Hagie Hi-Tractor 204 SP DETASSELER Operator's Manual 493232 - PDF DOWNLOAD

TECHNICAL INFORMATION 240-ELECTRICAL ............................................................................................................ 1-3 250-DRIVETRAIN ........................................................................................................ 1-219 270-HYDRAULICS......................................................................................................... 1-9

240 - 1

240 - 2

Converting the Speed Display from MPH to km/h

+ 12 VDC

HALL TYPE (PARM 5 =1)

COM.

RPM INPUT

+ BACK LIGHT

HA8.0 MPH \ RPM Indicator Record the current speed parameter value: Press and hold the right MPH push button until all 8’s appear (88:88).

Release the push button and record the value that is displayed. For our example we are going to record the displayed value as 119.2 To convert from MPH to km/h we multiply the value by 1.609 For this example 119.2 x 1.609 = 191.8 The new km/h parameter will be 191.8 for this example.

Leave idle for 5 seconds and the display will return to the normal mode before going on to the next step.

Enter the new speed parameter value for km/h: The display will return to the normal mode if left idle for 5 seconds so the next steps need to be performed quickly.

Press and hold the right MPH push button until all 8’s appear (88:88) and then release.

Use the two push buttons to change the speed parameter to the new value. For our example the new value is 191.8 Leave both buttons idle for 5 seconds and the display will return to the normal mode.

The displayed speed will now be in km/h.

NOTE: The value can be changed faster by first pressing one button and while holding it depressed, press the other button. It can also be sped up by pressing and holding one button down for a couple of seconds.

DATE: 11-7-13 bas SIE, INC.

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Series 90 Pumps Service Manual

250 - 34

Service Manual

HISTORY OF REVISIONS

Table of Revisions Date

Page 70 -

2

250 - 35

520L0818

2008

Changed

Rev.

Service Manual

INTRODUCTION

7 7 7 7 7 8 9 0

OPERATION

2 2 2

OPERATING PARAMETERS 7 7 7 8 8 8 9 TECHNICAL SPECIFICATIONS

250 - 36

20 20 20 20

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2008

3

Service Manual

INITIAL STARTUP PROCEDURES

2 2

PRESSURE MEASUREMENTS

2 2

TROUBLESHOOTING

2 2 2 27 27 28 28 28 29

ADJUSTMENTS

0

7 7 8 9 2

4

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Service Manual

MINOR REPAIR

7 8 0 2

8 9 0

2

7 8 8

TORQUE CHART

250 - 38

9 70 70

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5

Service Manual

OVERVIEW

Sales and Service

WARRANTY

GENERAL INSTRUCTIONS w Remove the unit

e Keep it clean

d Replace all O-rings and gaskets

t Secure the unit

6

250 - 39

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Service Manual

SAFETY PRECAUTIONS

Unintended machine movement W Warning

Flammable cleaning solvents W Warning

Fluid under pressure W Warning

Personal safety W Warning

250 - 40

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7

Service Manual

SYMBOLS USED IN SAUER-DANFOSS LITERATURE







 







































 sleeve







8

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Service Manual

DESIGN

Cross section Piston Slider block

Slipper Displacement control

Servo arm Servo piston

Feedback linkage

Cradle bearing Bushing Cylinder block

Roller bearing

Valve plate

Shaft seal

Rear bushing

Input shaft

Swashplate

Charge pump

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2008

Cradle guide

P106 648E

9

Service Manual

THE SYSTEM CIRCUIT

The basic closed circuit

Basic closed circuit diagram

Reservoir Input

Output

MF

PV

Flow (Bi-directional)

Case drain line P104 120E

Case drain and heat exchanger

System circuit diagram Control handle

Displacement control valve Heat exchanger bypass valve Reservoir

Orificed check valve

Vacuum gauge Heat exchanger Charge pressure relief valve

Reversible variable displacement pump

Servo control cylinder

Purge relief valve

P102 000

Fixed displacement motor

Multi-function valve

To pump case Servo pressure relief valves

Charge pump Input shaft

Output shaft Multi-function valve

Pump swashplate

Motor swashplate Loop flushing valve

Servo control cylinder Pump

Working loop (high pressure)

10

250 - 43

Motor Working loop (low pressure)

520L0818

2008

Suction line

Control fluid

Case drain fluid

Service Manual

THE SYSTEM CIRCUIT (continued) Pump schematic

M3 X5 A M1

M5 M4

M2 B

L1

L2

S

P104 126E

250 - 44

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2008

11

Service Manual

CHARGE PUMP

Pump charge system Case drain line

Charge relief valve System check valves

Input

PV

PF Charge pump

Inlet filter P104 121E

Tank

CHARGE RELIEF VALVE

Charge pressure relief valve

Charge pressure

MULTI-FUNCTION VALVES

P106 157E

Multi-function valve Pressure limiter housing Pressure limiter lock nut

High pressure relief / check valve poppet

Check valve poppet

Pressure limiter adjustment screw

Bypass actuator

12

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2008

Pressure limiter valve poppet

Bypass P104 122E

Service Manual

PRESSURE LIMITER AND HIGH PRESSURE RELIEF VALVES

Circuit diagram showing pressure control mechanism To control Multi-function valve Servo piston

Bypass adjustment

Port "A" Servo Pres.

Relief Valve Port "B"

Charge pressure relief valve

Servo piston

Multi-function valve P104 123E

SYSTEM CHECK VALVES

BYPASS VALVES

SPEED SENSORS

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Service Manual

FILTRATION OPTIONS

Suction filtration

Suction filtration – option S

Charge pressure filtration – option R, T, P, and L

Charge pressure filtration Screen

Hydraulic fluid reservoir

Adjustable charge pressure relief valve Charge pump Filter

To low pressure side and control

PRESSURE OVERRIDE (POR) – 180 FRAME SIZE ONLY

To pump case P102 004E

POR-Valve (180 frame size only) To control

Multi-function valve Pressure override control valve

Bypass adjustment

Port "A"

Port "B"

Shuttle valve

Multi-function valve Charge pressure relief valve P104 124E

14

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Service Manual

MANUAL DISPLACEMENT CONTROL (MDC)

NON-LINEAR MDC

SOLENOID OVERRIDE VALVE FOR MDC

NEUTRAL START SWITCH (NSS)

HYDRAULIC DISPLACEMENT CONTROL (HDC)

ELECTRIC DISPLACEMENT CONTROL (EDC)

AUTOMOTIVE CONTROL (FBA II B)

3-POSITION (FNR) ELECTRIC CONTROL

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Service Manual

OVERVIEW

INPUT SPEED

Minimum speed

Continuous speed

Maximum speed

BLN-9884 Pressure and speed limits W Unintended vehicle or machine movement hazard

SYSTEM PRESSURE

System pressure

Continuous pressure

Maximum pressure

16

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Service Manual

CHARGE PRESSURE

Minimum charge pressure

Maximum charge pressure

2

CHARGE INLET PRESSURE

rated charge inlet pressure Minimum charge inlet pressure

rated case pressure CASE PRESSURE C Possible component damage or leakage

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2008

17

Service Manual

TEMPERATURE AND VISCOSITY

Temperature rated temperature maximum intermittent temperature

minimum temperature

Viscosity recommended range Minimum viscosity

Maximum viscosity

18

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Service Manual

FLUID AND FILTER RECOMMENDATIONS

Fluid and filter change interval Reservoir type

Max oil change interval

C

520L0463 Fluids and Filtration 520L0465 Biodegradable Hydraulic Fluids

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2008

19

Service Manual

OVERVIEW

FEATURES AND OPTIONS

Model Mount

Series 90 Pumps

Pump type Rotation Installation position Input shafts Control options

OPERATING PARAMETERS

Parameter

Unit

Pressure

Minimum

Parameter

Unit

Displacement

cm³

Minimum speed

min -1

Rated speed

min-1

Maximum speed Maximum attainable speed at maximum displacement

min-1

042

055

075

Frame size 100

130

180

250

min-1

Theoretical torque at maximum displacement kg

Weight

FLUID SPECIFICATIONS

20

250 - 53

Parameter

520L0818

88

Unit mm2

2008

Minimum 7

Continuous

β

β ≥

β

β ≥

Maximum

Service Manual

GENERAL W

START-UP PROCEDURE

C

250 - 54

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21

Service Manual

START-UP PROCEDURE (continued)

C C

22

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Service Manual

REQUIRED TOOLS

PORT LOCATIONS AND GAUGE INSTALLATION

Port information Port identifier Pressure obtained

Gauge size

Port size

M1, M2 M3 (M6) M4, M5 L1, L2

X1, X2 X3 S

250 - 56

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23

Service Manual

PORT LOCATIONS AND GAUGE INSTALLATION (continued) Pump with side port end cap and manual displacement control Servo / displacement cylinder pressure gauge port M4

Case drain port L1

Servo / displacement cylinder pressure gauge port M5

System pressure port B

External control pressure supply port X3

System pressure gauge port M2 Speed sensor Charge inlet pressure (vacuum)

System pressure gauge port M1

Carge pump inlet port S

24

250 - 57

System pressure port A

520L0818

Case drain port L2

2008

Charge pressure gauge port M3

P106 158E

Service Manual

PORT LOCATIONS AND GAUGE INSTALLATION (continued) Pump with twin port end cap and manual displacement control Servo / displacement cylinder pressure gauge port M4

Case drain port L1

Servo / displacement cylinder pressure gauge port M5 System pressure gauge port M2 System pressure port B

Charge pump inlet port S System pressure port A System pressure gauge port M1

Case drain port L2 P106 160E

Pump with side port end cap and remote pressure filtration

Charge pressure gauge port M6 (before the filter)

Pump with side port end cap and integral pressure filtration

Port E (from filter)

Port D (to filter)

Charge pressure gauge port M3 (back side-after the filter)

Charge pressure gauge port M3 (after the filter)

P106 163E

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25

Service Manual

OVERVIEW

Introduction

NEUTRAL DIFFICULT OR IMPOSSIBLE TO FIND Item

Description

Action

Description

Action

SYSTEM OPERATING HOT Item

26

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2008

Service Manual

TRANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY Item

Description

Action

Description

Action

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION Item

Pump charge relief valve Charge pressure with pump in stroke.

Charge pumps.

250 - 60

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2008

27

Service Manual

LOW MOTOR OUTPUT TORQUE Item

Description

Action

Description

Action

Description

Action

IMPROPER MOTOR OUTPUT SPEED Item

SYSTEM NOISE OR VIBRATION Item

28

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Service Manual

SYSTEM RESPONSE IS SLUGGISH Item

Description

250 - 62

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Action

2008

29

Service Manual

STANDARD PROCEDURES, INSPECTIONS, AND ADJUSTMENTS

30

250 - 63

CCaution

520L0818

2008

Service Manual

ADJUSTMENTS Pressure measurements

CHARGE PRESSURE RELIEF VALVE ADJUSTMENT W Warning

Charge pressure relief valve G B

K90

t

G B t

Charge pressure ranges Model code

Measured charge pressure*

20

28

250 - 64

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2008

31

Service Manual

CHARGE PRESSURE RELIEF VALVE ADJUSTMENT (continued)

Lock nut wrench size

32

250 - 65

Frame size

Wrench size

520L0818

2008

Service Manual

MULTI-FUNCTION VALVE PRESSURE ADJUSTMENT W

W

Multi-function valve adjustment

G B t I h t

M2 G B t G B t

250 - 66

520L0818

2008

33

Service Manual

MULTI-FUNCTION VALVE PRESSURE ADJUSTMENT (continued)

Pressure limiter adjustment data Frame size

Lock nut wrench size and torque

Adjusting

Approximate pressure change

screw size

per revolution of adjusting screw

8 mm

34

250 - 67

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Service Manual

ENGAGING THE BYPASS FUNCTION

C

Bypass actuator wrench size Frame size

Wrench size

Multi-Function Valve with Bypass Function Engaged Bypass actuator

Opening bypass valve allows flow to circuit through multi-function valves

P104 144E

Bypass actuator torque Frame size

250 - 68

520L0818

2008

Torque

35

Service Manual

PRESSURE OVERRIDE (POR) VALVE PRESSURE ADJUSTMENT (OPTION FOR 180 FRAME SIZE)

Pressure override valve for 180 frame size Operation section Pressure override valve

Adjusting screw Lock nut

W Warning

P104 145E

36

250 - 69

520L0818

2008

Service Manual

DISPLACEMENT LIMITER ADJUSTMENT Displacement limiter adjustment

C

C

I

Frame size

Lock nut wrench size and torque

Adjusting screw size

Approximate displacement change per revolution of adjusting screw

STANDARD MANUAL DISPLACEMENT CONTROL (MDC) ADJUSTMENT

250 - 70

520L0818

2008

37

Service Manual

NON-LINEAR MANUAL DISPLACEMENT CONTROL (MDC)

W Warning

MDC neutral adjustment

Ser 8

Serv G B t

8

M72 I

M90

38

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2008

Service Manual

NON-LINEAR MANUAL DISPLACEMENT CONTROL (MDC) (continued)

MDC NEUTRAL START SWITCH (NSS) ADJUSTMENTS

MDC with neutral start switch A

A

Control shaft

Switch cam

Switch lock nut Neutral start switch Eccentric plug Switch pin Special lock nut for eccentric plug

View at section A-A

Orifice check valve seat Control spool assembly Control link assembly View A-A

250 - 72

520L0818

2008

P104 146E

39

Service Manual

MDC NEUTRAL START SWITCH (NSS) ADJUSTMENTS (continued)

Neutral start switch adjustment requirements NSS deadband (switch closed, ON)

NSS deadband

Control shaft (free-play)

Control deadband (neutral) Total control shaft rotation

Control shaft

control deadband

P104 147E

40

250 - 73

520L0818

2008

Service Manual

MDC NEUTRAL START SWITCH (NSS) ADJUSTMENTS (continued)

Neutral start switch eccentric plug adjustment (condition i)

Eccentric plug adjustment tool 12.7 [0.5]

9.14 [0.36]

3.175 [0.125]

1.52 [0.06] 25.4 [1.0] P104 149E

NSS with eccentric plug

B

W

W

Switch lock nut

Eccentric plug Switch pin

B

Special lock nut for eccentric plug

Neutral start switch

Special lock nut for eccentric plug Control mounting surface

Eccentric plug

View B-B (switch and lock nut removed)

250 - 74

520L0818

2008

Switch pin

P104 150E

41

Service Manual

MDC NEUTRAL START SWITCH (NSS) ADJUSTMENTS (continued)

Eccentric plug adjustment Switch pin

Eccentric plug

90°

Control mounting surface

90°

Eccentric plug adjustment range P104 151E

C

NSS deadband adjustment (conditions ii & iii)

42

250 - 75

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2008

Service Manual

MDC NEUTRAL START SWITCH (NSS) ADJUSTMENTS (continued)

Neutral start switch

Control shaft

Switch lock nut Neutral start switch Switch cam

Switch pin

1-1/8 in t) P104 148E

250 - 76

520L0818

2008

43

Service Manual

CHECKING SWITCH CONTINUITY

W

W

Checking switch continuity Ser G B t

Serv G B t

44

250 - 77

520L0818

8

2008

8

Service Manual

HYDRAULIC DISPLACEMENT CONTROL (HDC) AND ELECTRIC DISPLACEMENT CONTROL (EDC) ADJUSTMENT W

W HDC and EDC neutral adjustment Ser G Serv

B t

G B t

M72 I

M90 h t

250 - 78

520L0818

2008

45

Service Manual

SPEED SENSOR ADJUSTMENT

Cross section view of speed sensor in variable pump

Gap

Speed sensor Magnetic speed ring Cylinder block P104 152E

Positioning speed sensor relative to pump shaft Shaft centerline 1/2 inch wrench flats 22°

22°

Speed sensor with packard connector

Speed sensor with turck connector Shaft centerline

1/2 inch wrench flats

22° Speed sensor with packard connector

22° Speed sensor with turck connector P104 155E

46

250 - 79

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Service Manual

STANDARD PROCEDURES

Removing the pump

CCaution

Disassembly

Inspection

Reassembly

250 - 80

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2008

47

Service Manual

SHAFT SEAL AND SHAFT REPLACEMENT

Shaft removal

Shaft assembly L70 L60 L30 L40 L50 L20

L10

L100

P106 181E

48

250 - 81

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2008

Service Manual

SHAFT SEAL AND SHAFT REPLACEMENT (continued)

Inspection

Reassembly

Shaft retainer screw torque Frame size

250 - 82

520L0818

2008

Torque

49

Service Manual

MULTI-FUNCTION VALVE CARTRIDGES

Multi-function valve removal / installation

P2B1

See multifunction valves - Pre 1988

P13 P06

P2A1 P106 180E

Removal

Multi-function valve wrench size Frame size

50

250 - 83

520L0818

2008

Wrench size

Service Manual

MULTI-FUNCTION VALVE CARTRIDGES (continued)

Multi-function valve P04

P03 P01 P02 P05

P06 P07 P08

P17 P16 P15 P14

P09

P11 P13 P12

E101 531E

Inspection

Reassembly

C

C

C Multi-function valve torque Frame size

250 - 84

520L0818

Torque

2008

51

Service Manual

MULTI-FUNCTION VALVE CARTRIDGES - PRE 1988

Removal

Multi-function valve wrench size Frame size

Wrench size

Inspection

Multi-function valve - pre 1988 P14 P19 P12

P06 P21

P15 P14

P09

P11 P13

P22 P1

E101 532E

52

250 - 85

520L0818

2008

Service Manual

MULTI-FUNCTION VALVE CARTRIDGES - PRE 1988 (continued)

Reassembly

C

C

C Multi-function valve torque Frame size

PRESSURE OVERRIDE VALVE (OPTION FOR 180 FRAME SIZE)

Torque

Removal

Pressure override valve components Screws

Pressure override valve

Inspection

O-rings

Reassembly

E101 079E

250 - 86

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2008

53

Service Manual

CHARGE PRESSURE RELIEF VALVE Removal

Lock nut wrench size Frame size

Wrench size

Charge pressure relief valve Inspection h

K90

t h d

K K70

Reassembly

K80

Charge pressure adjustments

54

250 - 87

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2008

Service Manual

AUXILIARY PAD

Removal C

Aux. pad screw wrench size Frame size

Wrench sizes

Inspection

C

Auxiliary pad components (typical) J50

J80 Endcap screw Screw torque

J70

J60 See appropriate table for wrench size and torque E101 084E

Inspection

Reassembly

End cap screw torque Frame size

250 - 88

520L0818

2008

Torque

55

Service Manual

CHARGE PUMP Removal Auxiliary Pad C

Retainer screw wrench size Frame size

Wrench size

Current charge pump configuration

H40 H05 H60 H50

H31

J50 J15

J30 H70 E101 082E

H80

Sauer-Danfoss Series 90 service parts manual

56

250 - 89

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Service Manual

CHARGE PUMP (continued)

Inspection

Reassembly Orienting alignment pin Discharge

Discharge Gerotor assembly Alignment pin Inlet

Inlet Alignment pin Gerotor assembly Left hand rotation (outside looking into pump)

Right hand rotation (outside looking into pump) P104 160E

250 - 90

520L0818

2008

57

Service Manual

CHARGE PUMP (continued)

C “Auxiliary Pad Installation”

Retainer screw torque Frame size

Torque

ADDING AN AUXILIARY PAD TO A PUMP PREVIOUSLY WITHOUT ONE

Auxiliary pad

58

250 - 91

520L0818

Charge pump

2008

Service Manual

INTEGRAL CHARGE PRESSURE FILTER REPLACEMENT

Removal

Lock nut wrench size and torque Frame size

Wrench size

Torque

Inspection

Reassembly

C

C

Integral charge pressure filter

N20

N25

Fi

N15

N36A N36 11/16 in t] N40

N10 N35A N35 11/16 in t]

250 - 92

520L0818

2008

P106 182E

59

Service Manual

PUMP CONTROL COVER PLATE

Removal

C Reassembly

Pump controls cover plate M90 h

d

60

250 - 93

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2008

Service Manual

DISPLACEMENT CONTROL ORIFICES

Underside of an HDC/EDC module showing orifice locations A B TA

P TB

Orifice plugs Orifice check valve E101 085E

DISPLACEMENT CONTROL ORIFICE CHECK VALVE

Underside of an MDC module showing orifice locations B

TA A

TB

P

Orifice plugs Orifice check valve E101 086E

DISPLACEMENT CONTROL ADAPTER PLATE (EARLY PRODUCTION 130 PUMPS ONLY)

Displacement control adapter plate (early production 130 cm³ pumps only) Adapter plate screws 6 mm

O-rings

Adapter plate

Seal

E101 087E

250 - 94

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2008

61

Service Manual

MANUAL DISPLACEMENT CONTROL (MDC)

Removal

C Reassembly

MDC removal/installation h

M70

I

d

62

250 - 95

520L0818

2008

M72 h 8 mm

Service Manual

MANUAL DISPLACEMENT CONTROL (MDC) (continued)

W

MDC Neutral start switch adjustment

SOLENOID OVERRIDE VALVE FOR MDC

Removal

Reassembly

Solenoid override valve removal/installation M90 (x6) 5 mm

M77 ]

M76A M76C M76B M76

M75

M78 (x2) 5 mm ] P106 186E

250 - 96

520L0818

2008

63

Service Manual

SOLENOID OVERRIDE VALVE FOR MDC WITH PRESSURE RELEASED BRAKE

Removal

Reassembly

Solenoid override valve removal/installation M98 (x4) 4 mm t]

M96 M97

M9

M95 M92 (x4) 4 mm t] P106 192E

64

250 - 97

520L0818

2008

Service Manual

HYDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS

Removal

C Reassembly

Hydraulic/Electric displacement control M90 I

d

250 - 98

520L0818

2008

65

Service Manual

PRESSURE CONTROL PILOT (PCP) FOR ELECTRIC DISPLACEMENT

Removal

Inspection Reassembly

PCP removal/installation

M90 (x6) 5 mm ] Seal washer location (42, 180, 250 cc)

M97 M96 (x3)

M98 (x4) 4 mm

M9 t]

66

250 - 99

520L0818

P106 194E

2008

Service Manual

3-POSITION (FNR) ELECTRIC CONTROL

Removal

C

C Inspection must

Reassembly C

FNR removal/installation I

d

I

M900

d

250 - 100

520L0818

2008

67

Service Manual

DISPLACEMENT CONTROL FILTER SCREENS

Filter screen installation B90 P106 690E

SPEED SENSOR

Removal

Reassembly

Speed sensor adjustment

Typical location of speed sensor B83 O-ring plug ] B83A

B83

B83A ]

E101 095E

68

250 - 101

520L0818

2008

Service Manual

FASTENER SIZE AND TORQUE CHART

Item B83 E60

Fastener

Frame size Wrench size

Torque

E60

F211 G97

H80 J80

K10 K90 L70

M72 M78 M85 M88 M90 M92 M98 N10

8 mm

N37 P2A1

250 - 102

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69

Service Manual

PLUG SIZE AND TORQUE CHART

C

C

Item

O-ring plug

Wrench size

Torque

B70, B72 B71 B80 B82, B83 G18 G45-G50 G52-G54 H90 (not shown) N35, N36 (not shown) N37

FASTENERS AND PLUGS

Fastener and plug locations G90 End cap screw

J80 Auxilliary pad / end cap screw

B70, B72 O-ring plug 9/16-18 M90 Control bolt

H80 Charge pump retaining screw

L70 Shaft seal retaining screw

G53, G54 O-ring plug 9/16-18

K10 Charge pressure relief valve plug

M88 Neutral start switch lock nut M85 Eccentric plug lock nut

K90 Charge pressure relief valve lock nut B80 O-ring plug 1-1/16-12

P2B1 Multi-function valve

G97 End cap screw

B71 O-ring plug 9/16-18

B82 O-ring plug 9/16-18

B83 Speed sensor / O-ring plug 9/16-18

G50 O-ring plug 9/16-18

G49 O-ring plug 9/16-18 G48 O-ring plug 9/16-18

N37 Filter plug assembly F111 / F211 Servo cylinder screw

N10 Filter reducer assembly

E60 Side cover screw

P2A1 Multi-function valve

70

250 - 103

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2008

P106 189E

Service Manual

250 - 104

520L0818

2008

71

OUR PRODUCTS

Sauer-Danfoss Mobile Power and Control Systems – Market Leaders Worldwide

ü ü

520L0818

250 - 105

2008

Series 90 Axial Piston Pumps

Technical Information

250 - 106

Series 90 Axial Piston Pumps Technical Information Revisions HISTORY OF REVISIONS

Table of Revisions Date

Page

Changed

Rev.

July 2007 March 2004

Various -

Minor edits and dimension changes Revision F

FB F

© 2007 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.

Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group.

2

250 - 107

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Contents GENERAL DESCRIPTION

Series 90 family of pumps and motors ................................................................................................... 5 Plus+1 Compliant controls and sensors................................................................................................. 5 Design ................................................................................................................................................................ 6 Pictorial circuit diagram ............................................................................................................................... 7 System schematic........................................................................................................................................... 7

TECHNICAL SPECIFICATIONS

Features and options .................................................................................................................................... 8 Operating parameters .................................................................................................................................. 8 Fluid specifications ........................................................................................................................................ 9

OPERATING PARAMETERS

Overview .........................................................................................................................................................10 Input speed ....................................................................................................................................................10 System pressure ............................................................................................................................................10 Case Pressure .................................................................................................................................................10 Hydraulic Fluids.............................................................................................................................................11 Temperature and viscosity ........................................................................................................................11

SYSTEM DESIGN PARAMETERS

Fluid and filtration........................................................................................................................................12 Charge pressure ............................................................................................................................................12 Independent braking system...................................................................................................................12 Reservoir ..........................................................................................................................................................12 Case drain........................................................................................................................................................13 Sizing equations ...........................................................................................................................................13 Shaft Loads .....................................................................................................................................................14

FEATURES AND OPTIONS

Shaft Availability and Torque Ratings ...................................................................................................15 Filtration options ..........................................................................................................................................16 Displacement limiter ...................................................................................................................................16 Suction filtration – option S ................................................................................................................16 Charge pressure filtration – option R, T, P, and L ...........................................................................16 Overpressure protection ......................................................................................................................17 Pressure limiting function....................................................................................................................17 Multi-function valves ..................................................................................................................................17 Bypass Function ......................................................................................................................................18 Speed sensor ..................................................................................................................................................19 Charge Pump .................................................................................................................................................19 Charge pump sizing/selection ...........................................................................................................20 Charge pump flow and power curves .............................................................................................20 Auxiliary Mounting Pads............................................................................................................................21 Mating pump requirements ...............................................................................................................21 Mounting Flange Loads .............................................................................................................................22 Estimating overhung load moments ...............................................................................................22

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3

Series 90 Axial Piston Pumps Technical Information Contents CONTROL OPTIONS

3 -Position (FNR) Electric Control ............................................................................................................23 Response time .........................................................................................................................................23 Electric Displacement Control (EDC) .....................................................................................................24 Operation ...................................................................................................................................................24 Features and Benefits ............................................................................................................................24 (continued)................................................................................................................................................25 Control signal requirements ...............................................................................................................25 Response time .........................................................................................................................................25 Pump output flow direction vs. control current ..........................................................................25 Hydraulic Displacement Control (HDC)................................................................................................26 Operation ...................................................................................................................................................26 Features and benefits of the hydraulic displacement control: ...............................................26 Control signal requirements ...............................................................................................................27 Response time .........................................................................................................................................27 Manual Displacement Control (MDC) ...................................................................................................28 Operation ...................................................................................................................................................28 Features and benefits of the manual displacement control:...................................................28 External control handle requirements ............................................................................................29 Response time .........................................................................................................................................29 Non-linear Manual Displacement Control (MDC) .............................................................................30 Features and benefits of the non-linear manual displacement control:.............................30 External control handle requirements ............................................................................................31 Response time .........................................................................................................................................31 Non feedback proportional electric control (NFPE) ........................................................................32 Features and benefits of the NFPE control when used with sauer-danfoss microcontroller ........................................................................................................................................33 Input signal requirements ...................................................................................................................33

INSTALLATION DRAWINGS

Frame size 042 ...............................................................................................................................................34 Frame size 055 ...............................................................................................................................................36 Frame size 075 ...............................................................................................................................................40 Frame size 100 ...............................................................................................................................................44 Frame size 130 ...............................................................................................................................................48 Frame size 180 ...............................................................................................................................................51 Frame size 250 ...............................................................................................................................................55 Cover plate......................................................................................................................................................59 3-position (F-N-R) electric control ..........................................................................................................59 Electric Displacement Control (EDC) with MS-Connector or Packard® connector ...............60 Hydraulic Displacement Control (HDC)................................................................................................60 Manual Displacement Control (MDC) with neutral start switch .................................................61 Non-linear Manual Displacement Control (MDC) .............................................................................61 Electrohydraulic Displacement Control (NFPE) .................................................................................62 (except 075 NFPE) ........................................................................................................................................62 Integral Pressure Filter ................................................................................................................................63 Remote pressure – without filter ............................................................................................................63 Frame size 075 NFPE....................................................................................................................................64

4

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250 - 109

Series 90 Axial Piston Pumps Technical Information 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 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.

• • • • • • • • • •

Series 90 – advanced technology today Seven sizes of variable displacement pumps Five sizes of fixed displacement motors One variable displacement motor SAE and cartridge mount configurations Efficient axial piston design Proven reliability and performance Compact, lightweight Worldwide sales and service Plus+1™ compliant controls and sensors

PLUS+1 COMPLIANT CONTROLS AND SENSORS

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.sauerdanfoss.com/plus1.

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5

Series 90 Axial Piston Pumps Technical Information General description DESIGN

Series 90 pump cross-section Piston Slider block

Slipper Displacement control

Servo arm Servo piston

Feedback linkage

Cradle bearing Bushing Cylinder block

Roller bearing

Valve plate

Shaft seal

Rear bushing

Input shaft

Swashplate

Charge pump

Cradle guide

Name plate

Model-No./Ident-No.

501829

Model Number

N - 88 - 126 - 67890

Serial Number

Model Code

Model Code Serial-No.

Made in USA

P104 291E

Place of Manufacture 6

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520L0603 • Rev FB • July 2007

P106 648E

Series 90 Axial Piston Pumps Technical Information General description PICTORIAL CIRCUIT DIAGRAM Control handle

This configuration shows a hydrostatic transmission using a Series 90 axial piston variable displacement pump and a Series 90 fixed displacement motor.

Displacement control valve Heat exchanger bypass valve Reservoir

Orificed check valve

Vacuum gauge Heat exchanger

Purge relief valve

Charge pressure relief valve Reversible variable displacement pump

Servo control cylinder

P102 000

Fixed displacement motor

Multi-function valve

To pump case Servo pressure relief valves

Charge pump Input shaft

Output shaft Multi-function valve

Pump swashplate

Motor swashplate Loop flushing valve

Servo control cylinder Pump

Working loop (high pressure)

Motor Working loop (low pressure)

Suction line

Control fluid

Case drain fluid

L2

M1

SYSTEM SCHEMATIC

M3

A

A

B

B

M3

M1 M4 M5

M

M2

L2

S

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L1

M2

P104 286E

7

Series 90 Axial Piston Pumps Technical Information Technical specifications FEATURES AND OPTIONS

Flow at rated speed

Unit cm³/rev [in³]/rev l/min

042 42 [2.56] 176

055 55 [3.35] 215

075 75 [4.59] 270

Frame 100 100 [6.10] 330

130 130 [7.93] 403

180 180 [10.98] 468

250 250 [15.25] 575

(theoretical) Torque at maximum

[US gal/min]

N•m/bar

[46] 0.67

[57] 0.88

[71] 1.19

[87] 1.59

[106] 2.07

[124] 2.87

[160] 3.97

[410] 0.0023 [0.0017] 34 [75] B

[530] 0.0060 [0.0044] 40 [88] C

[1750] 0.0380 [0.0280] 136 [300] E

[2433] 0.0650 [0.0479] 154 [340] E

Feature Displacement

displacement (theoretical) Mass moment of inertia of rotating components Weight (with control opt. MA) Mounting (per SAE J744) Rotation Main ports: 4-bolt split-flange

[lbf•in/1000 psi]

kg•m² [slug•ft²] kg [lb]

mm

(per SAE J518 code 62) [in] Main port configuration Case drain ports (SAE O-ring boss) UNF thread (in.)

Other ports

19.05

25.4

[0.75] Radial 0.875–14

[1.0]

[730] [970] [1260] 0.0096 0.0150 0.0023 [0.0071] [0.0111] [0.0170] 49 [108] 68 [150] 88 [195] C C D Clockwise or Counterclockwise 25.4 25.4 31.75

31.75

[1.0] [1.0] [1.25] [1.25] Radial or axial Radial 1.0625–12 1.0625–12 1.0625–12 1.625–12 1.625–12 SAE O-ring boss. See Installation drawings, page 34.

38.1 [1.5] 1.625–12

Shafts Auxiliary mounting

Splined, straight keyed, and tapered shafts available. See Shafts, page 15.

Installation position

Installation is recommended with control on the top or side. Consult your Sauer-Danfoss representative for nonconformance guidelines. The housing must remain filled with hydraulic fluid.

SAE-A, B, C

SAE-A, B, C, D

SAE-A, B, C, D, E

OPERATING PARAMETERS Parameter Input speed

Unit Minimum Continuous min-1(rpm) Maximum

042

055

075

Frame 100

130

180

250

500 4200 4600

500 3900 4250

500 3600 3950

500 3300 3650

500 3100 3400

500 2600 2850

500 2300 2500

System pressure Rated Maximum bar [psi] Minimum low loop Inlet pressure (charge inlet) Minimum (continuous) bar (abs.)

Minimum (cold start) [in. Hg vac.]

420 [6000] 450 [6500] 10 [150] 0.7 [9] 0.2 [24]

Case pressure Continuous bar [psi] Maximum (cold start)

8

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3 [40] 5 [75]

Series 90 Axial Piston Pumps Technical Information Technical specifications FLUID SPECIFICATIONS

Viscosity mm²/sec (cSt) [SUS] Minimum Continuous

7 [49] 12-80 [70-370]

Maximum

1600 [7500]

Temperature °C [°F] Minimum

-40 [-40]

Continuous Maximum

104 [220] 115 [240]

Filtration

250 - 114

Cleanliness Efficiency (suction filtration)

18/13 or better per ISO 4406 β35-45=75 (β10≥2)

Efficiency (charge filtration) Recommended inlet screen size

β15-20=75 (β10≥10) 100-125 μm [0.0039-0.0049 in]

520L0603 • Rev FB • July 2007

9

Series 90 Axial Piston Pumps Technical Information Operating parameters OVERVIEW

Maintain operating parameters within prescribed limits during all operating conditions.

This section defines operating limits given in the table Operating parameters, page 8.

INPUT SPEED

Minimum speed is the lowest input speed recommended during engine idle condition.

Operating below minimum speed limits the pump’s ability to maintain adequate flow for lubrication and power transmission.

Continuous speed is the highest input speed recommended at full power condition.

Operating at or below this speed should yield satisfactory product life.

Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed limit under any operating conditions.

Consult Pressure and speed limits, BLN-9984, when determining speed limits for a particular application.

W Warning Unintended vehicle or machine movement hazard.

Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss.

SYSTEM PRESSURE

System pressure is the differential pressure between system ports A and B. It is the dominant operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life. System pressure must remain at or below continuous pressure during normal operation to achieve expected life.

Continuous pressure is the average, regularly occurring operating pressure. Operating at or below this pressure should yield satisfactory product life.

Maximum pressure is the highest intermittent pressure allowed. Maximum machine load should never exceed this pressure. For all applications, the load should move below this pressure.

All pressure limits are differential pressures referenced to low loop (charge) pressure.

Subtract low loop pressure from gauge readings to compute the differential.

CASE PRESSURE

Under normal operating conditions, the maximum continuous case pressure must not exceed 3 bar (44 psi). Maximum allowable intermittent case pressure during cold start must not exceed 5 bar (73 psi). Size drain plumbing accordingly.

C Caution Possible component damage or leakage Operation with case pressure in excess of these 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.

10

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Series 90 Axial Piston Pumps Technical Information Operating parameters HYDRAULIC FLUIDS

Ratings and 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.

Fire resistant fluids are also suitable at modified operating conditions. Please see SauerDanfoss publication 520L0463 for more information. Refer to publication 520L0465 for information relating to biodegradable fluids.

Suitable Hydraulic fluids: • Hydraulic fluids per DIN 51 524, 2-HLP, • Hydraulic fluids per DIN 51 524, 3-HVLP, • API CD, CE and CF engine fluids per SAE J183, • M2C33F or G automatic transmission fluids (ATF), • Dexron II (ATF), which meets the Allison C3- and Caterpillar TO-2 test, • Agricultural multi purpose oil (STOU), • Premium turbine oils.

TEMPERATURE AND VISCOSITY

Temperature and viscosity requirements must be concurrently satisfied. The data shown in the table Fluid specifications, page 9, assume petroleum-based fluids are used.

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 rated temperature. The maximum 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.

For maximum unit efficiency and bearing life the fluid viscosity should remain in the recommended operating 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.

Heat exchangers should be sized to keep the fluid within these limits. Testing to verify that these temperature limits are not exceeded is recommended.

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11

Series 90 Axial Piston Pumps Technical Information System design parameters FLUID AND FILTRATION

To prevent premature wear, it is imperative that only clean fluid enter 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.

The filter may be located either on the inlet (suction filtration) or discharge (charge pressure filtration) side of the charge pump. 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 may 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 β35-45 = 75 (β10 ≥ 2) or better has been found to be satisfactory. For 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 β15-20 = 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, 520L0467, for more information.

CHARGE PRESSURE

The charge pressure setting listed in the model code is based on the charge flow across the charge pressure relief valve at fluid temperature of 50 °C [120 °F].

INDEPENDENT BRAKING SYSTEM

W Warning Unintended vehicle or machine movement hazard.

The loss of hydrostatic drive line power, in any mode of operation (forward, neutral, or reverse) may cause the system to lose hydrostatic braking capacity. You must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss.

RESERVOIR

The reservoir should be designed to accommodate maximum volume changes during all system operating modes and to promote de-aeration of the fluid as it passes through the tank.

A suggested minimum total reservoir volume is 5/8 of the maximum charge pump flow per minute with a minimum fluid volume equal to 1/2 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.

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.

1

12

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Series 90 Axial Piston Pumps Technical Information System design parameters RESERVOIR (continued)

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 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

A case drain line must be connected to one of the case outlets (L1 or L2) to return internal leakage to the system reservoir. The higher of the two case outlets should be used to promote complete filling of the case. Since case drain fluid is typically the hottest fluid in the system, it is advantageous to return this flow through the heat exchanger.

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, BLN-9885, 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.

SI units

Output flow Q = V • n • η g

Input torque M =

M•n•π

(N•m) Q • Δp

= 600 • η

(kW)

t

Output flow Q =

Vg • n • ηv (US gal/min) 231

Input torque M =

Vg • Δp 2 • π • ηm

Vg = Δp =

Q • Δp

t

520L0603 • Rev FB • July 2007

n = ηv = ηm = ηt =

(lbf•in)

M•n•π Input power P = 198 = 1714 • η (hp) 000

250 - 118

Vg = Δp =

Vg • Δp 20 • π • ηm

Input power P = 30 000 US units

(l/min)

v

1000

n = ηv = ηm = ηt =

Displacement per revolution (cm3/rev) pO - pi (system pressure) (bar) Speed (min-1(rpm)) Volumetric efficiency Mechanical efficiency Overall efficiency (ηv • ηm) Displacement per revolution (in3/rev) pO - pi (system pressure) (psi) Speed (min-1(rpm)) Volumetric efficiency Mechanical efficiency Overall efficiency (ηv • ηm)

13

Series 90 Axial Piston Pumps Technical Information System design parameters SHAFT LOADS

Normal bearing life in B10 hours is shown in the table below. The figures reflect a continuous differential pressure of 240 bar [3500 psi], 1800 min-1 (rpm) shaft speed, maximum displacement, and no external shaft side load. The data is based on a 50% forward, 50% reverse duty cycle, standard charge pump size, and standard charge pressure.

Bearing life Frame size Bearing life – B hrs Series 90 pumps are designed with 42 18 060 bearings that can accept external radial 55 22 090 and thrust loads. The external radial 75 22 970 shaft load limits are a function of the 100 22 670 load position and orientation, and the 130 17 990 operating conditions of the unit.

10

The maximum allowable radial load (Re), is based on the maximum external moment (Me), and the distance (L) from the mounting flange to the load. It may be determined using the table and formula below. Thrust (axial) load limits are also shown.

180

16 150

250

12 020

Radial and thrust load position L 0˚Re Re 270˚ Re Tout Tin

90˚ Re

Re = Me / L 180˚Re

Pump swashplate

P104 292E All external shaft loads affect bearing life.

In applications with external shaft loads, minimize the impact by positioning the load at 90° or 270° as shown in the figure.

Contact your Sauer-Danfoss representative for an evaluation of unit bearing life if: • continuously applied external loads exceed 25 % of the maximum allowable radial load (Re).

• the pump swashplate is positioned on one side of center all or most of the time.

• the unit bearing life (B10) is critical.

Sauer-Danfoss recommends tapered input shafts or clamp-type couplings for applications with radial shaft loads.

Allowable external shaft load

14

250 - 119

Parameter External moment (Me)

042 126

055 101

075 118

100 126

130 140

180 161

250 176

N•m [lbf•in] Maximum shaft thrust in (Tin)

[1114] 2635

[893] 3340

[1043] 4300

[1114] 5160

[1238] 5270

[1424] 7000

[1556] 7826

N [lbf] Maximum shaft thrust out (Tout)

[592] 1020

[750] 910

[996] 930

[1160] 1000

[1184] 688

[1573] 1180

[1759] 1693

N [lbf]

[229]

[204]

[209]

[224]

[154]

[265]

[380]

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Features and options SHAFT AVAILABILITY AND TORQUE RATINGS

Through torque diagram

Third stage

Second stage

First stage

P102 014E M e 1 for the first pump

M e 2 for the second pump

M e Input torque

M e 3 for the next pump

Torque required by auxiliary pumps is additive. Ensure requirements don’t exceed shaft torque ratings.

Shaft availability and torque ratings Shaft description

Contact your Sauer-Danfoss representative for tapered shaft torque ratings.

Legend: —

Not available

+

Not recommended for front pump in tandem configurations

*

Based on external moment load on shaft equal to half the maximum torque valve

250 - 120

and option code 15 teeth 16/32 pitch C3 spline 19 teeth 16/32 pitch C5 spline 21 teeth 16/32 pitch C6 spline 23 teeth 16/32 pitch C7 spline 27 teeth 16/32 pitch C8 spline 13 teeth 8/16 F1 pitch spline 14 teeth 12/24 pitch S1 spline

Shaft availability and torque ratings N•m [lbf•in] 042

055

075

100

130

180

250

530 [4700]

—

—

—

—

—

—

900 [8000]

—

—

—

—

—

—

—

1130 [10 000]

—

—

—

—

—

—

—

1580 [14 000]

1580 [14 000]

—

—

—

—

—

—

—

2938 [26 000]

2938 [26 000]

2938 [26 000]

—

—

—

1810 [16 000]

1810 [16 000]

1810+ [16 000]+

1810+ [16 000]+

—

735 [6500]

735 [6500]

735+ [6500]+

—

—

—

768* [6800]

—

—

—

—

—

1130* [10 000]

—

—

—

—

1582* [14 000]

—

—

—

1.375 Str key

K1

—

1.5 Str key

K2

—

1.75 Str key

K3

—

—

—

1.375 tapered

T1

—

768* [6800]

—

—

—

—

1.5 tapered

T2

—

—

768* [6800] 1130* [10 000]

1130* [10 000]

—

—

—

1.75 tapered

T4

—

—

—

—

1582* [14 000]

—

—

1.00 tapered

T3

497* [4400]

—

—

—

—

—

—

520L0603 • Rev FB • July 2007

15

Series 90 Axial Piston Pumps Technical Information Features and options FILTRATION OPTIONS

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.

Suction filtration

The use of a filter contamination monitor is recommended.

Charge pressure filtration – option R, T, P, and L The pressure filter can be mounted Charge pressure filtration Screen directly on the pump or mounted remotely for ease of servicing. A 100Hydraulic fluid reservoir 125 µm mesh screen, located in the reservoir or the charge inlet line, is recommended when using charge Charge pump pressure filtration. This system requires a filter capable of withstanding charge Filter To low pressure. pressure

Adjustable charge pressure relief valve

To pump case

side and control

DISPLACEMENT LIMITER

All Series 90 pumps are designed with optional mechanical displacement (stroke) limiters.

P102 004E

Displacement limiter Displacement limiter adjustment screw

The maximum displacement of the pump can be set independently for forward and reverse using the two adjustment screws.

Servo piston

Servo cylinder P102 005E

Displacement limiter location Pump rotation

Right

Displacement limiter mounted

Displacement limitation at high

on servo side 1 2

pressure side A B

Left

16

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1

B

2

A

Series 90 Axial Piston Pumps Technical Information Features and options MULTI-FUNCTION VALVES

Overpressure protection The Series 90 pumps are designed with a sequenced pressure limiting system and high pressure relief valves. When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump to limit the system pressure. For unusually rapid load application, the high pressure relief valve is also available to limit the pressure level. The pressure limiter sensing valve acts as the pilot for the relief valve spool, such that the relief valve is sequenced to operate above the pressure limiter level.

Both the pressure limiter sensing valves and relief valves are built into the multi-function valves located in the pump endcap. The sequenced pressure limiter/high pressure relief valve system in the Series 90 provides an advanced design of overpressure protection.

The pressure limiter avoids system overheating associated with relief valves and the sequenced relief valves are available to limit pressure spikes which exist in severe operating conditions.

Because the relief valves open only during extremely fast pressure spike conditions, heat generation is minimized during the short time that they might be open. For some applications, such as dual path vehicles, the pressure limiter function may be defeated such that only the relief valve function remains. The relief response is approximately 20 ms whether used with or without the pressure limiter function.

Pressure limiting function When set pressure is exceeded, the pressure sensing valve (A) flows oil through passage (B) and across an orifice in the control spool raising pressure on the servo which was at low pressure. Servo pressure relief valves (C) limit servo pressure to appropriate levels. The pressure limiter action cancels the input command of the displacement control and tends to equalize servo pressure. Swashplate moments assist to change the displacement as required to maintain system pressure at the set point.

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17

Series 90 Axial Piston Pumps Technical Information Features and options MULTI-FUNCTION VALVES (continued)

Multifunction valve, pressure limiter, pressure regulation, option 1

To control Multifunction valve

M3

A

M1 M4

A

Servo piston

Bypass hex adjustment

Port A

M5

B

M

Servo pressure relief valves

Port B

C

Charge pressure relief valve

Servo piston

M2 B S

L2

Multifunction valve

P102 007E

Bypass Function In some applications it is desirable to bypass fluid around the variable displacement pump when pump shaft rotation is either not possible or not desired. For example, an inoperable vehicle may be moved to a service or repair location or winched onto a trailer without operating the prime mover. To provide for this, Series 90 pumps are designed with a bypass function.

The bypass is operated by mechanically rotating the bypass hex on both multifunction valves three (3) turns counterclockwise (CCW). This connects working loop A and B and allows fluid to circulate without rotating the pump and prime mover.

C Caution Possible pump and/or motor damage Bypass valves are intended for moving a machine or vehicle for very short distances at very slow speeds. They are NOT intended as tow valves.

18

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Series 90 Axial Piston Pumps Technical Information Features and options SPEED SENSOR

An optional speed sensor for direct measurement of speed is available. This sensor may also be used to sense the direction of rotation.

Specifications

Required current Max. current

12 mA at 5 VDC, 1 Hz 20 mA at 5 VDC, 1 Hz

A special magnetic ring is pressed onto the outside diameter of the cylinder block and a Hall effect sensor is located in the housing. The sensor accepts supply voltage and outputs a digital pulse signal in response to the speed of the ring. The output changes its high/low state as the north and south poles of the permanently magnetized speed ring pass by the face of the sensor. The digital signal is generated at frequencies suitable for microprocessor based controls.The sensor is available with different connectors (see below).

Max. frequency

15 kHz

Voltage output (high) Voltage output (low)

Supply -0.5 V min.

0.5 V max.

Temperature range

-40° to 110°C [-40° to 230°F]

Supply voltage*

4.5 to 8.5 VDC

Supply voltage (regulated) 15 VDC max.

* Do not energize the 4.5 to 8.5 VDC sensor with 12 VDC battery voltage. Use a regulated power supply. If you need to energize the sensor with battery voltage, contact your Sauer-Danfoss representative for a special sensor.

To use the speed sensor in a PLUS+1 Guide application, download HWD file 10106825 from www.sauer-danfoss. com/Plus1.

Pulse frequency 042

055

075

100

130

180

250

48

52

58

63

69

77

85

Pulse per revolution

Speed sensor with Turck® Eurofast connector Turck Eurofast Connector Keyway (Ref) 4 pin 2 (Supplied Connector) Mating Connector straight right angle No.: K14956 No.: K14957 Id.-No.: 500724 Id.-No.: 500725

P001 492

3

P001 755E

1

4

Speed sensor with Packard® Weather-Pack connector Red White Black Green P002 108E

CHARGE PUMP

Packard Weather-Pack 4 pin A (Supplied Connector) B Mating Connector C D No.: K03379 Id.-No.: 505341

P001 758E

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. 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.

250 - 124

520L0603 • Rev FB • July 2007

19

Series 90 Axial Piston Pumps Technical Information Features and options CHARGE PUMP (continued)

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. Sauer-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.

Please refer to BLN-9885, Selection of Drive line Components, for a detailed procedure.

Available charge pump sizes and speed limits Charge pump size Rated speed System features and conditions which cm³ [in³] min-1 (rpm) may invalidate the 10% guideline include B 11 [0.69] 4200 (but are not limited to): C 14 [0.86] 4200 • Continuous operation at low input D 17 [1.03] 3900 speeds (< 1500 min-1 (rpm)) E 20 [1.20] 3600 • High shock loading F 26 [1.60] 3300 • Excessively long system lines (> 3m G 26 [1.60] [9.8 ft]) 3100 (130 cm3 pump) • Auxiliary flow requirements H 34 [2.07] 3100 • Use of low speed high torque motors J 47 [2.82] 2600 K

65 [3.90]

2300

Contact your Sauer-Danfoss representative for application assistance if your application includes any of these conditions.

70

18

ev

60

3 /R

15

1.2

6 3

l/min

US gal/min

9

40

5

6 4 5 ev /R

3

30

2

v /re n v 3i e 0 . /r 1 3 • n v m .86 i / re c 17 3 • 0 .69 in m 0 c 3• 14 cm 11

3

4

in 3 • .03 ev /R •1 cm n 0 m 6i 2 c 8 .

17 •0 cm 14

50 12

in

65 cm 3 • 3.9 47 34 cm 3 in cm /re 3 • 2.

•2 v 9 in .07 /re in v / re v 26 cm 3 20 •1 cm .60 3 •1 in .2 /re in v /re v

21

80

7

2

kW

90

HP

24

65 c 3 m• 47 3.9 in 3 cm 3 /Rev • 2.9 in 3 / R e 34 v cm 3 26 •2 cm .07 in 3 •1 /R .60 ev in /R ev

Charge pump output flow

Charge pump flow and power curves Charge pressure: 20 bar [290 psi] Case drain: 80 °C (8.2 cSt) 180 °F (53 SUS) Reservoir temperature: 70 °C (11 cSt) 160 °F (63 SUS) Charge pump power requirements

1 1

20 10

0 0

0 0

500

1000

2000

Speed min¯¹ (rpm)

20

250 - 125

3000

4000

4500

P102 012E

520L0603 • Rev FB • July 2007

500

1000

2000

Speed min -1 (rpm)

3000

4000

4500

P102 013E

Series 90 Axial Piston Pumps Technical Information Features and options AUXILIARY MOUNTING PADS

Auxiliary mounting pads specifications Minimum spline Mounting pad size

*

Option code

SAE A

AB

SAE B

BC

SAE B-B

BB

SAE C

CD

SAE D

DE

SAE E

EF

SAE E

EG

Rated torque N•m [lbf•in]

Internal spline size

engagement

9 teeth

mm [in] 13.5

16/32 pitch 13 teeth 16/32 pitch 15 teeth 16/32 pitch 14 teeth

[0.53] 14.2 [0.56] 16.1 [0.63] 18.3

[950] 256 [2200] 347 [2990] 663*

12/24 pitch 13 teeth

[0.72] 20.8

[5700]* 1 186

8/16 pitch 13 teeth 8/16 pitch 27 teeth 16/32 pitch

[0.82] 20.8 [0.82] 27.0 [1.06]

[10 500] 1 637 [14 500] 2 362 [20.91]

107

For the 055 pump the rated torque is limited to 445 N•m [3830 lbf•in]

Mating pump requirements The accompanying drawing provides the dimensions for the auxiliary pump mounting flange and shaft.

Pump mounting flanges and shafts with the dimensions noted below are compatible with the auxiliary mounting pads on the Series 90 pumps.

Auxiliary pump mounting flange and shaft

P diameter 82.55

B maximum 7.4

D 32

F minimum 13.5

[3.25] 101.6

[0.29] 10.7

[1.26] 41

[0.53] 14.2

[4.00] 101.6

[0.42] 10.7

[1.61] 46

[0.56] 16.1

SAE E

[4.00] 127.0 [5.00] 152.4 [6.00] 165.1

[0.42] 14.3 [0.56] 14.3 [0.56] 18.0

[1.81] 56 [2.20] 75 [2.95] 75

[0.63] 18.3 [0.72] 20.8 [0.82] 20.8

13 teeth SAE E

[6.50] 165.1

[0.71] 18.0

[2.95] 75

[0.82] 27.0

27 teeth

[6.50]

[0.71]

[2.95]

[1.06]

SAE A SAE B SAE B-B SAE C SAE D

250 - 126

mm [in]

520L0603 • Rev FB • July 2007

D

E Mounting flange (Ref)

F min.

Minimum spline engagement

[+0.000] [-0.002]

Units

0

Flange size

Ø P -0.05

Auxiliary pump dimensions

Coupling

0.8 [0.03] R B max.

preferred

P102 015E

21

Series 90 Axial Piston Pumps Technical Information Features and options 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. The overhung load moment for multiple pump mounting may be estimated as shown in the accompanying figure.

Overhung load example

Estimating overhung load moments W = Weight of pump (kg) L = Distance from mounting flange to pump center of gravity (m) (refer to pump installation drawings) MR = GR (W1L1 + W2L2 + ... + WnLn) MS = GS (W1L1 + W2L2 + ... + WnLn) Where: MR = MS = GR = GS = *

Rated load moment (N•m) Shock load moment (N•m) Rated (vibratory) acceleration (G’s) * (m/sec²) Maximum shock acceleration (G’s) * (m/sec²)

Calculations will be carried out by multiplying the gravity (g = 9.81 m/sec²) with a given factor.

This factor depends on the application.

Allowable overhung load moment values are shown in the accompanying table.

Exceeding these values requires additional pump support.

Allowable overhung load moments

22

250 - 127

Frame size

Rated moment (MR)

Shock load moment (M S)

042

N•m 860

lbf•in 7600

N•m 3020

lbf•in 26 700

055 075

1580 1580

14 000 14 000

5650 5650

50 000 50 000

100

1580

14 000

5650

50 000

130 180

3160 6070

28 000 54 000

10 730 20 600

95 000 182 000

250

6070

54 000

20 600

182 000

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Control options 3 -POSITION (FNR) ELECTRIC CONTROL

The 3-Position (F-N-R) control uses an electric input signal to switch the pump to a full stroke position. To use the FNR control in a PLUS+1 Guide application, download HWD file 10106826 from www.sauer-danfoss.com/Plus1.

Solenoid connector

3-position electric control hydraulic schematic

Solenoid plug face for DIN 43650 connector SAUER-DANFOSS mating parts kit Part No. K09129

b

a

Not connected

1

Voltage between terminals 1 and 2

2

T P

M5 M4

P102021

P102 022

Displacement

Pump displacement vs. electrical signal

-b

100 %

"0"

Solenoid Data

b

Voltage 12 VDC

Power 33 W

Connector Din 46350

24 VDC

33 W

Din 46350

Voltage VDC

100 % P102 023

Response time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes are available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Pump output flow direction vs. control signal

250 - 128

Input shaft rotation Signal at solenoid

a

b

a

b

Port A flow Port B flow

Out In

In Out

In Out

Out In

Servo cylinder active

M5

M4

M5

M4

520L0603 • Rev FB • July 2007

CW

CCW

23

Series 90 Axial Piston Pumps Technical Information Control options ELECTRIC DISPLACEMENT CONTROL (EDC)

Operation The electric displacement control uses an electrohydraulic Pressure Control Pilot (PCP) valve to control the pilot pressure. The PCP converts an electrical input signal to a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston. The servo piston tilts the cradle swashplate, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction.

The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular position of the swashplate. The electrical displacement control is designed so the angular rotation of the swashplate (pump displacement) is proportional to the electrical input signal. Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, will activate the valve and supply pressure to the servo piston, maintaining the swashplate in its preset position.

Features and Benefits • The electric displacement control is a high gain control: With only a small change of the input current, the servo valve moves to a full open position thus porting maximum flow to the servo cylinder.

• Oil filled PCP case lengthens control life by preventing moisture ingression and dampening component vibrations.

• All electrical displacement controls are equipped with dual coil PCPs. The user has the option of using a single coil or both coils (in series or parallel).

• Internal mechanical stops on the servo valve allow rapid changes in input signal voltages without damaging the control mechanism.

• Precision parts provide repeatable accurate displacement settings.

• The swashplate is coupled to a feedback mechanism. The control valve drains the ends of the servo piston when an electric input signal is not present.

• Benefits: - Simple, low cost design - Pump returns to neutral after prime mover shuts down - Pump returns to neutral if external electrical input signal fails or if there is a loss of charge pressure Electric displacement control schematic X2

Cross-section

X1

P C P X2

X1

T M4 P M5 T P102 025

Feedback from swashplate

24

250 - 129

M5

520L0603 • Rev FB • July 2007

M4

T

P

P102 024E

To use the EDC control in a PLUS+1 Guide application, download HWD file 10106626 from www.sauer-danfoss. com/Plus1.

Series 90 Axial Piston Pumps Technical Information Control options Control signal requirements Control current Coil

a

b

configuration mA mA Single coil 14 ± 5 85 ± 18 Dual coil 7 ± 3 43 ± 9 in series Dual coil 14 ± 5 85 ± 18 parallel

Pump displacement vs. control current 100 %

Pin connections A&B or C&D A&D (C B common) -b

AC & BD

Maximum input current under any condition: 250 mA PWM frequency: 200 Hz Coil resistance at 24°C [75°F]: A-B coil 20 Ω C-D coil 16 Ω MS connector (option KA) MS 3102C-14S-2P

Displacement

ELECTRIC DISPLACEMENT CONTROL (EDC) (continued)

-a

"0"

Current mA a

b

100 %

P102 026E

Packard® Weather-Pack (option KP) 4-way shroud connector

Response time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 Electric Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Pump output flow direction vs. control current EDC using a single coil or dual coils in parallel (A and C common, B and D common) Input shaft rotation Positive current to term Port A flow Port B flow Servo cylinder

CW

CCW

A or C Out

B or D In

A or C In

B or D Out

In M5

Out M4

Out M5

In M4

A

D

A

D

Out In

In Out

In Out

Out In

M5

M4

M5

M4

EDC using a dual coil or dual coils in series (B and C common) Input shaft rotation Positive current to term Port A flow Port B flow Servo cylinder

CW

CCW

Refer to Installation drawings, page 59, for port locations.

250 - 130

520L0603 • Rev FB • July 2007

25

Series 90 Axial Piston Pumps Technical Information Control options HYDRAULIC DISPLACEMENT CONTROL (HDC)

Operation The hydraulic displacement control uses a hydraulic input signal to operate a 4-way servo valve, which ports hydraulic pressure to either side of a double acting servo piston.

The servo piston tilts the cradle swashplate, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction.

The control has a mechanical feedback mechanism which moves the servo valve in relation to the input signal and the angular rotation of the swashplate. The hydraulic displacement control is designed so the angular position of the swashplate (pump displacement) is proportional to the hydraulic input signal pressure. Due to normal operating force changes, the swashplate tends to drift from the position preset by the machine operator. Drift, sensed by feedback linkage system connecting the swashplate to the control valve, activates the valve to supply pressure to the servo piston, maintaining the swashplate in its preset position.

Features and benefits of the hydraulic displacement control: • The hydraulic displacement control is a high gain control: With only small change of the input signal, the servo valve moves to a full open position porting maximum flow to the servo cylinder.

• Internal mechanical stops on the servo valve allow rapid changes in input signal pressure without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The swashplate is coupled to a feedback mechanism. The control valve drains the ends of the servo piston when an input signal is not present.

• Benefits: - Simple - low cost design.

- Pump returns to neutral after prime mover shuts down.

- Pump returns to neutral if there is a loss of input signal pressure or if there is a loss of charge pressure.

Hydraulic signal pressure range*

Hydraulic displacement control schematic

a b

X2

3 ± 0.5 bar 11 ± 0.5 bar

[43 ± 6 psi] [160 ± 6 psi]

X1

Cross-section X1

X2

T M4 P M5 T

M5 M4 P102 030

*see diagram page 27

26

250 - 131

520L0603 • Rev FB • July 2007

Feedback from swashplate

T P P102029

Series 90 Axial Piston Pumps Technical Information Control options Control signal requirements Maximum allowable signal pressure is 60 bar [870 psi].

Pump displacement vs. signal pressure 100 %

Response time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

Displacement

HYDRAULIC DISPLACEMENT CONTROL (HDC) (continued)

-b

-a

"0"

Signal pressure

a

b

A range of orifice sizes are available for the Series 90 hydraulic displacement 100 % P102 031E control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Pump output flow direction vs. control pressure Input shaft rotation Control pressure to

CW

CCW

port Port A flow Port B flow

X2

X1

X2

X1

In Out

Out In

Out In

In Out

Servo cylinder

M4

M5

M4

M5

Refer to Installation drawings, page 60, for port locations.

250 - 132

520L0603 • Rev FB • July 2007

27

Series 90 Axial Piston Pumps Technical Information Control options MANUAL DISPLACEMENT CONTROL (MDC)

Operation The manual displacement control converts a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate. The control is designed so that the angular rotation of the swashplate is proportional to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Features and benefits of the manual displacement control: • Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting maximum flow to the servo cylinder. This is a high response system with low input force.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• The double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with no input signal the servo valve is open centered and thus no fluid is ported to the servo cylinder.

• Benefits: - Pump returns to neutral after prime mover shuts down.

- Pump returns to neutral if external control linkage fails at the control handle or if there is a loss of charge pressure.

Manual displacement control schematic

Cross-section Control handle input signal

A–0–B

Neutral Start Switch Feedback from swashplate

28

250 - 133

M5

520L0603 • Rev FB • July 2007

M4

T

P

P102 035E

T M5 P M4 T

P102 033E

Series 90 Axial Piston Pumps Technical Information Control options External control handle requirements • Torque required to move handle to maximum displacement is 0.68 to 0.9 N•m [6 to 8 lbf•in].

•

Pump displacement vs. control lever rotation 100 % Displacement

MANUAL DISPLACEMENT CONTROL (MDC) (continued)

Torque required to hold handle at given displacement is 0.34 to 0.57 N•m [3 to 5 lbf•in].

"A"

-24˚ to 30˚

-2

"0"

-35 max.

•

•

Torque required to overcome the override mechanism is 1.1 to 2.3 N•m [10 to 20 lbf•in] with the maximum torque required for full forward to full reverse movement.

35 max.

"B" 24˚ to 30˚

Lever rotation 2

100 %

P102 034E

Maximum allowable input torque is 17 N•m [150 lbf•in]

Response time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

A range of orifice sizes is available for the Series 90 manual displacement control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Pump output flow direction vs. control handle rotation Input shaft rotation Handle rotation

A CCW

B CW

A CCW

B CW

Port A flow

Out

In

In

Out

Port B flow Servo cylinder

In M5

Out M4

Out M5

In M4

CW

CCW

Refer to Installation drawings, page 61, for handle connection requirements

250 - 134

520L0603 • Rev FB • July 2007

29

Series 90 Axial Piston Pumps Technical Information Control options NON-LINEAR MANUAL DISPLACEMENT CONTROL (MDC)

The manual displacement control device a mechanical input signal to a hydraulic signal that tilts the cradle swashplate through an angular rotation varying the pump`s displacement from full displacement in one direction to full displacement in the opposite direction.

The manual displacement control has a mechanical feedback mechanism which moves a servo valve in the proper relationship to the input signal and the angular position of the swashplate. The control is designed so that the angular rotation of the swashplate is progressive to the mechanical input signal. The control is designed with an internal override mechanism which allows the mechanical input to be moved at a faster rate than the movement of the swashplate without damage to the control.

Features and benefits of the non-linear manual displacement control: • The manual displacement control is a high gain control: With only small movement of the control handle (input signal), the servo valve moves to full open position porting maximum flow to the servo cylinder. This is a high response system with low input force.

• Low spool dead band results in good down hill and braking capability.

• Smooth acceleration is possible.

• The integral override mechanism allows rapid changes in input signal without damaging the control mechanism.

• Precision parts provide repeatable, accurate displacement settings with a given input signal.

• A double-acting servo piston is coupled to a spring centering mechanism. The servo control valve is spring centered such that with “no input signal” the servo valve is open centered and thus no fluid is ported to the servo cylinder.

• Benefits: - Pump returns to neutral after prime mover shut down.

- Pump returns to neutral if external control linkage fails at the control handle, or there is loss of charge pressure.

Non-linear MDC schematic

Cross section Control handle input signal

A–0–B

Feedback from M5 M4 swashplate

T P

T M4 P M5

P102 032E

S1 = servo side 1 S2 = servo side 2

30

250 - 135

520L0603 • Rev FB • July 2007

P102 036E

Series 90 Axial Piston Pumps Technical Information Control options External control handle requirements •

Torque required to move handle to maximum displacement is 0.68 to 0.9 N•m [6 to 8 lbf•in].

•

Maximum allowable input torque is 17 N•m [150 lbf•in].

Pump displacement vs. control lever rotation 100 % Displacement

NON-LINEAR MANUAL DISPLACEMENT CONTROL (MDC) (continued)

-31˚

"A"

-3

"0"

-33˚ max.

Response time The time required for the pump output flow to change from zero to full flow (acceleration) or full flow to zero (deceleration) is a function of the size of the orifice in the control flow passage.

33˚ max.

3

Lever rotation 31˚

100 %

"B"

P102 037E

A range of orifice sizes is available for the Series 90 Manual Displacement Control to assist in matching the rate of swashplate response to the acceleration and deceleration requirements of the application. Testing should be carried out to determine the proper orifice selection for the desired response.

Pump output flow direction vs. control handle rotation Input shaft rotation Handle rotation

CW

CCW

“A” CCW

“B” CW

“A” CCW

“B” CW

Port A flow Port B flow

Out In

In Out

In Out

Out In

Servo cylinder

M5

M4

M5

M4

Refer to Installation drawings, page 61, for handle connection requirements.

250 - 136

520L0603 • Rev FB • July 2007

31

Series 90 Axial Piston Pumps Technical Information Control options NON FEEDBACK PROPORTIONAL ELECTRIC CONTROL (NFPE)

The Non Feedback Proportional Electric (NFPE) control is an electrical automotive control in which an electrical input signal activates one of two proportional solenoids that port charge pressure to either side of the pump servo cylinder. The NFPE control has no mechanical feedback mechanism.

The pump displacement is proportional to the solenoid signal current, but it also depends upon pump input speed and system pressure. This characteristic also provides a power limiting function by reducing the pump swashplate angle as system pressure increases. A typical response characteristic is shown in the accompanying graph.

Resistance Table Supply Voltage

Coil Resistance

12 V

5.4 Ohms

24 V

21.6 Ohms

NFPE Schematic M6

M5

M3

M4

M1

A

M2

B L1

S

L2 P003 174

32

250 - 137

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Control options NON FEEDBACK PROPORTIONAL ELECTRIC CONTROL (NFPE) (continued)

Features and benefits of the NFPE control when used with sauer-danfoss microcontroller • Creep mode • Two automotive control ramps via mode switch • Engine overspeed protection • Electric control • Anti-stall function • Smooth operation • Electronic ramp control is superior to hydraulic control with orifices Input signal requirements The NFPE control requires a pulse-width-modulated (PWM) input current to optimize performance. The recommended PWM frequency is 200 Hz. The minimum PWM frequency is 80 Hz. The NFPE control uses an AMP® Junior Power Timer connector. The solenoids are compatible with Sauer-Danfoss microcontrollers and joysticks.

250 - 138

NFPE pump displacement vs. input signal

Solenoid data

Shaft rotation Active solenoid

Voltage

A

B

A

B

Port A flow Port B flow

Out In

In Out

In Out

Out In

Servo cylinder

M5

M4

M5

M4

CW

520L0603 • Rev FB • July 2007

CCW

Start 12 V 24 V

Control current End Max

~ 440 mA ~ 220 mA

1290 mA 645 mA

1500 mA 750 mA

33

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 042

Manual displacement control (MDC), endcap twin ports, option 80 86 [3.39]

12.2 (2x) [0.48] 114.5 [4.51] Port L2 130 [5.12] 207.8 [8.18]

50.8 [2.00] Approximate center of gravity

Ø14.3

"Z"

Shaft spline data: Pitch diameter = 23.813 [0.9375] Pressure angle = 30 Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

33 [1.30] Approximate center of gravity

73 [2.875]

Port L2 case drain 7/8-14UNF-2B 146 [5.75]

View "X"

Gauge port M1 system pressure A 9/16-18UNF-2B

View "Y"

Gauge port M4 servo pressure 9/16-18UNF-2B

Charge pressure relief valve

83 (3.27)

41.6 [1.64]

Multifunction valve

Gauge port M3 charge pressure 9/16-18UNF-2B Multifunction valve

Port L1 Case drain use highest port as outlet 7/8-14UNF-2B

Gauge port M5 servo pressure 9/16-18UNF-2B

56.9 [2.24]

143.5 [5.65] 258 [10.16]

Manual displacement control handle dimensions Ø 6.33 [Ø 0.249]

Torque applied to control handle shaft not to exceed 17 Nm [150 lb•in] R 50.8 [R 2.0]

"A"

28

Neutral position

minim

"B"

28 um minimum

Maximum displacement

Maximum displacement

34

250 - 139

12.70 [0.50]

4.78 [0.188]

41.67 [1.64]

R 25.4 [R 1.0] Ø6,73 2x [Ø0.265]

520L0603 • Rev FB • July 2007

P102 040

[Ø 0.562]

[-0.002]

CW

80 [3.15] Port L2

R 0.8 maximum 9.7 [0.03 maximum] [0.38]

0

7.9 [0.31] Ø25.4 [Ø1.0] Ø70 maximum [maximum 2.76 Ø]

Ø 22.1 [Ø 0.87]

CCW

81.4 [3.20]

23.8 [0.94]

52 [2.047]

52 [2.047]

Rotation

A

Ports A and B 3/4 – 6000 psi split flange boss per SAE J518 (Code 62) 3/8-16UNC-2B 20 [0.787] minimum full thread

145 [5.71]

Splined shaft option C3

B

"X"

"W"

Length of full spline

20 [0.79] 7.9 [0.31]

108 [4.25] Port L1

129 [5.08]

Port S: Charge pump inlet 1-1/16-12UN-2B

111 [4.37]

Coupling may not protrude beyond this surface

38±0.25 [1.5±0.01]

Ø101.6 -0.05 [Ø4] [+0.000]

Gauge port M2 system pressure B 9/16-18UNF-2B

View "Z"

Control MDC, option MA 9.4 [0.37]

"Y"

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 042 (continued)

Auxiliary mounting pad – options AB, BC, BB View "X"

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 33.5 [1.32]

106.38 [4.188]

[- 0.000]

+ 0.13

Ø82.6 0 [Ø3.252] [+0.005]

"X"

SAE A, option AB

4 threads 3/8-16UNC-2B 17.8 [0.70] deep

18 [0.71]

for O-ring Ø82.27 x 1.78 [Ø3.24 x 0.07]

288 [11.34]

106.38 [4.188]

301.85 [11.88]

View "X"

Coupling spline data: Pitch diameter = 20.638 [0.8125] Pressure Angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.5 [1.0]

for O-ring Ø101.32 x 1.78 [Ø3.99 x 0.07]

146 ([5.75]

[- 0.000]

+ 0.05

Ø101.64 0 [Ø4.002] [+0.002]

"X"

SAE B, option BC

4 threads 1/2-13UNC-2B 22 [0.87] deep

20.5 [0.81] 282.92 [11.14]

146 [5.75]

300.37 [11.83]

View "X" Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure Angle = 30° Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 15. 2 [0.598]

For O-ring Ø101.32 x 1.78 [Ø3.99 x 0.07]

146 [5.75]

[- 0.000]

+ 0.05

Ø101.65 - 0.00 [Ø4.002] [+0.002]

"X"

SAE B-B, option BB

4 threads 1/2-13UNC-2B 22 [0.87] deep

30.8 [1.21] 282.92 [11.14] 300.37 [11.83]

250 - 140

520L0603 • Rev FB • July 2007

146 [5.75] P102 041

35

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 055

Manual displacement control (MDC), endcap side ports, option 60 View "Z"

27.9 [1.10]

121.9 [4.80] port B 117.6 [4.63] port L1

7.9 [0.31]

111.1 [4.37]

93.7 [3.69]

Coupling may not protrude beyond this surface

"W"

Length of full spline

Splined shaft option S1

149.9 [5.90]

9.4 [0.37]

47.6 [1.88]

Approximate center of gravity

Gauge port M1 system pressure A 9/16-18UNF-2B

243.7 [9.60] Port S

Port L1 case drain use highest port as outlet 1-1/16-12UN-2B

120.4 [4.74] port L2

14.2 [0.56] 152.4 [6.00]

288.8 [11.37]

View "Y"

32.5 [1.28]

27.76 [1.093]

Gauge port M5 Servo pressure 7/16-18UNF-2B

72.9 [2.87] 168.9 [6.65] 231.9 [9.13]

88.9 [3.50] 86.2 [3.39] Port L2

0

[-0.002]

(4x)

114.5 [4.50]

Port L2 case drain 1-1/16-12UN-2B (2x)

View "X" Charge pressure relief valve

Splined shaft option C6 Multifunction valve

Gauge port M3 charge pressure 9/16-18UNF-2B

Ø 29 [Ø 1.14] Ports A and B 1.00 - 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B except 21 [0.83] minimum full thread

Approximate center of gravity

57.25 [2.254]

Length of full spline

41.2 [1.62]

57.15 [2.25]

43.7 [1.72]

Ø14.27 [Ø 0.562]

Coupling may not protrude beyond this surface

Ø 34.42 [Ø 1.355]

7.9 [0.31]

"Z"

Shaft spline data: Pitch diameter = 29.633 [1.1667] Pressure angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 5, fillet root side fit 47.6 [1.88]

Gauge port M4 servo pressure 7/16-20UNF-2B

CW

Shaft spline data: Pitch diameter = 33.338 [1.3125] Pressure angle = 30° Number of teeth = 21 Pitch = 16/32 ANSI B92.1-1970, class 5, Fillet Root side fit

82.6 [3.25]

"X"

R 0.76 maximum [0.03 maximum] 12.45±0.25 [0.49±0.01]

CCW

Ø 127 -0.05 [Ø 5] [+0.000]

Ø 24.9 [Ø 0.98]

17.8 [0.70] Ø 31.14 [Ø 1.226] Ø 84.8 maximum (maximum Ø 3.34

Rotation

90.4 [3.56] port A

133.9 [5.27]

Control MDC, option MA

"Y"

Gauge port M2 system pressure B 9/16-18UNF-2B

Multifunction valve

Port S: Charge pump inlet 1-5/16-12UN-2B

58.4 [2.30]

Manual Displacement Control Handle Dimensions Torque applied to control handle shaft not to exceed 17 N•m [150 lbf•in]

B Neutral position

A

28° 28° um minimum minim

Maximum displacement

Maximum displacement

36

250 - 141

R 50.8±0.3 [R 2.0±0.01]

R 25.4±0.3 [R 1.0±0.01] Ø 6.73±0.13 2x [Ø 0.265±0.005]

520L0603 • Rev FB • July 2007

P102 042

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 055 (continued)

Manual displacement control (MDC) endcap twin ports, option 80

"Y"

Gauge port M2 system pressure B 9/16-18UNF-2B

Control MDC, option MA

Port S: charge pump inlet 1-5/16-12UN-2B

27.76 [1.093]

57.9 [2.28]

57.9 [2.28]

B

A

Ports A and B 1 – 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 [0.83] minimum full thread

57.15 [2.25]

Gauge port M1: system pressure A 9/16-18UNF-2B 232.2 [9.14] 247.1 [9.73]

85.1 [3.35] port S

88.9 [3.54]

View "Y"

P102 043

250 - 142

520L0603 • Rev FB • July 2007

37

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 055 (continued)

Auxiliary mounting pad – options AB, BC, CD, BB

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 37.13 [1.46]

View "X"

Ø 82.6 [Ø 3.252]

106.375 [4.188]

+ 0.13 0 [+0.005] [- 0.000]

SAE A, option AB

"X"

4 threads 3/8-16UNC-2B 22.8 [0.90] deep

15.13 [0.59]

For O-ring Ø 82.27 x 1.78 [Ø 3.24 x 0.07]

316.6 [12.46]

106.375 [4.188]

330.4 [13.01] Coupling spline data: Pitch diameter = 20.6375 [0.8125] Pressure angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 29.51 [1.16]

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 0 [Ø 4.002] [+0.005]

"X"

View "X" SAE B, option BC

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

17.66 [0.70]

4 threads 1/2-13UNC-2B 22.0[0.87] deep

311.5 [12.26]

146 [5.75]

329 [12.95] Coupling spline data: Pitch diameter = 29.6333 [1.167] Pressure angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 18.97 [0.747]

For O-ring Ø 126.72 x 1.78 [Ø 4.98 x 0.07]

114.5 [4.51]

[- 0.000]

+ 0.13

Ø 127.03 0 [Ø 5.00] [+0.005]

"X"

View "X" SAE C, option CD

30.73 [1.21]

6 threads 1/2-13UNC-2B 22 (0.87) deep

314 [12.36] 331 [13.03]

38

250 - 143

520L0603 • Rev FB • July 2007

P102 044

114.5 [4.51] 181 [7.13]

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 055 (continued)

Auxiliary mounting pad – options AB, BC, CD, BB

Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure angle = 30˚ Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 24.43 [0.96]

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 0 [Ø 4.002] [+0.005]

"X"

View "X" SAE B-B, option BB

20.75 [0.82]

4 threads 1/2-13UNC-2B 22 [0.87] deep

311.5 [12.26] 329 [12.95]

250 - 144

520L0603 • Rev FB • July 2007

146 [5.75]

P102 045

39

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075

Manual Displacement Control (MDC) Endcap Side Ports, Option 60 View "Z"

"Y"

99.3 [3.91]

9.4 [0.37]

139.7 [5.50]

129 [5.08] port B

Splined shaft option S1

262.6 [10.34] Port S

Port L1 Case drain use highest port as outlet 1-1/16-12UN-2B

14.2 [0.56]

141.7 [5.58] Port L2

306,1 (12.05)

47.62 [1.875]

Gauge port M4 servo pressure 9/16-18UNF-2B

[-0.002]

93.7 [3.69] 91.7 [3.61] port L2

0

Shaft spline data: Pitch diameter = 29.633 [1.1667] Pressure angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, Fillet Root Side Fit

155.7 [6.13]

View "Y"

"Z"

34.8 [1.37]

7.9 [0.31]

Splined Shaft Option C7

41.6 [1.64]

27.76 [1.093]

172.2 [6.78] 248.2 [9.77]

A

Maximum displacement

40

250 - 145

Port L2 case drain 1-1/16-12UN-2B

114.5 [4.50]

(2x)

View "X"

Multifunction valve

Gauge port M3 charge pressure 9/16-18UNF-2B

Multifunction valve

61.85±0.64 [2.435±0.025]

Ø 6.33 [Ø 0.249]

65 [2.56]

Coupling must not protrude beyond 56.4 [2.22] max +0.00 SQ Key x 38.1 long -0.05 [1.5] +0.000 [0.375] -0.002 38.07±0.03 [1.499±0.001]

12.70 [0.50] R 25.4±0.3 [R 1.0±0.01]

Port S: charge pump inlet 1-5/16-12UN-2B

9.525

R 50.8±0.3 [R 2.0±0.01]

28° 28° um minimum minim

Neutral position

Approximate center of gravity

(4x)

length of full spline

Shaft spline data: Pitch diameter = 36.513 [1.4375] Pressure angle = 30 Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

81.3 [3.20]

Torque applied to control handle shaft not to exceed 17 N•m [150 lbf•in]

B

57.25 [2.254]

A

Gauge port M5 servo pressure 9/16-18UNF-2B

Manual displacement control handle dimensions

Maximum displacement

[-0.007]

Charge pressure relief valve

Ø 32.3 [Ø 1.27] Ports A and B 1 – 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B 20 [0.79] minimum full thread

40.6 [1.60]

Coupling may not protrude beyond this surface

?Ø 37.59 [Ø 1.48]

57.15 [2.25]

+0.25

Ø 14.27 -0.18 [Ø 0.562] [+0.010]

84.0 [3.31]

Approximate center of gravity

R 0.8 maximum [0.03 maximum] 12.45 ±0.25 [0.49] [±0.01]

CW

M4

Gauge port M1 system pressure A 9/16-18UNF-2B

Ø 1267 -0.05 [Ø 5] [+0.000]

3.8 94.5 [3.72] port A

Ø 24.9 [Ø 0.98]

[0.15] Ø 31.14 [Ø 1.226] Ø 94 maximum [Ø 3.70 maximum]

Rotation CCW

B

124.2 [4.89] port L1

length of full spline

27.9 [1.10]

M5

"X"

"W"

Coupling may not protrude beyond this surface

47.6 [1.88] 7.9 [0.31]

110.7 [4.36]

155.7 [6.13]

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, option MA

4.78 [0.188]

41.67 [1.64]

Ø 6.73±0.13 3x [Ø 0.265±0.005]

520L0603 • Rev FB • July 2007

SHAFT OPTION K2

P102

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 (continued)

Manual Displacement Control (MDC), endcap twin ports, option 80

"Y"

Gauge port M2 system pressure B 9/16-18UNF-2B

Control MDC, option MA

Port S: charge pump inlet 1-5/16-12UN-2B

27.76 [1.093]

61 [2.402]

99 [3.90]

61 [2.402]

B

A

57.15 [2.25] Ports A and B 1 - 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B except 20.8 [0.82] minimum full thread

Gauge port M1: system pressure A 9/16-18UNF-2B 242.3 [9.54] 248 [9.76]

92 [3.62]

View "Y"

P102 047

250 - 146

520L0603 • Rev FB • July 2007

41

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 (continued)

Auxiliary mounting pad – Options AB, BC, CD, BB

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 37.13 [1.46]

View "X" SAE A, option AB

B

M4

106.375 [4.188]

Ø 82.6 [Ø 3.252]

+ 0.13 0 [+0.005] [- 0.000]

M5

"X"

A For O-ring Ø 82.27 x 1.78 [Ø 3.24 x 0.07]

4 threads 3/8-16UNC-2B 22.8 [0.90] deep

15.13 [0.59] 333.93 [13.14]

106.375 [4.188]

347.8 [13.69] Coupling spline data: Pitch diameter = 20.6375 [0.8125] Pressure angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 29.51 [1.16]

B

M4

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

146 [5.75]

+ 0.13

[- 0.000]

Ø 101.65 0 [Ø 4.002] [+0.005]

M5

"X"

View "X" SAE B, option BC

A

4 threads 1/2-13UNC-2B 22 [0.87] deep

17.66 [0.70] 328.9 [12.95]

146 [5.75]

346.5 [13.64] Coupling spline data: Pitch diameter = 29.6333 [1.167] Pressure angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 18.97 [0.747]

114.5 [4.51]

[- 0.000]

+ 0.13

Ø 127.03 0 [Ø 5.001] [+0.005]

M4 6 threads 1/2-13UNC-2B 22 [0.87] deep

30.73 [1.21] 331.4 [13.05] 348.4 [13.72]

250 - 147

B

For O-ring Ø 126.72 x 1.78 [Ø 4.98 x 0.07]

42

M5

"X"

View "X" SAE C, option CD

520L0603 • Rev FB • July 2007

A 114.5 [4.51] 181 [7.13] P102 048

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

Auxiliary mounting pad – options AB, BC, CD, BB

Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure angle = 30˚ Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 24.43 [0.96]

146 [5.75]

[- 0.000]

+ 0.13

Ø 101. 65 0 [Ø 4.002] [+0.005]

M4

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

4 threads 1/2-13UNC-2B 22 [0.87] deep

22.75 [0.896] 328.9 [12.95] 346.5 [13.64]

250 - 148

B

"X"

View "X" SAE B-B, option BB M5

FRAME SIZE 075 (continued)

520L0603 • Rev FB • July 2007

A 146 [5.75] P102 049

43

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 100

Manual Displacement Control (MDC), endcap side ports, option 60 View "Z"

"Y"

Control MDC, option MA

108.5 [4.27]

49.5 [1.95]

143.3 [5.64] port B 139.1 [5.48] port L1

7.9 [0.31]

"W"

Coupling may not protrude beyond this surface Length of full spline

Splined shaft option F1

Approximate center of gravity

Gauge port M1 system pressure A 9/16-18UNF-2B

161 [6.34] Port L2

288 [11.34] port S

Port L1 case drain use highest port as outlet 1-1/16-12UN-2B

14.2 [0.56]

339.0 [13.35]

View "Y"

Gauge port M4 Servo pressure 9/16-18UNF-2B

47.6 [1.88] 38.9 [1.53]

27.76 [1.093]

Gauge port M5 servo pressure 9/16-18UNF-2B

87.3 [3.44] 204.6 [8.06]

277.7 [10.93]

View "X"

Splined shaft option C7

Multifunction valve

Gauge port M3 charge pressure 9/16-18UNF-2B

Multifunction valve

Shaft spline data: Pitch diameter = 36.513 [1.4375] Pressure angle = 30° Number of teeth = 23 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

Manual displacement control handle dimensions

Neutral position

"A"

30° 30° um minimum minim

"B"

R 50.8±0.3 [R 2.0±0.01]

Maximum displacement

44

250 - 149

Ø 6.33 [Ø 0.249] 12.70 [0.50] 41.67 [1.64]

R 25.4±0.3 [R 1.0±0.01]

4.78 [0.188]

Ø 6.73±0.13 3x [Ø 0.265±0.005]

520L0603 • Rev FB • July 2007

A Port S: charge pump inlet 1-5/8-12UN-2B

Coupling must not protrude beyond 64.0 [2.52] max

Torque applied to control handle shaft not to exceed 17 Nm [150 lbf•in] Maximum displacement

Approximate center of gravity

Charge pressure relief valve

Ø 32.3 [?Ø 1.27] Ports A and B 1.00 - 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B except 21 [0.83] minimum full thread

Port L2 (2x) case drain 1-1/16-12UN-2B 114.5 (2x) [4.508]

57.25 [2.254]

Length of full spline

33 [1.30]

57.15 [2.25]

42 [1.65]

Ø 14.27 [Ø 0.562]

Coupling may not protrude beyond this surface

Ø 37.59 [Ø 1.48]

7.9 [0.31]

100.37 [3.95] port L2

102 [4.02]

[-0.002]

0

"Z"

Shaft spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 5, fillet root side fit

180.3 [7.10]

CW

89.7 [3.53]

"X"

R 0.8 maximum [R 0.03 maximum] 12.5 ±0.3 [0.49] [±0.01]

CCW

Ø 127 -0.05 [Ø 5] [+0.000]

Ø 34.5 [Ø 1.36]

20.3 [0.80] Ø 43.94 [Ø 1.73] Ø 100.6 maximum [maximum 3.96 Ø]

Rotation

99.1 [3.90] port A

148.7 [5.85]

66.7 [2.625]

119.6 [4.71]

164.2 [6.46]

9.4 [0.37]

Gauge port M2 system pressure B 9/16-18UNF-2B

66 [2.60]

61.86±0.64 [2.435±0.025] +0.00 SO Key x 38.1 Lo -0.05 [1.5] +0.000 [0.375] -0.002 9.525

44.425±0.025 [1.749±0.001]

SHAFT OPTION K3

P102 050

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 100 (continued)

Manual Displacement Control (MDC), endcap twin ports, option 80

Gauge port M2 system pressure B 9/16-18UNF-2B

"Y"

Control MDC, option MA 47.6 [1.875]

Port S: charge pump inlet 1-5/8-12UN-2B

7.9 [0.31]

30.5 [1.20]

Coupling may not protrude beyond this surface Length of full spline

Splined shaft option S1

Ø 24.9 [Ø 0.98]

A

Ports A and B 1 - 6000 psi split flange boss per SAE J518 (Code 62) 7/16-14UNC-2B 21 [0.83] minimum full thread

57.15 [2.25]

Gauge port M1: system pressure A 9/16-18UNF-2B 277.9 [10.94] 280.5 [11.04]

Ø 31.14 [Ø 1.2258]

27.76 [1.093]

66.8 [2.63]

66.8 [2.63]

B

Shaft spline data: Pitch diameter = 29.634 [1.1667] Pressure Angle = 30 Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 5, fillet root side fit

99.8 [3.93] port S

108 [4.25]

View "Y"

P102 051

250 - 150

520L0603 • Rev FB • July 2007

45

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 100 (continued)

Auxiliary mounting pads, SAE AB, SAE BC, SAE CD

COUPLING SPLINE DATA: Pitch Dia = 14,288 (.5625) Pressure Angle = 30 Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 37,13 (1.46)

View "X"

106,375 (4.188)

"X"

ø82,6 (3.252 Dia)

+ 0,13 0 (+.005) (- .000)

SAE A, Option AB

A 4 Threads 3/8-16UNC-2B 17 (.67) deep

15,13 (.60)

for O-Ring ø82,27 x 1,78 (3.24 Dia x 0.07)

366,02 (14.41)

106,375 (4.188)

379,69 (14.95) COUPLING SPLINE DATA: Pitch Dia = 20,6375 (.8125) Pressure Angle = 30 Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 29,51 (1.16)

for O-Ring ø101,32 x 1,78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

+ 0,13

ø101,65 0 (4.002 Dia) (+.005)

"X"

View "X" SAE B, Option BC

4 Threads 1/2-13UNC-2B 22 (.87) deep

17,66 (.70) 360,9 (14.21)

146 (5.75)

378,3 (14.89) COUPLING SPLINE DATA: Pitch Dia = 29,6333 (1.167) Pressure Angle = 30 Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 18,97 (.747)

for O-Ring ø126,72 x 1,78 (4.98 Dia x 0.07)

114,5 (4.51)

(- .000)

+ 0,13

ø127,03 0 (5.001 Dia) (+.005)

"X"

View "X" SAE C, Option CD

6 Threads 1/2-13UNC-2B 22 (.87) deep

30,73 (1.21) 363,47 (14.31) 380,27 (14.97)

46

250 - 151

520L0603 • Rev FB • July 2007

A 114,5 (4.51) 181 (7.13)

P106 645E

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 100 (continued)

Auxiliary mounting pad, SAE BB

COUPLING SPLINE DATA: Pitch Dia = 23,8125 (.9375) Pressure Angle = 30 Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, Class 6, Fillet Root Side Fit Length of spline = 24,43 (.96)

for O-Ring ø101,32 x 1,78 (3.99 Dia x 0.07)

146 (5.75)

(- .000)

+ 0,13

ø101,65 0 (4.002 Dia) (+.005)

"X"

View "X" SAE B-B, Option BB

4 Threads 1/2-13UNC-2B 22 (.87) deep

22,75 (.896) 360,9 (14.21) 378,3 (14.89)

250 - 152

520L0603 • Rev FB • July 2007

146 (5.75) P106 646E

47

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 130

Manual Displacement Control (MDC), end cap twin ports, option 80 View "Z"

"Y"

110.5 [4.35]

Port S: charge pump inlet 1-5/8-12UN-2B

42.5 [1.67]

66.68 [2.63]

166 [6.54] port L2 Approximate center of gravity 300 [11.81]

Gauge port M1 System pressure A 9/16-18UNF-2B

View "Y"

290 [11.42]

16 [0.63]

66.68 [2.625] 42.5 [1.67]

101.5 [4.00] 209.3 [8.24]

370 [14.58]

80.8 [3.181]

(2x) 161.6 [6.36]

Port L2 case drain 1-5/16-12UN-2B (2x)

[-0.002]

View "X"

Length of full spline

Splined shaft option C8 Multifunction valve

48 [1.89] 111 [4.37]

Gauge port M5 servo pressure 9/16-18UNF-2B

Approximate center of gravity

Charge pressure relief valve

Gauge port M3 charge pressure 9/16-18UNF-2B

Ø 37 [Ø 1.46]

Port L1 case drain use highest port as outlet 1-5/16-12UN-2B

48.8 [1.92]

Ø 20.6 [Ø 0.81]

Coupling may not protrude beyond this surface

Ø 44.35 [Ø 1.75]

7.9 [0.31]

CW

"Z"

Shaft spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 5, fillet root side fit

185 [7.28]

Gauge port M4 servo pressure 9/16-18UNF-2B

0

R 0.8 maximum [0.03 maximum] 12.7 - 0.5 [0.50] [-0.02]

111.6 [4.39]

"X"

CCW

100 [3.94] port L2

Ø 34.54 [Ø 1.36]

A

Ports A and B 1- 1/4 - 6000 psi split flange boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 [0.906] minimum full thread

Splined shaft option F1

Rotation

31.75 [1.25]

77 [3.03]

B

Length of full spline

Ø 152.4 -0.05 [Ø 6.00] [+0.000]

147.1 [5.79] port L1 77 [3.03]

7.9 [0.31]

"W"

Coupling may not protrude beyond this surface

15 [0.59] Ø 43.89 [Ø 1.728] Ø 114 maximum [maximum 4.49 Ø]

168.5 [6.63]

66.68 [2.63]

184.5 [7.26]

9.4 [0.37]

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, option MA

Multifunction valve

Shaft spline data: Pitch diameter = 42.862 [1.6875] Pressure angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

Manual displacement control handle dimensions Torque applied to control handle shaft not to exceed 17 N•m [150 lbf•in] R 50.8 [R 2.00]

"B" Neutral position

m

"A"

30° 30° m inimum inimum

Maximum displacement

Maximum displacement

48

250 - 153

R 25.4 [R 1.00] Ø 6.73 2x [Ø 0.265]

520L0603 • Rev FB • July 2007

P102 052

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 130 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, BB View "X"

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30° Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 22.4 [0.88]

"X"

For O-ring Ø 82.27 x 1.78 [3.24 diameter x 0.07]

106.375 [4.188]

Ø 82.6 [Ø 3.252]

+ 0.13 0 [+0.005] [- 0.000]

SAE A, option AB

4 threads 3/8-16UNC-2B 17.8 [0.70] deep

15.6 [0.61] 400.89 [15.78]

106.375 [4.188]

414.56 [16.32] Coupling spline data: Pitch diameter = 20.6375 [0.8125] Pressure angle = 30° Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 28.77 [1.1])

View "X"

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

146 [5.75]

"X"

[- 0.000]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.002] [+0.005]

SAE B, option BC

4 threads 1/2-13UNC-2B 22 [0.87] deep

18.2 [0.72] 408 [16.06]

146 [5.75]

425.65 [16.76]

View "X"

Coupling spline data: Pitch diameter = 29.6333 [1.167] Pressure Angle = 30° Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 29.97 [1.18]

For O-ring Ø126.72 x 1.78 [Ø 4.98 x 0.07]

114.5 [4.51]

[-0.000]

+ 0.13

Ø 127.03 0 [Ø 5.001] [+0.005]

"X"

SAE C, option CD

6 threads 1/2-13UNC-2B 22 [0.87] deep

31.4 [1.24] 411.05 [16.18] 427.75 [16.84]

250 - 154

520L0603 • Rev FB • July 2007

P102 053

114.5 [4.51] 181 [7.13]

49

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 130 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, BB View "X"

Coupling spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30˚ Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.22 [0.993]

161.6 [6.36]

"X"

[- 0.000]

+ 0.13

Ø 152.45 - 0.00 [Ø 6.002] [+0.005]

SAE D, option DE

4 threads 3/4-10UNC-2B 41 [1.6] deep

50.84 [2.00]

For O-ring Ø 153 x 3.0 [Ø 6.02 x 0.118]

415.62 [16.36]

161.6 [6.36]

439.22 [17.29] Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure angle = 30˚ Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 24.59 [0.96]

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.002] [+0.005]

"X"

View "X" SAE B-B, option BB

4 threads 1/2-13UNC-2B 22 [0.87] deep

23.3 [0.92] 408 [16.06] 425.65 [16.76]

50

250 - 155

520L0603 • Rev FB • July 2007

146 [5.75] P102 054

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 180

Manual Displacement Control (MDC), end cap twin ports, option 80 View "Z"

"Y"

Ports A and B 1- 1/4 -6000 psi split flange boss per SAE J518 (Code 62) 1/2-13UNC-2B 23 [0.906] minimum full thread

66.68 [2.63]

186 [7.32] port L2

Approximate center of gravity 326 [12.83]

Gauge port M1 system pressure A 9/16-18UNF-2B

Gauge port M4 servo pressure 9/16-18UNF-2B

66.68 [2.63] 42.5 [1.67]

201.5 [7.93] [-0.002]

Approximate center of gravity

398 [15.67]

Port L2

(2x) case drain 1-5/8-12UN-2B 224.5 (2x) [8.84] CPRV

View "X"

Length of full spline

Splined shaft option C8 Multifunction valve

56 [2.20] 228 [8.97]

56 [2.20] 112.25 [4.42]

Coupling may not protrude beyond this surface

Gauge port M3 charge pressure 9/16-18UNF-2B

138 [5.43]

108 [4.25]

Gauge port M5 servo pressure 9/16-18UNF-2B

112.25 [4.42]

Ø 20.6 [Ø 0.81]

Ø 39 [Ø 1.54] Port L1 case drain use highest port as outlet 1-5/8-12UN-2B

cw

"Z"

Shaft spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 5, fillet root side fit

200 [7.87]

7.9 [0.31]

ccw

142 [5.59] port L2

R 0.8 maximum [0.03 maximum] 15.65 ±0.25 [0.616][±0.01]

Ø 44.35 [Ø 1.75]

View "Y"

321 [12.64]

20 [0.79]

Splined shaft option F1

143 [5.63]

Ø 34.04 [Ø 1.34]

"W"

Length of full spline

0

195 [7.68] 31.75 [1.25]

93 [3.66] 93 [3.66]

"X"

Coupling may not protrude beyond this surface

Ø165.1 -0.05 [Ø 6.5] [+0.000]

42.5 [1.67]

156.42 [6.16]

12 [0.47] Ø 43.89 [Ø 1.73] Ø 114 maximum [maximum 4.49 Ø]

9.4 [0.37]

7.9 [0.31]

66.68 [2.63]

Port S: charge pump inlet 1-5/8-12UN-2B

181 [7.13] port L1

204 [8.03]

Gauge port M2 System pressure B 9/16-18UNF-2B

Control MDC, option MA

Multifunction valve

Shaft spline data: Pitch diameter = 42.8625 [1.6875] Pressure angle = 30˚ Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

View "W"

Manual displacement control handle dimensions Torque applied to control handle shaft not to exceed 17 Nm [150 lbf•in]

"B" Null position

"A"

30 30 um minimum minim

Maximum displacement

Maximum displacement

250 - 156

R 50.8 [R 2.0]

R 25.4 [R 1.0] Ø 6.73 2x [Ø 0.265] 191 [7.52]

520L0603 • Rev FB • July 2007

Port N (optional), speed pick-up 9/16-18UNF-2B P102 057

51

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 180 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, EF, EG, BB

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30˚ Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 17.8 [0.70]

View "X"

For O-ring Ø 82.27 x 1.78 [Ø 3.24 x 0.07]

106.375 [4.188]

"X"

Ø 82.6 [Ø 3.252]

+ 0.13 - 0.00 [+0.005] [- 0.000]

SAE A, option AB

4 threads 3/8-16UNC-2B 17.8 [0.70] deep

15 [0.59] 429.3 [16.90]

106.375 [4.188]

442.9 [17.44] Coupling spline data: Pitch diameter = 20.6375 [0.8125] Pressure angle = 30˚ Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 29.5 [1.16]

View "X"

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.002] [+0.005]

"X"

SAE B, option BC

4 threads 1/2-13UNC-2B 22 [0.87] deep

17.5 [0.69] 436.4 [17.18]

146 [5.75]

454.1 [17.88] Coupling spline data: Pitch diameter = 29.6333 [1.167] Pressure angle = 30˚ Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 22.1 [0.87]

250 - 157

114.5 [4.51]

[- 0.000]

+ 0.13

For O-ring Ø 126.72 x 1.78 [Ø 4.98 x 0.07]

52

View "X"

Ø 127.03 - 0.00 [Ø 5.001] [+0.005]

"X"

SAE C, option CD

30.5 [1.20]

439.4 [17.30]

6 threads 1/2-13UNC-2B 22 [0.87] deep 456.1 [17.96]

520L0603 • Rev FB • July 2007

P102 058

114.5 [4.51] 181 [7.13]

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 180 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, EF, EG, BB

Coupling spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.9 [1.02]

View "X"

"X"

161]6 [6.36]

+ 0.13

[- 0.000]

Ø152.45 - 0.00 [Ø 6.002] [+0.005]

SAE D, option DE

For O-ring Ø 153 x 3.0 [Ø 6.02 x 0.118]

49.9 [1.96]

448.1 [17.64]

4 threads 3/4-10UNC-2B 41 [1.61] deep 464.8 [18.30]

Coupling spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.9 [1.02]

SAE E, option EF

View "X"

For O-ring Ø 164.77 x 2.62 [6.48 x 0.10]

224.5 [8.84]

[- 0.000]

+ 0.13

Ø 165.15 - 0.00 [Ø 6.501] [+0.005]

"X"

161.6 [6.36]

46.5 [1.83]

469.1 [18.47]

4 threads 3/4-10UNC-2B 41 [1.61] deep

224.5 [8.84]

494.1 [19.45]

Coupling spline data: Pitch diameter = 42.862 [1.687] Pressure angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 28.5 [1.12]

View "X"

Ø 165.15 [Ø 6.501]

"X"

For O-ring Ø 164.77 x 2.62 [Ø 6.48 x 0.10]

250 - 158

224.5 [8.84]

+ 0.13 - 0.00 [+0.005] [- 0.000]

SAE H, option EG

46.5 [1.83]

448.1 [17.64]

4 threads 3/4-10UNC-2B 41 [1.61] deep 473.7 [18.65]

520L0603 • Rev FB • July 2007

224.5 [8.84]

P102 059

53

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 180 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, EF, EG, BB

Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure angle = 30˚ Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 24.49 [0.96]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.002] [+0.005]

146 [5.75]

"X"

View "X" SAE B-B, option BB

[- 0.000]

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

4 threads 1/2-13UNC-2B 22 [0.87] deep

22.6 [0.89] 436.4 [17.18] 454.1 [17.88]

54

250 - 159

520L0603 • Rev FB • July 2007

146 [5.75] P102 060

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 250

Manual Displacement Control (MDC), end cap twin ports, option 80 Control MDC, option MA

View "Z"

7.9 [0.31]

66.68 [2.63]

B

Splined shaft option F1

186 [7.32] port L2

79.38 [3.13] Approximate center of gravity

341 [13.43]

Ports A and B 1- 1/2 - 6000 psi split flange boss per SAE J518 (Code 62) 5/8-11UNC-2B, 25 [0.98] minimum full thread

Gauge port M4 servo pressure 9/16-18UNF-2B

Rotation

66.68 [2.63] 56 [2.20]

142 [5.59] port L2

143 [5.63] Ø 20.6 [Ø 0.81] Approximate center of gravity

Charge pressure relief valve

228 [8.98] 419 [16.5]

Gauge port M2 system pressure B 9/16-18UNF-2B

Splined shaft option C8 Multifunction valve

56 [2.20] 108 [4.25]

Gauge port M5 servo pressure 9/16-18UNF-2B

Port L2 (2x) case drain 1-5/8-12UN-2B 224.5 (2x) [8.84]

Length of full spline

Gauge port M3 Charge pressure 9/16-18UNF-2B

136 [5.35]

M2

56 [2.20] 112.25 [4.42]

View "X"

Coupling may not protrude beyond this surface

Ø 39 [Ø 1.54]

Port L1 case drain use highest port as outlet 1-5/8-12UN-2B

CW

[- 0.002]

"Z"

Shaft spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30°?

Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 5, fillet root side fit

210 [8.27]

7.9 [0.31]

+ 0.00

R 0.8 maximum [R 0.03 maximum] 15.5 ± 0.25 [0.61][± 0.01]

Ø 44.35 [Ø 1.75]

View "Y"

331 [13]

20 [0.79]

Ø 165.1 - 0.05 [Ø 6.5] [+0.000]

Ø 34.04 [Ø 1.34]

36.5 [1.44]

Port S: charge pump Inlet 1- 1/2 3000 psi split flange boss per SAE J518 (Code 61) 1/2-13UNC-2B 24 [0.94] minimum full thread

185.5 [7.30]

98 [3.86]

35.71 [1.41] 69.85 [2.75] A

12 [0.47] Ø 43.89 [Ø 1.73] Ø 114 maximum [maximum 4.49 Ø]

"X"

Length of full spline

CCW

98 [3.86]

181 [7.13] port L1

42.5 [1.67]

"W"

Coupling may not protrude beyond this surface 201.5 [7.93]

212 maximum [8.35]

9.4 [0.37]

"Y"

Shafte spline data: Pitch diameter = 42.8625 [1.6875] Pressure angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, class 5, fillet root side fit

Multifunction Valve

Gauge port M10 charge pump Inlet 9/16-18UNF-2B

Gauge port M1 system pressure A 9/16-18UNF-2B

View "W"

Manual displacement control handle dimensions Torque applied to control handle shaft not to exceed 17 Nm (150 lbf•in] R 50.8 [R 2.0]

"A"

30

Null position

Maximum displacement

250 - 160

minim

"B"

30 um minimum

Maximum displacement

R 25.4 [R 1.0] Ø 6.73 2x [Ø 0.265] 191 [7.52]

520L0603 • Rev FB • July 2007

Port N (optional), speed pick-up 9/16-18UNF-2B P102 061

55

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 250 (continued)

Auxiliary mounting pad - options AB, BC, CD, DE, EF, EG, BB View "X"

Coupling spline data: Pitch diameter = 14.288 [0.5625] Pressure angle = 30˚ Number of teeth = 9 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 17.8 [0.70]

"X"

For O-ring Ø 82.27 x 1.78 [Ø 3.24 x 0.07]

106.375 [4.188]

Ø 82.6 [Ø 3.252]

+ 0.13 - 0.00 [+ 0.005] [- 0.000]

SAE A, option AB

15 [0.59]

450.30 [17.73]

4 threads 3/8-16UNC-2B 17.8 [0.70] deep 463.90 [18.26]

Coupling spline data: Pitch diameter = 20.6375 [0.8125] Pressure angle = 30˚ Number of teeth = 13 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 29.5 [1.16]

SAE B, option BC

View "X"

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.002][+0.005]

"X"

17.5 [0.69]

For O-ring Ø 101.32 x 1.78 [Ø 3.99 x 0.07]

457.4 [18.01]

4 threads 1/2-13UNC-2B 22 [0.87] deep

View "X"

114.5 [4.51]

[- 0.000]

+ 0.13

For O-ring Ø 126,72 x 1.78 [Ø 4.98 x 0.07]

250 - 161

SAE C, option CD

Ø 127.03 - 0.00 [Ø 5.001] [+0.005]

"X"

146 [5.75]

475.1 [18.70]

Coupling spline data: Pitch diameter = 29.6333 [1.167] Pressure angle = 30˚ Number of teeth = 14 Pitch = 12/24 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 22.1 [0.87]

56

106.375 [4.188]

30.5 [1.20]

460.4 [18.13]

6 threads 1/2-13UNC-2B 22 [0.87] deep 477.1 [18.78]

520L0603 • Rev FB • July 2007

P102 062

114.5 [4.51] 181 [7.13]

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 250 (continued)

Auxiliary mounting pad – options AB, BC, CD, DE EF, EG, BB

Coupling spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30° Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.9 [1.02]

View "X"

"X"

161.6 [6.36]

+ 0.13

[- 0.000]

Ø 152.45 - 0.00 [Ø 6.002] [+0.005]

SAE D, option DE

For O-ring Ø 153 x 3.0 [Ø 6.02 x 0.118]

49.9 [1.96]

469.1 [18.47]

4 threads 3/4-10UNC-2B 41 [1.61] deep 485.8 [19.13]

Coupling spline data: Pitch diameter = 41.275 [1.625] Pressure angle = 30 Number of teeth = 13 Pitch = 8/16 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 25.9 [1.02]

View "X"

For O-ring Ø 164,77 x 2.62 [Ø 6.48 x 0.10]

224.5 [8.84]

[- 0.000]

+ 0.13

Ø 165.15 - 0.00 [Ø 6.501] [+0.005]

"X"

SAE E, option EF

161.6 [6.36]

48.5 [1.91]

469.1 [18.47]

Coupling spline data: Pitch diameter = 42.862 [1.687] Pressure angle = 30° Number of teeth = 27 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 28.5 [1.12]

4 threads 3/4-10UNC-2B 41 [1.61] deep

224.5 [8.84]

494.1 [19.45]

Ø 165.15 [Ø 6.501]

"X"

For O-ring Ø 164.77 x 2.62 [Ø 6.48 x 0.10]

250 - 162

224.5 [8.84]

+ 0.13 - 0.00 [+0.005] [- 0.000]

SAE H, option EG

46.5 [1.83]

469.1 [18.47]

P102 063

4 threads 3/4-10UNC-2B 41 [1.61] deep

224.5 [8.84]

494.1 [19.45]

520L0603 • Rev FB • July 2007

57

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 250 (continued)

Auxiliary mounting pad – options AB, BC, CD, DE, EF, EG, BB View "X"

Coupling spline data: Pitch diameter = 23.8125 [0.9375] Pressure angle = 30 Number of teeth = 15 Pitch = 16/32 ANSI B92.1-1970, class 6, fillet root side fit Length of spline = 24.49 [0.96]

For O-ring Ø 101,32 x 1.78 [Ø 3.99 x 0.07]

58

250 - 163

146 [5.75]

[- 0.000]

+ 0.13

Ø 101.65 - 0.00 [Ø 4.00] [+0.005]

"X"

SAE B-B, option BB

22.6 [0.89]

4 threads 1/2-13UNC-2B 22 [0.87] deep 457.4 [18.01]

475.1 [18.70]

520L0603 • Rev FB • July 2007

146 [5.75] P102 064

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

COVER PLATE

C2

Option CA

View "W"

C4 maximum

C1

C3

C1

C4 maximum

Port M4

Displacement limiter option 4 limitation both sides Port M5

P102065

"W"

Dimensions Frame size 042 055 075

C1 67.9 [2.67] 69.2 [2.72] 74.2 [2.92]

C2 129.5 [5.10] 179.4 [7.06] 185.7 [7.31]

C3 99.5 [3.92] 103.6 [4.08] 109.4 [4.31]

C4 maximum (option 4) 108 [4.25] 114 [4.48] 118 [4.65]

100 130

83.3 [3.28] 86.6 [3.41]

183.3 [7.22] 209.3 [8.24]

118.3 [4.66] 137.2 [5.40]

136 [5.35] 141 [5.55]

180

-

-

-

184 [7.24]

250

-

-

-

184 [7.24]

3-POSITION (F-N-R) ELECTRIC CONTROL

View "W"

Option DC & DD

C5.2

C5 maximum

C5.1

a

b

P102065a

"W"

Dimensions Frame size

C5 maximum

C5.1

C5.2

042 055 075 100

196.5 [7.74] 200.6 [7.90] 207.9 [8.19] 216.8 [8.54]

108.8 [4.28] 108.8 [4.28] 108.8 [4.28] 117.4 [4.62]

106.2 [4.18] 106.2 [4.18] 106.2 [4.18] 97.6 [3.84]

130 180 250

235.7 [9.28] 252.4 [9.94]

102.4 [4.03] 94.6 [7.32]

112.6 [4.43] 120.4 [4.74

210.4 [8.28]

94.6 [7.32]

120.4 [4.74

[option DD only]

250 - 164

520L0603 • Rev FB • July 2007

59

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

ELECTRIC DISPLACEMENT CONTROL (EDC) WITH MS-CONNECTOR OR PACKARD® CONNECTOR View "W"

Option KA & KP

C7

C6

Port X1

Port X2

C7 (Frame size 042 only)

PackardConnector option KP

P102 066

Frame size 042 only

"W"

Dimensions Frame size 042

C6 95.3 [3.75]

C7 168.6 [6.64]

055

95.3 [3.75]

141.2 [5.56]

075 100

105.2 [4.14] 114.0 [4.49]

144.8 [5.70] 153.7 [6.05]

130 180 250

99.1 [3.90] 93.4 [3.68] 93.4 [3.68]

172.7 [6.80] 190.0 [7.48] 226.2 [8.91]

HYDRAULIC DISPLACEMENT CONTROL (HDC) Port X1

C12

Port X2

View "W"

Option HF

C8.1 (port X2)

C8.2 (port X1)

C10

C9

C11

"W"

Dimensions

60

Frame size

C8.1

C8.2

C9

C10

C11

C12

042

143.5 [5.65]

135.0 [5.31]

71.0 [2.79]

75.7 [2.98]

89.6 [3.52]

99.2 [3.90]

055

150.8 [5.94]

139.0 [5.47]

71.0 [2.79]

75.7 [2.98]

105.6 [4.15]

115.2 [4.53]

075 100

148.9 [5.86] 158.0 [6.22]

139.0 [5.47] 149.0 [5.86]

68.2 [2.68] 76.8 [3.02]

67.0 [2.63] 67.0 [2.63]

121.8 [4.79] 127.9 [5.03]

125.3 [4.93] 131.4 [5.17]

130

176.7 [6.95]

167.7 [6.60]

61.8 [2.43]

67.0 [2.63]

142.1 [5.59]

145.6 [5.73]

180/250

194.0 [7.63]

185.0 [7.28]

54.0 [2.12]

67.0 [2.63]

148.6 [5.85]

152.1 [5.99]

250 - 165

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

MANUAL DISPLACEMENT CONTROL (MDC) WITH NEUTRAL START SWITCH C13

View "W"

C14

Option MB

Neutral start switch

P102 067

"W"

Dimensions Frame size

C13

C14

042

0.35 [0.014]

96.0 [3.78]

055 075

18.0 [071] 25.0 [0.98]

100.0 [3.94] 106.9 [4.21]

100

31.3 [1.23]

115.8 [4.56]

130 180

46.0 [1.81] 52.0 [2.04]

134.5 [5.29] 151.8 [5.97]

250

52.0 [2.04]

151.8 [5.97]

NON-LINEAR MANUAL DISPLACEMENT CONTROL (MDC) "V" Option NA

View "W"

View "V"

"B" Null position

"A"

"W"

31 31 um minimum minim

Maximum displacement

Maximum displacement

C15

Torque applied to control handle shaft not to exceed 17 Nm (150 lbf•in) R 50.8 (R 2.0)

R 26.4 (R 1.04) Ø 8.26 2x [Ø 0.325] P102 067a

Dimensions

250 - 166

Frame size

C15

075

178.9 [7.04]

100 130

187.8 [7.39] 209.4 [8.24]

520L0603 • Rev FB • July 2007

61

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

Option FA, FB, FC, FD

View "V"

Option FG, FH

View "W"

Y

X

ELECTROHYDRAULIC DISPLACEMENT CONTROL (NFPE) (EXCEPT 075 NFPE)

Y

"V"

P003 165

"W"

Dimensions Frame Size 042 055 075 100 100 130 180 250

62

250 - 167

520L0603 • Rev FB • July 2007

Option “X” FA, FB, FC, FD 169.30 [6.67] FA, FB, FC, FD 207.00 [8.15] Special version see page 63 FA, FB, FC, FD 235.00 [9.25] FG, FH FG, FH 244.10 [9.61] FG, FH 290.00 [11.42] — —

“Y” 140.00 [5.51] 145.00 [5.71] 161.10 [6.34] 176.60 [6.95] 195.50 [7.70] 213.00 [8.39] —

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

INTEGRAL PRESSURE FILTER

View "X"

Option P & L

Gauge port M6 charge pressure before filter 9/16-18UNF Ø 94.2 maximum [Ø 3.71 maximum]

180

"X"

180 Gauge port M3 charge pressure after filter 9/16-18UNF

Required for removal

20.3 minimum [0.80 minimum]

22.86 [0.90]

F1 = short filter cartridge (option P)

F4 maximum

Frame size 042 – 130 = option P Frame size 042 – 250 = option L

REMOTE PRESSURE – WITHOUT FILTER

View "X"

F2 = long filter cartridge (option L) F3

Option R & T

Port E from filter 7/8-14UNF (option R) 1 1/16 -12UN (option T)

5.6 [0.22]

180

5.6 [0.22]

"X" 180

Port D to filter 7/8-14UNF (option R) 1 1/16 -12UN (option T)

F5 maximum F6 maximum

Frame size 042 – 130 = option R Frame size 180 – 250 = option T

F7 maximum

Gauge port M3 charge pressure after filter 9/16-18UNF

28.5 [1.12] F3

P102 068

Dimensions Frame size

F1

F2

F3

F4 maximum

F5 maximum

F6 maximum

F7 maximum

042

174.5 [6.87]

262.6 [10.34]

201.4 [7.93]

207.7 [8.12]

112.7 [4.44]

152.7 [6.01]

168.0 [6.61]

055 075

174.5 [6.87] 174.5 [6.87]

262.6 [10.34] 262.6 [10.34]

240.9 [8.19] 253.2 [9.67]

209.6 [8.25] 214.4 [8.44]

114.3 [4.50] 119.1 [4.69]

154.3 [6.07] 159.1 [6.26]

169.6 [6.68] 174.4 [6.86]

075 NFPE 100

174.5 [6.87] 174.5 [6.87]

262.4 [10.34] 262.6 [10.34]

253.7 [9.99] 280.7 [11.05]

214 [8.441] 223.0 [8.78]

119 [4.691] 127.7 [5.03]

159 [6.264] 167.7 [6.60]

174 [6.866] 183.0 [7.20]

130

174.5 [6.87]

262.6 [10.34]

299.9 [11.81]

223.0 [9.17]

137.7 [5.03]

177.7 [6.99]

193.0 [7.60]

180 250

-

-

327.8 [12.90] 342.8 [13.49]

-

182.0 [7.16] 182.0 [7.16]

236.8 [9.32] 236.8 [9.32]

259.2 [10.2] 259.2 [10.2]

250 - 168

520L0603 • Rev FB • July 2007

63

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 NFPE

Integrated NFPE control, endcap side ports

System pressure B Gage port M2 9/16-18UNF-2B

"C" 306 [12.043]

Connector AMP Junior Typ A

14 [0.56]

65 [2.543]

"B"

47.6 [1.874] System pressure A Gage port M1 9/16-18UNF-2B Charge pump inlet M10 9/16-18UNF-2B

156 [6.142] Approx center of gravity

95 [3.755]

91.7 [3.611]

31.2 [1.228]

"D"

57.25 [2.254]

0

[51] [0] [-0.002]

Ø127 -0.05

Ø34.42 [1.355]

4 [0.157]

94.5 [3.722]

Ø28.7 [1.13]

12.45±0.25 [0.490±0.010] 7.95 [0.313] R0.8 max.

[0.03]

124.2 [4.89] to case drain L1

"A"

View "B" 54 [2.118]

Case drain L1 1-1/16-12UN-2B

Spline data: Pitch dia:

33.3375 [1.3125] Pressure angle: 30 Number of teeth: 21 Pitch 16/32 ANSI B92.1 -1970, class 5 Fillet root side fit

Ø14.3 +0.25 -0.13 [0.565] [+0.10] [-0.005]

57.25 [2.254]

Case drain L2 1-1/16-12UN-2B P104 324E

"E"

View "C" View "A" Charge pressure relief valve

Multifunction valve

110.8 [4.362]

Split flange boss (2x) DN 25 TypII 40MPa series per ISO 6162 Thread: 0.4375-14UNC-2B [7/16-14UNC-2B] 0.83 min. full thread depth

84 [3.31]

27.76 [1.093]

Connector Deutsch: DTM 06-3 S

221 max.

[8.701]

Gage port M4 Servo pressure 9/16-18UNF-2B

57.15 [2.250]

248 [9.772]

172 [6.780]

Gage port M5 Servo pressure 9/16-18UNF-2B

64

250 - 169

Multifunction valve

Charge pump inlet S 1-5/16-12UN-2B P104325E

520L0603 • Rev FB • July 2007

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 NFPE (continued)

Integrated NFPE control, endcap side ports (continued)

141 [5.557]

View "D"

Charge pressure Gage port M3 9/16-18UNF-2B

Optional: Part for speed pick up 9/16-18UNF-2B 253 [9.962] P104 326E

View "E" 262.4 [10.332]

39.4 [1.551]

65 [2.558]

141.7 [5.581]

P104 327E

250 - 170

520L0603 • Rev FB • July 2007

65

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 NFPE (continued)

Integrated NFPE control, endcap twin ports "C" 306 [12.043] Case drain L1 1-1/16-12UN-2B

54 [2.118] Connector AMP Junior Typ A

14 [0.56]

99.0 [3.90] Split flange boss (2x) DN 25 TypII 40MPa series per ISO 6162 Thread: 0.4375-14UNC-2B [7/16-14UNC-2B] 0.83 min. full thread depth

57.15 [2.25]

System pressure A Gage port M1 9/16-18UNF-2B

156 [6.142] 242 [9.54] 248 [9.75]

P104 328E

View "C"

Connector Deutsch: DTM 06-3 S

Gage port M5 Servo pressure 9/16-18UNF-2B

520L0603 • Rev FB • July 2007

172 [6.780] P104 329E

221 max.

[8.701]

Gage port M4 Servo pressure 9/16-18UNF-2B

250 - 171

[51] [0] [-0.002]

0 Ø127 -0.05

Spline data: Pitch dia: 33.3375 [1.3125] Pressure angle: 30 Number of teeth: 21 Pitch 16/32 ANSI B92.1 -1970, class 5 Fillet root side fit

Approx center of gravity

"E"

66

"B"

31.2 [1.228] 47.6 [1.874]

Charge pump inlet 1-5/16-12UN-2B

Ø34.42 [1.355]

"A"

61 [2.402]

61 [2.402]

4 [0.157]

124.2 [4.89]

27.76 [1.093]

12.45±0.25 [0.490±0.010] 7.95 [0.313] R0.8 max.

[0.03] Ø28.7 [1.13]

System pressure B Gage port M2 9/16-18UNF-2B

Series 90 Axial Piston Pumps Technical Information Installation drawings mm [in]

FRAME SIZE 075 NFPE (continued)

Auxiliary mounting pad SAE-A 348 [13.704]

Thread 3/8-16UNC-2B 0.89 deep

334 [13.141]

Ø82.6 +0.13 0

106.376 [4.118]

106.376 [4.188]

250 - 172

[3.252] [+0.005] [ 0]

15.13 [0.596]

for O-ring Ø82.27x1.78 [3.24x0.07]

520L0603 • Rev FB • July 2007

Spline data: Pitch dia: 14.288 [0.562] Pressure angle: 30 Number of teeth: 9 Pitch 16/32 ANSI B92.1 -1970, class 6 Fillet root side fit effective lengh of spline: 37.13 [1.46]

P104 330E

67

OUR PRODUCTS

Sauer-Danfoss Mobile Power and Control Systems – Market Leaders Worldwide

Hydrostatic transmissions Hydraulic power steering

Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market.

Electric power steering Electrohydraulic power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Orbital motors Transit mixer drives Planetary compact gears Proportional valves Directional spool valves Cartridge valves

Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others.

We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them.

Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Global Service Partners strategically located in all parts of the world.

Hydraulic integrated circuits Hydrostatic transaxles

Local address:

Integrated systems Fan drive systems Electrohydraulics Microcontrollers and software Electric motors and inverters Joysticks and control handles Displays Sensors

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000 Fax: +1 515 239-6618

Sauer-Danfoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444 Fax: +45 7488 4400

Sauer-Danfoss GmbH & Co. OHG Postfach 2460, D-24531 Neumünster Krokamp 35, D-24539 Neumünster, Germany Phone: +49 4321 871-0 Fax: +49 4321 871 122

Sauer-Danfoss-Daikin LTD Sannomiya Grand Bldg. 8F 2-2-21 Isogami-dori, Chuo-ku Kobe, Hyogo 651-0086, Japan Phone: +81 78 231 5001 Fax: +81 78 231 5004

www.sauer-danfoss.com 520L0603 • Rev FB • July 2007 250 - 173

250 - 174

250 - 175

250 - 176

250 - 177

250 - 178

250 - 179

250 - 180

250 - 181

K and L Frame Variable Motors, Cartridge Mount

Service Manual

250 - 182

K and L Frame Variable Motors, Cartridge Mount Service Manual Revisions HISTORY OF REVISIONS

Table of Revisions Date

Page

Changed

Rev.

November 2006 July 2004

14 Various

Added loop flushing valve First edition

B A

© 2006 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.

Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group.

Front cover illustrations: F101 216, F101 218, F101 416

2

250 - 183

520L0631 • Rev B • November 2006

K and L Frame Variable Motors, Cartridge Mount Service Manual Contents INTRODUCTION

Overview ........................................................................................................................................................... 4 Safety precautions ......................................................................................................................................... 4 Unintended machine movement ....................................................................................................... 4 Flammable cleaning solvents ............................................................................................................... 4 Fluid under pressure ................................................................................................................................4 Personal safety ........................................................................................................................................... 4 Symbols used in Sauer-Danfoss literature............................................................................................. 5 Design ................................................................................................................................................................ 6 The System circuit .......................................................................................................................................... 7

TECHNICAL SPECIFICATIONS

Overview ...........................................................................................................................................................8 Features and options .................................................................................................................................... 8 Specifications................................................................................................................................................... 8 Operating parameters .................................................................................................................................. 8 Fluid specifications ........................................................................................................................................ 8

FEATURES

Output shafts ................................................................................................................................................... 9 Controls.............................................................................................................................................................. 9 Brake release port .......................................................................................................................................... 9 Control orificing ........................................................................................................................................ 9

PRESSURE MEASUREMENTS

Required tools ...............................................................................................................................................10 Port locations and gauge installation ...................................................................................................10

INITIAL START-UP PROCEDURES

General ............................................................................................................................................................11 Start-up procedure ......................................................................................................................................11

FLUID AND FILTER MAINTENANCE

Recommendations.......................................................................................................................................12

TROUBLESHOOTING

Excessive noise and / or vibration ..........................................................................................................13 System operating hot .................................................................................................................................13 Won’t shift or slow to shift.........................................................................................................................13

MINOR REPAIR

Shaft seal replacement...............................................................................................................................14 Remove the shaft seal ...........................................................................................................................14 Inspect the components ......................................................................................................................14 Install the new shaft seal ......................................................................................................................14 Loop flushing valve......................................................................................................................................15 Remove the loop flushing valve ........................................................................................................15 Inspect the components ......................................................................................................................15 Install the loop flushing valve ............................................................................................................15

250 - 184

520L0631 • Rev B • November 2006

3

K and L Frame Variable Motors, Cartridge Mount Service Manual Introduction OVERVIEW

This manual includes information for the installation, maintenance, and minor repair of the K and L Frame Cartridge Mount Variable Motors. The manual includes a description of the units and their individual components, troubleshooting information, and minor repair procedures. Performing installation, maintenance, and minor repair of K and L Frame Variable Motors according to the procedures in this manual will not affect your warranty.

Performing minor repairs requires the unit to be removed from the vehicle/machine.

Thoroughly clean the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing.

A worldwide network of Sauer-Danfoss Authorized Service Centers (ASCs) is available for major repairs. Major repairs require the removal of the unit’s endcap, which voids the warranty unless done by an ASC. Sauer-Danfoss ASCs are trained by the factory and certified on a regular basis. You can locate your nearest ASC using the distributor locator at www.sauer-danfoss.com.

SAFETY PRECAUTIONS

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system.

Unintended machine movement  Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable / disconnect the mechanism while servicing.

Flammable cleaning solvents  Warning Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.

Fluid under pressure  Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns.

Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic fluid.

Personal safety  Warning Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.

4

250 - 185

520L0631 • Rev B • November 2006

K and L Frame Variable Motors, Cartridge Mount Service Manual Introduction SYMBOLS USED IN SAUER-DANFOSS LITERATURE

 WARNING may result in injury

 Tip, helpful suggestion

 CAUTION may result in damage to product or property

 Lubricate with hydraulic fluid

 Reusable part  Non-reusable part, use a new part  Non-removable item  Option – either part may exist  Superseded – parts are not interchangeable

 Apply grease / petroleum jelly  Apply locking compound  Inspect for wear or damage  Clean area or part  Be careful not to scratch or damage  Note correct orientation

 Measurement required

 Mark orientation for reinstallation

 Flatness specification

 Torque specification

 Parallelism specification

 Press in – press fit

 External hex head

 Pull out with tool – press fit

 Internal hex head

 Cover splines with installation sleeve

 Torx head  O-ring boss port

 Pressure measurement / gauge location or specification

The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader.

In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.

250 - 186

520L0631 • Rev B • November 2006

5

K and L Frame Variable Motors, Cartridge Mount Service Manual Introduction DESIGN

K and L Frame Variable Motors (KC/LC) are low to medium power, two-position axial piston motors incorporating an integral servo piston. They are designed for operation in both open and closed circuit applications. KC/LC motors have a cartridge style mounting configuration. The standard control is a direct acting single line hydraulic control. The integral servo piston controls motor displacement.

The motor is spring biased to maximum displacement and hydraulically shifted to minimum displacement. Minimum and maximum displacement can be set with fixed internal stops. The large diameter servo piston allows smooth acceleration and deceleration with relatively large circuit orificing.

The motor is ideally configured for installations requiring compact packaging and optimized plumbing, such as wheel ends. One face of the motor contains all hydraulic porting.

KC/LC cross section Servo piston Bias spring Swashplate

Output shaft Cylinder block

Shaft seal Endcap Bearing Valve plate

6

250 - 187

520L0631 • Rev B • November 2006

Piston

Slipper

P104 161E

K and L Frame Variable Motors, Cartridge Mount Service Manual Introduction THE SYSTEM CIRCUIT

The circuit below shows the KC/LC motor in a simple closed-loop hydrostatic propel application. The motor is driven by a Series 42 medium power axial piston pump with manual displacement control. Control pressure applied through an external control valve shifts the motor to minimum displacement; spring force returns the motor to maximum displacement in the absence of control input.

System circuit diagram High loop pressure Case pressure Charge/low loop pressure Control pressure Inlet pressure

Servo piston Reservior

Motor displacement control valve

Displacement control spool

Pump control handle and feedback linkage

Servo piston

Swashplate Input shaft

Charge relief valve Output shaft Charge pump

Check valves w/high pressure relief valves and bypass plunger Filter Pump swashplate

Cylinder block assembly

Slipper

P104 250E

250 - 188

520L0631 • Rev B • November 2006

7

K and L Frame Variable Motors, Cartridge Mount Service Manual Technical specifications OVERVIEW

Specifications and operating parameters for KC/LC motors are given here for reference.

FEATURES AND OPTIONS

Mount Motor type

SAE-B (LV/KV) Cartridge (LC/KC) Inline, axial piston, positive displacement, two-speed variable motors

Displacement

L: 25, 30, or 35 cm3 [1.50, 1.83, or 2.14 in3] K: 38 or 45 cm3 [2.32 or 2.75 in3]

Rotation Installation position

Bidirectional Discretionary: Housing must always be filled with hydraulic fluid

Porting

SAE O-ring boss, axial or twin radial

Output shafts Control options

Splined 13 or 15 tooth 16/32 pitch, 0.875 Splined 13 or 15 tooth 16/32 pitch in. straight keyed, and 1:8 taper Single or dual line hydraulic control Single line hydraulic control

Displacement limiter

Fixed maximum and minimum displacement limiters available

Speed sensor Loop Flushing Valve

Available on L Frame SAE-B motors, in development* on K frame and cartridge motors Available

SPECIFICATIONS

OPERATING PARAMETERS

Parameter

Unit

L25

L30

L35

K38

K45

Displacement (maximum) Weight (cartridge and SAE-B)

cm3 [in3] kg [lb]

25 [1.50]

30 [1.83]

35 [2.14] 15.4 [34]

38 [2.32]

45 [2.75]

Mass moment of inertia of

kg•m2

0.001666

0.001582

0.001530

0.002326

0.002286

rotating components Theoretical torque

[slug•ft2] [0.001229] [0.001167] [0.001128] [0.001716] [0.001687] N•m/bar 0.40 0.48 0.56 0.60 0.72 [lbf•in/1000psi] [244] [293] [347] [366] [439]

Parameter System

Unit continuous bar [psi]

L25 210

L30 175

L35 140

K38 210

K45 175

maximum

[3045] 415

[2540] 350

[2030] 280

[3045] 415

[2540] 350

continuous min-1 (rpm) maximum

[6020] 3400 3950

[5075] 3500 4150

[4060] 3600 4300

[6020] 3600 4000

[5075] 3500 3900

continuous

4400

4450

4500

4650

4500

maximum continuous bar [psi]

5000

5150

5300 2 [29]

5200

5050

pressure

Speed limit (at max. disp) Speed limit (at min. disp) Case pressure

maximum

FLUID SPECIFICATIONS Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing oxidation, rust, and foam inhibitors.

8

250 - 189

SAE O-ring boss, twin radial

Parameter Viscosity Temperature

Unit mm2/sec (cSt) [SUS] °C [°F]

Cleanliness Filtration efficiency

6 [87]

Minimum 7 [47] -40 [-40]

Continuous 12-60 [70-278] 82 [180] ISO 4406 Class 18/13 or better

suction filtration charge filtration

520L0631 • Rev B • November 2006

β35-44=75 (β10≥1.5) β15-20=75 (β10≥10)

Maximum 1600 [7500] 104 [220]

K and L Frame Variable Motors, Cartridge Mount Service Manual Features OUTPUT SHAFTS

KC/LC motors may have a 13 or 15 tooth shaft, 16/32 pitch, and ANSI B92.1 1970-Class 5.

For dimensions, refer to L and K Frame Variable Motors Technical Information, 520L0627.

CONTROLS

KC/LC motors are designed to operate in Control input pressure limits KC/LC with single line 14 to 69 bar two positions: maximum and minimum control [200 to 1000 psi] displacement. The motors are spring biased to maximum displacement and hydraulically shifted to minimum displacement. KC/LC motors can operate with a single line control only. Pressure applied at port X1 shifts the motor to minimum displacement.

Refer to the table above for control input pressure range.

Control orificing KC/LC motors can have optional, internal, supply and drain orifices installed to regulate control response times.

KC/LC motors rely on external valving and orificing to regulate shift speeds. You can achieve quick acceleration (shift to min) and slow deceleration (shift to max) simply by installing an orifice in the tank line of the external control valve.

BRAKE RELEASE PORT

KC/LC motors are equipped with a brake release port to allow access to the brake-release feature of the gear box from the rear of the motor. This consists of a simple passage through the motor housing with a rear-facing 7/16 in. SAE O-ring boss port. Applications using this brake release port require an O-ring to seal the passage against the gear box.

While all motors will have the brake release port, not all gearboxes are compatible with this motor feature. Consult your gearbox manufacturer for suitability and compatibility. If your gearbox is not compatible with this feature, simply leave the port plugged.

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9

K and L Frame Variable Motors, Cartridge Mount Service Manual Pressure measurements REQUIRED TOOLS

The service procedures described in this manual can be performed using common mechanic’s hand tools. Special tools, if required are shown. Calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges.

PORT LOCATIONS AND GAUGE INSTALLATION

For economical reasons, the LC motor does not contain any designated gauge installation ports. All pressure measurements can be obtained by installing tee fittings to the connections at the locations listed in the table / drawing below. Recommended gauge sizes are also listed.

Port information Port identifier

Size

Pressure obtained

Gauge size, bar [psi]

X1

[0.5625]-18 UNF-2B

Control signal

600 [10 000]

Case drain port A

[0.750]-16 PER SAE [1.0625]-12 PER SAE

Case drain System pressure

10 [100] 600 [10 000]

B Brake release port

[1.0625]-12 PER SAE [0.4375]-20 PER SAE

System pressure N/A

600 [10 000] N/A

Twin radial port locations Control port (X1) Brake release port

Case drain port System port (B)

System port (A) P104 249E

10

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520L0631 • Rev B • November 2006

K and L Frame Variable Motors, Cartridge Mount Service Manual Initial start-up procedures GENERAL

Follow this procedure when starting-up a new motor installation or when restarting an installation in which the motor has been removed.

WWarning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable / disconnect the mechanism while servicing.

Prior to installing the motor, inspect for damage incurred during shipping. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling with fluid.

START-UP PROCEDURE

1. Fill the reservoir with recommended hydraulic fluid. Always filter fluid through a 10 micron filter when pouring into the reservoir. Never reuse hydraulic fluid.

2. Fill the inlet line leading from the pump to the reservoir. Check the inlet line for properly tightened fittings and be certain it is free of restrictions and air leaks.

3. Fill the pump and motor housing with clean hydraulic fluid. Pour filtered oil directly into the upper most case drain port.

4. To ensure the pump and motor stay filled with oil, install case drain lines into the upper most case drain ports.

5. Install a 0 to 35 bar [0 to 500 psi] gauge in the charge pressure gauge port of the pump to monitor system pressure during start up.

Follow recommendations in the vehicle / machine operator’s manual for prime mover start up procedures.

7. While watching the pressure gauge, jog the prime mover or run at the lowest possible speed until system pressure builds to normal levels (minimum 11 bar [160 psi]). Once system pressure is established, increase to full operating speed. If system pressure is not maintained, shut down the prime mover, determine cause, and take corrective action. Refer to Troubleshooting, page 13.

8. Operate the hydraulic system for at least fifteen minutes under light load conditions.

9. Check and adjust pump control settings as necessary after installation.

10. Shut down the prime mover and remove the pressure gauge. Replace plug at the charge pressure gauge port.

11. Check the fluid level in the reservoir; add clean filtered fluid if necessary.

The motor is now ready for operation.

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11

K and L Frame Variable Motors, Cartridge Mount Service Manual Fluid and filter maintenance RECOMMENDATIONS

To ensure optimum life of KC/LC products, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when servicing.

Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid immediately if these conditions occur. Correct the problem immediately.

Change the fluid and filter per the vehicle / machine manufacturer’s recommendations or at these intervals:

Fluid and filter change interval Reservoir type Sealed

Max oil change interval 2000 hours

Breather

500 hours

Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater that the recommended maximum.

Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.

Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to change the filter. Replace all fluid lost during filter change.

12

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520L0631 • Rev B • November 2006

K and L Frame Variable Motors, Cartridge Mount Service Manual Troubleshooting EXCESSIVE NOISE AND / OR VIBRATION Item

Description

Action

Check oil level in reservoir Insufficient hydraulic fluid could lead to cavitation that and oil supply to the motor. would cause system noise.

Fill the reservoir to the proper level and ensure that oil supply to the motor is adequate and the lines are

Check for air in the system.

Air trapped within the system lines, or the motor itself,

unobstructed.

Ensure that all of the system lines and components are

Inspect the output shaft

could result in cavitation that would cause system noise. purged of air.

A loose or incorrect shaft coupling will produce vibrations Ensure that the correct coupling is used and that it fits

couplings.

that could result in system noise.

Inspect the output shaft

Misaligned shafts create excessive frictional vibration that Ensure that the shafts are properly aligned.

alignment.

Hydraulic oil viscosity

could result in system noise.

Viscosity above acceptable limits will result in cavitation

Replace hydraulic oil with appropriate fluid for operating

above limits.

that would lead to system noise.

conditions. Refer to publication 5200L0463 for

properly onto the shaft.

information on fluid selection.

SYSTEM OPERATING HOT Item

Description

Action

Check oil level in reservoir

Insufficient amount of hydraulic fluid will not meet the

Fill the reservoir to the proper level.

and oil supply to the pump. cooling demands of the system.

Inspect the heat exchanger, If the heat exchanger fails, or becomes obstructed, it may

Ensure that heat exchanger is receiving adequate air

(if so equipped).

not meet the cooling demands of the system.

flow and that the heat exchanger is in good operating

Check the system relief valves.

condition. Repair or replace as necessary.

If a system relief valve becomes unseated for an extended Repair or replace any malfunctioning relief valves as period of time or fails for any other reason, the system applicable and verify that the loads on the machine are could become overheated.

not excessive.

WON’T SHIFT OR SLOW TO SHIFT Item

Description

Action

Check the signal line to the

Obstructed or restricted flow through the servo control

Ensure that the signal lines are not obstructed or

servo control port.

signal lines could result in slow shift or no shift conditions within the motor.

restricted and that signal pressure is adequate to shift the motor.

Check that the correct

Supply and drain orifices determine the shift rate of the

Ensure that the proper control orifices are installed in the

supply and drain orifices are properly installed, and

motor. The smaller the orifice, the longer the time it takes to shift the motor. Obstruction will also increase shift

motor and verify that they are not obstructed. Clean or replace as necessary.

are not obstructed.

times.

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520L0631 • Rev B • November 2006

13

K and L Frame Variable Motors, Cartridge Mount Service Manual Minor repair SHAFT SEAL REPLACEMENT

Remove the shaft seal 1. Remove the snap ring (B002) retaining the shaft seal and support washer.

2. Remove the support washer (M004).

3. Carefully pry out the shaft seal (M003).

Replacing the shaft seal B002 M004

M003

To avoid damaging the shaft during removal, install a large sheet metal screw into the chuck of a slide hammer. Drive the screw into the seal surface and use the slide hammer to pull the seal.

4. Discard the seal.

Inspect the components Inspect the new seal, the motor housing seal bore, and the sealing area on the shaft for rust, wear, and contamination.

Polish the shaft and clean the housing if necessary.

P104 251

Install the new shaft seal 1. Cover the shaft splines with an installation sleeve to protect the shaft seal during installation.

2. Install a new shaft seal (M003) with the cupped side facing the motor. Press seal into housing until it bottoms out. Press evenly to avoid binding and damaging the seal.

3. Install seal support washer (M004).

4. Install snap ring (B002).

5. Remove the installation sleeve.

14

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520L0631 • Rev B • November 2006

K and L Frame Variable Motors, Cartridge Mount Service Manual Minor repair LOOP FLUSHING VALVE

Remove the loop flushing valve 1. Using a 11/16 in internal hex wrench remove plug (E020) and (E010).

2. Using a 1/4 in hex wrench remove plug (E042).

3. Remove O-rings (E020B, E042A, and E010B).

4. Using pliers, remove centering springs (E041, E020C, and E010C).

5. Remove spring retaining washers (E020D and E010D).

6. Remove shift spool (E030). Remove orifice poppett (E040).

Loop flushing valve E010B E010C E010D E010 11/16 in 37 N·m [27 lbf·ft]

E020D E020C E020B

E030

E020 11/16 in 37 N·m [27 lbf·ft] E042A

E040 P106 508E

E041 E042

5/8 in 27 N·m [20 lbf·ft]

Inspect the components Inspect sealing area for rust, wear, or contamination. Also check springs and poppett for wear.

Install the loop flushing valve 1. Install orifice poppett (E040). Install shift spool (E030).

3. Install spring retaining washers onto springs (E020D and E010D).

4. Carefully install centering springs (E041, E020C, and E010C).

5. Install new O-rings (E010B, E020B, and E042A).

6. Using a 1/4 in hex wrench torque plug (E042) to X N•m [X ft•lbs].

7. Using a 11/16 in internal hex, torque plugs (E010 and E020) to X N•m [X lbf•ft].

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520L0631 • Rev B • November 2006

15

OUR PRODUCTS

Sauer-Danfoss Mobile Power and Control Systems – Market Leaders Worldwide

Hydrostatic transmissions Hydraulic power steering

Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market.

Electric power steering Electrohydraulic power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Orbital motors Transit mixer drives Planetary compact gears Proportional valves Directional spool valves Cartridge valves

Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others.

We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them.

Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advanced total system design.

Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Global Service Partners strategically located in all parts of the world.

Hydraulic integrated circuits Hydrostatic transaxles

Local address:

Integrated systems Fan drive systems Electrohydraulics Microcontrollers and software Electric motors and inverters Joysticks and control handles Displays Sensors

520L0631 • Rev B • November 2006 250 - 197

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000 Fax: +1 515 239-6618

Sauer-Danfoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444 Fax: +45 7488 4400

Sauer-Danfoss GmbH & Co. OHG Postfach 2460, D-24531 Neumünster Krokamp 35, D-24539 Neumünster, Germany Phone: +49 4321 871-0 Fax: +49 4321 871 122

Sauer-Danfoss-Daikin LTD Sannomiya Grand Bldg. 8F 2-2-21 Isogami-dori, Chuo-ku Kobe, Hyogo 651-0086, Japan Phone: +81 78 231 5001 Fax: +81 78 231 5004

www.sauer-danfoss.com

KPP Pulse Pickup (PPU)

Technical Information

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11029257

Technical Information KPP Pulse Pickup (PPU) Revisions Version

Revisions Date

Page

Changed

09 Jul 2013

7

10 Aug 2009

6, 9-12, 18

25 Sep 2008

Various pages

Corrected illustration title to Non-adjustable Wire Con guration ( at BB end and conical end) Various content updated; Ordering Information; PPU Quick BA Reference table; Connector Pin Assignments Updated BLN-95-9045 to Technical Information (TI) format; updated AA Part Number Quick Reference table and various content

Rev.

© 2013 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.

Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be made without a ecting agreed speci cations. All trademarks in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the Sauer-Danfoss Group.

2

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Technical Information KPP Pulse Pickup (PPU) Contents Product Overview

Description ....................................................................................................................................................... 4 Features ............................................................................................................................................................. 4 Technical Data ................................................................................................................................................. 4 Theory of Operation ...................................................................................................................................... 5 Improvements ................................................................................................................................................. 6 D Revision (June 1996)............................................................................................................................ 6 E Revision (September 1996) ................................................................................................................ 6 F Revision (June 1999) ............................................................................................................................ 6 G Revision (February 2002) ................................................................................................................... 6 Dimensions .......................................................................................................................................................7 Considerations ................................................................................................................................................ 8 Supply Voltage ........................................................................................................................................... 8 Directional versus Non-directional KPPs .......................................................................................... 8 Housings ...................................................................................................................................................... 8 4-wire KPP.................................................................................................................................................... 8

Ordering Information

Ordering Nomenclature............................................................................................................................... 9 Ordering Nomenclature Codes and De nitions ...............................................................................10 PPU Quick Reference...................................................................................................................................11 Speed Rings ....................................................................................................................................................13

Product Installation

Procedures for Flat End and Conical End Models .............................................................................14 Procedure A .............................................................................................................................................14 Procedure B: ..............................................................................................................................................14 Procedure C ...............................................................................................................................................15 Procedure D ..............................................................................................................................................15 Procedure E ...............................................................................................................................................15 Installation Diagrams ..................................................................................................................................16 System Wiring Guidelines..........................................................................................................................17 Connector Pin Assignments .....................................................................................................................18 Troubleshooting Steps ...............................................................................................................................18

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3

Technical Information KPP Pulse Pickup (PPU) Product Overview Description

The KPP pulse pickup accepts a supply voltage and, in response to the speed of a permanently magnetized speed ring on the motor’s cylinder block or shaft, outputs a digital pulse signal. The output changes its high/low state as the north and south poles of the speed ring pass by the sensor’s face. Because the output is digital, the KPP is ideal for low-speed measurement.

The KPP is designed for rugged outdoor, mobile, or heavy industrial speed-sensing applications that do not allow contact with the rotating shaft. It is custom-designed for Sauer-Danfoss pumps and motors.

Features

Choice of directional or non-directional devices Choice of Delphi/Packard Weather-Pack®, Turck Eurofast® or Deutsch® connectors Rugged housing designed to withstand extreme environments You can order pre-mounted in Sauer-Danfoss pumps and motors You can use with digital or analog controllers Suitable for zero speed measurements

Technical Data

Electrical and Environmental Data Electrical Supply voltage (two ranges) Regulated 4.5 to 8.5 Vdc Maximum operating current

Battery 7 to 32 Vdc

20 mA at 1 Hz and 5 Vdc supply Required current 12 mA at 5 Vdc (no load) Output voltage in high state Supply voltage minus 0.5 Vdc minimum (no load) Output voltage in low state 0.5 Vdc, maximum (no load) Maximum frequency 15 kHz Load 15 kΩ to both ground and supply Peak transient voltage 80 Vdc for 2 milliseconds, 300 Vdc for 2 milliseconds, 200 Vdc for 100 milliseconds, 4.5 to 8.5 Vdc models 7 to 32 Vdc models 7 to 32 Vdc models Peak reverse voltage -15 Vdc continuous, 4.5 to 8.5 Vdc models -32 Vdc continuous, 7 to 32 Vdc models Environmental Operating and storage temperature -40° to 110° C [-40° to 230° F]

4

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11029257

Technical Information KPP Pulse Pickup (PPU) Product Overview Theory of Operation

An external source powers the KPP pulse pickup (PPU). It needs a magnetic eld to pass by its Hall switch(s) to provide a speed signal. The speed ring on the cylinder block has alternately magnetized north and south segments. For the non-directional PPU (KPPX12X), when a north segment is above the Hall switch, the switch output voltage is high, and when a south segment is above the switch, output is low. The digital (on-o on-o ) pulse train feeds to a controller, that interprets its rate of change as a speed.

The direction-sensing PPU (KPPA13X) uses two Hall sensors mounted side-by-side in the same case. With proper orientation, the pulse train output from one sensor leads the other sensor by 90°. A logic circuit decodes the two signals to give a direction indication at the speed output (high or low depending on direction). For quadrature directional signal, the logic is bypassed and the direction signal is phase shifted by a nominal of 90° from the signal A. Refer to Directional Pulse Train, on this page below.

Do not attempt to apply a quadrature output PPU without rst consulting with a Sauer-Danfoss eld applications engineer for speci c application requirements.

The KPPC,D,E models are an improved version of the KPPA12X PPU. It is not necessary to align the ats on its housing with the speed ring for proper speed readings.

Refer to Typical Speed Control, page 13, as an example of a simple closed-loop speed control application for the PPU. Connections for a three and four-wire application, refer to Connection Diagram, page 17.

The KPPXN8Nnn divides the standard signal output by two.

Directional Pulse Train HI

HI

Speed signal B

LOW HI Clockwise rotation

Speed signal B

LOW HI

Direction D

LOW

Counter-clockwise rotation

Direction D

LOW 2189

Quad Directional Pulse Train HI

HI

Speed signal B

LOW HI

HI

Direction D

LOW Clockwise rotation

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11029257

Speed signal B

LOW Direction D

LOW Counter-clockwise rotation

2190

5

Technical Information KPP Pulse Pickup (PPU) Product Overview Improvements

Continuous improvements to reduce environmental e ects of moisture and corrosive liquids found in some mobile environments include: D Revision (June 1996) Use of a potting compound around the lead wires exiting the housing was eliminated.

– The sealing now works like an O-ring: The internal cavity of the housing was lled with a silicone oil.

The wires now pass through a molded rubber piece compressed between two plates.

E Revision (September 1996) Silicone oil was replaced with a rm compound.

External housing was changed to a zinc chromate nish.

F Revision (June 1999) The internal wire to the circuit board joint was modi ed.

A new seal received and the circuit board assembly was improved.

G Revision (February 2002) The housing is now machined from a solid block of aluminum-silicone-bronze.

6

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11029257

Technical Information KPP Pulse Pickup (PPU) Product Overview Dimensions

Common Lead Wire Con guration ( at end) Speed ring

Air gap approximately 1/2 to 1 turns of thread 9/16-18 UNF-2A THD (all models)

1.52 [0.060] maximum

Red White Black

O-ring P/N 9004201-3700 Locking nut P/N K13988

Torque lock nut

Green

t] 57.15 [2.25]

3520

Con guration Used Only for Series 51 and 51-1 Cartridge Motors (conical end) Orientation notch 22.9 [.90]

1.52 [0.060] maximum

Air gap approximately 2-3 turns of thread 9/16-18 UNF -2A THD Speed ring 3521

Non-adjustable Wire Con guration (conical end) 8.99 [0.35] 02.7 [0.11] 45.5 [1.79]

1.52 [0.060] maximum

Speed ring 3522

Dimensions in mm [inches].

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11029257

7

Technical Information KPP Pulse Pickup (PPU) Ordering Information Considerations

When specifying the pulse pickup there are important considerations listed below. For KPP selection see Ordering Nomenclature, page 9 and Part Number Quick Reference, pages 11 to 12.

Supply Voltage You cannot power most KPP models directly from a battery because of the voltage transients (voltage spikes above 15 Vdc) that may cause permanent damage. Battery voltage transients are a common occurrence with 12 or 24 Vdc systems.

Most mobile systems have an alternator that helps ensure a given voltage level but does not prevent against voltage transients. Therefore you must use a separate voltage regulator as the voltage source for the majority of KPP models.

Those applications using a microcontroller can utilize their 5 Vdc regulated power supply to power the KPP models that are rated 4.5 to 8.5 Vdc. It is acceptable when powering the 4.5 to 8.5 Vdc models to use a regulated 15 Vdc maximum.

Directional versus Non-directional KPPs When sensing speed only and supplying the KPP directly from the battery, always specify a KPP model that is rated 7 to 32 Vdc. If you require directional sensing, ensure the supply voltage is regulated.

Housings There are two basic housings at end and conical end. Refer to Dimensions, page 7.

4-wire KPP The 4-wire KPP can be used when only speed sensing is required. For these applications connect to pins A, B, C. Fill the unused cavity (D) with a cavity plug (refer to Common Lead Wire Con guration ( at end), page 7). Use the cavity plug o ered in the 4 pin mating electrical connector kit, which is used with the 4 pin Delphi/Packard Weather-Pack connector (Sauer-Danfoss part umber K03379).

8

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11029257

Technical Information KPP Pulse Pickup (PPU)

KPP

Ordering Nomenclature

X

X

X

X

XX

Hall e ect PPU Revision Mechanical con guration (housing) 1

Flat end

2

Conical end

3

Conical end, xed position

4

Flat end, xed position

Electrical con guration 2

Regulated supply 4.5 to 8.5 Vdc, 3 connection, non-directional, wire fault detection

3

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional, wire fault detection, low current

4

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional, wire fault on speed signal, open collector on direction signal

5

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional wire fault detection, high current, ltered speed output

6

Battery supply 7 to 32 Vdc, 3 connection, non-directional, limited wire fault detection

7

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional, wire fault detection, low current, quad output**

8

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional, wire fault detection, low current, output signal divided by 2

9

Regulated supply 4.5 to 8.5 Vdc, 4 connection, directional, wire fault detection, high current, quad output**

A

Battery supply 7 to 32 Vdc, 4 connection, directional, limited wire fault detection, high current, quad output**

B

Regulated supply 4.5 to 8.5 Vdc, 3 connection, non-directional, wire fault detection, high current, ltered speed output

Electrical connector 1

Amp Mate-n-Lok

4

1

Delphi/Packard Weather-Pack (3 pin)

2

Delphi/Packard Weather-Pack (4 pin), used when direction signal is required

5

Delphi/Packard Metri-Pack

6

Integral Turck Eurofast (no leadwires)

7

1

Deutsch DT04 (3 pin)

2

Deutsch DT04 (4 pin), used when direction signal is required

8

Delphi/Packard Metri-Pack 150 series plug

9

Delphi/Packard Metri-Pack 150 series jack

All leadwire length is described in inches unless denoted with m (meters) Specialties A

Special connector pinouts

B

Special connector pins

**Do not attempt to apply a quadrature output PPU without rst consulting with a Sauer-Danfoss eld applications engineer for speci c application requirements.

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9

Technical Information KPP Pulse Pickup (PPU)

Ordering Nomenclature Codes and De nitions

Mechanical Con guration (Housing) Code 1 2

Description Flat end: Typical use, Sauer-Danfoss Series 90 pump and motor, M46 pump and motor, Series 42 pump (M46 pump pending) Conical end: Typical use, Sauer-Danfoss Series 51 and 51-1 MV cartridge type motor

Electrical Con guration Code 2 3

4

5

6 7 8 9

A B

Description Non-directional: Common, supply voltage 4.5 to 8.5 Vdc, 3 wire connection, speed sensing only with wire fault detection Directional: Common, supply voltage 4.5 to 8.5 Vdc, 4-wire connection, direction and speed sensing with wire fault detection capability on both its speed and direction signals. Can also be used if only speed sensing is required (3 wire connection) Directional: Special, supply voltage 4.5 to 8.5 Vdc, 4-wire connection, directional sensing signal compatible with the standard DC2 digital input lines. Higher current sinking capability and no wire fault detection for the direction signal only which can sink up to 20 mA and source nothing (open collector).

Directional: Special, supply voltage 4.5 to 8.5 Vdc, 4-wire connection, direction and speed sensing with wire fault detection capability on both its speed and direction signals. Capable of driving higher currents from its outputs. Special provision to lter the speed output signal for reducing electromagnetic emissions Non-Directional: Common, supply voltage 7 to 32 Vdc, 3 wire connection, speed sensing only with limited wire fault detection Directional: Special, supply voltage 4.5 to 8.5 Vdc, 4 wire connection, direction and speed sensing with wire fault detection capability, low current, features quadrature (decoded) directional output** Directional: Common, supply voltage 4.5 to 8.5 Vdc, 4 wire connection, direction and speed divided by 2 sensing with wire fault detection capability on both its speed and direction signals Directional: Special, supply voltage 4.5 to 8.5 Vdc, 4 wire connection, high current, direction and speed sensing with wire fault detection capability, high current, features quadrature (decoded) directional output** Directional: Special, supply voltage 7 to 32 Vdc, 4 wire connection, direction and speed sensing with wire fault detection capability, high current, features quadrature (decoded) directional output** Non-directional: Special, supply voltage 4.5 to 8.5 Vdc, 3 wire connection, speed sensing with wire fault detection capability, high current, ltered speed output

**Do not attempt to apply a quadrature output PPU without rst consulting with a Sauer-Danfoss eld applications engineer for speci c application requirements.

Electrical Connector Code Mating connector kit description 4 Delphi/Packard Weather Pack 3 pin shroud Delphi/Packard Weather Pack 4 pin tower, used when directional signal is required 5 Delphi/Packard Metri-Pack 3 pin 6 7 8 9

10

250 - 207

Turck Eurofast 4 pin Deutsch, 3 pin Deutsch, 4 pin, used when directional signal is required Delphi/Packard Metri-Pack 4 pin plug Delphi/Packard Metri-Pack 4 pin jack

11029257

Sauer-Danfoss part number K08620 K03379 K10309 K14956 (straight); K14957 (right angle) K22335 K23511 K22254 K32219

Technical Information KPP Pulse Pickup (PPU)

PPU Quick Reference

KPPG12408

Supply voltage (Vdc) 4.5 to 8.5 7 to 32 X

Application Common Special X

41

KPPG12508

X

X

5

KPPG126 KPPG12703A

X X

X

KPPG12704A KPPG12730A

Material number

Table continues on page 12.

Reference Ordering Nomenclature and Nomenclature Codes and De nitions, pages 9 and 10.

11046858

X

6 71

X X

X X

71 71

KPPG1273MA

X

X

71

KPPG13403 KPPG13408

X X

X

42 42

KPPG13436 KPPG136

X X

X X

42 6

KPPG13703

X

X

72

KPPG13704 KPPG13808

X X

KPPG14408 KPPG146

11029257

X

X

72 8

X X

X X

42 6

KPPG15408

X

X

42

KPPG156 KPPG15824

X X

X X

6 8

X

KPPG16008 KPPG16408

X X

X X

42 41

KPPG16508

X

X

5

KPPG16511 KPPG166

X X

X X

5 6

KPPG16703A KPPG16704A

X X

KPPG16708

X

X

71

KPPG16708B KPPG16719

X X

X

71 71

X X

71 71

KPPG18408 KPPG18708

X X

X

42 72

KPPG197XXB

X

X

71

KPPG22408 KPPG23408

X X

X

41 42

KPPG236

X

X

6

KPPG23703 KPPG23808

X X

X X

72 8

KPPG256 KPPG25808

X X

X

X X

6 8

X

42

KPPG26008

X

KPPG26408 KPPG26508

X X

X X

41 5

KPPG266 KPPG26708

X X

X X

6 71

KPPG26708B

X

X

KPPG26724A KPPG33703*

X

KPPG356* * Conical end, xed position.

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Electrical connector

X X

71 X

71 72

X

6

X

11

Technical Information KPP Pulse Pickup (PPU)

PPU Quick Reference (continued)

Material number

Reference Ordering Nomenclature and Nomenclature Codes and De nitions, pages 9 and 10.

KPPG35708* KPPG35808* KPPG36708* KPPG36708B* KPPG36708B* KPPG456** 11068105 KPPG4A408** KPPG4B724B** * Conical end, xed position. ** Flat end, xed position.

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Supply voltage (Vdc) 4.5 to 8.5 X X

7 to 32

X X X X X X

Application Common

Special X X X X X X X X

Electrical connector 72 8 71 71 72 6 42 71

Technical Information KPP Pulse Pickup (PPU)

Speed Rings

Speed rings vary according to the diameter of cylinder block to which they are attached.

You may order them directly from the pump manufacturer or a Sauer-Danfoss Global Service Partner may retro t them to existing pumps and motors (mounting requires some specialized tooling). Order them using numbers in the following table. Pump and motor listed is typical. Several may use the same speed ring.

Speed Ring Part Numbers Speed ring part number

Pump/motor

Total pole pairs per revolution

KK14701 KK14702

51V060 51V080

45 49

KK14703

51V110

54

KK14704 KK14705

51V160 51V250

61 71

KK14706

M25 & 90P030

43

KK14707 KK14708

90P042 90P055

48 52

KK14709 KK14710

90P075 90P100

58 63

KK14711

90P130

69

KK14712 KK14713

LV25 &42P028 40P046

41 51

KK14714

SMF21089

65

KK14715 KK14716

60/470 60/1048

78 101

KK14717 KK14718

60/1750 60/780

121 93

KK14719

60/606

86

KK14720 KK14721

90P180 90P250

77 85

KK14722 KK14723

42P041 MF035 & 044D

47 46

Typical Speed Control Electrical displacement control (EDC)

Speed ring

Pulse pickup

Microcontroller 1668A

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Technical Information KPP Pulse Pickup (PPU) Product Installation Procedures for Flat End and Conical End Models

Refer to Installation Diagrams, page 16, regarding these procedures.

Procedure A Non-directional KPP at end models. Models included: KPPG12XXX, KPPG16XXX. Installation steps: 1. Turn in (CW) by hand until bottom end gently touches the speed ring.

2. Back out (CCW) 1/2 to 3/4 turn.

3. with an 11/16 inch hex wrench.

Procedure B: Directional KPP at end models. Models included: KPPG13XXX, KPPG14XXX, KPPG15XXX, KPPG18XXX. Installation steps: 1. Turn in (CW) by hand until bottom end gently touches the speed ring.

2. Back out (CCW) 1/4 turn. Continue backing out until the ats are 22° (most open-end wrenches have a 22° o set) either side of pump or motor shaft center line (20° to 30° is acceptable). Do not back out the KPP more than 3/4 of a turn from touching.

3. with an 11/16 inch hex wrench.

4. Special KPP FLAT END models include: KPPG17XXX, KPPG19XXX, KPPG1AXXX. Installation range is application speci c: 5. Turn in (CW) by hand until bottom end gently touches the speed ring.

6. Back out (CCW) 1/4 turn. Continue backing out until the ats are 22° (most openend wrenches have a 22° o set) either side of pump or motor shaft center line (acceptable range is determined per application). Do not back out the KPP more than 3/4 of a turn from touching.

7. with an 11/16 inch hex wrench.

14

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Procedures for Flat End and Conical End Models (continued)

Procedure C Non-directional and Directional KPP conical end models. Models included: KPPG2XXXX. Installation steps: 1. Turn in (CW) by hand until bottom end gently touches the speed ring.

2. Back out (CCW) 2 turns. Continue backing out until the KPP orientation notch is 180±15° to motor shaft center line, (reference Directional Conical End Models, Series 51 and 51-1 Cartridge Motors Only, page 17).

3. with an 11/16 inch hex wrench.

Special KPP CONE END models include: KPPG29XXX. Installation range is application speci c: 1. Turn in (CW) by hand until bottom end gently touches the speed ring.

2. Back out (CCW) 1 turn. Continue backing out until the KPP Orientation Notch is 180° to motor shaft center line, acceptable range is determined per application, (reference Directional Conical End Models, Series 51 and 51-1 Cartridge Motors Only, page 17).

3. Using the 1/2 inch wrench to hold the KPP, torque the lock nut to 13 N·m [10 lbf·ft] with an 11/16 inch hex wrench.

Procedure D When Directional KPP at end models are used for sensing speed only, the same installation steps in Procedure A are acceptable. Models included: KPPG13XXX, KPPG14XXX, KPPG15XXX, KPPG18XXX.

Procedure E Fixed position. Non-directional and Directional KPP conical end models KPP3XXXX and at end models KPP4XXXX. Installation steps: 1. Insert PPU housing; align the hole in mounting ange with mounting hole in block housing.

2.

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Technical Information KPP Pulse Pickup (PPU)

Installation Diagrams

Pulse Pickup Installation

Gap

11/16 hex wrench

To after adjustment Magnetic speed ring

Hold sensor in position while tightening locknut

Speed sensor

12,7 [0.50] Flats 22°

t]

Shaft cernterline 22°

12,7 [0.50] Flats 22°

22° Shaft cernterline

Sensor with Turck Eurofast connector

Sensor with Packard connector

2055A

Directional Conical End Models, Series 51 and 51-1 Cartridge Motors Only

180° ± 15°

Orientation notch Speed sensor

16

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Technical Information KPP Pulse Pickup (PPU)

Installation Diagrams (continued)

Connection Diagram Speed ring S N

S

Red

N S

N SN S NS NS N

Pulse Pickup

Supply voltage Supply 0.5 V

White

Speed

Black

S

N

Green

Supply ground Direction Applies only to direction and quadrature models

S

NS

N

1669C

System Wiring Guidelines

1. Protect all wires from mechanical abuse. Run wire in exible metal or plastic conduits.

2. Separate high current wires such as solenoids, lights, alternators, or fuel pumps from control wires.

3. Run wires along the inside of, or close to metal machine frame surfaces where possible. This simulates a shield, which minimizes the e ects of EMI/RFI radiation.

4. Do not run wires near sharp metal corners. Consider running the wire through a grommet when rounding a corner.

5. Do not run wires near hot machine member or engine exhaust pipes 6. Provide strain relief for all wires.

7. Avoid running wires near moving or vibrating components.

8. Avoid long, unsupported wire spans.

9. Use harness anchors that allow wires to oat rather than rigid anchors.

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Technical Information KPP Pulse Pickup (PPU)

Connector Pin Assignments

3 pin Deutsch Plug DT Series connector

3 or 4 pin Delphi Connector

B Speed

A

Power +

B

Speed

C

Ground

D

Direction

A Power +

C Ground

3524A

3523

4 pin Deutsch® Plug DT Series Connector

4 pin Turck Eurofast connector Keyway ref

Troubleshooting Steps

1 Power +

3 Ground

2 Speed

4 Direction

3525

B Direction

A Power +

C Speed

D Ground 12.7 [0.50] Flats

3526

The following steps require a 1/2 inch open end wrench with standard 22° o set and a Volt Ohm Meter (VOM): 1. Installation First ensure that KPP is installed correctly. There are distinct directional and installation procedures, (reference Procedures for Flat End and Conical End Models, page 14 to 15).

2. Speed Signal Check for speed output using a VOM. Place VOM across the ground and speed pins or terminals, (reference Dimensions, page 7) and set VOM to the DC Volt scale and low range. To check for an output, turn pump or motor very slowly by hand or check output just as the prime mover is coming to a stop. Note a voltage pulse at meter. It will likely be di cult to read exactly, simply note a pulse (approximately. 60 pulses per rev.). If there is no indication of a pulse, replace KPP. 3. Directional Signal Check for a direction signal change using a VOM. Use the same VOM setup as in the above speed signal check. Turn the motor slowly and note a polarity change (±) on the VOM display as you change the motor direction.

18

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Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems

Sauer-Danfoss is a global manufacturer and supplier of highquality hydraulic and electronic components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile o -highway market.

Building on our extensive applications expertise, we work closely with our customers to ensure exceptional performance for a broad range of o -highway vehicles.

We can help speed up system development, reduce costs and bring your vehicles to market faster. Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.

Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps

Go to www.sauer-danfoss.com for further product information.

Orbital Motors PLUS+1™ GUIDE

Wherever o -highway vehicles are at work, so is Sauer-Danfoss.

Proportional Valves Sensors Steering Transit Mixer Drives

Members of the Sauer-Danfoss Group

We o er expert worldwide support for our customers, ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide comprehensive global service for all of our components.

Local address:

Comatrol www.comatrol.com Schwarzmüller-Inverter www.schwarzmueller-inverter.com Turolla www.turollaocg.com

Hydro-Gear www.hydro-gear.com Sauer-Danfoss-Daikin www.sauer-danfoss-daikin.com

250 - 217

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239 6000 Fax: +1 515 239 6618

Sauer-Danfoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444 Fax: +45 7488 4400

Sauer-Danfoss GmbH & Co. OHG Postfach 2460, D-24531 Neumünster Krokamp 35, D-24539 Neumünster, Germany Phone: +49 4321 871 0 Fax: +49 4321 871 122

Sauer-Danfoss-Daikin LTD. Shin-Osaka TERASAKI 3rd Bldg. 6F 1-5-28 Nishimiyahara, Yodogawa-ku Osaka 532-0004, Japan Phone: +81 6 6395 6066 Fax: +81 6 6395 8585

www.sauer-danfoss.com

P164378 - Printable Page

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Rev: 06/20/12

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SP 10-09-001 204 Steering Setup Procedure - Bleeding the system - Adjusting wheel toe

SP 10-09-001 Setting Toe on 204 Machines 2

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Rev: 06/20/12

Base end

Rod end

Line A

Information within this document is the property of Hagie Manufacturing Company. Electronic version is available. All information is subject to change without notice. Information is ONLY valid for 2 days after Print Date. FOR REFERENCE ONLY – UNCONTROLLED COPY Print Date: 8/17/2015 2 of 9

Disconnect

2. With the machine off, disconnect hydraulic Line A from the rod end port of the left steering cylinder.

1. Start with both cylinders fully retracted and the cylinders unpinned from the legs.

If only toe set is to be performed, skip Step 1 and go to Step 2.

has been opened for any reason.

Objective: To bleed any air from the system. This portion of the procedure should be used when replacing a cylinder or when the system

Step 1: Bleeding Steering Arm Cylinders

SP 10-09-001 Setting Toe on 204 Machines 2

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Rev: 06/20/12

Line A

Line A

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Bleed hose

4. Start the machine and slowly turn the steering wheel to the right. The right cylinder will extend. Fluid will flow out of Line A, first with inconsistent flow, becoming consistent but milky. Continue to turn the steering until the fluid has turned from milky to clear.

Bleed hose

3. Connect a bleed hose to the rod end port of the left cylinder and direct the bleed hose and hydraulic Line A, disconnected in Step 2, to an oil catch pan.

SP 10-09-001 Setting Toe on 204 Machines 2

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NOTE: Once these steps are complete both cylinders should be fully extended.

Bleed hose

5. Slowly turn the steering wheel to the left. The left cylinder will extend and fluid will pass through the bleed hose. Continue turning the steering to the left until the fluid flow is consistent and clear

SP 10-09-001 Setting Toe on 204 Machines 2

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9. Reconnect the line to the rod end port of the left steering cylinder.

10. Turn the steering wheel to the right until the steering cylinder is fully retracted.

11. Turn the steering wheel at least 10 more turns to the right.

12. Turn the steering wheel to the left until the steering cylinder is fully retracted.

13. Turn the steering wheel at least 10 more turns to the left.

NOTE: Holding the hose upright over the catch pan at the level of the port and slowly turning the steering wheel a small amount will accomplish this. Make sure the hose end is the highest point of the hose and the port fitting is turned so it is pointed down.

6. Remove the bleed hose from the rod end port of the left cylinder.

7. Loosen the rod end fitting and orient the fitting so it is pointing down.

8. Make sure the line disconnected in Step 2 is full of oil and reconnect the line to the rod end port of the left steering cylinder

SP 10-09-001 Setting Toe on 204 Machines 2

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3. Unpin steering cylinders from legs.

4. Center steering cylinders by measuring distance each cylinder is extended and turning the steering wheel until they both are extended 3.5”.

This may require re-phasing the cylinders.

1. Unfold toolbar to field position 2. Set suspension so front steering cylinders are level

Objective: Make sure machine rigged correctly to set toe

Step 2: Preparing machine for setting toe

SP 10-09-001 Setting Toe on 204 Machines 2

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5. Measure the rim lip from the front of the right wheel to the rear of the left wheel at the height of hub center (distance B4, see Fig 1 below). Measure from the front of the left wheel to the rear of the right wheel at the height of hub center (distance B3). Adjust the wheels until the diagonal measurements are equal.

4. Measure the rim lip from the front of the right wheel to the front of the left wheel at the height of hub center (distance A1, see Fig 1below). Complete a similar measurement at the rear of the wheels (distance A2). Adjust the wheels evenly and double-check measurements until the front and rear width measurements are equal.

3. Visually align the tires from front to rear both right and left sides.

2. Mark this distance on the inner edge of the rim on the front side and back side of both front rims (4 marks total). All measurements will be taken to these marks.

1. Measure the distance from the ground to the center of the hub (all four hubs should measure the same).

Objective: Position the front wheels so they are parallel and square.

Step 3: Align Wheels

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Rear

Front

Rear

Rev: 06/20/12

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With both cylinders extended 3.5”, adjust the tie-rods until they line up with the square and parallel wheels.

Turn the tie rods one more turn such that each wheel will toe in.

Nudge the wheels to align with the tie rods and install the bolts.

Secure main bolt and lock-collar.

Machine should be driven and toe re-checked. a. Front toe = +0.00”, - 0.50” total (toed in) 6. Repeat Step 3: Align Wheels & Step 4: Set Toe for the rear wheels. a. Rear toe = +0.00”, -0.00”

1.

2.

3.

4.

5.

Step 3: Set Toe

6. Continue to cycle between steps 4 and 5 until Then and only then are the wheels both parallel and square (any time a wheel is adjusted all four measurements should be checked).

Front

Figure 1

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Description Initial Release

Revised By T Rosenbloom

Revision 1.0

Rev: 06/20/12

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Date 7/12/12

REVISION LOG

SP 10-09-001 Setting Toe on 204 Machines 2