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Series 90 Axial Piston Pumps
User guide
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Danfoss Series 90 Axial Piston Pumps User guide

Technical Information
Series 90
Axial Piston Pumps
www.danfoss.com
Technical Information
Series 90 Axial Piston Pumps
Revision history Table of revisions
Date Changed Rev
March 2022 Additional note onto Mating pump requirements at Features and Options 0910
September 2021 Modified KN at control option "M" on MMC 0909
June 2021 Deleted Size 042 information. 0908
March 2020 Removed restricted options 0907
February 2020 Changed document number from BC00000015 and increased version by 0101 0906
January 2020 Corrected 075 dimension drawing 0805
March 2016 Minor edit 0804
January 2015 correction to O-ring sizing - page 77 HC
February 2014 Danfoss Layout HA
2 | © Danfoss | March 2022 BC152886483413en-000910
Technical Information
Series 90 Axial Piston Pumps

Contents

General Description
Series 90 Family of Pumps and Motors.....................................................................................................................................5
PLUS+1 Compliant Controls and Sensors................................................................................................................................5
Design...................................................................................................................................................................................................6
Series 90 Pictorial Circuit Diagram............................................................................................................................................. 7
System schematic.............................................................................................................................................................................7
Technical Specifications
General Specifications.................................................................................................................................................................... 8
Features and Options......................................................................................................................................................................8
Operating Parameters.....................................................................................................................................................................9
Fluid Specification............................................................................................................................................................................9
Operating Parameters
Input Speed......................................................................................................................................................................................10
Independent Braking System...............................................................................................................................................10
System Pressure..............................................................................................................................................................................10
Servo Pressure.................................................................................................................................................................................12
Charge Pressure..............................................................................................................................................................................12
Charge Pump Inlet Pressure.......................................................................................................................................................12
Case Pressure...................................................................................................................................................................................12
External Shaft Seal Pressure....................................................................................................................................................... 13
Temperature.................................................................................................................................................................................... 13
Viscosity.............................................................................................................................................................................................13
System Design Parameters
Filtration System.............................................................................................................................................................................14
Filtration Options...........................................................................................................................................................................14
Suction filtration – Option S................................................................................................................................................. 14
Charge pressure filtration (partial charge pump flow)............................................................................................... 15
Remote charge pressure filtration......................................................................................................................................15
Fluid Selection.................................................................................................................................................................................15
Reservoir............................................................................................................................................................................................15
Case Drain.........................................................................................................................................................................................16
Pump Life..........................................................................................................................................................................................16
Charge Pump...................................................................................................................................................................................16
Charge pump sizing/selection.............................................................................................................................................16
Bearing Loads and Life.................................................................................................................................................................17
Applications with external shaft loads..............................................................................................................................17
Understanding and Minimizing System Noise....................................................................................................................18
Sizing Equations............................................................................................................................................................................. 18
Mounting Flange Loads...............................................................................................................................................................19
Master Model Code
Series 90 Master Model Code Breakdown............................................................................................................................ 21
S90 Rotation and Size Options..................................................................................................................................................21
Control Options.............................................................................................................................................................................. 22
Pressure, Aux Mounting, Ports, Filtration, Displacement Limitation Options......................................................... 23
Shaft and Charging System........................................................................................................................................................24
Control Orifice Options................................................................................................................................................................25
Special Hardware and Pressure Settings...............................................................................................................................26
Control Features
3-Position (FNR) Electric Control - DC, DD............................................................................................................................ 27
Response time........................................................................................................................................................................... 28
Electric Displacement Control (EDC), Options KA, KP, KT................................................................................................28
Features and Benefits..............................................................................................................................................................28
Response time........................................................................................................................................................................... 31
Pump output flow direction vs. control current............................................................................................................31
Manual Over Ride (MOR)............................................................................................................................................................. 32
Hydraulic Displacement Control (HDC), Option HF, HS...................................................................................................33
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Danfoss | March 2022 BC152886483413en-000910 | 3
Technical Information
Series 90 Axial Piston Pumps
Contents
Operation.....................................................................................................................................................................................33
Features and Benefits..............................................................................................................................................................33
Response time........................................................................................................................................................................... 34
Pump output flow direction vs. control pressure.........................................................................................................34
Manual Displacement Control (MDC), Options MA, MB.................................................................................................. 35
Features and benefits..............................................................................................................................................................35
External control handle requirements..............................................................................................................................36
Response Time...........................................................................................................................................................................36
Pump output flow direction vs. control handle rotation...........................................................................................37
Neutral start switch (NSS) for MDC..........................................................................................................................................37
Non Feedback Proportional Electric Control (NFPE) ........................................................................................................37
Control response.......................................................................................................................................................................37
NFPE control used with a Danfoss microcontroller......................................................................................................38
Input signal requirements.....................................................................................................................................................38
Features and Options
Multi-Function Valves...................................................................................................................................................................40
Overpressure protection........................................................................................................................................................40
Pressure limiting function..................................................................................................................................................... 40
Bypass Function........................................................................................................................................................................ 41
Auxiliary Mounting Pads............................................................................................................................................................. 41
Mating pump requirements................................................................................................................................................. 41
Displacement Limiter................................................................................................................................................................... 42
Shaft Torque.....................................................................................................................................................................................43
Shaft torque and spline lubrication................................................................................................................................... 43
Shaft torque for tapered shafts............................................................................................................................................43
Shaft Availability and Torque Ratings.....................................................................................................................................44
Tapered Shaft Customer Acknowledgement.................................................................................................................45
Charge Pump...................................................................................................................................................................................45
Charge pump sizing/selection.............................................................................................................................................45
Charge pump flow and power curves...............................................................................................................................46
Speed Sensor...................................................................................................................................................................................47
Connector Pin Assignments.......................................................................................................................................................49
Installation Drawings
Frame Size 055................................................................................................................................................................................ 50
Frame Size 075................................................................................................................................................................................ 54
Frame Size 075 NFPE Options FK, FL, FM, FN.......................................................................................................................57
Frame Size 100................................................................................................................................................................................ 62
Frame Size 130................................................................................................................................................................................ 67
Frame Size 180................................................................................................................................................................................ 71
Frame Size 250................................................................................................................................................................................ 75
Cover Plate........................................................................................................................................................................................78
3-Position (F-N-R) Electric Control........................................................................................................................................... 79
Electric Displacement Control (EDC) with MS-Connector or Packard® connector.................................................80
Hydraulic Displacement Control (HDC)................................................................................................................................. 80
Manual Displacement Control (MDC) with neutral start switch................................................................................... 81
Electrohydraulic Displacement Control (NFPE)(except 075 NFPE).............................................................................. 82
Integral Pressure Filter................................................................................................................................................................. 83
Remote pressure – without filter..............................................................................................................................................83
4 | © Danfoss | March 2022 BC152886483413en-000910
Technical Information
Series 90 Axial Piston Pumps

General Description

Series 90 Family of Pumps and Motors

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
BC152886483265.

PLUS+1 Compliant Controls and Sensors

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. Software development that used to take months can now be done in just a few hours. For more information on PLUS+1 GUIDE, visit www.sauer-danfoss.com/plus1.
Series 90 pumps can be used together in combination with other Danfoss pumps and motors in the overall hydraulic system. Danfoss hydrostatic products are designed with many different displacement, pressure and load-life capabilities.
Go to the Danfoss website or applicable product catalog to choose the components that are right for your complete closed circuit hydraulic system.
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Danfoss | March 2022 BC152886483413en-000910 | 5
P106 648E
Slider block
Servo piston
Servo arm
Displacement control
Cradle bearing
Charge pump
Swashplate
Cradle guide
Feedback linkage
Roller bearing
Shaft
Piston
Slipper
Valve plate
Cylinder block
Input shaft
Rear bushing
Bushing
seal
Model-No./Ident-No.
Model Code
Serial-No.
Made in USA
Place of Manufacture
Model Number
Serial Number
Model Code
A - 88 - 126 - 67890
501829
P108494E
90L055 KA 1 N 6 S 3 C6 C 03 NNN 35 35 24
Technical Information
Series 90 Axial Piston Pumps
General Description

Design

Series 90 pump cross-section
Typical name plate
Series 90 pumps are also manufactured in Europe and China. Place of manufacture shown on nameplate will correspond with the actual place of manufacture.
6 | © Danfoss | March 2022 BC152886483413en-000910
Pump Motor
Working loop (low pressure)
Control fluid
Suction line
Case drain fluid
Working loop (high pressure)
Motor swashplate
Loop flushing valve
Displacement control valve
Heat exchanger bypass valve
Reservoir
Vacuum gauge
Purge relief valve
Fixed displacement motor
Output shaft
Multi-function valve
Charge pump
To pump
case Servo pressure relief valves
Servo control cylinder
Pump swashplate
Input shaft
Reversible variable displacement pump
Servo control cylinder
Heat exchanger
Multi-function valve
Charge pressure relief valve
Orificed check valve
Control handle
P102 000
M
BB
L2
M2
M1
M4
M5
M3
A A
S
L2 M1
M2
L1
M3
P104 286E
Technical Information
Series 90 Axial Piston Pumps
General Description

Series 90 Pictorial Circuit Diagram

The circuit diagram shows a hydrostatic transmission using a Series 90 axial piston variable displacement pump and a Series 90 fixed displacement motor.

System schematic

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Danfoss | March 2022 BC152886483413en-000910 | 7
Technical Information
Series 90 Axial Piston Pumps

Technical Specifications

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
or at the side, with the top position preferred. Vertical input shaft installation is acceptable. If input shaft is at the top 1 bar case pressure must be maintained during operation. The pump housing must be filled 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 pressure with internal charge pump. For reference see Operating Parameters. Will be case
pressure with external charge supply. Please verify mating pump shaft seal capability.

Features and Options

Feature Unit Frame
055 075 100 130 180 250
Displacement cm³/rev.
[in³]/rev.
Flow at rated speed (theoretical) l/min.
[US gal/min.]
Torque at maximum displacement (theoretical)
Mass moment of inertia of rotating components
Weight (with control opt. MA) kg [lb] 40 [88] 49 [108] 68 [150] 88 [195] 136 [300] 154 [340] Mounting (per ISO 3019-1) Flange
Rotation Right hand or Left hand rotation Main ports: 4-bolt split-flange
(per SAE J518 code 62) Main port configuration Twin or side port Twin port Case drain ports (SAE O-ring boss) UNF thread
Other ports SAE O-ring boss Shafts Splined, and tapered shafts available Auxiliary mounting SAE-A, B, C SAE-A, B, C, D SAE-A, B, C, D, E
N•m/bar [lbf•in/1000 psi]
kg•m² [slug•ft²]
mm [in]
(in.)
55 [3.35]
215 [57]
0.88 [530]
0.0060 [0.0044]
127-4 (SAE C)
25.4 [1.0]
1.0625–12 1.0625–12 1.0625–12 1.3125–12 1.625–12 1.625–12
75 [4.59]
270 [71]
1.19 [730]
0.0096 [0.0071]
25.4 [1.0]
100 [6.10]
330 [87]
1.59 [970]
0.0150 [0.0111]
25.4 [1.0]
130 [7.93]
403 [106]
2.07 [1260]
0.023 [0.0170]
Flange 152-4 (SAE D)
31.75 [1.25]
180 [10.98]
468 [124]
2.87 [1750]
0.0380 [0.0280]
Flange 165-4 (SAE E)
31.75 [1.25]
250 [15.25]
575 [160]
3.97 [2433]
0.0650 [0.0479]
38.1 [1.5]
8 | © Danfoss | March 2022 BC152886483413en-000910
Technical Information
Series 90 Axial Piston Pumps
Technical Specifications

Operating Parameters

Parameter Unit Frame
055 075 100 130 180 250
Input speed Minimum min-1(rpm) 500 500 500 500 500 500 Rated Speed 3900 3600 3300 3100 2600 2300 Maximum 4250 3950 3650 3400 2850 2500
Operating parameters
System pressure Maximum working pressure bar [psi] 450 [6525]
Maximum pressure 480 [6960] Maximum low loop 45 [650] Minimum low loop pressure 10 [145]
Charge pressure Minimum bar [psi] 18 [261]
Maximum 34 [493]
Control pressure Minimum (at corner power for EDC and FNR) bar [psi] 14 [203]
Minimum (at corner power for NFPE) 22 [319] Maximum 40 [580]
Charge pump inlet pressure
Case pressure Rated bar [psi] 3.0 [44]
Lip seal external pressure Maximum bar [psi] 0.4 [5.8}
Rated bar (absolute) [in Hg vacuum] 0.7 [9] Minimum (cold start) 0.2 [24] Maximum bar [psi] 4.0 [58]
Maximum 5.0 [73]

Fluid Specification

Viscosity
Intermittent Minimum Recommended range Maximum
1)
Intermittent = Short term t < 1 min per incident and not exceeding 2 % of duty cycle based load-life.
1)
5 mm2/s [42 SUS]
7 mm2/s [49 SUS]
12 – 80 mm2/s [66 – 370 SUS]
1600 mm2/s [7500 SUS]
Temperature
Minimum Rated Recommended range Maximum Intermittent
1)
Cold start = Short term t > 3 min, p ≤ 50 bar [725 psi], n ≤ 1000 min-1 (rpm).
2)
At the hottest point, normally case drain port.
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Danfoss | March 2022 BC152886483413en-000910 | 9
1)
2)
-40°C [-40°F]
104°C [220°F]
60 – 85°C [140 – 185°F]
115°C [240°F]
W
Technical Information
Series 90 Axial Piston Pumps

Operating Parameters

Input Speed

Minimum speed
Rated speed is the highest input speed recommended at full power condition. Operating at or
Maximum speed
During hydraulic braking and downhill conditions, the prime mover must be capable of providing sufficient braking torque in order to avoid pump over speed. This is especially important to consider for turbo-charged and Tier 4 engines.
For more information please see Pressure and Speed Limits, BC152886484313, when determining speed limits for a particular application.

Independent Braking System

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.
below this speed should yield satisfactory product life. Operating conditions between rated and maximum speed should be restricted to less
than full power and to limited periods of time.
is the highest operating speed permitted. Exceeding maximum speed reduces product life and can cause loss of hydrostatic power and braking capacity. For most drive systems, maximum unit speed occurs during downhill braking or negative power conditions.
Warning
Never exceed the maximum speed limit under any operating conditions.

System Pressure

Unintended vehicle or machine movement hazard. Exceeding maximum speed may cause a loss of
hydrostatic drive line power and braking capacity. Machine manufacturer is responsible to 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. The braking system must also be sufficient to hold the machine in place when full power is applied.
Hydraulic unit life depends on the speed and normal operating — or weighted average — pressure that can only be determined from a duty cycle analysis.
System pressure is the differential pressure between high pressure system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life.
Application pressure
Maximum working pressure
is the high pressure relief or pressure limiter setting normally defined within the order code of the pump. This is the applied system pressure at which the drive line generates the maximum calculated pull or torque in the application.
is the highest recommended application pressure and is not intended to be a continuous pressure. Propel systems with application pressures at, or below this pressure should yield satisfactory unit life given proper component sizing. Application pressures above maximum working pressure will only be considered with duty cycle analysis and factory approval.
Pressure spikes are normal and must be considered when reviewing maximum working pressure.
10 | © Danfoss | March 2022 BC152886483413en-000910
Technical Information
Series 90 Axial Piston Pumps
Operating Parameters
Maximum pressure
Minimum low loop pressure
is the highest intermittent pressure allowed under any circumstances. Applications with applied pressures between rated and maximum require factory approval with complete application, duty cycle, and life expectancy analysis.
must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop pressure from gauge readings to compute the differential.
©
Danfoss | March 2022 BC152886483413en-000910 | 11
Technical Information
Series 90 Axial Piston Pumps
Operating Parameters

Servo Pressure

Servo pressure is the pressure in the servo system needed to position and hold the pump on stroke. It depends on system pressure and speed. At minimum servo pressure the pump will run at reduced stroke depending on speed and pressure.
Minimum servo pressure at corner power holds the pump on full stroke at max speed and max
Maximum servo pressure is the highest pressure typically given by the charge pressure setting.

Charge Pressure

An internal charge relief valve regulates charge pressure. Charge pressure supplies the control with pressure to operate the swashplate and to maintain a minimum pressure in the low side of the transmission loop.
The charge pressure setting listed 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/s [150 SUS].
Pumps configured with no charge pump (external charge supply) are set with a charge flow of 30 l/min [7.93 US gal/min] and a fluid viscosity of 32 mm2/s [150 SUS].
The charge pressure setting is referenced to case pressure. Charge pressure is the differential pressure above case pressure.
pressure.

Charge Pump Inlet Pressure

Case Pressure

Minimum charge pressure
Maximum charge pressure
At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure (vacuum).
Minimum charge inlet pressure
Maximum charge inlet pressure
Under normal operating conditions, the rated case pressure must not be exceeded. During cold start case pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly.
The auxiliary pad cavity of axial pumps configured without integral charge pumps is referenced to case pressure. Units with integral charge pumps have auxiliary mounting pad cavities referenced to charge inlet (vacuum).
is the 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 tables.
is the highest charge pressure allowed by the charge relief adjustment, and which provides normal component life. Elevated charge pressure can be used as a secondary means to reduce the swashplate response time.
is only allowed at cold start conditions. In some applications it is
recommended to warm up the fluid (e.g. in the tank) before starting the
engine and then run the engine at limited speed.
may be applied continuously.
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.
12 | © Danfoss | March 2022 BC152886483413en-000910
C
Technical Information
Series 90 Axial Piston Pumps
Operating Parameters

External Shaft Seal Pressure

In certain applications the input shaft seal may be exposed to external pressure. In order to prevent damage to the shaft seal the maximum differential pressure from external sources must not exceed 0.4 bar (5.8 psi) over pump case pressure.
The case pressure limits of the pump must also be followed to ensure the shaft seal is not damaged.
Regardless of the differential pressure across the shaft seal, the shaft seal has been known to pump oil from the external source (e. g. gear box) into the pump case.

Temperature

The high temperature limits apply at the hottest point in the transmission, which is normally the motor case drain. The system should generally be run at or below the quoted rated temperature.
The maximum intermittent temperature is based on material properties and should never be exceeded.
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. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Caution

Viscosity

For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range. The minimum viscosity should be encountered only during brief occasions of maximum ambient
temperature and severe duty cycle operation. The maximum viscosity should be encountered only at cold start.
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Danfoss | March 2022 BC152886483413en-000910 | 13
W
Charge pump
Filter
Hydraulic fluid reservoir
Adjustable charge pressu re relief valve
To pump case
To low loop and control
Manomete r
P102 003E
Technical Information
Series 90 Axial Piston Pumps

System Design Parameters

Filtration System

To prevent premature wear, ensure only clean fluid enters the hydrostatic transmission circuit. A filter capable of controlling the fluid cleanliness to ISO 4406 class 22/18/13
(SAE J1165) or better, under normal operating conditions, is recommended. These cleanliness levels can not be applied for hydraulic fluid residing in the component housing/case or
any other cavity after transport. The filter may be located on the pump (integral) or in another location (remote). The integral filter has a filter bypass sensor to signal the machine operator when the filter requires
changing. Filtration strategies include suction or pressure filtration. The selection of a filter depends on a number of factors including the contaminant ingression rate, the generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance interval. Filters are selected to meet the above requirements using rating parameters of efficiency and capacity.
Filter efficiency can be measured with a Beta ratio¹ (βX). For simple suction-filtered closed circuit transmissions and open circuit transmissions with return line filtration, a filter
with a β-ratio within the range of β some open circuit systems, and closed circuits with cylinders being supplied from the same reservoir, a considerably higher filter efficiency is recommended. This also applies to systems with gears or clutches using a common reservoir.
For these systems, a charge pressure or return filtration system with a filter β-ratio in the range of β 75 (β10 ≥ 10) or better is typically required.
Because each system is unique, only a thorough testing and evaluation program can fully validate the filtration system. Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information, BC152886482150 for more information.
1
Filter βx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a given diameter (“x” in microns) upstream of the filter to the number of these particles downstream of the filter.
= 75 (β10 ≥ 2) or better has been found to be satisfactory. For
35-45
15-20
=

Filtration Options

Warning
Clogged filters can cause cavitation, which damages the charge pump. We recommend a filter bypass with a filter bypass sensor to prevent damage due to blocked suction filters.

Suction filtration – Option S

The suction filter is placed 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
14 | © Danfoss | March 2022 BC152886483413en-000910
To pump case
Charge pump
Hydraulic fluid reservoir
Filter
To low pressure side and control
Screen
Adjustable charge pressure relief valve
P102 004E
W
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters

Charge pressure filtration (partial charge pump flow)

Two types of pressure filtration exist for most Series 90 pumps. The two types are: remote pressure filtration (filter remotely mounted on vehicle) and integral pressure filtration (filter mounted to the endcap). Verify option availability in the size specific technical information.
In either case the filtration circuit is the same with the filter element situated in the circuit downstream the charge pump and upstream of the charge relief valve such that full charge flow is continuously filtered, as shown in the accompanying illustrations. Charge pressure filtration can mitigate high inlet vacuum in cold start-ups and provides fluid filtration immediately prior to entrance to the loop and the control system. Pressure filtration provides a higher level of filtering efficiency than suction filtration.
Filters used in charge pressure filtration circuits must be rated to at least 35 bar [508 psi] pressure. A 100 – 125 μm screen located in the reservoir or in the charge inlet line is recommended when using charge pressure filtration.
Technical data according to ISO 16889
Nominal flow at 30mm2/s and ∆P 0.5 bar[7.3 psi] (clean filter element only) Minimum β-ratio
Short 60 l/min β7.5(C)=75 (β5(C) ≥10) Long 105 l/min

Remote charge pressure filtration

A special adapter head is available to allow for the charge filter to be located conveniently for easy service and replacement. Care should be taken to minimize the hydraulic pressure drops associated with long connecting lines, small diameter hoses, or restrictive port adaptors at the filter head or endcap. Ensure the normal operating pressure drop across the remote filtration in and out ports is sufficiently below the crack pressure setting of the recommended filter bypass valve.
Charge pressure filtration
Warning
Remote filter heads without bypass and poor plumbing design can encounter excessive pressure drops that can lead to charge pump damage in addition to contaminants being forced through the filter media and into the transmission loop.

Fluid Selection

Ratings and performance data are based on operating with hydraulic fluids containing oxidation, rust and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion, and corrosion of pump components.
Never mix hydraulic fluids of different types.

Reservoir

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Danfoss | March 2022 BC152886483413en-000910 | 15
The hydrostatic system reservoir should accommodate maximum volume changes during all system operating modes and promote de-aeration of the fluid as it passes through the tank. A suggested
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters
minimum total reservoir volume is 5⁄8 of the maximum charge pump flow per minute with a minimum fluid volume equal to ½ of the maximum charge pump flow per minute. This allows 30 seconds fluid dwell for removing entrained air at the maximum return flow. This is usually adequate to allow for a closed reservoir (no breather) in most applications.
Locate the reservoir outlet (charge pump inlet) above the bottom of the reservoir to take advantage of gravity separation and prevent large foreign particles from entering the charge inlet line. A 100-125 μm screen over the outlet port is recommended. Position the reservoir inlet (fluid return) to discharge below the normal fluid level, toward the interior of the tank. A baffle (or baffles) will further promote de-aeration and reduce surging of the fluid.

Case Drain

All single S90 pumps are equipped with multiple drain ports. Port selection and case drain routing must enable the pump housing to maintain a volume of oil not less than half full and normal operating case pressure limits of the unit are maintained. Case drain routing and design must consider unit case pressure ratings.
A case drain line must be connected to one of the case outlets to return internal leakage to the system reservoir.
Do not over torque the fitting on case drain port L2 (located on the side cover). The proper torque is 100 N•m [74 lbf•ft] maximum. Over torquing the fitting may change the neutral position of the swashplate.

Pump Life

Charge Pump

Pump life depends on several factors, such as speed, pressure, and swashplate angle. For detailed product life calculation, please contact your Danfoss representative.
Charge flow is required on all Series 90 pumps applied in closed circuit installations. The charge pump provides flow to make up internal leakage, maintain a positive pressure in the main circuit, provide flow for cooling and filtration, replace any leakage losses from external valving or auxiliary systems, and to provide flow and pressure for the control system.
Many factors influence the charge flow requirements and the resulting charge pump size selection. These factors include system pressure, pump speed, pump swashplate angle, type of fluid, temperature, size of heat exchanger, length and size of hydraulic lines, control response characteristics, auxiliary flow requirements, hydrostatic motor type, etc. When initially sizing and selecting hydrostatic units for an application, it is frequently not possible to have all the information necessary to accurately evaluate all aspects of charge pump size selection.
Unusual application conditions may require a more detailed review of charge pump sizing. Charge pressure must be maintained at a specified level under all operating conditions to prevent damage to the transmission. Danfoss recommends testing under actual operating conditions to verify this.

Charge pump sizing/selection

In most applications a general guideline is that the charge pump displacement should be at least 10 % of the total displacement of all components in the system. Unusual application conditions may require a more detailed review of charge flow requirements. Refer to Selection of Drive line Components, BC157786484430, for a detailed procedure.
System features and conditions which may invalidate the 10 % guideline include (but are not limited to):
16 | © Danfoss | March 2022 BC152886483413en-000910
B
A
P108 549E
0°Re
90° Re
270° Re
180°Re
L
Re
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters
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Bearing Loads and Life

In vehicle propel drives with no external shaft loads , and where the system pressure and swashplate angle are changing direction and magnitude regularly, the normal L20 bearing life (80% survival) will exceed the hydraulic life of the unit.
In non-propel drives, such as vibratory drives, conveyor drives and fan drives, the operating speed and pressure are often nearly constant and the swashplate angle is predominantly at maximum. These drives have a distinct duty cycle compared to a propulsion drive. In these types of applications, a bearing life review is recommended.
For bearing life, speed, pressure, swashplate angle, plus external loads will be considered. Other factors that affect bearing life include fluid type, viscosity, and cleanliness.
Continuous operation at low input speeds (< 1500 min-1 (rpm)) High shock loading and/or long loop lines High flushing flow requirements Multiple Low Speed High Torque motors High input shaft speeds

Applications with external shaft loads

External loads are found in applications where the pump is driven with a side/thrust load (belt drive or gear drive) as well as in installations with misalignment and improper concentricity between the pump and drive coupling. All external loads act to reduce bearing life.
In applications where you cannot avoid external radial shaft loads, orient the load to 0° or 180° position. Use tapered output shafts or clamp-type couplings where radial shaft loads are present.
In addition, external thrust loads can reduce bearing life in systems with low delta pressure or in combination with external radial loads/bending moments.
Re = Me / L Me = Shaft moment L = Flange distance Re = External force
Radial load position
Maximum allowable external shaft load
Parameter 055 075 100 130 180 250
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External moment (Me) N•m [lbf•in]
* no tapered shaft available
101 [893]
118 [1043]
126 [1114]
140 [1238]
* *
Outp ut f ow Q = (l/min..)
Inp ut torque M = (N•m)
Inp ut power P = = (kW)
SI units Vg= Displacement pe r revolution
(cm3/rev)
∆p = pO- pi(system pressure)
(bar) n = Speed (min-1(rpm)) ηv= Volumetric eff ciency ηm= Mechanical eff ciency ηt= Overall effciency (ηv• ηm)
Vg• n • η
v
1000
Vg• ∆p
20 • π • η
m
Q •∆p
600 • η
t
M • n • π
30 000
g
= Displacement pe r revolution
(in3/rev) ∆p = pO- pi(system pressure)
(psi) n = Speed (min-1(rpm)) ηv= Volumetric eff ciency ηm= Mechanical eff ciency ηt= Overall effciency (ηv• ηm)
Outp ut f ow Q = (US gal/min..)
Inp ut torque M = (lbf•in)
Inp ut power P = = (hp)
Vg• n • η
v
231
Vg• ∆p
2 •π • η
m
Q •∆p
1714 • η
t
M • n • π 198 000
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters
If continuous applied external radial loads are 25% of the maximum allowable or more or thrust loads/ bending moments known to occur, contact your Danfoss representative for an evolution of bearing life.
Avoid external thrust loads in either direction.

Understanding and Minimizing System Noise

Noise is transmitted in fluid power systems in two ways: as fluid borne noise, and structure borne noise. Fluid-borne noise (pressure ripple or pulsation) is created as pumping elements discharge oil into the
pump outlet. It is affected by the compressibility of the oil, and the pump's ability to transition pumping elements from high to low pressure. Pulsations travel through the hydraulic lines at the speed of sound (about 1400 m/s [4600 ft/sec] in oil) until there is a change (such as an elbow) in the line. Thus, amplitude varies with overall line length and position.
Structure born noise is transmitted wherever the pump casing connects to the rest of the system. The way system components respond to excitation depends on their size, form, material, and mounting.
System lines and pump mounting can amplify pump noise.
Follow these suggestions to help minimize noise in your application:
Use flexible hoses.
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Limit system line length.
•
If possible, optimize system line position to minimize noise.
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If you must use steel plumbing, clamp the lines.
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If you add additional support, use rubber mounts.
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Test for resonants in the operating range; if possible avoid them.
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Sizing Equations

The following equations are helpful when sizing hydraulic pumps. Generally, the sizing process is initiated by an evaluation of the machine system to determine the required motor speed and torque to perform the necessary work function. Refer to Selection of drive line components, BC157786484430, for a more complete description of hydrostatic drive line sizing. First, the motor is sized to transmit the maximum required torque. The pump is then selected as a flow source to achieve the maximum motor speed.
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First stageSecond stage
Third
stage
P108 511E
L1
L2
L3
F2 F1
F3
R
= g • GR(W1L1+ W2L2+ ... + WnLn)
S
= g • GS(W1L1+ W2L2+ ... + WnLn)
R
= Rated load moment N•m
S
= Shock load mome nt N•m
2
R
= Calculation factor for rated (vibratory) acceleration (G’s)*
S
= Calculation factor for maximum shock acceleration (G’s)*
MR= GR(W1L1+ W2L2+ ... + WnLn) MS= GS(W1L1+ W2L2+ ... + WnLn)
Based on US units
W = Weight of pump [lb] L = Distance from mounting f ang e [in] to pump center of gravity
Where: MR= Rated load moment N•m MS= Shock load mome nt N•m
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters

Mounting Flange Loads

Adding tandem mounted auxiliary pumps and/or subjecting pumps to high shock loads may result in excessive loading of the mounting flange.
Applications which experience extreme resonant vibrations or shock may require additional pump support. The overhung load moment for multiple pump mounting may be estimated using the formula below.
Overhung load example
Estimated maximum and rated acceleration factors for some typical applications are shown in the table below.
Use these values for a rough load estimation in the absence of specific data.
Typical G loads for various applications
Application Calculation factor
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Danfoss | March 2022 BC152886483413en-000910 | 19
Skid Steer Loader 8 15-20 Trencher (rubber tires) 3 8 Asphalt Paver 2 6 Windrower 2 5
Rated (vibratory) acceleration G
R
Maximum (shock) acceleration G
S
Technical Information
Series 90 Axial Piston Pumps
System Design Parameters
Typical G loads for various applications (continued)
Application Calculation factor
Aerial Lift 1.5 4 Turf Care Vehicle 1.5 4 Vibratory Roller 6 10 T000 165E
Allowable overhung load moment values are shown in the following table.
Allowable overhung load moments
Frame size Rated moment (MR) Shock load moment (MS)
055 1580 14 000 5650 50 000 075 1580 14 000 5650 50 000 100 1580 14 000 5650 50 000 130 3160 28 000 10 730 95 000 180 6070 54 000 20 600 182 000 250 6070 54 000 20 600 182 000
Rated (vibratory) acceleration G
N•m lbf•in N•m lbf•in
R
Maximum (shock) acceleration G
S
20 | © Danfoss | March 2022 BC152886483413en-000910
R Size M P J G N F L H T W Y Z K
S90
Technical Information
Series 90 Axial Piston Pumps

Master Model Code

Series 90 Master Model Code Breakdown

S90 Rotation and Size Options

R – Rotation
Code Description 055 075 100 130 180 250
R Right hand [CW] X X X X X X L Left hand [CCW] X X X X X X
Size
055 55 cc [3.36 in3] max displacement per revolution X 075 75 cc [4.58 in3] max displacement per revolution X 100 100 cc [6.10 in3] max displacement per revolution X 130 130 cc [7.93 in3] max displacement per revolution X 180 180 cc [10.98 in3] max displacement per revolution X 250 250 cc [15.26 in3] max displacement per revolution X
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Technical Information
Series 90 Axial Piston Pumps
Master Model Code
S90 Control Options
M – Controls
Code Description 055 075 100 130 180 250
CA Cover plate without feedback link, no control X X X X X X DC 3 position F-N-R solenoid control (12V, DC) DIN
connector
DD 3 position F-N-R solenoid control (24V, DC) DIN
connector HF HDC 2, std. porting, 3, 0-11 bar [44-160 psi] X X X X X X KA EDC, MS connector, std. porting, dual coil (14-85 mA) X X X X X X KN EDC, MS connector, std. porting, 643 Ohm single coil
(4-20 mA) KT EDC DEUTSCH connector, std. porting, dual coil (14-85
mA) KP EDC, Weatherpack connector, std. porting, dual coil
(14-85 mA) MA MDC X X X X X X MB MDC with neutral start switch X X X X X X FA NFPE control with 12V Amp connector; proportional
solenoid with pressure reducing valve (25 bar) FB NFPE control with 24V Amp connector; proportional
solenoid with pressure reducing valve (25 bar) FC NFPE control with 12V Amp connector; proportional
solenoid with pressure reducing valve (32 bar) FD NFPE control with 24V Amp connector; proportional
solenoid with pressure reducing valve (32 bar) FG NFPE control with 12V Amp connector; proportional
solenoid with pressure reducing valve (32 bar) fast
response FH NFPE control with 24V Amp connector; proportional
solenoid with pressure reducing valve (32 bar) fast
response FK NFPE control with 12V AMP connector; proportional
solenoid with pressure reducing valve (25 bar) FL NFPE control with 24V AMP connector; proportional
solenoid with pressure reducing valve (25 bar) FM NFPE control with 12V Amp connector; proportional
solenoid with pressure reducing valve (32 bar) fast
response FN NFPE control with 24V Amp connector; proportional
solenoid with pressure reducing valve (32 bar)
X X X X X
X X X X X X
X X X X X X
X X X X X X
X X X X X X
X X
X X X
X X
X X
X X X X
X X X X
X
X
X
X
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Technical Information
Series 90 Axial Piston Pumps
Master Model Code
S90 Pressure, Aux Mounting, Ports, Filtration, Displacement Limitation
P – High pressure regulation
Code Description 055 075 100 130 180 250
1 Pressure limiter for port A and B (140-450 bar) X X X X X X 2 High pressure relief valves for port A and B (90-450
bar)
J – Auxiliary Mounting Pad
AB SAE-A with sealed cover, 9 teeth coupling X X X X X X BB SAE-B with sealed cover, 15 teeth coupling X X X X X X BC SAE-B with sealed cover, 13 teeth coupling X X X X X X CD SAE-C with sealed cover, 4 bolt adapter, 14 teeth
coupling DE SAE-D with sealed cover, 13 teeth coupling X X X EF SAE-E with sealed cover, 13 teeth coupling X X NN No auxiliary mounting pad X X X X X X
X X X X X X
X X X X X X
G – Endcap ports
60 Side ports X X X 80 Twin ports X X X X X X
N – Filtration
D External charge pump X X X X X X L Pressure integral (long filter) X X X X P Pressure integral (short filter) X X X X R Remote pressure X X X X T Remote pressure with SAE 1 1/16 thread ports for
high flow S Suction filtration X X X X X X
X X
F – Displacement limitation
C No limiters (180 cc only) X M Limitation on both sides (180 cc only) X 3 No limiters X X X X X 4 Limitation on both sides X X X X X 7 No limiters, special servo cylinder side 1 with hard
spring (for pumps with NFPE control only)
X X X X X
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Technical Information
Series 90 Axial Piston Pumps
Master Model Code
S90 Shaft and Charging System
L – Shaft Options
Code Description 055 075 100 130 180 250
C6 Splined shaft, 21 teeth, 16/32 pitch X X X C7 Splined shaft, 23 teeth, 16/32 pitch X X C8 Splined shaft, 27 teeth, 16/32 pitch X X X F1 Splined shaft, 13 teeth, 8/16 pitch X X X X S1 Splined shaft, 14 teeth, 12/24 pitch X X X G1 Splined shaft, 25 teeth, 20/40 pitch X X T1 Tapered shaft, 34.925 mm diameter X X T6 Tapered shaft, 38.1 mm diameter X X T8 Tapered shaft, 25.4 mm diameter T4 Tapered shaft, 44.45 mm diameter X
H – Charging System
B 11 cc/rev nominal flow X C 14 cc/rev nominal flow X X D 17 cc/rev X X X E 20 cc/rev X X F 26 cc/rev X X H 34 cc/rev X X J 47 cc/rev X X K 65 cc/rev X L External charge pump with internal charge pressure
relieve valve for units with auxiliary mounting pad
N External charge pump with internal charge pressure
relieve valve for units without auxiliary mounting pad
X X X X X X
X X X X X
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Technical Information
Series 90 Axial Piston Pumps
Master Model Code
S90 Control Orifice Options
T – Control Orifice Options for MDC
Code Inlet P Drain TA Drain TB Servo A Servo B 055 075 100 130 180 250
00 None 1.6 03 0.81 1.6 05 1.37 1.6
*
*
*
C5 0.81 1.4 1.4 None None X X X X X X C6 1.37 1.4 1.4 None None X X X X X X
*
No orifice installed in control,orifice hole in control spool
T – Control Orifice Options for EDC
Code Inlet P Drain TA Drain TB Servo A Servo B 055 075 100 130 180 250
00 None 1.3 1.3 None None X X X X X X 03 0.81 1.3 1.3 None None X X X X X X 05 1.37 1.3 1.3 None None X X X X X X 33 0.81 None None None None X X X X X X
1.6
1.6
1.6
*
*
*
None None X X X X X X None None X X X X X X None None X X X X X X
T – Control Orifice Options for FNR
Code Inlet P Drain T Servo A Servo B 055 075 100 130 180 250
G1 None 1.2 None None X X X X X X G4 0.46 1.2 None None X X X X X X G8 0.66 1.2 None None X X X X X X GB 0.81 1.2 None None X X X X X X GD 1.57 1.2 None None X X X X X X
T – Control Orifice Options for HDC
Code Inlet P Drain TA Drain TB Servo A Servo B 055 075 100 130 180 250
00 None 1.3 1.3 None None X X X X X X 003 0.81 1.3 1.3 None None X X X X X X 005 1.37 1.3 1.3 None None X X X X X X
T – Control Orifice Options for NFPE
Code Inlet P Drain T Servo A Servo B 055 075 100 130 180 250
B1 None 1.5 None None X X X X X X B2 None None 1.2 1.2 X X X X X X B6 None None None None X
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Technical Information
Series 90 Axial Piston Pumps
Master Model Code
S90 Special Hardware and Pressure Settings
W – Special Hardware Features
Code Description 055 075 100 130 180 250
EEG Speed ring, no sensor, CP30 + 4.3° valve plate X X X X EFC Speed sensing, Turck connector (KPP x 156), CP15 +
EFI Speed sensing Turck connector (KPP x 156) CP30 +
FAC Nest T-bar springs CP15 + 1.5° valve plate X X X X X FAD Nested T-bar springs CP15 + 0.5° valve plate X X X X GBA CP15 + 0.5° valve plate X X X X GCA CP15 + 1.5° valve plate X X X X X GLA CP30 + 4.3° valve plate, CP30 valve plug X X X X X X NNN
1.5° valve plate X X X X X X
4.3° valve plate
180cc: CP15 + 0.5° valve plate 250cc: CP15 + 1.5° valve plate, nested T-bar springs
Y – High Pressure Setting A
26 260 bar X X X X X X 32 320 bar X X X X X X 35 350 bar X X X X X X 38 380 bar X X X X X X 40 400 bar X X X X X X 42 420 bar X X X X X X
X X X
X X
Z – High Pressure Setting B
26 260 bar X X X X X X 32 320 bar X X X X X X 35 350 bar X X X X X X 38 380 bar X X X X X X 40 400 bar X X X X X X 42 420 bar X X X X X X
K – Charge Pressure Setting
20 20 bar X X X X X X 22 22 bar X X X X X X 24 24 bar X X X X X X 26 26 bar X X X X X X 28 28 bar X X X X X X 30 30 bar X X X X X X 32 32 bar X X X X X 34 34 bar X X X X X
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