danfoss Hydraulic Pump Repair Manual

Danfoss Hydraulic Pump Repair Manual is the only book that provides detailed and clear instructions for troubleshooting, maintenance and repair of hydraulic pumps. It is ideal for technicians and students of all trades, who wish to improve their understanding on how a pump works and how it can be repaired. The book gives you an insight into all aspects required in identifying and repairing these pumps effectively.

Supply:

• Series 90 hydrostatic pumps and motors can be applied together or combined with other products in a system to transfer and control hydraulic power. They are intended for closed circuit applications.
• • Series 90 – advanced technology
• • Seven sizes of variable displacement pumps
• • Proven reliability and performance
• • Compact, lightweight
• • Worldwide sales and service
• • PLUS+1™ compliant controls and sensors
• Series 90 variable displacement pumps are compact, high power density units. All models utilize the parallel axial piston/slipper concept in conjunction with a tiltable swashplate to vary the pump’s displacement. Reversing the angle of the swashplate reverses the flow of oil from the pump and thus reverses the direction of rotation of the motor output.
• Series 90 pumps include an integral charge pump to provide system replenishing and cooling oil flow, as well as control fluid flow. They also feature a range of auxiliary mounting pads to accept auxiliary hydraulic pumps for use in complementary hydraulic systems. A complete family of control options is available to suit a variety of control systems (mechanical, hydraulic, electric).
• Series 90 motors also use the parallel axial piston/slipper design in conjunction with a fixed or tiltable swashplate. They can intake/discharge fluid through either port; they are bidirectional. They also include an optional loop flushing feature that provides additional cooling and cleaning of fluid in the working loop. For more information on Series 90 motors, refer to Series 90 Motors Technical Information 520L0604.

Tools:

• -Ball Peen Hammer
• -Plastic Tip Hammer
• -Flat Tip Screw Driver
• -Snap Ring Pliers
• -Torque Wrench
• -Magnet Stick
• -1-1/4″Vrench
• -1-3/8″Vrench
• -4 mm Allen Wrench
• -3/32″Allen Wrench
• -Impact Screwdriver
• -Sliding Bearing Remover Hammer
• -Dial Indicator and Accessories
• -Marker or Paint Pen
• -Petroleum Jelly
• -Cleaning Solvent

Materials: A wide range of Series 90 controls and sensors are PLUS+1™compliant. PLUS+1 compliance means our controls and sensors are directly compatible with the PLUS+1 machine control architecture. Adding Series 90 pumps to your application using PLUS+1 GUIDE software is as easy as drag-and-drop.

danfoss Series 90 pump Design

Series 90 pump cross-section

danfoss Series 90 pump Technical Information

Series 90 Axial Piston Pumps General Description

Series 90 Axial Piston Pumps General Specifications

Design	Axial piston pump of cradle swashplate design with variable displacement
Direction of rotation	Clockwise, counterclockwise
Pipe connections	Main pressure ports: ISO split flange boss Remaining ports: SAE straight thread O-ring boss
Recommended installation position	Pump installation position is discretionary, however the recommended control position is on the top orat the side, with the top position preferred. Vertical input shaft installation is acceptable. lfinput. shaft is at the top 1 bar case pressure must be maintained during operation. The pump housing must be flled with hydraulic fluid under all conditions; including after a long period of shutdown. Before operating the machine, ensure the pump housing and case drain lines are free of air. Recommended mounting for a multiple pump stack is to arrange the highest power flow towards the input source. Consult Danfoss for nonconformance to these guidelines.
Auxiliary cavity pressure	will be inlet prssure with interna charge pump. For reference see Operating Parameters. will be Ccase pressure with external charge supply. Please verify mating pump shaft seal capability.

Series 90 Axial Piston Pumps Features and Options

Feature	Unit	Frame
042	055	075	100	130	180	250
Displacement	cm*/rev.	42	[ 55	75	100	130	1 80	250
[in]/rev.	[2.56]	[3.35]	[4.59]	[6.10]	[7.93]	[10.98]	[15.25]
Flow at rated speed (theoretical)	I/min.	176	[ 215	270	330	403	[ 468	575
[US gal/	[46]	[ [57]	[71]	[87]	[106]	[ [124]	[160]
min.]
Torque at maximum	Nm/bar	0.67	[ 0.88	1.19	1.59	2.07	[ 2.87	3.97
displacement (theoretical)	[lbf.in/1000	[410]	[ [530]	[730]	[970]	[1260]	[1750]	[2433]
	psi]
Mass moment of inertia of	kg.m?	0.0023	0.0060	0.0096	0.0150	0.023	0.0380	0.0650
rotating components	[slug.ft]	[0.0017]	[0.0044]	[0.0071]	[0.0111]	[0.0170]	[0.0280]	[0.0479]
Weight (with control opt. MA)	kg [lb]	34 [75]	40 [88]	49 [108]	68 [150]	88 [195]	136 [300]	154 [340]
Mounting (per ISO 3019-1)	Flange 102-2 (SAE B)	Flange 127-4 (SAEC)	Flange 152-4 (SAE D)	Flange 165-4 (SAE E)
Rotation	Right hand or Left hand rotation
Main ports: 4-bolt split-flange	mm	1 9.05	[ 25.4	25.4	25.4	31.75	31.75	38.1
(per SAE J518 code 62)	[in]	[0.75]	[ [1.0]	[1.0]	[1.0]	[1.25]	[1.25]	[1.5]
Main port configuration	Twin port	Twin or side port	Twin port
Case drain ports (SAE O-ring boss)	UNF thread (in.)	0.875-14	1.0625-12	1 .0625-12	1.0625-12	1.3125-12	1 .625-12	1.625-12
Other ports	SAE O-ring boss
Shafts	Splined, and tapered shafts available
Auiliary mounting	SAE-A,B,C SAE-A,B,C,D SAE-A, B,C,D,E

For more danfoss Series 90 pump Technical Information, please click the pdf below to view

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danfoss Series 90 pump Accessories map

Item	Date	Part Number	Part Name	Qty. per Model/Kit
B10	95-6	8000387	Housing (SB-1992-003)	1
B50	87-02	9004800-3708	Pin	2
B70	87-02	327007 (9005110-4400)	Plug assembly	1
B72	87-02	327007 (9005110-4400)	Plug assembly	1
B80	87-02	664524 (90051 10-9000)	Plug assembly	1
B82	87-02	9005110-5600	Plug assembly (SB-1992-003)	1
B90	87-02	9803390	Control fiter screen	3
D10	88-14	8000318	Servo arm assembly (SB-1993-015)	1
D50	88-14	8000188	Swashplate (SB- 1988-009)	1
D55	87-02	666032 (9007276-0107)	Screw	1
D60	87-02	8800669	Swashplate guide	1
D65	87-02	9007375-0044	Screw (SB-1992-011)	1
D70	87-02	9009625-0146	Washer	1
D75	87-02	9004875-0098	Spiral head pin	1
D80	87-02	8100506	Cage locator link (SB-1994-017)	1
D85	04-43	8801235	Pin (SB-2004-012)	1
D85	87-02	8801135	Pin (SB-1998-018)	1
D95	87-02	8100035	Spring	1
E10	95-50	8000400	Side cover (SB- 1995 -025)	1
E20	87-02	8000094	Leveler (SB-1989-003)	1
E22	87-02	358838	Spring seat (SB 1989-003	2
E24	92-06	8801225	Shim (SB-1989-003 & SB-2000-041)	2
E30	95-50	1 1056530	Guide post	2
E30	Feb-87	8100353	Guide post (SB-1995-025)	2
E40	87-02	505412 (9003509-0008)	Seal nut	2
E50	87-02	056739 (9004104 1580)	O-ring	1
E60	87-02	5000206	Screw (SB-1994-018)	6
E70	87-02	664524 (9005110-9000)	Plug assembly	1
E80	87-02	8000186	Spring	2
E90	95-50	513886	Insert assembly (SB-1995-025 & SB-1999-041)	1
F20	88-14	11116313	Slider block (SB-1988-009 & SB-2015-005)	1
L10	87-02	5000504	Roller bearing	1
L20	87-02	9006300-0137	Retaining ring	1
L25	10-40	11083637	Seal carrier assembly	1
L 40	10-40	11013519	Lip seal (SB-2010-025)	1
L50	87-02	071845 (9004104-1510)	O-ring	1
L 60	87-02	11083638	Retainer plate (SB -2010-025)	1
L70	87-02	041160 (9007314-0605)	Screw	3
QB30	87-02	8000131	Bearing/pin assembly	1
QD50	88-14	8000200	Swashplate kit (SB-1988-009)	1
QD50	87-02	8000201	Swashplate kit	1

Item		Date	Part Number	Part Name	Qty. per Model/Kit
EAB & NMS	883	92 06	KPPG12508	Speed sensor	1
& NWN	C06	92 06	8000336	Cylinder block assembly,with speed ring	1
	C80	92 06	11015185	Valve plate	1
	E82	92 06	8000203	Spring	2
	Q883	92 06	085043 (9004201 3700)	O·ring	1
	QC04	92 06	85 10362	Cylinder block kit with speed r ng	1
E8C	883	96 06	KPPG13408	Speed sensor	1
	C06	96-06	8000336	Cylinder block assembly,with speed ring	1
	C80	96-06	11015186	Valve plate	1
	Q883	96-06	085043 (9004201 3700)	0-ring	1
	QC04	96-06	85 10362	Cylinder block kit with speed r ng	1
EDC	883	96 39	KPPG13403	Speed sensor	1
	C06	96-39	8000336	Cylinder block assembly,with speed ring
	C80	96-39	11018343	Valve plate,CW	1
	E82	96-39	8000203	Spring	2
	Q883	96 39	085043 (9004201 3700)	0-ring	1
	QC04	96-39	85 10362	Cylinder block kit with speed r ng	1
EEB	883	96-06	9005110 5600	Plug assembly	1
	C06	96-06	8000336	Cylinder block assembly,with speed ring	1
	C80	96-06	11015186	Valve plate	1
	QC04	96-06	85 10362	Cylinder block kit with speed r ng	1
EEC	883	94 51	9005110 5600	Plug assembly	1
	C06	94 51	8000336	Cylinder block assembly,with speed ring	1
	C80	94 51	11018330	Valve plate,CCW	1
	C80	94 51	11018343	Valve plate,CW	1
	E82	94 51	8000203	Spring	2
	QC04	94-5 1	85 10362	Cylinder block kit with speed r ng	1
EEG	883	00-06	9005110 5600	Plug assembly	1
	C06	00-06	8000336	Cylinder block assembly,with speed ring	1
	C80	00-06	11018330	Valve plate,CCW	1
	C80	00 06	11018343	Valve plate,CW	1
	QC04	00 06	85 10362	Cylinder block kit with speed r ng	1
EFI	883	07 38	KPPG156	Speed sensor	1
	C06	07 38	8000336	Cylinder block assembly,with speed ring	1
	C80	07·38	11018343	Valve plate,CW	1
	Q883	07 38	085043 (9004201-3700)	0-ring	1
	QC04	07 38	8510362	Cylinder block kit, with speed r ng	1

Item		Date	Part Number	Part Name	Qty. per Model/Kit
EFU	883	14-04	KPPG1S6	Speed sensor	1
	C06	14-04	8000336	Cylinder block assembly,with speed ring	1
	C80	14 04	11018343	Valve plate,CW	1
	Q883	14 04	08S043 (9004201 3700)	0-ring	1
	QC04	14-04	8S 10362	Cylinder block kit with speed r ng	1
EHA	883	99-14	KPPG16408	Speed sensor	1
	C06	99-14	8000336	Cylinder block assembly,with speed ring	1
	C80	99-14	1101S186	Valve plate	1
	Q883	99-14	08S043 (9004201 3700)	0-ring	1
	QC04	99-14	8S 10362	Cylinder block kit with speed r ng	1
EHC	883	99-14	KPPG12408	Speed sensor	1
	C06	99-14	8000336	Cylinder block assembly,with speed ring	1
	C80	99-14	1101S186	Valve plate	1
	Q883	99-14	08S043 (9004201 3700)	0-ring	1
	QC04	99-14	8S 10362	Cylinder block kit with speed r ng	1
FAA & NDN	883	91 04	900S11O S600	Plug assembly	1
	cos	91 04	8000128	Cylinder block assembly,without speed ring	1
	C80	91-04	11017478	Valve plate	1
	E82	91-04	8000203	Spring	2
	QC04	91-04	8S 10363	Cylinder block kit without speed ring	1
FA8 & NBN	883	91-46	900S11O S600	Plug assembly	1
	cos	91-46	8000128	Cylinder block assembly,without speed ring	1
	C80	91-46	363713	Valve plate	1
	E82	91-46	8000203	Spring	2
	QC04	91 46	8S 10363	Cylinder block kit without speed ring	1
FAC	883	94-23	900S11O-S600	Plug assembly	1
	cos	94-23	8000128	Cylinder block assembly,without speed ring	1
	C80	94-23	1101S18S	Valve plate	1
	E82	94-23	8000203	Spring	2
	QC04	94 23	8S 10363	Cylinder block kit without speed ring	1
FAD & NSN	883	94-23	900S11O S600	Plug assembly	1
	cos	94-23	8000128	Cylinder block assembly,without speed ring	1
	C80	94-23	1101S186	Valve plate (SB 1997 003)	1
	E82	94-23	8000203	Spring	2
	QC04	94-23	8S 10363	Cylinder block kit without speed ring	1
	Q883	07 38	085043 (9004201-3700)	0-ring	1
	QC04	07 38	8510362	Cylinder block kit, with speed r ng	1

For more danfoss Series 90 pump accessories drawings and lists, please click the pdf below to view

danfoss Hydraulic Pump Troubleshooting

Item	Description	Action
Check fluid level in reservoir.	Insufficient hydraulic fluid causes cavitation.	Fill the reservoir to proper level.
Check for air in system.	Air in system causes noisy, erratic control.	Purge air and tighten fittings. Check inlet for leaks.
Check pump inlet pressure/vacuum.	Improper inlet conditions cause erratic behavior and low output flow.	Correct pump inlet pressure / vacuum conditions. Refer to the Hydraulic Parameters topic.
Inspect shaft couplings.	A loose or incorrect shaft coupling causes excessive noise and/or vibration.	Repair or replace coupling and ensure that correct coupling is used.
Check shaft alignment.	Misaligned shafts create excessive noise and/or vibration.	Correct shaft misalignment.
Hydraulic fluid viscosity above acceptable limits.	Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly.	Allow system to warm up before operating, or use fluid with the appropriate viscosity grade for expected operating temperatures. See Hydraulic Fluids and Lubricants Technical Information Manual, 520L0463.
Actuator response is sluggish
Check external system relief valve setting.	Low external relief valve setting slows down system.	Adjust external relief valve setting following manufacturer’s recommendations. External relief setting must be above PC setting to operate properly.
Check PC and LS control setting.	Low PC setting prevents the pump from achieving full stroke. Low LS setting limits output flow.	Adjust PC and LS setting. Refer to the Adjustments chapter.
Check LS control signal pressures.	Incorrect LS signal will not allow pump to operate correctly.	Inspect system to ensure that proper LS signal transmit to pump.
Internal system leaks.	Worn internal parts don’t allow the pump to operate properly.	Refer to Authorized Service Center for required repair.
Hydraulic fluid viscosity above acceptable limits.	Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly.	Allow system to warm up before operation or sue fluid with the appropriate viscosity grade for expected operating temperatures. See Hydraulic Fluids and Lubricants Technical Information Manual, 520L0463.
Check external system valving.	Malfunctioning valving may not allow system to respond properly.	Repair or replace system valving as required.
Check pump case pressure.	High case pressure causes the system to be sluggish.	Correct case drain line restrictions.
Check pump inlet pressure/vacuum.	High inlet vacuum causes low output flow.	Correct inlet pressure conditions.
System operating hot
Check fluid level in reservoir.	Insufficient volume of hydraulic fluid will not meet cooling demands of system.	Fill reservoir to proper level. Verify proper size of reservoir.
Inspect heat exchanger. Check air flow and input air temperature for the heat exchanger.	Insufficient air flow, high input air temperature, or undersized heat exchanges will not meet cooling demands of the system.	Clean, repair, or replace heat exchanger as required. Verify proper size of heat exchanger.
Troubleshooting
Check external system relief valve setting.	Fluid passing through relief valve adds heat to system.	Adjust external system relief valve setting following manufacturer’s recommendations. External relief valve setting must be above PC setting for proper operation.
Check pump inlet pressure/vacuum.	High inlet vacuum adds heat to system.	Correct inlet pressure/vacuum conditions.
Low pump output flow
Check fluid level in reservoir.	Insufficient hydraulic fluid will limit output flow and cause internal damage to pump.	Fill the reservoir to proper level.
Hydraulic fluid viscosity above acceptable limits.	Fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly.	Allow system to warm up before operating, or use fluid with the appropriate viscosity grade for expected operating temperatures. See Hydraulic Fluids and Lubricants Technical Information Manual, 520L0463.
Check external system relief valve setting.	Eternal relief valve set below PC setting causes low output flow.	Adjust external relief valve following manufacturer’s recommendation. External relief valve setting must be above PC setting to operate properly.
Check PC and LS control setting.	Low PC setting prevents the pump from achieving full stroke.	Adjust PC and LS setting. Refer to the Adjustments chapter.
Check pump inlet pressure/vacuum.	High inlet vacuum causes low output flow.	Correct inlet pressure conditions.
Check input speed.	Low input speeds decrease flow.	Adjust input speed.
Check pump rotation.	Incorrect rotational configuration causes low flow.	Use pump with appropriate rotational configuration.
Pressure or flow instability
Check for air in system.	Air in system causes erratic operation.	Activate PC allowing system to bleed air. Check inlet line for leaks and eliminate source of air ingression.
Check control spools.	Sticking control spools cause erratic operation.	Inspect spools for free movement in bore. Clean or replace.
Check LS setting.	Low LS setting may cause instability.	Adjust LS setting to proper level. See the Adjustments chapter.
Check LS signal line.	Blocked LS signal line interferes with proper LS operation.	Remove blockage.
Check external relief valve and PC setting.	Insufficient pressure differential between PC setting and external relief valve.	Adjust external relief valve or PC control settings to appropriate level. Relief valve setting must be above PC setting to operate properly.
Check external relief valve.	Chattering external relief valve may cause unstable feedback to pump control.	Adjust or replace relief valve.
Troubleshooting System pressure not reaching PC setting
Check PC control setting.	System pressure will not rise above PC setting.	Adjust PC to appropriate setting. Refer to the Adjustments chapter.
Check external relief valve.	External relief valve setting below PC setting presents pressure compensation.	Adjust external relief valve according to manufacturer’s recommendations. External relief valve must be set above PC setting to operate properly.
Inspect PC control spring.	Broken, damaged, or missing spring will cause erratic operation.	Replace the spring as required.
Inspect PC spool for wear.	Wear of PC spool causes internal leakage in the control.	Replace the spool as required.
Inspect PC spool for proper orientation.	Improper orientation results in poor operation.	Correct orientation of spool.
Check PC control for contamination.	Contamination may interfere with movement of the PC spool.	Clean PC control components, take appropriate action to eliminate contamination.
High inlet vacuum
Check fluid temperature.	Low temperature increases viscosity. High fluid viscosity causes high inlet vacuum.	Allow system to warm up before operating.
Inspect inlet screen.	Blocked or restricted inlet screen causes high inlet vacuum.	Clean screen/remove blockage.
Check inlet piping.	Too many fittings, bends, or long piping causes high inlet vacuum.	Eliminate fittings to make path more direct.
Hydraulic fluid viscosity above acceptable limits.	High fluid viscosity causes high inlet vacuum.	Select fluid with appropriate viscosity for expected operating temperature. See Hydraulic Fluids and Lubricants Technical Information Manual, 520L0463.

danfoss Hydraulic Pump disassembly Video

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