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Danfoss
Water Pump
90 Series
Danfoss 90 Series Service Manual
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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
Service Manual
Series 90 Pumps
2
520L0818 •
Rev 0101
•
August 2015
1
3
Table of Contents
Default Chapter
3
Table of Contents
3
Overview
5
Warranty
5
General Instructions
5
Safety Precautions
6
Unintended Machine Movement
6
Flammable Cleaning Solvents
6
Fluid under Pressure
6
Personal Safety
6
Symbols Used in Danfoss Literature
7
Design
7
The System Circuit
8
The Basic Closed Circuit
8
Case Drain and Heat Exchanger
9
Operation
11
Charge Pump
11
Charge Relief Valve
11
Multi-Function Valves
11
Pressure Limiter and High Pressure Relief Valves
12
System Check Valves
12
Bypass Valves
12
Speed Sensors
13
Filtration Options
13
Pressure Override (POR) - 180 Frame Size Only
13
Manual Displacement Control (MDC)
14
Non-Linear MDC
14
Solenoid Override Valve for MDC
14
Neutral Start Switch (NSS)
14
Hydraulic Displacement Control (HDC)
14
Electric Displacement Control (EDC)
15
Automotive Control (FBA II B)
15
3-Position (FNR) Electric Control
15
Operating Parameters
16
Overview
16
Input Speed
16
System Pressure
16
Charge Pressure
16
Charge Inlet Pressure
17
Case Pressure
17
Temperature and Viscosity
17
Fluid and Filter Recommendations
17
Technical Specifications
19
Overview
19
Features and Options
19
Operating Parameters
19
Fluid Specifications
19
Initial Start-Up Procedure
21
General
21
Start-Up Procedure
21
Pressure Measurement
22
Required Tools
22
Port Locations and Gauge Installation
22
Troubleshooting
25
Overview
25
Neutral Difficult or Impossible to Find
25
System Operating Hot
25
Transmission Operates Normally in One Direction Only
25
System will Not Operate in Either Direction
26
Low Motor Output Torque
26
Improper Motor Output Speed
26
System Noise or Vibration
27
System Response Is Sluggish
27
Adjustments
28
Standard Procedures, Inspections, and Adjustments
28
Charge Pressure Relief Valve Adjustment
28
Multi-Function Valve Pressure Adjustment
30
Engaging the Bypass Function
31
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size)
32
Displacement Limiter Adjustment
33
Standard Manual Displacement Control (MDC) Adjustment
33
Non-Linear Manual Displacement Control (MDC)
34
MDC Neutral Start Switch (NSS) Adjustments
35
Checking Switch Continuity
38
Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment
39
Speed Sensor Adjustment
40
Minor Repair
42
Standard Procedures
42
Removing the Pump
42
Shaft Seal and Shaft Replacement
42
Multi-Function Valve Cartridges
44
Multi-Function Valve Cartridges - Pre 1988
46
Pressure Override Valve (Option for 180 Frame Size)
47
Charge Pressure Relief Valve
48
Adding an Auxiliary Pad to a Pump Previously Without One
50
Auxiliary Pad
51
Charge Pump
52
Integral Charge Pressure Filter Replacement
55
Pump Control Cover Plate
56
Displacement Control Orifices
57
Displacement Control Orifice Check Valve
57
Displacement Control Adapter Plate (Early Production 130 Pumps Only)
58
Manual Displacement Control (MDC)
59
Solenoid Override Valve for MDC
60
Solenoid Override Valve for MDC with Pressure Released Brake
61
Hydraulic and Electric Displacement Controls
62
Pressure Control Pilot (PCP) for Electric Displacement Control (EDC)
63
3-Position (FNR) Electric Control
63
Displacement Control Filter Screens
65
Speed Sensor
66
Torque Chart
68
Fastener Size and Torque Chart
68
Plug Size and Torque Chart
69
Fasteners and Plugs
70
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Danfoss 90 Series Specifications
General
Brand
Danfoss
Model
90 Series
Category
Water Pump
Language
English
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