adjustments MDC Neutral start switch NSS adjustments The Neutral Start Switch NSS provides a means to prevent the system prime mover from starting while the pump control handle is in stroke When the control input shaft is in its neutral position the switch pin engages a slot on the eccentric cam attached to the control shaft This allows the spring loaded NSS to close completing the electrical starting circuit for the prime mover When the control input shaft is not in its neutral position the eccentric cam opens the NSS switch The neutral start switch is threaded into the special lock nut for the eccentric plug Turning the NSS clockwise CW moves the NSS closer to the switch cam on the control shaft and narrows the NSS deadband Turning the NSS counterclockwise CCW moves the NSS farther from the switch cam on the control shaft widening the NSS deadband The switch pin is located in an eccentric plug which is turned to move the center of the NSS deadband MDC
33. centric plug normally requires between 5 1 2 and 6 1 2 turns to install into the control housing Eccentric plug adjustment Switch pin Eccentric plug an mounting Eccentric plug surface adjustment range P104 151E 520L0818 s Rev 0101 s August 2015 37 Service Manual Series 90 Pumps Adjustments Checking switch continuity Caution Do not turn the eccentric plug into or out of the housing beyond specifications 7 Once the switch is correctly adjusted hold the switch in place and tighten the lock nut to 27 Nem 20 Ibf ft torque NSS deadband adjustment conditions ii amp iii The NSS deadband must be wide enough so the NSS will not open within the control shaft free play area and it must be narrow enough so the NSS will open before the unit builds 7 bar 100 psi differential system pressure in either direction 1 Install two 1000 bar 10 000 psi pressure gauges in the system pressure gauge ports M1 and M2 2 Using two 1 1 8 inch wrenches hold the neutral start switch from turning and loosen the lock nut 3 4 Attach a continuity checker to the terminals of the switch With the control shaft in its neutral Disconnect the external control linkage and make certain the control shaft is in its neutral position position turn the switch clockwise CW until the switch opens then turn the switch counterclockwise CCW until it closes Turn the switch counterc
34. changing the system filter and when removing hoses or plumbing A worldwide network of Danfoss Global Service Partners GSPs is available for major repairs Danfoss trains GSPs and certifies their facilities on a regular basis You can locate your nearest ASC using the distributor locator at www DanfossPower Solutions com Click on the Sales and Service link Performing installation maintenance and minor repairs according to the procedures in this manual will not affect your warranty Major repairs requiring the removal of a unit s rear or side cover voids the warranty unless done by a Danfoss Authorized Service Center Follow these general procedures when repairing Series 90 variable displacement closed circuit pumps Remove the unit A Prior to performing major repairs remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses after removal to prevent contamination Keep it clean Al 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 part
35. d and filter Contaminated fluid is the main cause of unit failure Maintain fluid cleanliness when servicing Check the reservoir daily for proper fluid level the presence of water and rancid fluid odor Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir Rancid odor indicates the fluid has been exposed to excessive heat Change the fluid immediately if these conditions occur Correct the problem immediately Inspect vehicle for leaks daily 520L0818 Rev 0101 s August 2015 17 2z Service Manual Series 90 Pumps Operating parameters Change the fluid and filter per the vehicle machine manufacturer s recommendations or at the intervals shown in the table Change fluid after first 500 hours Fluid and filter change interval Reservoir type Max oil change interval Sealed 2000 hours Breather 500 hours Caution High temperatures and pressures result in accelerated fluid aging Change fluid more frequently if operating under extreme conditions Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater than the recommended maximum Dispose of used hydraulic fluid properly Never reuse hydraulic fluid Change filters whenever the fluid is changed or when the filter indicator indicates a filter change Replace all fluid los
36. d install the gauge port plugs Pressure override valve for 180 frame size Pressure override valve Adjusting screw P104 145E 32 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Adjustments Displacement limiter adjustment You can limit the maximum displacement in either direction 1 Loosen the lock nut F212 while holding the adjusting screw F213 steady 2 Rotate the adjusting screw some amount using information in the following table Rotating the adjusting screw clockwise decreases the maximum displacement of the pump while rotating the adjusting screw counterclockwise increases the maximum displacement OO Caution Take care in adjusting displacement limiters to avoid undesirable flow or speed conditions Re torque lock nut F212 after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation 3 One turn of the adjusting screw changes the maximum displacement as shown in table below 4 After establishing the desired maximum displacement setting torque the lock nut to the torque shown in table below Displacement limiter adjustment F212 P106 164E Adjusting screw Lock nut Lock nut torque Frame size Lock nut wrench size and torque Adjusting Approx
37. ducer assembly P106 189E P2A1 Multi function valve 70 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps 520L0818 Rev 0101 s August 2015 71 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors PLUS 1 GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Comatrol www comatrol com Schwarzmiiller Inverter www schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 D 24539 Neum nster Germany Phone 49 4321 871 0 Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic 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 Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles t
38. e Danfoss publication BLN 9884 Pressure and speed limits A 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 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 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 Operating at or below this pressure should yield satisfactory product life Maximum pressure is the highest intermittent pressure allowed Maximum machine load should never exceed this pressure For all applications the load should move below this pressure All pressure limits are differential pressures referenced to low loop charge pressure Subtract low loop pressure from gauge readings to compute the differential An internal charge relief valve regulates charge pressure The charge pump supplies the control with pressure to operate the swashplate and to maintain a minimum pressure in the low side of the transmission loop Minimum charge pressure is t
39. e and foreign material Reassembly 1 Install a new gasket M11 Inspect control to assure that the control orifice check valve and spring are in their proper position in the control 2 Install the control Engage the pin on the control linkage into the mating hole in the link attached to 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 return to center remove the control and repeat the above procedure If removed install the control handle M70 and locking nut M72 with washer M71 Hold the position of the handle and torque the locking nut to 13 5 Nem 10 Ibf ft using an 8mm hex wrench 4 Align the control gasket and install the screws Torque the screws to 16 Nem 12 Ibfeft A Warning The neutral start switch neutral must be readjusted after reassembling the MDC module Install a sealing washer under the head of mounting screws that are installed into through holes in the housing 5 If the control is equipped with a neutral start switch refer to MDC Neutral start switch adjustment instructions 520L0818 s Rev 0101 s August 2015 59 Service Manual Series 90 Pumps Minor repair MDC removal installation S40 O Z 27 Nem 20 Ibf ftJ M90 x6 CH Z 8 mm 13 5 Nem 10 Ibfeft
40. e 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 shipping damage 1 Ensure that the hydraulic fluid and system components reservoir hoses valves fittings and heat exchanger are clean and free of contamination 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 M 4 Fill the housing by adding filtered fluid in the upper case drain port Open the case plug in the top of the control to assist with 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 6 Disconnect the pump control input signal After start up the fluid level in the reservoir may drop due to filling of the system components Check the level in the reservoir to maintain a full fluid level throughout the start up procedure Caution Damage to hydraulic components may occur from failure to maintain fluid supply 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 then crank the engine a second time
41. ecssseesssuteccsnesssuecessnecessuceesuseessuseeseneessaeeeesee 22 O EAA EW enee ENESE T EE A EAA EE ENT EEE E 25 Neutral difficult or impossible to find 25 System operating Ot ssszesssiciecdcccsss ccassaaicsgetessdtanescvesosscsiastugussvecnsessscasaigusvccopasesscasyuedusecgcassleaascataseccteadiateusaosansdtcadaaguusscctasndaiaieiee 25 520L0818 Rev 0101 s August 2015 3 Service Manual Series 90 Pumps Contents Adjustments Minor repair Torque chart Transmission operates Normally in ONE direction only 25 System will not operate in either AirectiOn seccssssecsssessccsseccssescssseescsuseccssececsusecssneesesueecsuecessueessuseessucesesueccsneeeesueeesenees 26 Low motor OUTPUT torque 26 Improper motor output speed 26 System noise or vibration 27 System response is sluggish Standard procedures inspections and adiustments ENEE e M Charge pressure relief valve adjustment Multi function valve pressure adjustment Engaging the bypass function Pressure override POR valve pressure adjustment option for 180 frame size Displacement limiter adiustment EEN Standard manual displacement control MDC adiustrment EENEG Non linear manual displacement control IMIDC s s lt EE EEEEAEEEELEEEELETEE LSEEE LETEE LEEEEELEEEELerrrrkrri MDC Neutral start switch NSS adiustments ENEE Checking SWItCH COlitINU EWiosaixsassagisgbax
42. ent Pump with side port end cap and remote pressure filtration Pump with side port end cap and integral pressure filtration CH Charge pressure j TT gauge port M6 Port E before the filter from filter Port D to filter 7 Charge pressure J gauge port M3 back side after the filter IEF LU HG To IR J E Charge pressure gauge port M3 after the filter ao P106 163E 24 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Troubleshooting Overview This section provides general steps to follow if certain undesirable system conditions occur Follow the steps in a section until you solve the problem Some of the items are system specific For areas covered in this manual we reference the section Always observe the safety precautions listed in the Introduction section and those relating to your specific equipment Neutral difficult or impossible to find Item Input to pump control Description Input to control module is operating improperly Action Check control input and repair or replace as necessary Pump displacement control Control linages are not secure control orifices are blocked Adjust repair or replace control module as necessary Multifuncti
43. et into the pump 3 Ensure the surrounding areas are clean and free of contaminants 4 Inspect the system for contamination 5 Visually inspect the hydraulic fluid for signs of system contamination fluid discoloration foam in the fluid sludge or small metal particles 6 If there are signs of contamination in the hydraulic fluid replace all filters drain and flush the hydraulic system and fill with the correct filtered hydraulic fluid 7 Flush the lines before replacing the hydraulic fluid This section offers instruction on inspection and adjustment of pump components Read through the entire related section before beginning a service activity Refer to Pressure measurement for location of gauge ports and suggested gauge sizes Charge pressure relief valve adjustment The following procedure explains how to check and adjust the charge pressure relief valve A Warning The following procedure may require the vehicle machine to be disabled wheels raised off the ground work function disconnected etc in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle machine 1 Install a 50 bar 1000 psi pressure gauge in the pump charge pressure gauge port M3 Install a 10 bar 100 psi gauge to measure case pressure tee into L1 or L2 or use servo gauge port M4 or M5 Operate the system with the pump in neutral zero displacement when measuring pump charge pre
44. eutral zero flow In forward or reverse charge pressure is lower The pump model code specifies the charge relief valve setting Charge pressure relief valve tt bag ax 1 IC 2 TTT N OT seg Z7 Charge pressure P106 157E The multi function valve incorporates the system check valve the pressure limiter valve the high pressure relief valve and the bypass valve in a replaceable cartridge These functions are described separately There are two multi function valve cartridges in each Series 90 pump to handle functions in either direction See corresponding sections for adjustments and repairs 520L0818 Rev 0101 s August 2015 11 Service Manual Series 90 Pumps Operation Multi function valve High pressure Pressure limiter housing relief check Pressure limiter valve poppet lock nut J See Check valve poppet Pressure limiter 4 adjustment screw TEKN SEEN E B actuator Pressure limiter yas P104 122E valve poppet Some multi function valves do not include a pressure limiter valve Pressure limiter and high pressure relief valves System check valves Series 90 pumps have a sequenced pressure limiting system and high pressure relief valves When the system pressure reaches the preset the pressure limiter system rapidly de strokes the pump
45. ft Caution Protect exposed surfaces and cavities from damage and foreign material Install a sealing washer under the head of any mounting screws that are installed into through holes in the housing 2 Install new O rings W701A and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter plate Install screws W702 Torque to 5 4 Nem 4 lbf ftl 64 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair FNR removal installation mg e 5mm 5 4Nem 4 lbfeft HIO W701A M90 x6 ee o 5 mm i 16 Nem 12 lbfeft ii 180 V i 1 T50 a Msoo Seal washer o A location 42 180 250 cc 5 9 S Q T40 P106 185E 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 facing the control until they are flush to 2 0 mm 0 08 inch below the surface of the housing 520L0818 s Rev 0101 s August 2015 65 Service Manual Series 90 Pumps Minor repair Filter screen installation B90 SC e d P106 690E Speed sensor Removal 1 Loosen the lock nut using a 11 16 in hex wrench 2 Unscrew the speed sensor B83 from the pump housing Remove and discard the O ring B83A
46. ft Cross section view of speed sensor in variable pump lt Tir gt Speed sensor Magnetic speed ring Cylinder block P104 152E Positioning speed sensor relative to pump shaft Speed sensor with Speed sensor with packard connector turck connector Shaft centerline 1 2 inch wrench flats Speed sensor with Speed sensor with packard connector turck connector P104 155E 520L0818 s Rev 0101 s August 2015 41 Service Manual Series 90 Pumps Minor repair Standard procedures Removing the pump Before working on the pump clean the outside of the pump 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 contamination does not enter the system Caution Contamination can damage internal components and void your warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines Disassembly 1 With the prime mover off thoroughly clean the outside of the pump 2 Tag cap and disconnect each hydraulic line connected to the pump As hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not enter the system 3 Remove the pump and its auxiliary pump if applicable as a single unit Inspection 1 Ensure the work surface and surrounding area are clean and free
47. he eccentric plug is necessary 38 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Adjustments A Warning The following procedure may require the vehicle machine to be disabled wheels raised off the ground work function disconnected etc while performing the procedure in order to prevent injury to the technician and bystanders Take necessary safety precautions before moving the vehicle machine Checking switch continuity Servo pressure gauge port M5 0 50 bar 0 1000 psi 9 16 18 Z 12 Nem 9 Ibf ft Servo pressure gauge port M4 C 0 50 bar 0 1000 psi 9 16 18 12 Nem 9 Ibf ft P106 166E 1 Install a 50 bar 1000 psi gauge in each of the two servo cylinder gauge ports M4 and M5 Attach a continuity checker to the terminals of the neutral start switch 2 Energize the starter circuit and start the prime mover 3 While operating at normal speed and with the pump in its neutral zero flow position note the pressure reading on the gauges Note this reading as the base pressure 4 Slowly move the control handle in one direction while observing the pressure gauges and the continuity checker The switch must open before the pressure on either gauge increases more than 1 bar 15 psi from the base pressure obtained at neutral 5 Slowly move the control handle in the opposite directi
48. he lowest pressure allowed to maintain a safe working condition in the low side of the loop Minimum control pressure requirements are a function of speed pressure and swashplate angle and may be higher than the minimum charge pressure shown in the operating parameters table Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment and provides normal component life You can use elevated charge pressure as a secondary means to reduce the swashplate response time The charge pressure setting 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 sec 150 SUS The charge 16 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Operating parameters Charge inlet pressure Case pressure Temperature and viscosity pressure setting is referenced to case pressure Charge pressure is the differential pressure above case pressure At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure Minimum charge inlet pressure is only allowed at cold start conditions In some applications it may be necessary to warm up the fluid by running the engine at limited speed until the system fluid temperature reaches an acceptable level Under normal operating conditions do not exceed the rated case pressure During cold start maintain the
49. ial Reassembly 1 Install a new gasket M11 Verify the control orifice check valve 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 Z M90 x6 5 mm 16 Nem 12 Ibfeft P106 187E 3 With the control in position move control assembly left and right to check engagement of pin in the link Proper engagement is indicated by an increasing resistance as the control is moved away from center position Non engagement of pin is indicated by lack of spring force In case of non engagement remove control and repeat the above procedure 62 520L0818 s Rev 0101 s August 2015 244 Service Manual Series 90 Pumps Minor repair 4 Align the control gasket and install the screws Torque the screws to 16 Nem 12 lbf ft Install a sealing washer under the head of any mounting screws that are installed into through holes in the housing Pressure control pilot PCP for electric displacement control EDC Removal 1 Thoroughly clean external surfaces of control 2 Using a 4 mm internal hex wrench remove the four screws M98 and remove the PCP M9 Inspection Check surfaces for nicks or damage Clean internal screens Reassembly Install new O rings M96 and M97 in PCP Housing Place PCP against EDC
50. id valve M9 with O rings from the adapter plate Discard the O rings 3 Using a 4 mm internal hex wrench remove the four adapter plate mounting 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 adapter plate Place the adapter plate into position and install the screws M98 Torque the screws to 5 4 Nem 4 lbfeft 2 Using petroleum jelly to retain them install new O rings onto the solenoid valve assembly M9 and install the solenoid valve onto the adapter plate Install the screws M92 and torque to 4 Nem 4 Ibf ft Solenoid override valve removal installation M98 x4 4mm 5 4 Nem 4 lbf ft E i 5 4 Nem 4 lbf ft P106192 520L0818 s Rev 0101 s August 2015 61 Service Manual Series 90 Pumps Minor repair Hydraulic and electric displacement controls Removal 1 Thoroughly clean external surfaces prior to removal of control 2 Using a5 mm internal hex wrench remove the six control mounting screws M90 Remove the control M1 with orifice check valve T40 and spring T30 and control gasket M11 from housing Discard the gasket Dr Caution Protect exposed surfaces and cavities from damage and foreign mater
51. ies 90 Pumps Introduction Basic closed circuit diagram q Reservoir Y Input py MF Output H A Flow Bi directional lt a N Case drain line P104 120E Case drain and heat exchanger The pump and motor require case drain lines to remove hot fluid from the system The topmost port drains the motor to ensure the case remains full of fluid Fluid routes through the lower drain port on the pump and out the topmost port to the reservoir A heat exchanger with a bypass valve cools the case drain fluid before it returns to the reservoir System circuit diagram Control handle Displacerrent control valve Heat exchanger bypass valve wy Reservor Orificed heck valve Vacuum gauge CT Heat exchager Purge relef valve Fizio Charge pressure relief valve Reversiblevariabe displacemat pump Servo control cylinder Multi funcion valve Fixed disphcementmot Se l e CP f Servo Zr NY H jj pressure ETS ten eo EE lr elief valves LS J Charge punp 4 Input shaf Output shat Multi fundion valve Motor swashplate Pump swashplate Servo control cylinder Loop flusting valve Pump Motor Working bop high pressure SS Working loop low pressure Suction line Control fluid Case drai
52. imate displacement change screw size per revolution of adjusting screw 030 13 mm 24 Nem 18 lbf ft 4mm 2 8 cm rev 0 17 in rev 042 13 mm 24 Nem 18 lbf ft 4mm 3 5 cm rev 0 21 in rev 055 13 mm 24 Nem 18 lbf ft 4mm 4 2 cm rev 0 26 in rev 075 13 mm 24 Nem 18 lbf ft 4mm 5 1 cm rev 0 31 in rev 100 13 mm 24 Nem 18 lbf ft 4mm 6 2 cm rev 0 38 in rev 130 17 mm 48 Nem 35 Ibfeft 5mm 8 8 cm rev 0 53 in rev 180 19 mm 125 Nem 92 Ibf ft 6mm 12 5 cm rev 0 76 in rev 250 19 mm 125 Nem 92 Ibfeft 6mm 17 3 cm rev 1 06 in rev Standard manual displacement control MDC adjustment There are no adjustable elements in the manual displacement control Centering springs and washers on each end of the control spool hold it in its neutral position Since there is no centering spring on the control input shaft the shaft automatically assumes the appropriate position when the control is installed on the pump 520L0818 Rev 0101 s August 2015 33 2z Service Manual Series 90 Pumps Adjustments Non linear manual displacement control MDC A centering spring located on the control input shaft locates the control shaft in its neutral position A bias spring on the control spool maintains a force on the spool and the control linkage to eliminate free play in the linkage Neutral adjustment is the only adjustment that can be made on the nonlinear manual displacement control All
53. in reservoir Insufficient hydraulic fluid causes sluggish response Fill reservoir to proper level Multi function valves pressure settings Pump inlet vacuum Incorrect pressure settings affects system reaction time High pump inlet vacuum reduces system pressure Adjust or replace multi function valves Measure charge inlet vacuum If high replace inlet filter Prime mover speed Low engine speed reduces system performance Adjust engine speed Charge and control pressures Incorrect charge or control pressures affects system performance Measure charge and control pressures and correct if necessary System internal leakage Internal leakage reduces system pressure Check for leakage in O rings gaskets and other fittings 520L0818 Rev 0101 s August 2015 27 Service Manual Series 90 Pumps Adjustments Standard procedures inspections and adjustments Adjustments Before working on the pump clean the outside of the pump 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 connected to the pump If hydraulic lines are disconnected plug each open port with a clean plug to ensure that dirt and contamination do not g
54. irements NSS deadband switch closed ON Control deadband neutral Total control shaft rotation Control shaft free play Control shaft P104 147E Neutral start switch eccentric plug adjustment condition i Center the NSS deadband and the control deadband in relation to each other Since you cannot adjust the position of the 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 installed on the pump and in its neutral position when adjusting the neutral start switch eccentric plug The accompanying drawing provides dimensions for an eccentric plug adjustment tool Eccentric plug adjustment tool 127 9 14 0 5 0 36 GE Y 3 175 1 52 0 125 0 06 be 254 1 0 P104 149E 36 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Adjustments NSS with eccentric plug Eccentric plug Special lock nut Kee 3 NAR NY for eccentric plug Neutral start switch Switch lock nut Switch pin Special lock nut for eccentric plug Control HE Eccentric plug mounting surface Seene View B B switch and lock nut removed P104 150E 1 Hold the switch and eccentric plug from turning and use a 1 1 8 inch wrench to loosen the lock nut Remove the neutral start
55. its bore pry it from its bore and or lightly tap the end of the shaft with a soft mallet 4 Remove the O ring L50 from the seal carrier and discard 5 Place seal carrier and seal in an arbor press and press out the seal L40 42 520L0818 s Rev 0101 s August 2015 244 Service Manual Series 90 Pumps Minor repair 6 Remove shaft L100 and roller bearing assembly L10 from pump You can transfer the bearing assembly to the new shaft 7 Using snap ring pliers remove the retaining ring L20 that secures the roller bearing assembly Remove the roller bearing assembly Shaft assembly L10 L100 P106 181E Inspection 1 Inspect the seal carrier the new seal and the O ring for any damage or nicks 2 Inspect 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 carrier L30 Be careful not to damage the seal If the shaft is not being replaced proceed to step 3 2 Place roller bearing assembly on new shaft and secure with the retaining ring 3 Install an installation sleeve or wrap spline or keyed end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation 520L0818 Rev 0101 s August 2015 43 Devt Service Manual Series 90 Pu
56. l includes a three position electric control to provide direction control 3 Position FNR electric control This control utilizes a 12 or 24 Vdc electrically operated spool valve to port pressure to either side of the pump servo piston Energizing one of the solenoids causes the pump to go to its maximum displacement in the corresponding direction All functions of the three position FNR electric control are preset at the factory 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Operating parameters Overview Input speed System pressure Charge pressure This section defines the operating parameters and limitations for Series 90 pumps with regard to input speeds and pressures For actual parameters refer to the operating parameters for each displacement Minimum speed is the lowest input speed recommended during engine idle condition Operating below minimum speed limits the pump s ability to maintain adequate flow for lubrication and power transmission Continuous 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 When determining speed limits for a particular application se
57. lism specification z Torque specification le External hex head z Press in press fit Internal hex head Ge Pull out with tool press fit Torx head Cover splines with installation sleeve O ring boss port O 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 Design Danfoss Series 90 closed circuit piston pumps convert input torque into hydraulic power The input 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 the pump prevents leakage where the shaft exits the pump housing The spinning cylinder block contains nine reciprocating pistons A ball joint at one end connects each piston to a brass slipper Fixed clearance hold down brackets keep the slippers in contact with the swashplate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation The valve plate connects one half of the cylinder block to low pressure and the other half to high pressure As each piston cycles in and out of its bore fluid is drawn fr
58. lockwise CCW an additional 1 4 turn 90 after the switch closes Hold the switch in place and tighten the lock nut to 27 Nem 20 lbf ft torque 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 position If the switch closes in neutral and satisfactorily opens in each direction proceed to check the switch with the prime mover running The switch must open before the unit builds 7 bar 100 psi differential system pressure in either direction If the switch opens after the unit builds system pressure in either direction loosen the switch lock nut and turn the switch clockwise CW 1 12 turn 30 Tighten the switch lock nut and recheck the switch operation Repeat this procedure if necessary If the switch does not open with an equal movement of the control handle in each direction turn off prime mover remove the pressure gauges and continue with the next section If neutral start switch operation is satisfactory turn off the prime mover remove the pressure gauges and reconnect the external control linkage Neutral start switch Switch cam Control shaft g Switch lock nut Neutral start switch Switch pin C 1 1 8 in Z 27 Nem 20 Ibf ft P104 148E Recheck switch continuity to determine whether additional adjustment of t
59. loosen the lock nut N20 using the wrench size corresponding to pump frame size 3 Rotate the filter head counterclockwise to remove it from the housing Remove and discard the O ring N15 4 Remove the hydraulic tube N25 from its bore in the endcap Lock nut wrench size and torque Frame size Wrench size Torque 030 042 1 3 8 inch 70 Nem 52 Ibfeft 055 130 1 5 8 inch 122 Nem 90 lbf ft 180 250 1 5 8 inch 156 Nem 115 lbf ft Inspection Inspect the filter head and lock nut sealing surfaces If you find any nicks or scratches replace the damaged components Reassembly 1 Install the hydraulic tube N25 into it s bore in the endcap Install the filter head N10 into the port using a new O ring N15 The hydraulic tube should go in with low force 2 After rotating the filter head clockwise so that the threads engage with the threads in the endcap continue to rotate it clockwise between 6 and 7 revolutions Position head as desired Q Caution Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore This may allow unfiltered oil to bypass the filter and enter the charge system 3 While holding the filter head in the desired position tighten the swivel lock nut N20 and torque as shown in table 4 Install a new filter canister N40 per the instructions on the filter canister
60. low A Warning Do not overtorque the multi function valve cartridges Multi function valve torque Frame size Torque 030 100 89 Nem 66 Ibfeft 130 250 210 Nem 155 Ibfeft Pressure override valve option for 180 frame size Removal Remove the four screws attaching the pressure override valve to the pump end cap with a5 mm internal hex wrench Remove and discard the O rings Inspection Clean and inspect valve for damage to parts Reassembly Install new O rings Install the valve onto the pump end cap and torque the screws to 16 Nem 12 Ibf ft 520L0818 s Rev 0101 s August 2015 47 Service Manual Series 90 Pumps Minor repair Pressure override valve components i Pressure override valve gg O rings E101 079E Charge pressure relief valve The charge pressure relief valve is shim adjustable early models or screw adjustable late models Screw adjustable charge relief valve is shown Removal 1 Remove the shim adjustable charge relief valve plug with a 1 inch hex wrench Before removing the screw adjustable relief valve plug mark the plug K90 lock nut K10 and housing to approximately maintain 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 size Wrench size 030 100 1 1 16 inch 130 25
61. mps Minor repair 4 Lubricate and install a new O ring L50 on the seal carrier Lubricate the seal with clean petroleum jelly 5 Assemble the seal carrier and seal over the shaft and into the housing bore Install the retainer plate if used 6 Install the screws and torque to the appropriate value in the table to the right Torque the screws in a sequenced pattern then recheck Shaft retainer screw torque Frame size Torque 030 042 12 Nem 9 Ibf ft 055 100 16 Nem 12 lbfeft 130 250 32 Nem 24 lbf ft Multi function valve cartridges Older multifunction valves pre 1988 contain different components See multifunction valves Pre 1988 for disassembly instructions Multi function valve removal installation P106 180E Removal 1 Remove multi function valves P2A1 and P2B1 using hex wrench listed in table Multi function valve wrench size Frame size Wrench size 030 100 1 1 4inch 130 250 1 5 8 inch 2 Remove and discard O rings P13 and P06 3 Relieve spring pressure by removing bypass actuator P03 using a 1 1 16 wrench To retain pressure setting do not separate adjusting screw P01 and locknut P04 from bypass actuator P03 44 520L0818 s Rev 0101 s August 2015 Danfoss Service Manual Series 90 Pumps Minor repair 4 Remove and discard O ring P02 Multi function valves are sold as complete
62. n fluid 520L0818 Rev 0101 s August 2015 Service Manual Series 90 Pumps Introduction Pump schematic P104 126E 10 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Operation Charge pump Charge relief valve Multi function valves The charge pump is necessary to supply cool fluid to the system to maintain positive pressure in the main 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 the transmission The charge pump is a fixed displacement gerotor type pump driven off the main pump shaft The charge relief valve limits charge pressure Pump charge system Case e drain Charge relief valve line e L System GH Z check E valves Input PV gt i Charge nme D j Inlet filter lt gt Tank P104 121E The charge relief valve on the pump maintains charge pressure 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 assumes the pump is in n
63. ng that the control is in its neutral position 5 Hold the neutral adjusting screw stationary Tighten the neutral adjusting screw lock nut to 7 Nem 62 Ibf in for the 6 mm screw or 13 5 Nem 120 lbf in for the 8 mm screw Do not overtorque the nut 6 Once the neutral position is set stop the prime mover remove the gauges and install the gauge port plugs Reconnect the external control input When installing or adjusting the speed sensor on a pump it must be set at a specific distance from the speed ring on the unit s cylinder To locate the position of the speed sensor on the unit or description see the corresponding section 1 Loosen the sensor lock nut with an 11 16 inch hex wrench 2 Turn the sensor clockwise CW by hand until it contacts the speed ring 40 520L0818 s Rev 0101 s August 2015 Danfoss Service Manual Series 90 Pumps Adjustments 3 Turn the sensor counterclockwise CCW 1 2 turn 180 to establish the nominal gap of 0 71 mm 0 028 inch 4 Then turn the sensor clockwise CW until the wrench flats on sensor body are positioned at a 22 angle to the pump shaft center line Most open end wrenches have a 22 handle offset 5 The final sensor position should be between 1 2 180 and 1 4 turn 90 counterclockwise CCW from the point where the sensor contacts the speed ring 6 Hold sensor in position with a 1 2 inch hex wrench while tightening the lock nut to 13 Nem 10 Ibfe
64. o market faster Danfoss Your Strongest Partner in Mobile Hydraulics Go to www powersolutions danfoss com for further product information Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Danfoss Power Solution representative nearest you Local address Danfoss Power Solutions Trading Danfoss Danfoss Shanghai Co Ltd Power Solutions GmbH amp Co OHG Power Solutions ApS Building 22 No 1000 Jin Hai Rd Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District DK 6430 Nordborg Denmark Phone 45 7488 2222 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 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 520L0818 Rev 0101 August 2015 www danfoss com Danfoss A S 2015
65. of contaminants 2 Inspect the system for contamination 3 Look at the hydraulic fluid for signs of system contamination fluid discoloration foam sludge or small metal particles Reassembly 1 Before replacing the pump on the machine replace all filters and drain and fill the hydraulic system with the correct 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 surrounding area thoroughly Disconnect and remove the pump from the unit and clean it thoroughly before starting repairs Mark all connections for later reassembly Shaft removal 1 Position the pump with the shaft facing up If the unit is positioned horizontally or moved or jarred while the shaft is out the cylinder block could move out of place making shaft installation difficult 2 Remove the three or four screws L70 holding the retainer plate L60 and seal carrier L30 to the housing using a 10 mm hex wrench 042 unit a 5 mm internal hex wrench 055 through 100 units or a6 mm internal hex wrench 130 through 250 units Remove the retainer plate Certain earlier production units use a one piece retainer plate and seal carrier 3 After removing the screws the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm 1 4 inch If the seal carrier does not move from
66. om the inlet and displaced to the outlet thereby imparting hydraulic power 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 piston 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 520L0818 s Rev 0101 s August 2015 7 Service Manual Series 90 Pumps Introduction Cross section Piston Slipper Displacement control Slider block S Servo arm Servo piston Feedback linkage Cradle bearing Bushing Cylinder block Roller bearing Shaft Valve plate seal Rear bushing Input shaft Charge pump Swashplate Cradle guide P106 648E The system circuit The 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 circuit Either of the hydraulic lines can be under high pressure In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow 8 520L0818 s Rev 0101 s August 2015 Service Manual Ser
67. on Again The switch must open before the gauge pressure increases more than 1 bar 14 5 psi from base pressure 6 Verify continuity again when the control is returned to neutral 7 If the switch does not open at base pressure plus 0 to 1 bar 0 to 14 5 psi in either direction stop the prime mover and readjust the eccentric plug as described in the previous section If the pressure difference is equal in each direction but greater than 1 bar 14 5 psi loosen the switch lock nut and turn the switch clockwise 1 12 turn 30 to increase the sensitivity Retighten the lock nut and recheck pressure differences and continuity 8 After verifying proper control and switch operation stop the prime mover Remove the continuity checker and pressure gauges Reinstall the servo pressure port plugs and reconnect the electrical leads from the machine starter circuit to the NSS Install and adjust the external control linkage if necessary Hydraulic displacement control HDC and electric displacement control EDC adjustment The neutral adjustment is the only adjustment that can be made on hydraulic and electric displacement controls All other functions are preset at the factory 520L0818 s Rev 0101 s August 2015 39 2z Service Manual Series 90 Pumps Adjustments Speed sensor adjustment Make this adjustment on a test stand or on the vehicle machine with the prime mover operating A Warning The following procedure may
68. on valve Multifunction valve is leaking Swap multifunction valves If system changes direction replace defective valve System operating hot 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 or repair leaky 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 settings are too low the relief valves will be overworked Verify settings of pressure limiters and high pressure relief valves and adjust or replace multi function valves as necessary For internal leakage in motor Leakage will reduce low side system pressure and overwork the system Monitor motor case flow without loop flushing in the circuit use defeat spool If flow is excessive replace motor
69. 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 Torque 030 58 N m 43 lbf ft 042 75 Nem 55 lbf ft 055 122 Nem 90 It 075 130 298 Nem 220 lbf ft 180 250 580 Nem 429 lbf ft Charge pump The following procedure shows how to remove and install a charge pump Removal 1 For pumps with an auxiliary mounting pad refer to the Auxiliary Pad instructions Caution On earlier production frame size 75 pumps with twin ports secure the endcap to the pump housing with a clamp to avoid gasket damage 2 Remove the six screws H80 holding the charge pump cover retainer H70 52 520L0818 s Rev 0101 s August 2015 2z4 Service Manual Series 90 Pumps Minor repair 3 Remove the retainer H70 and the charge pump cover J15 Remove and discard O ring J40 Note the orientation of the gerotor assembly H05 Retainer screw wrench size Frame size Wrench size 030 100 10mm 130 250 13mm Current charge pump configuration E101082 Refer to appropriate Danfoss Series 90 service parts manual for earlier charge pump configurations 4 Remove the charge pump coupling H50 and charge pump drive key H60 5 Remove the charge pump gerotor assembly H05 6 Remove the alignment pin H40 7 Remove the inner port pla
70. placement control Control linkages 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 Continue to next step System multi function valves Low motor output torque Defective multi function valves will cause system to pressure to be low Repair or replace multi function valve s Item Description Action System pressure at motor Low system pressure at the motor will reduce torque Measure system pressure at motor If pressure limiter setting is low increase setting displacement Variable motor stuck at minimum Minimum motor displacement yields low output torque Check control supply pressure or repair displacement control Check motor control orifices Internal leakage Internal leakage will reduce system pressure Check for leaking O rings gaskets and other fittings Repair unit as required or replace leaking unit Improper motor output speed Item Description Action Oil level in reservoir Insufficient hydraulic fluid will reduce motor speed Fill oil to proper level Pump output flow Incorrect outflow will affect output speed Incorrect output flow indicates the swashplate is out of position Measure pump output and check for proper pump speed Ensure the pump is in full stroke
71. r end cap screws J80 Remove and discard special washers J70 Caution On earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage 2 Remove the auxiliary pad J60 and discard the O rings J50 and J90 Aux pad screw wrench size Frame size Wrench sizes 030 early 042 8 mm internal hex late 042 10 mm internal hex 055 19 mm hex 075 100 24 mm hex 100 130 14 mm internal hex 180 250 17 mm internal hex Inspection 1 Inspect the auxiliary pad for damage and replace if any damage is found 520L0818 Rev 0101 s August 2015 51 Devt Service Manual Series 90 Pumps Minor repair 2 Take care to assure the surfaces are clean and free of any foreign material or paint prior to installing the auxiliary pad bm Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing Gasket damage and external leakage may result Auxiliary pad components typical Endcap screw e Screw torque See appropriate table for wrench size and torque E101 084E Reassembly 1 Lubricate and install O ring J50 on end cap pilot 2 Install the auxiliary mounting pad J60 on rear of endcap 3 Install four large screws J80 and new washers J70 through the mounting
72. r setting the pressure limit of the other multi function valve Move or activate the control input signal in the opposite direction so that high pressure develops in the opposite side of the closed circuit Engaging the bypass function The multi function valve cartridges perform the bypass function Shut down the prime mover when engaging the bypass function Open both the bypass valves to engage the bypass function Caution Damage to the pump and motor can result from rotating these components without charge flow for lubrication Bypass valves are intended for moving a machine or vehicle for very short distances at very slow speeds They are not tow valves 1 loosen the bypass actuator three turns Refer to table for wrench size Do not rotate more than 3 1 2 revolutions as additional rotation will permit external leakage 2 For units with an MDC type control prior to moving the vehicle or otherwise causing the motor shaft to turn move the control handle of the manual displacement control on the pump to the maximum full forward position Hold the handle in this position during bypass valve operation 3 To close the bypass valve tighten the bypass actuator See table provided for proper torque Bypass actuator wrench size Frame size Wrench size newer 030 100 1 1 16 inch 130 250 1 3 8 inch 520L0818 Rev 0101 s August 2015 31 Service Manual Series 90 Pumps Adjustments Mul
73. s electrical system the neutral start switch ensures that the prime mover can start only when the control is in neutral position Hydraulic displacement control HDC The hydraulic displacement control uses a hydraulic input signal to operate a spring centered four way servo valve This valve ports hydraulic pressure to either side of a dual acting servo piston The servo piston rotates the cradle swashplate through an angular rotation of 17 thus varying the pump s displacement from full displacement in one direction to full displacement in the opposite direction The angular position of the pump swashplate is proportional to input pressure 14 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Operation Electric displacement control EDC The electric displacement control uses a Pressure Control Pilot PCP valve to modulate pressure balance across the spring centered four way servo valve The PCP valve converts a DC electrical input signal to a hydraulic signal The servo valve ports hydraulic pressure to either side of a dual acting servo piston The servo piston rotates the swashplate through an angular rotation of 17 varying the pump s dis placement The angular position of the swashplate is proportional 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 contro
74. s 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 Replace all O rings and gaskets Use new O rings and gaskets during reassembly Lightly lubricate all O rings with clean petroleum jelly prior to assembly Secure the unit E3 520L0818 s Rev 0101 s August 2015 5 Devt Service Manual Series 90 Pumps Introduction Safety precautions For repair place the unit in a stable position with the shaft pointing downward It will be necessary to secure the pump while removing and torquing end covers controls and valves 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 A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A 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 A Warning Escaping hydraulic fluid under pressure can have sufficient
75. sessseessueccssusecssuseesssccessuseccsnesssueeessueceesueecesuseessuceessueccencsesueessaneessne 60 Solenoid override valve for MDC with pressure released brakke er xettrrxsttrrettrrkrrrkerrrrkee 61 Hydraulic and electric displacement controls EEN 62 Pressure control pilot PCP for electric displacement control ED 63 3 Position FNR electric Control 63 Displacement Control filter screens EEN 65 SDESO EE ee 66 Fastener size and torque chatt 68 Bluet stseepdrreterkgchatt gege aaa a R EAA EET a ARENOR RNR 69 Fasteners and PlUQS sseccsssscccssscssseesccssecssnseessssecesssecssnsecesssccssnsecesssecessucssssecessseccsnsscesssecssnsceecssscessucessnsceccaseessauseesaectenseessaneessaee 70 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Introduction Overview Warranty General instructions This manual includes information for the installation maintenance and minor repair of Series 90 axial piston 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 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
76. ssuitdedodetinildugiaicaikcttyakaicsltlicgignxeseisliraskascsnlebadgikuietdsidtAisdee Hydraulic displacement control HDC and electric displacement control EDC adjustment Speed sensor E dn Standard ProceCures sesccsssscssssseccssssessssscsseccssusscssussessseesssseeccsneesssseessanecessuseccsseeesasecsssuceccsnecesnseeesaneceesuceesssesessseessaseeccaeessaeeseas 42 REMOVING the DREES EE 42 Shaft seal and shaft replacement 42 Multi function valve cartridges Multi function valve Cartridges Pre 1988 sssssssseccssessssnsesssssecssseccssecssnecessuseccsssecesuesssusecssasceesaseessssceesnsecssaseeesneesesnseese Pressure override valve option for 180 frame size 47 Charge pressure relief Va Ve lt ccxeerrxetrrrrerrrerrre 148 Adding an Auxiliary pad to a pump previously without one 50 Auxiliary de E 5 T1 n c cCC CC an a G c ho 51 e ET E 52 Integral charge pressure filter reDlaCernerrtt s s k EEk xEEE1111111171131111112111171407111107111771 11A rkk 55 PUNO COMEO COVER EN 56 Displacement control oriflces EEN 57 Displacement control orifice check valve Displacement control adapter plate early production 130 pumps only Manual displacement Control MIDC s 5ccxssccvxeserrxerrrrreerrre 59 Solenoid override valve for MDC cssssscsssssecssecssssssccsses
77. ssure 28 520L0818 s Rev 0101 s August 2015 2z Service Manual Series 90 Pumps Adjustments 2 The table shows the acceptable pump charge pressure range for some charge relief valve settings These pressures assume 1500 min rpm and a reservoir temperature of 50 C 120 F and are referenced to case pressure Charge pressure relief valve Case drain port L1 M4 0 10 bar 0 100 psi ZA 11 16 12 115 Nem 85 lbf ft O Adjusting screw m K10 M5 Lock nut 4 52 Nem 39 Ibfeft Charge pressure gauge port M3 0 50 bar 0 1000 psi 6a 9 16 18 Z 23 Nem 17 Ibfft See appropriate table P106 162E Listed pressures assume a pump speed of 1500 min rpm At higher pump input speeds with higher charge flows the charge pressure will rise over the rated setting Charge pressure ranges Model code Measured charge pressure 20 18 1 21 7 bar 262 315 psi 24 22 0 26 9 bar 319 390 psi 28 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 relief valve Shim kits are available from Danfoss Remove the plug using a 1in hex wrench and exchange shims behind the spring to adjust charge pressure Torq
78. t during filter change For detailed filtration information see Danfoss publication 520L0463 Fluids and Filtration For information on biodegradable fluids see Danfoss publication 520L0465 Biodegradable Hydraulic Fluids 18 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Technical specifications Overview Features and options Specifications and operating parameters for pumps appear here for reference Model Series 90 Pumps Mount SAE B SAE C and E SAE J 744 Pump type Axial piston type Rotation Bidirectional Installation position Discretionary Housing must always be filled with hydraulic fluid Do not install with control on bottom Input shafts Splined Control options MDC with options EDC HDC FNR Operating parameters Parameter Unit Pressure System pressure Rated bar 420 6000 Maximum psi 480 7000 Minimum low loop 10 150 Charge pressure Minimum bar 10 150 Maximum psi 35 508 Charge inlet pressure Rated bar absolute 0 7 9 Minimum cold start ln Hg vacuum 0 2 24 Case pressure Rated bar 3 0 40 Maximum psi 5 0 75 Parameter Unit Frame size 042 055 075 100 130 180 250 Displacement cm 42 55 75 100 130 180 250 maximum in 2 56 3 35 4 57 6 10 7 93 10 98 15 25 Minimum speed min 1 rpm 500 500 500 500 500 500 500 Rated speed min
79. te H31 Inspection Inspect 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 late production pumps or outer spacer plate s intermediate production pumps must be replaced together If different thickness port plates are used in an early production charge pump assembly the thicker plate is the inner port plate installed next to the pump end cap Different production charge pump assemblies include a different quantity type of port plates and spacer plates Reassembly Be sure to install the charge pump in the proper orientation If unsure of charge pump rotation refer to the model code 520L0818 Rev 0101 s August 2015 53 2z Service Manual Series 90 Pumps Minor repair The orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap determine the charge pump rotation Do not mix charge pump parts from different production periods Always install as a complete assembly Orienting alignment pin Discharge Gerotor Discharge Z2 at A Ki jintet N Alignment pin Gerotor assembly Alignment pin Left hand rotation Right hand rotation outside looking into pump outside looking into pump P104 160E _ Install the inner port plate H31 and the gerotor assem
80. the service procedures described in this manual using common mechanic s tools Special tools if required are shown Use calibrated pressure gauges to ensure accuracy Use snubbers to protect pressure gauges Port locations and gauge installation The following sections list the ports for each type of hydraulic unit The fitting size and recommended pressure gauge are also specified The following table and drawings show the port locations and gauge sizes needed Port information Portidentifier 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 pressure 50 bar 1000 psi 9 16 18 L1 L2 Case pressure 10 bar 100 psi 030 042 7 8 14 055 100 1 1 16 12 130 1 5 16 12 180 250 1 5 8 12 X1 X2 HDC EDC control pressure 50 bar 1000 psi 7 16 20 or 9 16 18 X3 External control pressure 50 bar 1000 psi 9 16 18 S Charge pump inlet Vacuum gauge 030 042 1 1 16 12 Tee into inlet line 055 075 1 5 16 12 100 180 1 5 8 12 250 1 1 2 SAE split flange 22 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Pressure measurement Pump with side port end cap and manual displacement control System pressure gauge port M2 Charge inlet pressure vacuum System pressure gauge port M1 gt Carge pump J inlet port S Case drain Servo
81. ti Function Valve with Bypass Function Engaged Opening bypass valve allows flow to circuit Bypass through multi function valves actuator P104 144E Bypass actuator torque Frame size Torque newer 030 100 41 Nem 30 Ibf ft 130 250 100 Nam 75 lbf ft Pressure override POR valve pressure adjustment option for 180 frame size Pressure override valve operation is explained in the Operation section A 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 two 1000 bar 10 000 psi pressure gauges in the high pressure gauge ports M1 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 displacement load the work function and note the pressure as the POR valve operates pump displacement reduces to zero 4 Adjust the pressure override setting by loosening the lock nut with a 9 16 inch hex wrench and turning the adjustment screw with a 3 16 inch internal hex wrench Set the POR setting to at least 50 bar 750 psi below the high pressure relief valve setting of the multi function valves 5 Torque the lock nut to 43 Nem 32 Ibfeft 6 Shut down the prime mover and remove the gauges an
82. to atmosphere add case pressure Charge pressure filtration SE Screen Hydraulic fluid reservoir Adjustable charge pressure N i relief valve SEK Charge pump LJ To pump case Filter To low li i pressure side and control P102 004E Pressure override POR 180 frame size only The Pressure OverRide valve POR modulates control pressure to maintain a pump displacement which produces a system pressure level less than or equal to the POR setting For unusually rapid load application the high pressure relief valve function of the multi function valves is available to also limit the pressure level The pressure override consists of a three way normally open valve which operates in series with the pump displacement control Control supply pressure normally ports through the POR valve to the displacement control valve If the system demands a pressure above the override setting the POR valve 520L0818 s Rev 0101 s August 2015 13 2z Service Manual Series 90 Pumps Operation overrides the control by reducing the pressure to the displacement control As the control pressure reduces the internal forces rotating the swashplate overcome the force of the servo pistons and decreases the pump s displacement POR Valve 180 frame size only To contro t Q Lea va Multi function v
83. ue plug to 68 Nem 50 lbf ft 4 Later production Series 90 pumps have an external screw adjustable charge pressure relief valve Loosen locknut K10 and turn the adjusting screw K90 using a screwdriver or 1 2 in hex wrench to adjust charge pressure setting Lock nut wrench size Frame size Wrench size 030 100 1 1 16 inch 130 250 1 5 8 inch 5 Clockwise rotation of the plug increases the setting and counterclockwise rotation decreases the setting at a rate of approximately 3 9 bar 50 psi per turn Torque lock nut to 52 Nem 39 Ibf ft 520L0818 Rev 0101 s August 2015 29 2z Service Manual Series 90 Pumps Adjustments 6 Once you achieve the desired charge pressure setting remove the gauges and plug the ports Multi function valve pressure adjustment You accomplish adjustment of the pressure limiter setting and the high pressure relief valve HPRV setting simultaneously The HPRV setting is automatically set approximately 35 bar 500 psi above the pressure limiter setting Lock the motor output shaft by locking the vehicle s brakes or rigidly fixing the work function so it cannot rotate or cap the system ports A Warning Take necessary precautions that the motor shaft remains stationary during the adjustment procedure Multi function valve adjustment Charge pressure gauge port M3 0 50 bar 0 1000 psi 9 16 18 23 Nem 17 Ibf ft
84. videabente 8 Case drain and heat ExchanGel sssscsssssccssesccssesessnseessseecsssecssneseenseessssecsssseecssscesssueccuseesssseeessuecessseeessueeersueeeseaseccaneessaneets 9 Charg Te E 11 Charge rell f V V uc a c h c i te gu b3 c4ag c 01c ha aai iaat 11 OU ee leese 11 Pressure limiter and high pressure relief valves System check valves Bypass valves Speed sensors Filtration options 13 Pressure override POR 180 frame size only 13 Manual displacement control MDC ssssecsssssssssescssseccsssssecsseccssseecssnecessucessssscessueesesusessasecessueeccsnscessueesssuecssnesesneessneeesene 14 Nopere 14 Solenoid Override Valve for MIDD 14 Netitralistart SWitchi NSS sesssecescssosaseccsassscscosscssusesossascsssssssonsaasssossnaasssueabocvoscanesssousensovecoosbesuusesaddacssunsssonaieosdoacaeavesuonnestososendce 14 Hydraulic displacement control DC 14 Electric displacement control EDC Bak Automotive control FBA II B 3 Position FNR electric Control 15 e 16 Input speed T System pressure T Charge pressure te Charge Ed IC 17 VE 17 Temperature and ME 17 Fluid and filter recommendations EENEG 17 OVEN VIOW EE I E A TY 19 Features and options 19 le enee ETC 19 lte We 19 EU Start up procedure TT TOO E 22 Port locations and gauge installation ssssssscccsscccssscsssseccseessssssesssecesssecessus
85. with neutral start switch View at section A A A 4 Switch cam Switch lock nut Neutral start switch Eccentric plug Switch pin Special lock nut for eccentric plug Orifice check valve seat Control spool assembly Control link assembly View A A P104 146E Adjust the Neutral Start Switch to meet the following three requirements 1 The distance you can move the control handle without opening the NSS is the NSS deadband The distance you can move the control handle without moving the control spool enough to port hydraulic fluid to the pump displacement control cylinders is the control deadband These deadbands must be concentric Since you cannot adjust the position of the control deadband you must adjust the position of the NSS deadband to match it 2 The NSS deadband must be wide enough so the NSS will not open within the loose area of control handle movement caused by normal operating clearances in the control linkage control shaft free play By setting the NSS to open outside this area the control spool springs or control shaft centering spring can always return the handle to neutral and re close the NSS 3 The NSS deadband must be narrow enough so the NSS will open before the unit builds 7 bar 100 psi differential system pressure in either direction 520L0818 Rev 0101 s August 2015 35 Service Manual Series 90 Pumps Adjustments Neutral start switch adjustment requ
86. 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 auxiliary pad kit Orienting the alignment pin Gerotor J10 assembly N Alignment pin Left hand rotation outside looking into pump P108929 50 520L0818 s Rev 0101 s August 2015 Service Manual Series 90 Pumps Minor repair Retainer screw torque Frame size Torque 030 100 16 Nem 11 85 bt 130 250 32 5 Nem 24 lbf ft End cap screw torque Frame size Torque 030 58 Nem 43 lbf ft 042 75 Nem 55 lbf ft 055 122 Nem 90 It 075 130 298 Nem 220 Ibfeft 180 250 580 Nem 429 Ibfeft 3 Install the auxiliary drive coupling J10 The internally splined end of the coupling must engage the main pump shaft 4 Install the new charge pump cover assembly J15 into the endcap Ensure the cover is aligned properly with the alignment pin 5 Install the charge pump cover retainer H70 and the six internal hex screws H80 Torque the screws per the table using a criss cross pattern ON Lubricate and install O ring J50 on the endcap pilot N Install the auxiliary mounting pad J60 on the rear of the endcap Install four large screws J80 through the mounting pad and endcap into the housing Torque per the table using a criss cross pattern Auxiliary pad Removal 1 Remove the fou

Series 90 Variable Pumps Service Manual

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