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Series-90 MCV116G4201 Servo Characteristics
Series-90 MCV116G4201 Servo Characteristics
DESCRIPTION
The first stage, the MCV116 Pressure Control Pilot (PCP) is a torque-motor
actuated, double-nozzle flapper valve that produces a differential output
pressure proportional to the applied electrical signal. The second stage uses
the differential pressure to drive its unique spool arrangement and port oil to
the pump servo cylinders. The second-stage spool configuration allows a
null deadband (for machine safety) in the pump’s output
while maintaining optimum dynamic response to
control commands.
FEATURES
• Servo control deadband independent of signal null • Minimum long term null shift
deadband: offers safety combined with accurate and
• Dual coil torque motor can be used to sum two command
responsive control
sources
• Resistance to the environment: standard silicone oil
• Optional current (mA) ranges
filled torque motor, environmentally sealed first/second
stage interface, full environmental testing
• Intrinsically Safe option for use in hazardous areas (4 to
20 mA). See Control Option, page 6
ORDERING INFORMATION
TECHNICAL DATA
ELECTRICAL
OIL TEMPERATURE
FULL STROKE CURRENT -40° C (-40° F) minimum; 104° C (220° F) maximum
A (Configuration) 18 ± 1.5 mA (single coil)
S (Configuration) 18 ± 2.0 mA (single coil) OPERATING SUPPLY PRESSURE
B & E (Configuration) 85 ± 11.3 mA (dual coil) Typically 300-400 psi above case pressure
42 ± 5.6 mA (series coils)
RATINGS
85 ± 11.3 mA (parallel coils)
See Electrical Characteristics for complete range of cur-
rents SCALE FACTOR
A (Configuration) 6.2 psid/mA (single coil)
THRESHOLD CURRENT B & E (Configuration) 1.15 psi/mA (single coil)
A (Configuration) 5 ± 1.0 mA 2.3 psi/mA (coils in series)
S (Configuration) 6 ± 1.5 mA 1.15 psi/mA (coils in parallel)
B & E (Configuration) 14 ± 3.0 mA S (Configuration) 5.5 psid/mA (single coil)
HYDRAULIC
FILTRATION
The system hydraulics must have 10 micron or better
filtration. The pump will contain screen filters near the
interface to the EDC at the charge port and control port
locations. The pilot will have a screen filter at its input port
and internal output control ports screen.
FLUID
Automatic transmission fluid or hydraulic oil, such as Mobil
DTE 24 or equivalent. Fluid cleanliness is ISO 4406 code
18/15 or better.
OIL VISCOSITY
40-6000 SSU
BLN-95-9060-4
2
ELECTRICAL CHARACTERISTICS (B & E Configuration)
One of Dual Coils Dual Coils in Parallel Dual Coils in Series
A B C D A B C D A B C D Produces
Flow Out of
+ phasing to terminals + phasing to terminals
+ phasing to terminals Pump Port
Clockwise A or C A and C A A
PUMP SHAFT
ROTATION
Clockwise B or D B and D D B
Counterclockwise A or C A and C A B
Counterclockwise B or D B and D D A
A/B 14 mA with 0.3 Vdc
REQUIREMENTS
Full Stroke Current A/B 85 mA with 1.7 Vdc 85 mA with 0.75 Vdc 43 mA with 1.55 Vdc
± 11 mA
Start Current C/D 14 mA with 0.23 Vdc
(These Vdc levels are at 75°F (24°C). At this temperature the coil
± 3 mA
Full Stroke Current C/D 85 mA with 1.36 Vdc resistance is approximately 16 Ω for C/D and 20 Ω for A/B.)
± 11 mA
MAXIMUM CONTINUOUS VOLTAGE @ 93.9°C (200°F): 6 Vdc, if one coil or parallel, 12 Vdc, if coils in series.
Input Produces
Shaft
A B
Flow Out
Rotation Of Port
Clockwise A B A B
Counter
A B B A
Clockwise
Start Full Stroke Start Full Stroke Coil Ω Coil Ω
Current (mA) Current (mA) Voltage (Vdc) Voltage (Vdc) 75° F 220° F
± 4.5 - 5.5 ± 16.5 - 19.5 ± 2.9 - 3.6 ± 11 - 12.6 650
± 4.5 - 5.5 ± 16.5 - 19.5 ± 3.8 - 4.7 ± 14.0 - 16.5 650
201,0 mm
MS Connector 7.9 in
Option
Packard
Control Connector
Linkage Option 138,18 mm
5.44 in
89,41 mm
Spacer 3.52 in
(130, 180 cc) 55,37 mm
103,45 mm
2.18 in
4.073 in 38,07 mm
31,62 mm 1.42 in
1.245 in
49,78 mm
12,20 mm
108,46 mm 1.96 in 0.48 in
144,22 mm 4.27 in
5.56 in 169,67 mm 8,60 mm
185,70 mm 6.68 in 0.34 in
7.31 in
2016
Dimensions of the KVEA EDC for 75, 100, 130, 180, and 250 cc Pumps in Millimeters (Inches).
BLN-95-9060-4
3
DIMENSIONS, 55 cc PUMP EDC
13,00 mm REF
0.51 in REF
29,20 mm
1.15 in 9,70 mm
0.38 in
54,90 mm
2.16 in Neutral Adjust
181,60 mm
MS Connector 7.15 in
Option
Packard
Control Connector
Linkage 6 x 7,14 mm DIA 138,18 mm
Option 6 x .281 in DIA 5.44 in
89,41 mm
3.52 in
96,70 mm 55,37 mm
3.81 in 30,99 mm 38,07 mm 2.18 in
1.22 in 1.42 in
44,70 mm
1.76 in
99,06 mm
3.90 in 12,20 mm
131,06 mm 0.48 in
5.16 in
153,42 mm
5,6 mm
6.04 in
166,12 mm 0.22 in
6.54 in
2017
.51 REF
(13)
.38
(9,7)
NEUTRAL ADJUST
PACKARD
CONNECTOR
OPTION
MS CONNECTOR
OPTION
7.03
(178,6)
CONTROL
LINKAGE
6 x .281 DIA
(6 x 7,14 DIA) 3.94
(100,1)
3.200
(81,28)
2.61 1.640
(66,3) 1.220 1.270 (41,66)
(30,99) (32,26)
2.795 1.760
(70,99) (44,7) .325
3.900 (8,26)
3.68 (99,06)
(93,5) 5.160
(131,06) 6.040 .22
(153,42) (5,6)
6.540
(166,12)
2018
ARMATURE
POLE POLE
PIECE PIECE
C/D
COIL
A/B
COIL
PILOT
Ps Ps
P1 P2
Pt Ps Pt
BOOST STAGE
PUMP A B
SWASHPLATE
LINKAGE
2044
BLN-95-9060-4
5
APPLICATION
Advantages of the KVE are; These changes will not affect form or fit. In nearly all cases,
• Reduction in deceleration rollout characteristics function is not affected. There is one exception: When one
• Optional input currents (part number specific) side of the pilot valve is tapped to utilize the absolute pressure
• Uses no loctite, which eases repair and internal parts to pilot external devices such as a one line motor control (see
replacement details below).
The KVE is intended as a direct replacement for the MCV111. 1. Abnormal case drain pressures.
But when 2 or more EDC are used in a vehicle propel 2. Oil cleanliness.
application they should all be of one type or the other, don't
mix them for reasons as described in this application section. This change went into effect January 1, 1999. Various pump
frame sizes may incorporate this change at different times
The KVE and MCV use a torque-motor based electrical dependent upon the manufacturing location and initial con-
actuator scheme that is designed to work with a current (dc trol availability.
mA) signal, i.e., 75 mA will produce the same pump flow
every time. However, the KVE and MCV have different One line motor controls: It is always best to use a two line
electrical coil arrangements, resulting in the following pre- motor control when phasing a variable motor hydraulically
cautions: with a Series 90 pumps (via the X1 and X2 ports). Applica-
• Both are dual coil, but have different coil values (KVE 16 tions using only a one line hydraulic control rely on controlling
Ω and 20 Ω/MCV 25 Ω and 25 Ω). This may cause the variable motor with pressure from only one of the EDC
problems in applications where there is a mix of KVE and ports, either X1 or X2, but not both. The pump phasing in
MCV, they are controlled simultaneous and electrically these applications will be adversely affected by this EDC
tied together in a parallel arrangement. In those parallel change. Although the delta pressure (X1 - X2) versus coil
circuits the KVE pump will be stroked ahead of the MCV current is not affected by this change, the individual gage
by approximately 25%. Therefore to ensure that KVE and pressures at X1 and X2 are significantly reduced. Depending
MCV pumps stroke at the same rate use a series electri- on fluid temperature and viscosity, and the pump charge
cal connection, which will ensure that all EDCs receive pressure setting, this reduction in gage pressures will be in
the same electrical current. the range of 60 - 80 psig (current range of 120 - 160 psig).
• The MCV coils are arranged on a T-bar-style armature. If no change is made to the motor control threshold, and/or
This allows the coils to be physically separated by a small ramp in a one-line controlled motor, the motor shift will not
air gap. The KVE coils are arranged on a stand-up style occur until coil current reaches much higher levels. In fact, it
armature (which is the same used on all other dual coil may not even be possible to fully shift the motor with any coil
EDCs and servovalves) and they are stacked one atop current level. Therefore, any applications phasing a one-line
the other. In some rare instances, this may induce current hydraulically controlled motor with a Series 90 pump with one
changes resulting from the magnetic effects of one coil on of the above controls, the motor threshold and/or ramp levels
another (see Precautions When Driving Dual Coil PCPs must be changed, and coordinated with the timing of the
With A PWM Drive). Contact Sauer-Danfoss for applica- Series 90 pump EDC change. In the case of Series 51 motors
tions concerns. with one line controls, the threshold setting, and likely the
threshold spring and ramp spring will have to be changed.
KVEBXXXXX REPLACES KVEAXXXXX Please contact Sauer-Danfoss Applications Engineering for
assistance in determining the new motor specifications re-
The new control will be identified by a new letter in the control quired.
part number. The control will be designated KVEB, whereas
the previous control p/n was designated as KVEA. Since the delta pressure versus coil current relationship is not
affected by this nozzle change, the phasing of motors with
When servicing the new EDC, a different pilot valve part two line controls (controls which change motor displacement
number will be required (as compared to the existing EDC) based on the difference between X1 and X2) are not affected.
when replacement is necessary.
BLN-95-9060-4
6
APPLICATION (continued)
C2
EDC Pilot
Stage
(PCP)
C1
Lock Nut
13 mm
Pump Neutral
Adjust with
4 mm Wrench
X 1 Port X 2 Port
EDC Second
Stage 2139
PCP New Pressure Where Used PCP Replaces Pressure Where Used
Part Number Range psig EDC P/N Part Number Range psig EDC P/N
MCV116G4201 60-80 KVEBXXXXX MCV116F4201 120-160 KVEAXXXXX
MCV116G4204 60-80 KVEBXXXXX MCV116F4204 120-160 KVEAXXXXX
MCV116G4211 60-80 KVEBXXXXX MCV116F4211 120-160 KVEAXXXXX
MCV116H4201 60-80 MCV114XXXXX MCV116A4201 120-160 MCV114XXXXX
MCV116H4204 60-80 MCV114XXXXX MCV116A4204 120-160 MCV114XXXXX
CURRENT VS. SWASHPLATE ANGLE OF THE SINGLE COIL KVEA (B & E CONFIGURATION)
15¡
10¡
5¡
100 mA 80 60 40 20
20 40 60 80 100 mA
5¡
10¡
15¡
1390
BLN-95-9060-4
7
CONTROL OPTIONS
In the many industrial processes where flammable materials are handled, any leak or spillage may lead to an explosive
atmosphere. To protect both property and personnel, precautions must be taken to ensure that this atmosphere cannot be
ignited. The areas at risk are known as hazardous areas and the materials that are commonly involved include crude oil and
its derivatives, alcohol, natural and synthetic process starch, grain, fibers and flyings.
Intrinsic safety is based on the principle of restricting the electrical energy available in hazardous-area circuits such that any
sparks or hot surfaces that may occur as a result of electrical faults are too weak to cause ignition. Factory mutual Research
(FM) has approved the following model listed below for use in Class I, II, or III, Division 1, Group C, D, F, and G hazardous
locations as defined by the National Electrical code, NFPA-70 when used with approved barriers. This device is also factory
Mutual certified for use in Division 2, Group C, D, F, G. If a given application requires only Division 2 approval, an inline barrier
may bot be required.
WIRING
A suppression circuit is incorporated in the PCP torque motor cover but by itself does not insure intrinsic safety. An additional
suppression circuit (Zener barrier) must be connected in series with the valve coils. The Zener barrier and electrical controller
must be isolated from the hazardous area either through use of a purge enclosure or mounted in a safe area. The intrinsically
safe device enclosure grounding terminal is shown in the illustration of the KVEBS 1499 on the first page. Electrical connections
and suggested barrier model numbers are shown the connection diagram below.
A 3 (+)1
CONTROLLER
MCV BARRIER
B 4 2 OUTPUT
A 3 (±)1
CONTROLLER
MCV BARRIER
B 4 2 OUTPUT
To obtain a barrier or specific information about a barrier, contact R. Stahl, Inc. at 1-800-782-4357 or
e-mail at http://www.rstahl.com.
NO CHANGES TO THIS DRAWING WITHOUT PRIOR WRITTEN AUTHORIZATION FROM FACTORY MUTUAL.
BLN-95-9060-4
8
PRECAUTIONS WHEN DRIVING DUAL COIL PCPS WITH A PWM DRIVER
Sauer-Danfoss dual coil PCPs are constructed in such a 3. Some controllers are designed to diagnose shorts or
manner that magnetic flux generated in the circuit flows opens in the output circuit. The PWM-induced voltage
through the windings of both coils. This phenomenon is basic can affect some common detection schemes.
to the torque motor technology used. This is different from
some magnetic actuators, such as most proportional valves, 4. In the case of the PCP, a PWM signal is just like an
that have two distinctly separate magnetic circuits. alternating current applied to the primary of a trans-
former. A voltage is induced in the secondary coil
Since the flux generated in one coil flows through the other proportional to the turns ratio of the coils less losses in
coil, the device operates like, and in fact is, a transformer. the magnetic circuit. If the secondary coil is open cir-
cuited, there is no effect since no current flows, and
This fact is generally insignificant when the coils are driven hence no magnetic field is generated. However, if cur-
with dc currents, such as when the device is driven from a rent is allowed to flow in the secondary coil, it flows in a
potentiometric control handle or from dc current drivers such direction which will reduce the output of the actuator.
as the valve drivers in Sauer-Danfoss DC2 and SUSMIC
microcontrollers. 5. Most electronic drivers will conduct current when back
driven with excessive voltages. One example is a drive
Many controllers are set up to drive proportional solenoids that contains non-linear devices such as diodes or zener
through Pulse Width Modulation (PWM). Sometimes the diodes for re-circulatory currents. The induced voltages
scheme is used with the FET outputs of DC2s or SUSMIC may be sufficient to cause these devices to conduct,
controllers. These controls send an oscillating pulse width thereby causing current flow in the non-driven coil.
modulated dc current to the coil. This scheme has the
In position control systems where the control drives
advantages of providing dither to the actuator and, in some
toward null this generally is not a problem. However, in
cases, can simplify the electronics since they operate in a
propel systems, especially dual path propel systems,
digital mode. This can reduce heat output from the device.
the change in output velocity could be severe limitation.
In some cases filters can be designed to correct the
As with most things there are trade-offs or unwanted side
problem. A limitation of filters is this adds a lag in the
effects: Items 1 through 3 apply to all electrohydraulic
circuit which will adversely affect high response sys-
actuators. Items 4 and 5 relate more specifically to PCPs.
tems. Also it is impossible to design one filter to fit all
applications.
1. The pulsing current generates unwanted electromag-
netic radiation, which can interfere with related devices. In summary, the ability to drive the Sauer-Danfoss PCP
depends on many circumstances which must be understood
2. The actuators are generally responsive to current. PWM and accounted for by the user.
valve drivers are generally low impedance voltage
drives. As the coils heat up the resistance changes
(typically by as much as 50%), thus altering the re-
sponse of the device. For given PWM frequency and
duty cycle, both peak and average current into the driven
coil may strongly affect the coil's L/R (inductance/resis-
tance) time constant, potentially reducing both accuracy
and linearity. The effects vary considerably with valve
type and with temperature and are quite different be-
tween Sauer-Danfoss MCV116 and MCV110. PWM
drivers often require "current feedback" to maintain
sufficient accuracy as the temperature varies over the
operating range.
BLN-95-9060-4
9
PERFORMANCE
ENVIRONMENTAL
SHOCK 2. Resonance dwell for one million cycles for each
50 Gs for 11 milliseconds. Three shocks in both resonance point in each of the three axes.
directions of the three mutually perpendicular axes for a Subject to acceleration levels of 1 g to 46 Gs
total of 18 shocks Acceleration level varies with frequency
VIBRATION HUMIDITY
Withstands a vibration test designed for mobile After being placed in a controlled atmosphere of 95%
equipment control consisting of two parts: humidity at 49° C (120° F) for 10 days, the EDC will
perform within specification limits.
1. Cycling from 5 to 2000 Hz in each of the three axes. Meets MIL-STD-810B
WIRING
Common wiring styles are mentioned as follows: MS, 2. Strip back the insulation 5,5 millimeters on both wires.
Packard Weather-Pack, and Deutsch. The MS Connector
(MS3102C14S-2P) has four pins. See the MS Connector 3. Push a ribbed cable seal over each of the wires with the
Diagram for pin locations. See the Electrical Characteristics smaller diameter shoulder of the seals toward the wire
section for pump phasing. tip. Select the pair of seals that fits tightly over the wires.
The distance from the tip of the wires of the first (nearest)
Mating connectors must be ordered separately. For the MS rib should be 9.5 millimeters. Thus the insulation should
connector order part number K08106. The mating Packard just protrude beyond the seal.
connector is a bag assembly part number K03384,
comprised of : 4. Select the larger of the two sets of pins, as measured at
1. 4 14-16 gauge sleeves Dimension A (see the Dimension A drawing), if using
2. 4 18-20 gauge sleeves 14-16 gauge wire. Choose the smaller if using 18-20
3. 1 plastic housing gauge. Place the wire into the socket so that the seal
4. 4 green cable seals (accept 2 2-2, 8 mm wire diameter) edge is pushed through and extends slightly beyond the
5. 4 gray cable seals (accept 2 81-3, 49 mm wire diameter) circular tabs that hold it in place. Crimp in the locations
6. 4 blue cable seals (accept 3 50-4, 21 mm wire diameter) shown in the Packard Connector Crimp drawing with a
Packard 12014254 crimp tool. The distance from the
See Ordering Information. back of the tangs to the furthest rib may not exceed
19,5 mm.
TO ASSEMBLE THE FEMALE TOWER CONNECTOR
5. Manually insert the assembled wires into the back end 7. Plug the shroud connector from the valve into the tower
(large hole) of the plastic housing. Push until the wire connector just constructed. They are sealed with a
detents with an audible click, then pull back slightly to quadruple plug seal over the quadruple barrel of the
ensure proper seating (Observe the proper phasing of tower assembly. The two connector halves should
the wires when installing: Black wire to “A” hole, Red detent into each other. See the Packard Connector
wire to “B”, Black to “C” and Red to “D”). Terminals may Parts drawing.
be removed from the connector bodies with a Packard
12014012 removal tool.
A
DEUTSCH
4 1 19,7 mm
0.78 in B
D A 3 2
C B C
D
20,8 mm
1276 1622
0.82 in
2076
Pin Orientation of the Optional MS Pin orientation of the Mating 4-pin Pin orientation of the optional
Connector. This Part is not Field Deutsch Plug DT06-4S Series Packard Weather-Pack connector.
Replaceable. Connector. Part number K23511. Part number K03384.
1077 1792
Crimp Location and Distance from Tang to Third Rib of Packard Weather-Pack Interlocked Connector Halves
Packard Weather-Pack Connector. with Parts Identified.
DIMENSION A
DIMENSION A
1123
Dimension A for Selecting Correct Terminal.
BLN-95-9060-4
11
MOUNTING
123456789012345678901234567890121234567890123
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123456789012345678901234567890121234567890123 TO INSTALL THE NEW CONTROL
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WARNING
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123456789012345678901234567890121234567890123 1. Place a new gasket on the pump housing. If a charge
pressure control orifice is used ensure that the orifice
Exercise care when placing the valve on a surface before
and spring are in the proper position in the control.
mounting on a transmission. Dropping or otherwise force-
fully setting the valve down may damage the pin.
2. While setting the control into position, engage the pin on
the control linkage into the mating hole in the link
Before mounting the KVEB, remove the manual control or the attached to the pump swashplate.
blanking plate that comes with the pump. First thoroughly
clean all external surfaces of the pump with steam or solvent. 3. With the control in position against the pump housing,
Then remove the six hex head cap screws from the housing pin engagement can be check by one of two methods:
using a 5 mm internal hex wrench. Lift the manual control or a. Move control assembly left and right from center
plate from the pump. position, slight resistance will be noted if properly
engaged.
Before the new control is installed it is recommended that a b. Place a finger under the control connector and lift
new mounting gasket be installed. If going from a manual away form pump housing.
control to an EDC the same mounting bolts can be used. If If control tilts away more than approximately 1/4 to 3/8 of
going from a blanking plate to an EDC new mounting bolts are an inch,, the pin is not engaged.
required because of the different lengths. To help avoid a
mounting problem it may be necessary to order an EDC 4. Repeat steps 2 and 3 in case of non engagement.
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mounting kit. See Ordering Information.
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WARNING
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WARNING
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1234567890123456789012345678901212345678901234 Ensure positive pin engagement. Failure to do so may
result in pump output, and the vehicle may move.
The KVEB EDC cannot be hydraulically connected with
another device through the servo ports (X1 and X2). Do
not disconnect the SAE servo port fittings for this pur- 5. After control pin is engaged align the gasket and install
pose. Doing so may cause the EDC to go on stroke. The the cap screws (on 42 cc and 180/250 cc pumps use the
fittings are to be used only for troubleshooting purposes. included seal washer per the Seal Washer Location
When hydraulic connections are required, such as for a drawing) and torque to 16 Nm 10-12 ft•lbs.
staging function, the MCV114S must be used. Also an
orifice (Sauer-Danfoss orifice fitting part number
9002875-0039) must be located in each of the hydraulic
connections. See Ames Bulletin No. 9104 for details. SEAL WASHER
(USED ON 42, 180, AND
250 cc MODELS ONLY)
1396
BLN-95-9060-4
12
PUMP NEUTRAL ADJUSTMENT
Use the following procedure to bring the pump to neutral wrench angle rotation, until charge pressure decreases
once the electrical displacement control has been mounted. again (charge pressure will rise in neutral and drop when
going into stroke).
1. Install a 600 psi gauge into the charge pressure gauge
port on the pump. See the Pump Port Location drawing. 7. If the transmission operates as indicated by motor shaft
rotation, reduce speed to idle. Using a 3 mm internal hex
2. Using a 13 mm wrench, loosen the hex lock nut on the wrench, slowly turn the null adjustment screw clockwise
null adjustment screw. See the Dimension drawings. or counterclockwise until the transmission does not
operate. Repeat step 6. Note that charge pressure
3. Disconnect the electrical source at the connector. should drop with forward or reverse stroking of the pump
swashplate due to the shifting of the shuttle valve in the
4. Start the prime mover and run at low idle.
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123 motor manifold. Slowly turn the null adjustment screw
123456789012345678901234567890121234567890123
123456789012345678901234567890121234567890123 clockwise until charge pressure decreases.
WARNING
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8. With a 4 mm internal hex wrench, slowly turn the null
To adjust neutral requires operating the pump. Take the adjustment screw counterclockwise, observing the
necessary safety precautions, such as having wrench angle rotation, until charge pressure decreases
unnecessary personnel stand away from the machine. again (charge pressure will rise in neutral and drop when
Maximum system pressure may occur upon start-up, going into stroke).
and the machine may move. Ensure that the operator is
not in a position to be injured should the machine move. 9. Turn the adjustment screw clockwise half the amount of
the turn observed in step 8. This should be the center of
5. Warm the system up for several minutes to bleed air. neutral.
6. Slowly increase the prime mover speed to rated rpm. 10. Hold the adjustment screw and securely tighten the hex
lock nut on the adjustment screw to 14-18 foot-pounds.
7. If the transmission operates as indicated by motor shaft Note that if a motor is used that does not have a manifold,
rotation, reduce speed to idle. Using a 4 mm internal hex neutral should be adjusted (steps 8 - 10) by observing
wrench, slowly turn the null adjustment screw clockwise the motor shaft rotation without a load.
or counterclockwise until the transmission does not
operate. Repeat step 6. Note that charge pressure 11. Stop the prime mover.
should drop with forward or reverse stroking of the pump
swashplate due to the shifting of the shuttle valve in the 12. Reconnect the electrical signal source.
motor manifold. Slowly turn the null adjustment screw
13. Run the system briefly to ensure that it operates
clockwise until charge pressure decreases.
proportionally on both sides of null. Swashplate
8. With a 3 mm internal hex wrench, slowly turn the null movement can be verified by watching motor shaft
adjustment screw counterclockwise, observing the rotation without a load.
CHARGE PRESSURE
GAUGE PORT
2021
BLN-95-9060-4
13
TROUBLESHOOTING
PUMP FAILS TO STROKE PROPERLY gage differential readings are greater than 10 psi with no
If the pump does not reach its expected output flow with the command signal, the Pilot Valve should be replaced
proper input electrical signal when measured across the coils because of either contamination or a null pressure shift,
(approximately 2 to 2.5 Vdc and 12 to 15 Vdc for configuration the effect of which would likely be pump creep in one
A), the following should be checked: direction. If gage readings are less than 80 psi, charge
pressure is either low or is not getting to the EDC, which
1. Ensure pump maintains approximately 270 psi could be caused by a number of things, such as a
minimum charge pressure. blockage at either the EDC Pilot Stage inlet filter or EDC
inlet (charge pressure) orifice if applicable. See Service
2. Actuate the EDC manual operator several times from Parts for Pilot Stage filter location.
side to side, but first take the necessary safety
precautions in the event the pump reaches full output. If adequate pressure is noted at X1 and X2 as stated
above, but the X1 and X2 differential pressure (psid)
Pump Phasing With EDC Manual Operator (MO) reading fails to reach a minimum 100 psid (example, X1
Pump MO Pump Flow of 35 psi and X2 of 135 psi) with either the manual
Rotation Rotation Out Port operator or with full rated electrical signal, then replace
CW Towards Connector B the PCP. Note, a small percentage of the KVEA style
CCW Towards Connector A PCPs between date codes 9549 through 9753 may
experience a condition in which the manual operator will
not bring the pump to full stroke in one direction (see
3. If the pump fails to reach full output flow with the manual
Service Bulletin 9833 for details).
operator, shut the system off and place two 0-500 psi
pressure gages in the control ports X1 and X2 of the EDC
(see Service Parts). Once the gages are in place start
the system. Observe the gage readings. X1 and X2
should read between 45 to 85 psi for the KVEB and 90
to 170 psi for the KVEA and be within 5 psi of each other.
Note, the level of these readings will vary with respect to
charge pressure and oil temperature but should always
be within approximately 5 psi or less of each other. If
EDC ASSEMBLY
Manual Operator
Do not remove
cover screws (4)
Pilot Stage
Mounting screws (4)
EDC Pilot
Stage Lock Nut
(PCP) 13 mm
Pump Neutral
Adjust with
4 mm Wrench
X 1 Port X 2 Port
1 EDC Second 1
Stage
2071
BLN-95-9060-4
14
SERVICE PARTS
ITEM P/N QTY DESCRIPTION
1 K01291 5 SAE-6 Plugs
2 K07067 4 PCP Mounting Screws
3 K00860 1 PCP Cover Gasket
4 (2)(4) K02264 4 PCP Cover Screws
5* K00920 1 PCP Null Access Screw
6 (4)** K28475 1 PCP Cover Assy Replacement Kit
7 K21436 1 Silicone Oil Kit 4000 cs
8 (4) K04790 1 Connector Gasket
9 (4) K08687 4 Connector Screw for MS
10 (4) K01314 1 Connector MS
11 (4) K08688 4 Connector Screw for Packard
12 K08106 1 Mating Electrical Connector MS
13 (4) K08014 1 Feed Through Assy Cover Plate
14 (4) K07533 1 Feed Through Assy
4-pin Packard W-P
15 K03384 1 Mating Electrical Packard W-P
16 K00829 2 O-ring control port
17 K00830 1 O-ring return port
18 K08573 1 Filter Assy with O-rings
19 K08493 1 O-ring pressure port
20 KO2290 1 Spring Main Adjust
21 K17139 1 3-pin link/main adjust assy
(30 cc, 42 cc, 55 cc)
K17140 1 3-pin link/main adjust assy
(75 cc)
K17141 1 3-pin link/main adjust assy
(100 cc)
K17143 1 3-pin link/main adjust assy
(130 (long pin) (PV S/N < 92-19)
K17142 1 3-pin link/main adjust assy
(130 (short pin) (PV S/N * 92-19)
K17144 1 3-pin link/main adjust assy
(180 cc, 250 cc)
22 K16871 1 Neutral adjust screw
(thread m 8 x 45) 55 cc & down
K26150 1 Neutral adjust screw
(thread m 8 x 45) 75 cc & up
23 9003509-0008 1 EDC lock nut
24 K16887 1 1-pin link
25 K02288 1 Guide Shaft 55 cc & down
K02289 1 Guide Shaft 75 cc & up
26 K18519 1 Barrel Assy 55 cc & down (98 psi)
K18521 Barrel Assy 75 cc & up (98 psi)
27 K07066 2 Guide Shaft Screw
(all sizes)
28 (4) 2 Control Ports (meter in)
Thread Size M8
29 (3) K06041 2 Tank (PL) Orifices 0.052 in.
Thread Size M5
30 Spring
K17726 1 55 cc & down
K17727 1 75 cc & up
31 EDC Mounting Gasket
8800520 1 30/42/55 cc
8800923 1 75/100/130 cc
790345 1 180/250 cc
32 K17944 1 Plug
33 MCV116G4204 1 PCP, 14-85 mA, Packard
W-P connector
34 MCV116G4201 1 PCP, 14-85 mA, MS connector
35 (1) MCV116A3501 1 PCP, 4-20 mA, MS connector (single coil)
36 MCV116C1401 1 PCP, 4-20 mA, MS connector I. S. (single coil)
37 MCV116G4214 1 PCP, 14-85 mA, Deutsch connector
38 K25238 1 PCP Blanking Plate
* Item 5 see item 6
**Item 6 contains items 3, 5, 8
BLN-95-9060-4
15
SERVICE PARTS (continued)
7 8
6 9
5 10
3 11
12
2
1 13
14
33 34 35
19
36 17 18 16
21 16
20
15
31
22 32
23
24 25 26 27 28 29 30 2045A
(1) Item 35 has an internal scale factor (psid/mA) that is 1. Wipe down external surface to ensure that loose
factory calibrated to a special second stage which yields contaminants will not fall inside the housing.
4-20 mA control.
2. Place the valve in a firm position at 45° with the electrical
(2) Item 4. connector tilted upwards (PCPs built after 1988 are filled
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1234567890123456789012345678901212345678901234 with a silicon oil). Locate and remove the four connector
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WARNING
1234567890123456789012345678901212345678901234 screws in Item 7 if MS connector, or Item 9 if Packard
connector.
DO NOT Remove Cover Screws, unless replacing cover.
3. Hold the electrical connector and untwist wires by rotating
(3) Item 28. All units are factory shipped without orifices the connector CCW two turns while gently pulling away
installed, and are not recommended. from the housing.
(4) Items 4, 6, 8, 9, 10, 11, 13, 14. The following steps are 4. Clean the solder connections inside connection of the
recommended when servicing those piece parts listed in electrical connector with degreaser. Unsolder the wires
Service Parts-Table A. (page 11). noting which pin goes to which wire color (i.e., Pin A to
black, Pin B to red, Pin C to brown, etc.). With the
Preferred service tools are: connector held firmly, place the solder iron against the
• Screw driver TX 15 and TX 10 base solder cup if MS, and pin if Packard, until the wires
• Solder SN62 can be gently pulled away.
• Needle nose pliers, small tip
• Solder iron, electronic type 5. The cover can now be removed and replaced if required.
• Volt/ohm meter (VOM) Be sure the cover O-ring (Item 1) is firmly seated into the
• Cleaning solvent, Chemtronics 2000 ES 1601 cover base and is in good condition before cover is
• Torque wrench, 0-50 in•lb (0-66 N•m) installed. Torque cover screws to 8-10 in•lb (11-13 N•m).
BLN-95-9060-4
16
SERVICE PARTS (continued)
6. Verify that wire to pin connections are correct before 2. Loosen the null adjust lock nut using 13-mm wrench.
soldering wires. Also ensure that the connector gasket
(Item 3) is in place before soldering. 3. With a 4-mm internal hex wrench, turn the null adjustment
screw CCW 10 turns.
7a. For the MS style connector, ensure that the cups have
sufficient solder (approximately level). If additional 4. Move the link arm back and forth to eliminate any
solder is required, place solder iron against the base of binding. Using a bladed type screw driver, place it under
the cup and add solder. While solder is still liquid, place the main adjust and lift up until the 3-pin link/main adjust
wire in the cup, remove iron and let cool for several assembly lifts away from the housing.
seconds while holding wire firmly.
5. Note the 1-pin link, barrel, and guide shaft are also
7b. For the Packard style connector, the wire should extend removed at this time if changing them is required. When
around and contact the terminal post for at least 180° (1/ installing, ensure that the ball detents of the barrel align
2 wrap to a maximum of 270°). When ready to solder, with the internal spool sections. Then tighten guide shaft
heat the terminal and add solder, remove iron, and let holddown screws to 30 ± 3 in • lbs.
cool for several seconds while holding wire firmly.
6. Before installing the new link assembly, ensure that it is
8. After soldering, ensure that terminals and wires do not the correct one for the pump frame size. The link arm
contact one another. should be stamped per its frame size.
7. Installing the link/main adjust assembly requires the
9. If silicone oil is to be added, do so at this step with the large spring to be installed at the same time. Ensure
connector not yet attached to cover. Tilt cover upward engagement of the link pin into the 1-pin link and that the
and add 45-cc of oil from container. The container (P/N spring is properly seated.
K21436) holds enough for 3 fills.
8. Turn the null adjustment screw CW the same number of
10. Before attaching the connector to the cover, rotate turns from Step 3. To help ensure a positive EDC null,
connector CW two turns. This will bundle the wires the 3-pin link should be aligned approximately with the
together, finishing with the notch up when viewed from neutral adjust screw as shown in the drawing. While
the outward side of the MS connector, and lead wires holding the null adjustment screw firmly, tighten the lock
down for Packard connector (see page 11). Insert nut.
connector screws and torque to 8-10 in•lb (11-13 N•m).
9. Check for any binding by moving the 3-pin link back and
11. With a VOM, check for proper coil resistance between forth several times.
terminals A and B, and between C and D if PCP is a dual 1234567890123456789012345678901212345678901234
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coil. 1234567890123456789012345678901212345678901234
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WARNING
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CHANGING SERIES 90 EDC INTERNAL COMPONENTS EDC neutral setting is critical to ensure there is no machine
movement upon startup. Therefore, take the necessary
The following steps should be used as a guide when changing safety precautions in the event the pump builds pressure.
the 3-pin link/main adjust assembly: If pump system pressure does build, renulling the EDC
while it is mounted to the pump should restore the pump to
1. Place the control on a firm surface viewing the internal
neutral.
workings.
Main Adjust
3-pin Link
Snap Ring
2070
3-pin Link/Main Adjust Assembly.
BLN-95-9060-4
17
CUSTOMER SERVICE
NORTH AMERICA EUROPE
RETURN TO
BLN-95-9060-4
18