Hagie Hi-Tractor DTS 10 Sprayer Technical Manual 493617 - PDF DOWNLOAD

5 - DASH / AUTO Covers Machine Serial Numbers: SNU14011515001-200 © 2014-15 Hagie Manufacturing Company. Clarion, Iowa USA

Part No. 493617 Rev. 15C150320

Technical Information 240 - Electrical . ... .. 1 3 250 - Drivetrain............. ...

1-213 370 - Hydraulics................................................................................................................................. 1-4 280 - Solution System ..

1-54

5 - DASH / AUTO

Hagie Manufacturing Patent Decal (Located on the rear left-hand frame)

Any pictures contained within this operator’s manual that depict situations with shields, guards, rails, or lids removed are for demonstration only.

Hagie Manufacturing Company strongly urges the operator to keep all shields and safety devices in place at all times.

1-1

This symbol indicates operator awareness which, if not avoided, may result in personal or property damage.

Hagie Manufacturing Company 721 Central Avenue West P.O. Box 273 Clarion, IA 50525-0273 (515) 532-2861 OR (800) 247-4885 www.hagiehelp.com This symbol indicates a hazardous situation which, if not avoided, will result in serious injury or death.

This symbol indicates a potentially hazardous situation which, if not avoided, could result in moderate/ serious injury or death.

This symbol indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

1-2

Reference to right and left-hand used throughout this manual refers to the position when seated in the operator’s seat facing forward.

Sprayer Engine Identification Plate -Typical View Serial No. _______________________

Hydrostatic Pumps

Sprayer Serial Number -Typical View Serial No. _______________________

Engine

Hydrostatic Pump Identification Plates -Typical View Front _______________________ Rear _______________________

Wheel Motors

1-3

Front Wheel Motor

Rear Wheel Motor

Wheel Motor Identification Plates -Typical View Left Front: ____________________ Right Front: ___________________ Left Rear (w/sensor): _________________ Right Rear (w/o sensor): _______________

Wheel Hubs

Wheel Hub Identification Plate -Typical View _______________________ Right Front _______________________ Right Rear _______________________ Left Front _______________________ Left Rear

1-4

Detail

Description

Specification

A

Overall Machine Height**

• 133”/337.8 cm (from top of cab) • 152”/386.1 cm (from top of boom)

B

Raised Transom Height**

134” (340.4 cm)

C

Transom Lift Range

22.25” - 99.75” (56.5 - 253.4 cm) (77.5”/196.9 cm range)

D

Static Loaded Hub Height**

26” (66 cm)

E

Wheel Base

140” (355.6 cm)

F

Sprayer Length

322” (817.9 cm)

G

Rear Handrail Height

121” (307.3 cm)

H

Width (booms folded, 120” tread)

152”/386.1 cm (from tank to tank)

I

Frame Clearance**

66.5” (168.9 cm)

J

Center Clearance**

64.75” (164.5 cm)

K

Lower Leg Clearance**

20.5” (52.1 cm)

L

Tire (center to inside of lower leg)

14.5”/36.8 cm (rear)

M

Tread Width**

120”-144” (304.8 - 365.8 cm) - adjustable*

Optional

120” - 154” (304.8 - 391.2 cm) - adjustable*

1-5

General Information

Because Hagie Manufacturing Company offers a variety of options, the illustrations in this manual may show a machine equipped other than standard.

Height and weight do not consider options. Values may vary, depending on available equipment.

1-6

Spray System GPS Specifications -If Equipped

Detail

Description

Specification

A

Wheel Base

140” (355.6 cm)

B

Static Loaded Hub Height

26” (66 cm)

C

Overall Sprayer Height (from middle of GPS unit)

138.5” (351.8 cm)

D

Length (from front of boom spray tips to center of GPS unit)

164” (416.6 cm)

E

Length (from center of GPS unit to center of rear hub)

84” (213.4 cm)

1-7

Settings and Calibration

Units

• US (Acres)

• SI (Hectares)

Speed Sensor

• SP1 (Wheel Speed)

• SP2 (Radar/GPS)

Control Type

• Liquid Spray

• Gran 1 (Single Belt Bed)

• Gran 2 (Split Belt Bed/Single Encoder)

• Gran 3 (Split Belt Bed/Dual Encoders)

• Spinner RPM Control

Valve Type

• Standard Valve

• Fast Valve

• Fast Close Valve

• Pulse Width Modulated Valve

• Pulse Width Modulated Close Valve

Section Widths

Meter Cal

Rate Cal

Valve Cal

Tank Volume

Speed Cal 1.

1.

1.

1.

1.

1.

2.

2.

2.

2.

2.

3.

3.

3.

3.

3.

4.

4.

4.

4.

4.

5.

5.

5.

5.

5.

6.

7.

8.

9.

10.

1-8

• Turf (1,000 sq. ft./ 92 sq. m)

Description

Specification Engine

Manufacturer

Cummins®

Model

6BTA 6.7 QSB (turbo charged)

Type

In-Line, Liquid Cooled

Number of Cylinders

6

Displacement

6.7 Liter (408.9 c.i.)

Horse Power

215 (intermittent)

Fuel Type

No. 1 or 2 Diesel

Fuel System

Filtered, Direct-Injected

Air Cleaner

Dry-Type, Dual Element

Slow Idle

800 RPM

Fast Idle

2720 RPM (no load)

Power Train Hydrostatic Pump

Danfoss Tandem 90-Series

Range

132cc (66x2), Limited Stroke (variable displacement)

Drive Train

All-Time 4-Wheel Drive

Speed (depending on tire size) • Low • Medium • High

• 0-14 mph (0-22 km/h) • 0-18 mph (0-30 km/h) • 0-28 mph (0-45 km/h)

Hydrostatic Wheel Motor (Front/Rear)

Danfoss M46

Final Drives • Type - Front/Rear • Lubrication

• Planetary Gear Reduction Hubs • Torque Hub® 7000-Series (7HBA and 7HBX) • Oil Bath

Brakes • Type

Integral, Spring-Applied, Hydraulically Released

Steering • Type • Control • Steering Cylinders • Turning Radius (120”/304.8 cm tread setting)

• Hydraulic, Priority on Demand • Full-Time Power • Self-Centering, Double Action • 19.5” (49.5 cm)

Auxiliary Hydraulic System Type

Open

Pump Type

Tandem Gear

1-9

Pressure Setting

2600 PSI (179.3 bar)

Spray System Booms • Type • Standard • Optional • Controls • Hydraulic Level Shock Absorber

• Dry (with variable row spacing) • 60-ft. (3 spray sections) • 60/80-ft. or 90-ft. (5 spray sections) • Electro-Hydraulic, Fold/Lift/Level • Boom Level Accumulator

Hoses • Rear Fill Connection (Male w/Female Adapter) • Solution Hose from Tank • Boom Section Feeder Hose • Boom Nozzle Hose

• 2” (5.1 cm) I.D. • 1.5” (3.8 cm) I.D. • 1” (2.5 cm) I.D. • .75” (1.9 cm) I.D.

Solution Tanks • Standard

• (2) 500 Gallon (1892 L) Polyethylene Tanks with Sight Gauge • Mechanical, Hydraulically Driven w/Variable Speed Control

• Agitation General Spray System • Pump

• Centrifugal, Hydraulically Driven with Variable Speed Control • Electric Ball Valves • Glycerin Filled (100 PSI/6.9 bar) • Raven 4600 (GPS ready) • Standard

• Solution Valves • Pressure Gauge • Monitor • Fence Row Nozzle

Foam Marker System Make

Hagie Foam Marker

Type

Live Air

Rinse System Spray System Rinse (Solution Tanks, Pump, Booms)

Standard

High-Pressure Wash System

Optional

Electrical System General Electrical System • Battery • Alternator • Starter

• Single 12V, Negative Ground • 130 AMP, Voltage Regulated • 12V with Solenoid

Circuit Breakers • Main Breaker • Starter Relay • Highway/Field Lights • Work Lights • Foam Marker/Switch Panel Auxiliary Power • A/C and Storage Console Auxiliary Power • Engine

• 100 AMP • 30 AMP • 40 AMP • 30 AMP • 30 AMP • 30 AMP • 125 AMP (2x)

1-10

Fuses • Rinse System Power/Gauges • Hydraulic Tread Adjust/Seat • Spray Solution Valves • Flow Control/Agitation/Boom Folding Controls • Fuel/Brake • AM/FM Radio • CB Radio Power Supply/Dome Light • Tank Solution Valves/Rinse System Control • Hazard/Warning Lights, Turn Signals, Wiper • Boom Lift/Level Controls

• 10 AMP • 20 AMP • 10 AMP • 10 AMP • 15 AMP • 10 AMP • 10 AMP • 10 AMP • 10 AMP • 15 AMP

Lights • Front Cab • Rear Cab • Booms • Tank Shields

• (4) Trapezoidal Field Lights • (2) Trapezoidal Work Lights • (2) Trapezoidal Work Lights (1 each) • (2) Trapezoidal Highway Lights (1 each)

Auxiliary Power Supplies • Switch Panel

12V Binding Post-Type

Cab and Instruments General Cab

• Tilt Steering • Windshield Wipers/Washer • Flashing Hazard Warning Lights • Turn Signals • Side Mirrors • Dome Light • Tinted Glass

Temperature Control

Full Range

A/C Charge Type

R-134a

Fresh Air Filtration

Paper and Charcoal Filters

Seat (Air Ride w/Adjustment)

• Fore-Aft • Seat Cushion • Backrest • Height • Lumbar • Ride Firmness • Armrest Tilt

Storage

• Right Armrest/Control Station • Floor-Mounted Storage Console

1-11

Instruments • Dial Gauges

• Digital Gauge

• Engine Air Filter Restriction Monitor • Stereo

• Hour Meter • Fuel • Temperature • Alternator • Oil Pressure • Speedometer (MPH-km/h) • Tachometer (RPM) • Engine Warnings • Filter Minder • AM/FM Stereo/CD Player (w/dual speakers)

Fluid Capacities Solution Tanks (2)

500 Gallons (1892 L)/each

Fuel Tanks (2)

50 Gallons (189.3 L)/each, No. 1 or 2 diesel

Cooling System

10 Gallons (37.9 L), ethylene glycol

Hydraulic Reservoir

25 Gallons (94.6 L), anti-wear hydraulic oil

Rinse System Tank

55 Gallons (208.2 L)

Foam Marker Tank (if equipped)

36 Gallons (136.3 L)

Engine Oil Pan (including filter)

17 Quarts (16.1 L), SAE 15W-40

Engine Oil Dipstick (L-H mark)

2 Quarts (1.9 L)

Torque Hub (4)

23 oz. (.7 L)/each - approximate, 75W-90

1-12

TIRE SPECIFICATIONS (STANDARD) Size

Make

Model

Load Rating (Weight/ Speed)

Air Pressure (Max PSI)

Tread Width (inches)

Load Capacity (lbs.)

Overall Diameter (inches)

Static Load Radius* (inches)

Rolling Circum. (inches)

Gross Flat Plate (in2)

290/95R34

Goodyear®

DT730

131A8/B

35

11.1

4,300

55.4

25.4

167

N/A

320/85R34

Michelin®

Agribib

133A8/ 130B

35

13.2

4,540

55.9

25.6

167

175

320/85R34

Goodyear

Dyna Torque

133A8/B

35

12.6

4,540

55.4

25.8

167

N/A

320/85R34

Firestone®

9000 R-1W

133A8/B

35

12.4

4,540

55.4

25.7

167

160

TIRE SPECIFICATIONS (METRIC) Size

Make

Model

Load Rating (Weight/ Speed)

Air Pressure (Max Bar)

Tread Width (cm)

Load Capacity (kg)

Overall Diameter (cm)

Static Load Radius* (cm)

Rolling Circum. (cm)

Gross Flat Plate (cm 2)

290/95R34

Goodyear®

DT730

131A8/B

2.4

28.2

1,950

140.7

64.5

424.2

N/A

320/85R34

Michelin®

Agribib

133A8/ 130B

2.4

33.5

2,059

142.0

65.0

424.2

1,129

320/85R34

Goodyear

Dyna Torque

133A8/B

2.4

32.0

2,059

140.7

65.5

424.2

N/A

320/85R34

Firestone®

9000 R-1W

133A8/B

2.4

31.5

2,059

140.7

65.3

424.2

1,032

* Static load radius is suggested and will vary with load.

1-13

TIRE LOAD LIMITS (LBS) AT VARIOUS COLD INFLATION PRESSURES (PSI) Inflation (psi)

6

9

12

15

17

20

23

26

29

35

290/95R34

Goodyear DT730

1,650

2,040

2,340

2,680

3,000

3,300

3,640

3,860

4,080

4,300

320/85R34

Michelin Agribib

N/A

2,150

2,470

2,835

3,200

3,530

3,860

4,080

4,300

4,540

320/85R34

Goodyear Dyna Torque

1,760

2,150

2,470

2,830

3,200

3,520

3,860

4,080

4,300

4,540

320/85R34

Firestone 9000 R-1W

1,760

2,150

2,470

2,830

3,200

3,520

3,860

4,080

4,300

4,540

TIRE LOAD LIMITS (KG) AT VARIOUS COLD INFLATION PRESSURES (BAR) Inflation (bar)

.4

.6

.8

1.0

1.2

1.4

1.6

1.8

2.0

2.4

290/95R34

Goodyear DT730

748

925

1,061

1,215

1,360

1,496

1,651

1,750

1,850

1,950

320/85R34

Michelin Agribib

N/A

975

1,120

1,285

1,451

1,601

1,750

1,850

1,950

2,059

320/85R34

Goodyear Dyna Torque

798

975

1,120

1,283

1,451

1,596

1,750

1,850

1,950

2,059

320/85R34

Firestone 9000 R-1W

798

975

1,120

1,283

1,451

1,596

1,750

1,850

1,950

2,059

1-14

Hagie Manufacturing Company Product Warranty Hagie Manufacturing Company warrants each new Hagie product to be free under normal use and service from defects in workmanship and materials for a period of lesser of: two (2) years or 1,000 hours from the date of delivery on all Agricultural Products. Hagie Manufacturing Company makes this warranty from the original delivery date and is transferable to a purchaser from the original purchaser of this equipment, given there is remaining time left under the year and hour warranty standard stated above. This warranty shall be fulfilled by repairing or replacing free of charge any part that shows evidence of defect or improper workmanship, provided the part is returned to Hagie Manufacturing Company within thirty (30) days of the date that such defect or improper workmanship is discovered, or should have been discovered. Labor to repair said items will be covered by standard labor time rates. Freight charges of defective parts are not covered by this warranty and are the responsibility of the purchaser. No other express warranty is given and no affirmation of Hagie Manufacturing Company, by words or action, shall constitute a warranty.

Hagie Manufacturing Company limits its warranty to only those products manufactured by Hagie Manufacturing Company and does not warrant any part or component not manufactured by Hagie Manufacturing Company, such as parts or components being subject to their manufacturer’s warranties, if any. Excluded from this warranty are parts subjected to accident, alteration, or negligent use or repair. This warranty does not cover normal maintenance such as engine tune ups, adjustments, inspections, nor any consumables such as tires, rubber products, solution system valves, wear parts, wiper blades, etc.

Hagie Manufacturing Company shall not be responsible for repairs or replacements which are necessitated, in whole or in part; by the use of parts not manufactured by or obtainable from Hagie Manufacturing Company nor for service performed by someone other than Hagie authorized personnel, unless authorized

by Hagie Manufacturing Company. Customer acknowledges that it is not relying on Hagie Manufacturing Company’s skill or judgment to select finish goods for any purpose and that there are no warranties which are not contained in this agreement.

In no event shall Hagie Manufacturing Company’s tort, contract, or warranty liability exceed the purchase price of the product. The foregoing limitation will not apply to claims for personal injury caused solely by Hagie Manufacturing Company’s negligence.

Hagie Manufacturing Company shall not be liable for damages, including special, incidental or consequential damages or injuries (damage and repairs of equipment itself, loss of profits, rental or substitute equipment, loss of good will, etc.) arising out of or in connection with performance of the equipment or its use by customer, and Hagie Manufacturing Company shall not be liable for any special, incidental or consequential damages arising out of or in connection with Hagie Manufacturing Company’s failure to perform its obligation hereunder. HAGIE MANUFACTURING COMPANY’S ENTIRE LIABILITY AND THE CUSTOMER’S EXCLUSIVE REMEDY SHALL BE REPAIR OR REPLACEMENT OF PARTS COVERED UNDER THIS WARRANTY. THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

1-15

Do Not Bypass Safety Start Switch

Use Caution While Driving

5 - DASH / AUTO

This machine is designed for and intended to be used for the application of chemicals and fertilizers to field crops.

Use in any other way or for any other purpose is considered misuse of this machine.

2-1

Avoid Heating Near Pressurized Lines

Handle Fuel Safely

Keep Riders Off Machine

Remove Paint Before Welding or Heating

2-2

Operate Safely

Be Prepared

�

Wear Protective Clothing

2-3

Protect Against Noise

• While transporting or waiting for medical attention, apply compresses of iced water or immerse affected area in iced water. DO NOT ALLOW TISSUE TO FREEZE. • Do not apply creams or ointments until you have been seen by a physician.

If acid is swallowed: • Do NOT induce vomiting.

• Drink large amounts of water.

• Seek medical attention immediately!

• Do not neutralize the acid.

If fumes are inhaled:

Battery Acid Accident Prevention

• Move the person into fresh air.

• Do not give artificial respiration to a person that is able to breath on their own.

• Give CPR only if there is no breathing and no pulse.

• Seek medical attention immediately!

Handle Agricultural Chemicals Safely

Make sure to: • Fill batteries in a well ventilated area.

• Wear Personal Protective Equipment (PPE) when servicing a battery.

• Avoid breathing in the fumes when recharging with electrolyte.

• Avoid spilling or dripping electrolyte.

• When charging a battery, connect positive cable to positive terminal and negative cable to negative terminal. Failure to comply may result in an explosion and/or personal injury.

If you spill on yourself: • Flush affected area with cold water and remove contaminated clothes and shoes immediately.

Continue to flush the area for a minimum of 15 minutes.

• Call a physician.

2-4

General Maintenance Safety

Safe Hydraulic Maintenance

Tread Width -If Equipped

Beware of Exhaust Fumes Spray Booms

2-5

The Emergency Exit Tool is a permanent fixture of the machine. Do not remove from cab under any circumstances.

Seat Belt Operation

Emergency Exit Tool (Located on rear left-hand side of cab) -Typical View

Do not look directly at the glass when using the Emergency Exit Tool. Failure to comply may result in personal injury.

2-6

650210 (3) - Located on each NORAC® sensor -If Equipped

Safety Decal Locations 650175 (Located on rear left-hand cab window)

650296 (Located near battery)

650336 (Located on right-hand cab window) 650176 (Located on front left-hand cab window)

650337 (Located on right-hand cab window)

2-7

650339 (Located near steering column)

650348 (Located on air tank)

650350 (Located above booster terminals on rear mainframe)

650340 (Located near side console)

650367 (Located near top of hydraulic oil reservoir)

650347 (Located near engine on left-hand side of machine)

650372 (Located on rear mainframe near battery disconnect switch)

2-8

650831 (Located near side console)

650847 (Located on exterior rear left-hand side of cab)

650849 and 650954 (2) - Located on top of each fuel tank

650850 (2) - Located on top of each solution tank

650851 (Located on rear left and right-hand mainframe)

650852 (Located on cab storage console lid)

650981 (Located near radiator)

2-9

Lateral Isolator (3)

3

9

Ride Firmness Adjustment (4) 1

8 4

2 7 3

6 4

5

Fore-Aft Adjustment (5)

1

Height Adjustment (2)

5 - DASH / AUTO

Seat Cushion Adjustment (1)

5

Fore-Aft Isolator (6)

6 2

3-1

Backrest Adjustment (7) Front Console

7

Steering Column Tilt Adjust

Armrest Tilt Adjustment (8) Ensure the steering wheel and steering column are locked into place before operating the machine. Failure to comply may make it difficult to maintain control of the machine.

8

To adjust the steering column:

Lumbar Adjustment (9)

9

Seat Belt

3-2

Tilt Lock Lever (Located on the right-hand side of steering column) -Typical View

-Typical View

Steering Column Release Pedal (Located on the lower left-hand side of steering column) -Typical View

-Typical View

Steering Column Release Pedal Turn Signals

To release the steering column:

3-3

Side Console

• Turn Signal Indicators • Turn Signal Lever

Turn Signal Lever and Indicators (Located at top of steering column) -Typical View

Master Spray Switch

Master Spray Switch (Located on the lower right-hand side of steering column) -Typical View

3-4

Hydrostatic Drive Control Handle

Hydrostatic Drive Control Handle (Located near the side console) -Typical View

Speed Range Switch (Located near the Hydrostatic Drive Control Handle) -Typical View

Side Console Adjustment Lever

Speed Range Switch (High/Medium/Low)

3-5

Low Hydraulic Oil Indicator

Shut down the engine immediately if the low hydraulic oil indicator light illuminates. Failure to comply may result in severe system damage.

Console Adjust Lever (Located near Hydrostatic Drive Control Handle) -Typical View Low Hydraulic Oil Indicator (Located on the side console) -Typical View

Master Spray Indicator

-Typical View

Master Spray Indicator (Located on the side console) -Typical View

3-6

Boom Solution Valve Switches

Parking Brake Switch

The Parking Brake is not intended for normal or emergency stopping.

Boom Solution Valve Switches (Located on the side console) -Typical View

Fence Row Switch

Fence Row Switch (Located on the side console) -Typical View

Parking Brake Switch (Located on the side console) -Typical View

Solution Tank Valve Switches

3-7

Boom Fold Switches • Left Tank

• Right Tank

Solution Tank Valve Switches - Left/Right (Located on the side console) -Typical View

Rinse Switch

Boom Fold Switches (Located on the side console) -Typical View

Ignition Switch

Rinse Switch (Located on the side console) -Typical View

3-8

Agitation Valve Switch

Ignition Switch (Located on the side console) -Typical View

Agitation Valve Switch (Located on side console) -Typical View

Throttle Switch

Throttle Switch (Located on side console) -Typical View

Solution Pump Switch

Solution Pump Switch (Located on side console) -Typical View

3-9

Hydraulic Tread Adjust Switches

Fuel Tank Selector Switch

Stay clear. Ensure there are no bystanders nearby when adjusting tread width. Failure to comply may result in serious injury or death.

Never adjust the hydraulic tread width on a public roadway. Ensure the machine is on level ground where there are no ditches or valleys to interfere while you perform the adjustment.

Fuel Tank Selector Switch (Located on side console) -Typical View

Hydraulic Tread Adjust Switches (Located near side console - open armrest to access) -Typical View

3-10

Power Ports

Overhead Monitors and Controls

Interior Work Light

Power Port - Binding Post (Located on the side console) -Typical View

Interior Work Light (Located on cab headliner) -Typical View

Stereo/Radio

Power Port - Storage Console (Located on lower storage console on the left-hand side of operator’s seat) -Typical View

3-11

Air Conditioner Switch

Air Vents Stereo/Radio (Located on cab headliner) -Typical View

Climate Controls

• Fan Blower Speed

• Temperature Setting

Air Vents -Typical View • A/C Switch

Climate Controls (Located on cab headliner) -Typical View Fan Blower Speed

Temperature Setting

3-12

Windshield Wiper/Washer

• Low Fuel Indicator Light

Windshield Wiper/Washer Switch (Located on cab headliner) -Typical View

Fuel Gauge (Located near the side console) -Typical View

Engine Monitor

Immediately reduce engine speed and shut ignition off if any red indicator lights appear on the engine monitor.

Determine cause and correct issue before continuing operation.

Fuel Gauge

3-13

Lights Hazard/Warning Lights

Engine Monitor (Located near the side console) -Typical View

Spray System Console

Hazard/Warning Lights Switch (Located on cab headliner) -Typical View

Highway Lights

Spray System Console (Located near the side console) -Typical View

3-14

Highway Lights (Mounted on the center of each front tank shield) -Typical View

Highway Lights Switch (Located on cab headliner) -Typical View

Field Lights (Mounted on the front of cab) -Typical View

Field Lights Switch (Located on cab headliner) -Typical View

Field Lights

3-15

Running Lights

Work Lights Switch (Located on side console) -Typical View

Running Lights (Located on rear of machine) -Typical View

Work Lights

Work Lights (Located on the transom mount and rear of cab) -Typical View

3-16

®

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, and chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Cold Start Procedure

Use of starting fluid is not recommended.

5 - DASH / AUTO

CALIFORNIA PROPOSITION 65 WARNING WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects or other reproductive harm.

Start engine from the operator’s seat only. When running the engine in a building, ensure there is adequate ventilation.

Cold oil may not flow in quantities adequate to prevent pump cavitation.

Pre-Operational Checklist

4-1

CANtrak Engine Monitor (Located near the operator’s station) -Typical View * Start-up screen shown

When using jumper cables to start the engine, make sure to connect the cables in parallel - positive (+) to positive, and negative (-) to negative. When using an external electrical source to start the engine, turn the Battery Disconnect Switch to the OFF position. Remove key before attaching jumper cables to prevent unintentional starter engagement.

Immediately reduce engine speed and shut off ignition if any red warning indicator lights illuminate. Determine cause and correct before continuing operation.

4-2

To Lock/Unlock the Monitor

• Engine Speed

• Vehicle Speed

• Oil Pressure

• Coolant Temperature

Quad-Mode -Typical View

• Tri-Mode

• Uni-Mode

• Quad-Mode

• Contrast-Mode

• Active Alarm

Button Bar -Typical View

Active Alarm -Typical View

Configuration Menu

Tri-Mode • Total Engine Hours

• Systems Voltage

• Fuel Rate

Configuration Menu -Typical View

Tri-Mode -Typical View

Uni-Display

Hydrostatic Drive Components

Uni-Mode -Typical View

Active Alarm

4-3

Drive System Control

Diesel Engine -Typical View

Hydrostatic Pumps (Front/Rear) -Typical View

Speed Range

Wheel Motor -Typical View

Wheel Hub -Typical View

4-4

Throttle Switch (Located on side console) -Typical View

Speed Range Switch (Located near the Hydrostatic Drive Control Handle) -Typical View

Parking Brake

Throttle Switch

Never operate the machine at anything less than full recommended throttle.

The Parking Brake is not intended for normal or emergency stopping.

4-5

Parking Brake Switch (Located on the side console) -Typical View

4-6

Low Hydraulic Oil Indicator (Located on the side console) -Typical View

5 - DASH / AUTO

-If Equipped

Stay clear. Ensure there are no bystanders nearby when adjusting tread width. Failure to comply may result in serious injury or death.

Shut down the engine immediately if the low hydraulic oil indicator light illuminates. Failure to comply may result in severe system damage.

Never adjust the hydraulic tread width on a public roadway. Ensure the machine is on level ground where there are no ditches or valleys to interfere while you perform the adjustment.

5-1

Always adjust tread width between 1 and 2 mph (1.6 and 3.2 km/h).

Hydraulic Tread Adjust Switches (Located near the side console - open armrest to access) -Typical View

To Adjust Hydraulic Tread Width

If adjusting the front and rear legs independently, do not allow the difference between the two to become greater than 2 inches (5 cm) according to the tread width indicators. Failure to comply may result in machine damage See the following illustrations for correct and incorrect adjustment examples.

Correct Adjustment

5-2

Incorrect Adjustment

Tread Width Indicator (Located on each leg) -Typical View

To Recalibrate Toe-In

5-3

CALIFORNIA PROPOSITION 65 WARNING WARNING: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer and birth defects or other reproductive harm.

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, and chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Battery Access (Located on the rear right-hand side of machine - open hood to access) -Typical View

5 - DASH / AUTO

Charging

Disconnect the battery when servicing any part of the electrical system. Failure to comply may result in personal injury and property damage.

Access

6-1

Replacement

Storage

Auxiliary Battery Charging Posts (Located on the rear mainframe) -Typical View

To ensure sufficient electrical contact, battery terminal connections should be as clean and tight as possible.

Do not use the Battery Disconnect Switch as a safety device when performing work to the electrical system.

Disconnect the negative battery cable before servicing.

Cleaning

6-2

-Typical View * May vary depending on available equipment

Battery Disconnect Switch (Located on the rear mainframe) -Typical View

Circuit Breakers

Fuses

-Typical View Fuse Panel (Located on the right-hand side of the operator’s seat) -Typical View

6-3

* May vary depending on available equipment

Wire Harness Circuit Breaker

If it becomes necessary to remove a relay:

Main Circuit Breaker (Mounted on engine) -Typical View

Circuit Relays

-Typical View

-Typical View

6-4

Hydraulic and electrical control systems are optimized for use of the spray boom attachment. Any modification to these systems may lead to unintended and uncontrolled motion. DO NOT install add-on control systems that are not approved by Hagie Manufacturing Company.

When operating or positioning the booms, observe the following safety precautions. Failure to comply may result in injury or equipment damage.

Power Lines

5 - DASH / AUTO

• Do not unfold/fold boom extensions while main boom is in cradle.

• Do not operate machine with one boom out of cradle and the other boom in cradle.

• Ensure booms are folded and in cradle before transporting the machine.

When operating or positioning the booms, observe the following safety precautions: • Monitor both sides of the boom during fold procedure.

• Cradle booms when leaving the machine unattended.

• Ensure booms are folded when cradled.

• Select a safe area before unfolding/folding the booms.

• Clear area of personnel.

• Check for overhead obstructions.

• Do not unfold/fold booms near power lines.

Contact with power lines can result in serious injury or death.

• Spray equipment is designed for FIELD USE ONLY. Do not attempt to use machinery for anything other than it’s intended purpose.

7-1

Lift

-Typical View

Lift Cylinder -Typical View

Level

• Transom Raise Switch

• Transom Lower Switch

Transom Raise/Lower Switches (Located on the Hydrostatic Drive Control Handle) -Typical View

7-2

-Typical View

• Press to increase boom angle

Unfolding/Folding

• Press to decrease boom angle

-Typical View To Unfold/Fold Booms:

Left/Right Boom Level Switches (Located on the Hydrostatic Drive Control Handle) -Typical View

Boom Fold Switches (Left/Right) (Located on the side console) -Typical View Level Cylinder -Typical View

7-3

Boom Breakaway Mount Cylinder -Typical View

Boom Extension Switch (Located on the side console) -Typical View

Spray Boom Extensions

-Typical View To Unfold/Fold Boom Extensions:

Both of the left and right boom extension cylinders are activated when the Boom Extension Switch is pressed.

Boom Extension Cylinder -Typical View

Cradling the Booms

7-4

To Cradle the Booms:

Lower boom level until full weight of boom is resting in cradle -Typical View

80-ft. to 60-ft. Boom Conversion Raise boom level until it clears outer cradle stop -Typical View

7-5

To Convert an 80-ft. Boom to a 60-ft.

Boom:

-Typical View

Ensure outer boom extension is in the locked position when folded. Failure to comply may result in property damage.

Lock Pin (Located near the rear of each folded boom extension) -Typical View

7-6

Solution Tanks (2)

Solution Pump Switch

Solution Tank (Located on each side of machine) -Typical View

Solution Pump

Solution Pump Switch (Located on side console) -Typical View Solution Pump (Located near front of machine) -Typical View

Flow Meter

7-7

-Typical View

Flow Meter (Located on the right-hand side of machine) -Typical View

Pressure Gauge

Solution Tank Valves (Located near front of machine) -Typical View

Solution Tank Valve Switches

Pressure Gauge (Located on transom) -Typical View

Solution Tank Valves

7-8

• Left Tank

• Right Tank

Solution Tank Valve Switches - Left/Right (Located on the side console) -Typical View

Agitation Valve Switch

Agitator Motor (Located behind each solution tank) -Typical View

• Set Knob

• Adjustment Lever

-Typical View Agitation Valve Switch (Located on side console) -Typical View

Boom Solution Valve Switches

Agitator Motor

7-9

Master Spray Switch

Boom Solution Valve Switches (Located on the side console) -Typical View

Boom Solution Valve Indicators

• Left Fence Row Indicator

• Spray Section Indicators

• Right Fence Row Indicator

Boom Solution Valve Indicators (Located on transom) -Typical View

7-10

Master Spray Switch (Located on the lower right-hand side of steering column) -Typical View

Master Spray Indicator (Located on the side console) -Typical View

The Solution System has been tested using RV-type antifreeze. Fill solution tank with fresh water and drain before initial use.

Spray System Console Never attempt to operate the spray system without solution in the tanks.

Failure to comply will cause severe equipment damage and will void the warranty.

Getting Started

Spray System Console (Located near the side console) -Typical View

7-11

Do not allow the Solution Pump to run continuously while the Boom Solution Valve Switches are off. Failure to comply will generate overheating, causing severe pump damage and will void the warranty.

Agitation Valve Switch (Located on side console) -Typical View

Solution Pump Switch (Located on side console) -Typical View

• Left Tank

• Right Tank

Solution Tank Valve Switches - Left/Right (Located on the side console) -Typical View

• Press the Agitation Valve Switch in the UP position to turn ON. • Press the Agitation Valve Switch in the DOWN position to turn OFF.

7-12

Master Spray Switch (Located on the lower right-hand side of steering column) -Typical View

Master Spray Indicator (Located on the side console) -Typical View

Fence Row Switch (Located on the side console) -Typical View

Boom Solution Valve Switches (Located on the side console) -Typical View

Fence Row Indicators (Located on transom) -Typical View

60-ft. Spray Boom To Operate the Fence Row Nozzles

7-13

• Left Tank

• Right Tank

80/90-ft. Spray Booms

Solution Tank Valve Switches (Located on the side console) -Typical View

• Tank Fill Valve

Wear the appropriate clothing and Personal Protective Equipment (PPE) when working with agricultural chemicals. Do not store chemicalsoaked clothing inside the cab.

• Fill Port Cap

-Typical View

Front Fill -If Equipped

Rear Fill

7-14

• Solution Tank Fill Port

Rear Fill Assembly (Located beneath rear of machine) -Typical View

• Right Tank Fill Valve

-Typical View

• Left Tank Fill Valve

Tank Fill Valves (Located beneath rear of machine) -Typical View

Select a safe area to rinse the spray system and clean the sprayer where chemicals will not drift off to contaminate people, animals, vegetation, or water supply.

7-15

Step 1 - Rinsing the Solution Tank and Fill Lines Never attempt to operate the Rinse System without fresh water in the rinse tank. Failure to comply will result in equipment damage and will void the warranty.

Fill rinse tank with fresh water only.

Solution Tank Valve Switches - Left/Right (Located on the side console) -Typical View

Rinse System Components

A

B Solution Pump Switch (Located on side console) -Typical View

D G F C E

7-16

• Press and hold the Rinse Switch in the UP position to rinse the RIGHT solution tank.

• Press and hold the Rinse Switch in the DOWN position to rinse the LEFT solution tank.

• Release the Rinse Switch when rinsing is complete.

Rinse Switch (Located on side console) -Typical View

Master Spray Switch (Located on the lower right-hand side of steering column) -Typical View

Step 2 - Rinsing the Boom and Nozzles

Solution Tank Valve Switches - Left/Right (Located on the side console) -Typical View

Solution Pump Switch (Located on side console) -Typical View

7-17

F I E D

Boom Solution Valve Switches (Located on side console) -Typical View

C

H G B

A

- If Equipped

Foam Marker Operation

Maximum foam regulator pressure is 20 PSI (1.4 bar). Use of higher pressure may cause personal injury and system damage and will void the warranty.

Drain wet tank daily to avoid contamination.

Foam Marker Components

7-18

• Move the Foam Marker Switch LEFT if foam application is desired from the left foam drop.

• Move the Foam Marker Switch RIGHT if foam application is desired from the right foam drop.

• Move the Foam Marker Switch to the mid (center) position to turn OFF.

Pressure Adjustment

Foam Marker Switch (Located on the Hydrostatic Drive Control Handle) -Typical View

Foam Pressure Dial (Located near the rear left-hand side of machine -Typical View

Filling the Foam Tank

Do not stand directly over or in front of valves when opening. Failure to comply may result in serious injury.

Foam Marker Pressure Gauge (Located near the rear left-hand side of machine -Typical View Shut engine OFF and relieve system pressure before performing any service or refilling the foam tank.

7-19

• Ball Valve • Relief Valve

• Tank Level Sight Gauge

Foam Tank -Typical View

Nozzle Selection

7-20

Example of how to choose the proper nozzle:

GPM =

GPA x MPH x Nozzle Spacing 5940 (Constant)

l/min =

l/ha x km/h x Nozzle Spacing 60,000

Examples:

GPM =

22.6 x 10 x 20 5940

l/min =

= 4520 5940

211.3 x 16 x 50 60,000

= 0.76 GPM (per nozzle)

= 169040 60,000

= 2.82 l/min

7-21

English to Metric Conversion • Gallons per Acre (GPA) x 9.354 = Liters per Hectare (l/ha) • Gallons per Minute (GPM) x 3.785 = Liters per Minute (l/min)

Metric to English Conversion • Liters per Hectare (l/ha) x .1069 = Gallons per Acre (GPA) • Liters per Minute (l/min) x .26 = Gallons per Minute (GPM)

7-22

Standard Application Rate Chart Gallons per Acre (GPA) - 15” Nozzle Spacing Tip Cap.

Liquid Pressure (PSI)

Cap. 1 Nozzle (GPM)

Cap. 1 Nozzle (Oz./ Min.)

4

6

8

10

12

14

16

18

20

01

15 20 30 40 50 60 75 90

0.061 0.071 0.087 0.10 0.11 0.12 0.14 0.15

7.8 9.1 11 13 14 15 18 19

6.0 7.0 8.6 9.9 10.9 11.9 13.9 14.9

4.0 4.7 5.7 6.6 7.3 7.9 9.2 9.9

3.0 3.5 4.3 5.0 5.4 5.9 6.9 7.4

2.4 2.8 3.4 4.0 4.4 4.8 5.5 5.9

2.0 2.3 2.9 3.3 3.6 4.0 4.6 5.0

1.7 2.0 2.5 2.8 3.1 3.4 4.0 4.2

1.5 1.8 2.2 2.5 2.7 3.0 3.5 3.7

1.3 1.6 1.9 2.2 2.4 2.6 3.1 3.3

1.2 1.4 1.7 2.0 2.2 2.4 2.8 3.0

015

15 20 30 40 50 60 75 90

0.092 0.11 0.13 0.15 0.17 0.18 0.21 0.23

12 14 17 19 22 23 27 29

9.1 10.9 12.9 14.9 16.8 17.8 21 23

6.1 7.3 8.6 9.9 11.2 11.9 13.9 15.2

4.6 5.4 6.4 7.4 8.4 8.9 10.4 11.4

3.6 4.4 5.1 5.9 6.7 7.1 8.3 9.1

3.0 3.6 4.3 5.0 5.6 5.9 6.9 7.6

2.6 3.1 3.7 4.2 4.8 5.1 5.9 6.5

2.3 2.7 3.2 3.7 4.2 4.5 5.2 5.7

2.0 2.4 2.9 3.3 3.7 4.0 4.6 5.1

1.8 2.2 2.6 3.0 3.4 3.6 4.2 4.6

02

15 20 30 40 50 60 75 90

0.12 0.14 0.17 0.20 0.22 0.24 0.27 0.30

15 18 22 26 28 31 35 38

11.9 13.9 16.8 19.8 22 24 27 30

7.9 9.2 11.2 13.2 14.5 15.8 17.8 19.8

5.9 6.9 8.4 9.9 10.9 11.9 13.4 14.9

4.8 5.5 6.7 7.9 8.7 9.5 10.7 11.9

4.0 4.6 5.6 6.6 7.3 7.9 8.9 9.9

3.4 4.0 4.8 5.7 6.2 6.8 7.6 8.5

3.0 3.5 4.2 5.0 5.4 5.9 6.7 7.4

2.6 3.1 3.7 4.4 4.8 5.3 5.9 6.6

2.4 2.8 3.4 4.0 4.4 4.8 5.3 5.9

025

15 20 30 40 50 60 75 90

0.15 0.18 0.22 0.25 0.28 0.31 0.34 0.38

19 23 28 32 36 40 44 49

14.9 17.8 22 25 28 31 34 38

9.9 11.9 14.5 16.5 18.5 20 22 25

7.4 8.9 10.9 12.4 13.9 15.3 16.8 18.8

5.9 7.1 8.7 9.9 11.1 12.3 13.5 15.0

5.0 5.9 7.3 8.3 9.2 10.2 11.2 12.5

4.2 5.1 6.2 7.1 7.9 8.8 9.6 10.7

3.7 4.5 5.4 6.2 6.9 7.7 8.4 9.4

3.3 4.0 4.8 5.5 6.2 6.8 7.5 8.4

3.0 3.6 4.4 5.0 5.5 6.1 6.7 7.5

7-23

7-24

03

15 20 30 40 50 60 75 90

0.18 0.21 0.26 0.30 0.34 0.37 0.41 0.45

23 27 33 38 44 47 52 58

17.8 21 26 30 34 37 41 45

11.9 13.9 17.2 19.8 22 24 27 30

8.9 10.4 12.9 14.9 16.8 18.3 20 22

7.1 8.3 10.3 11.9 13.5 14.7 16.2 17.8

5.9 6.9 8.6 9.9 11.2 12.2 13.5 14.9

5.1 5.9 7.4 8.5 9.6 10.5 11.6 12.7

4.5 5.2 6.4 7.4 8.4 9.2 10.1 11.1

4.0 4.6 5.7 6.6 7.5 8.1 9.0 9.9

3.6 4.2 5.1 5.9 6.7 7.3 8.1 8.9

04

15 20 30 40 50 60 75 90

0.24 0.28 0.35 0.40 0.45 0.49 0.55 0.60

31 36 45 51 58 63 70 77

24 28 35 40 45 49 54 59

15.8 18.5 23 26 30 32 36 40

11.9 13.9 17.3 19.8 22 24 27 30

9.5 11.1 13.9 15.8 17.8 19.4 22 24

7.9 9.2 11.6 13.2 14.9 16.2 18.2 19.8

6.8 7.9 9.9 11.3 12.7 13.9 15.6 17.0

5.9 6.9 8.7 9.9 11.1 12.1 13.6 14.9

5.3 6.2 7.7 8.8 9.9 10.8 12.1 13.2

4.8 5.5 6.9 7.9 8.9 9.7 10.9 11.9

05

15 20 30 40 50 60 75 90

0.31 0.35 0.43 0.50 0.56 0.61 0.68 0.75

40 45 55 64 72 78 87 96

31 35 43 50 55 60 67 74

20 23 28 33 37 40 45 50

15.3 17.3 21 25 28 30 34 37

12.3 13.9 17.0 19.8 22 24 27 30

10.2 11.6 14.2 16.5 18.5 20 22 25

8.8 9.9 12.2 14.1 15.8 17.3 19.2 21

7.7 8.7 10.6 12.4 13.9 15.1 16.8 18.6

6.8 7.7 9.5 11.0 12.3 13.4 15.0 16.5

6.1 6.9 8.5 9.9 11.1 12.1 13.5 14.9

06

15 20 30 40 50 60 75 90

0.37 0.42 0.52 0.60 0.67 0.73 0.82 0.90

47 54 67 77 86 93 105 115

37 42 51 59 66 72 81 89

24 28 34 40 44 48 54 59

18.3 21 26 30 33 36 41 45

14.7 16.6 21 24 27 29 32 36

12.2 13.9 17.2 19.8 22 24 27 30

10.5 11.9 14.7 17.0 19.0 21 23 25

9.2 10.4 12.9 14.9 16.6 18.1 20 22

8.1 9.2 11.4 13.2 14.7 16.1 18.0 19.8

7.3 8.3 10.3 11.9 13.3 14.5 16.2 17.8

08

15 20 30 40 50 60 75 90

0.49 0.57 0.69 0.80 0.89 0.98 1.10 1.20

63 73 88 102 114 125 141 154

49 56 68 79 88 97 109 119

32 38 46 53 59 65 73 79

24 28 34 40 44 49 54 59

19.4 23 27 32 35 39 44 48

16.2 18.8 23 26 29 32 36 40

13.9 16.1 19.5 23 25 28 31 34

12.1 14.1 17.1 19.8 22 24 27 30

10.8 12.5 15.2 17.6 19.6 22 24 26

9.7 11.3 13.7 15.8 17.6 19.4 22 24

10

15 20 30 40 50 60 75 90

0.61 0.71 0.87 1.00 1.12 1.22 1.37 1.50

78 91 111 128 143 156 175 192

60 70 86 99 111 121 136 149

40 47 57 66 74 81 90 99

30 35 43 50 55 60 68 74

24 28 34 40 44 48 54 59

20 23 29 33 37 40 45 50

17.3 20 25 28 32 35 39 42

15.1 17.6 22 25 28 30 34 37

13.4 15.6 19.1 22 25 27 30 33

12.1 14.1 17.2 19.8 22 24 27 30

15

15 20 30 40 50 60 75 90

0.92 1.06 1.30 1.50 1.68 1.84 2.05 2.25

118 136 166 192 215 236 262 288

91 105 129 149 166 182 203 223

61 70 86 99 111 121 135 149

46 52 64 74 83 91 101 111

36 42 51 59 67 73 81 89

30 35 43 50 55 61 68 74

26 30 37 42 48 52 58 64

23 26 32 37 42 46 51 56

20 23 29 33 37 40 45 50

18.2 21 26 30 33 36 41 45

20

15 20 30 40 50 60 75 90

1.22 1.41 1.73 2.00 2.24 2.45 2.74 3.00

156 180 221 256 287 314 351 384

121 140 171 198 222 243 271 297

81 93 114 132 148 162 181 198

60 70 86 99 111 121 136 149

48 56 69 79 89 97 109 119

40 47 57 66 74 81 90 99

35 40 49 57 63 69 78 85

30 35 43 50 55 61 68 74

27 31 38 44 49 54 60 66

24 28 34 40 44 49 54 59

7-25

Metric Application Rate Chart Liters per Hectare (l/ha) - 40 cm Nozzle Spacing Tip Cap.

Liquid Press.

(Bar)

Cap. 1 Nozzle (l/min)

4

6

8

10

12

14

16

18

20

25

30

km/h

km/h

km/h

km/h

km/h

km/h

km/h

km/h

km/h

km/h

km/h

01

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.23 0.28 0.32 0.39 0.45 0.50 0.55 0.60

86.3 105 120 146 169 188 206 225

57.5 70.0 80.0 97.5 113 125 138 150

43.1 52.5 60.0 73.1 84.4 93.8 103 113

34.5 42.0 48.0 58.5 67.5 75.0 82.5 90.0

28.8 35.0 40.0 48.8 56.3 62.5 68.8 75.0

24.6 30.0 34.3 41.8 48.2 53.6 58.9 64.3

21.6 26.3 30.0 36.6 42.2 46.9 51.6 56.3

19.2 23.3 26.7 32.5 37.5 41.7 45.8 50.0

17.3 21.0 24.0 29.3 33.8 37.5 41.3 45.0

13.8 16.8 19.2 23.4 27.0 30.0 33.0 36.0

11.5 14.0 16.0 19.5 22.5 25.0 27.5 30.0

015

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.34 0.42 0.48 0.59 0.68 0.76 0.83 0.90

128 158 180 221 255 285 311 338

85 105 120 148 170 190 208 225

63.8 78.8 90.0 111 128 143 156 169

51.0 63.0 72.0 88.5 102 114 125 135

42.5 52.5 60.0 73.8 85.0 95.0 104 113

36.4 45.0 51.4 63.2 72.9 81.4 88.9 96.4

31.9 39.4 45.0 55.3 63.8 71.3 77.8 84.4

28.3 35.0 40.0 49.2 56.7 63.3 69.2 75.0

25.5 31.5 36.0 44.3 51.0 57.0 62.3 67.5

20.4 25.2 28.8 35.4 40.8 45.6 49.8 54.0

17.0 21.0 24.0 29.5 34.0 38.0 41.5 45.0

02

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.46 0.56 0.65 0.79 0.91 1.02 1.12 1.21

173 210 244 296 341 383 420 454

115 140 163 198 228 255 280 303

86.3 105 122 148 171 191 210 227

69.0 84.0 97.5 119 137 153 168 182

57.5 70.0 81.3 98.8 114 128 140 151

49.3 60.0 69.6 84.6 97.5 109 120 130

43.1 52.5 60.9 74.1 85.3 95.6 105 113

38.3 46.7 54.2 65.8 75.8 85.0 93.3 101

34.5 42.0 48.8 59.3 68.3 76.5 84.0 90.8

27.6 33.6 39.0 47.4 54.6 61.2 67.2 72.6

23.0 38.0 32.5 39.5 45.5 51.0 56.0 60.5

025

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.57 0.70 0.81 0.99 1.14 1.28 1.40 1.51

214 263 304 371 428 480 525 566

143 175 203 248 285 320 350 378

107 131 152 186 214 240 263 283

85.5 105 122 149 171 192 210 227

71.3 87.5 101 124 143 160 175 189

61.1 75.0 86.8 106 122 137 150 162

53.4 65.6 75.9 92.8 107 120 131 142

47.5 58.3 67.5 82.5 95.0 107 117 126

42.8 52.5 60.8 74.3 85.5 96.0 105 113

34.2 42.0 48.6 59.4 68.4 76.8 84.0 90.6

28.5 35.0 40.5 49.5 57.0 64.0 70.0 75.5

7-26

03

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.68 0.83 0.96 1.18 1.36 1.52 1.67 1.80

255 311 360 443 510 570 626 675

170 208 240 295 340 380 418 450

128 156 180 221 255 285 313 338

102 125 144 177 204 228 251 270

85 104 120 148 170 190 209 225

72.9 88.9 103 126 146 163 179 193

63.8 77.8 90.0 111 128 143 157 169

56.7 69.2 80.0 98.3 113 127 139 150

51.0 62.3 72.0 88.5 102 114 125 135

40.8 49.8 57.6 70.8 81.6 91.2 100 108

34.0 41.5 48.0 59.0 68.0 76.0 83.5 90.0

04

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

0.91 1.12 1.29 1.58 1.82 2.04 2.23 2.41

341 420 484 593 683 765 836 904

228 280 323 395 455 510 558 603

171 210 242 296 341 383 418 452

137 168 194 237 273 306 335 362

114 140 161 198 228 255 279 301

97.5 120 138 169 195 219 239 258

85.3 105 121 148 171 191 209 226

75.8 93.3 108 132 152 170 186 201

68.3 84.0 96.8 119 137 153 167 181

54.6 67.2 77.4 94.8 109 122 134 145

45.5 56.0 64.5 79.0 91.0 102 112 121

05

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

1.14 1.39 1.61 1.97 2.27 2.54 2.79 3.01

428 521 604 739 851 953 1046 1129

285 348 403 493 568 635 698 753

214 261 302 369 426 476 523 564

171 209 242 296 341 381 419 452

143 174 201 246 284 318 349 376

122 149 173 211 243 272 299 323

107 130 151 185 213 238 262 282

95 116 134 164 189 212 233 251

85.5 104 121 148 170 191 209 226

68.4 83.4 96.6 118 136 152 167 181

57.0 69.5 80.5 98.5 114 127 140 151

06

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

1.37 1.68 1.94 2.37 2.74 3.06 3.35 3.62

514 630 728 889 1028 1148 1256 1358

343 420 485 593 685 765 838 905

257 315 364 444 514 574 628 679

206 252 291 356 411 459 503 543

171 210 243 296 343 383 419 453

147 180 208 254 294 328 359 388

128 158 182 222 257 287 314 339

114 140 162 198 228 255 279 302

103 126 146 178 206 230 251 272

82.2 101 116 142 164 184 201 217

68.5 84.0 97.0 119 137 153 168 181

08

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

1.82 2.23 2.58 3.16 3.65 4.08 4.47 4.83

683 836 968 1185 1369 1530 1676 1811

455 558 645 790 913 1020 1118 1208

341 418 484 593 684 765 838 906

273 335 387 474 548 612 671 725

228 279 323 395 456 510 559 604

195 239 276 339 391 437 479 518

171 209 242 296 342 383 419 453

152 186 215 263 304 340 373 403

137 167 194 237 274 306 335 362

109 134 155 190 219 245 268 290

91 112 129 158 183 204 224 242

10

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

2.28 2.79 3.23 3.95 4.56 5.10 5.59 6.03

855 1046 1211 1481 1710 1913 2096 2261

570 698 808 988 1140 1275 1398 1508

428 523 606 741 855 956 1048 1131

342 419 485 593 684 765 839 905

285 349 404 494 570 638 699 754

244 299 346 423 489 546 599 646

214 262 303 370 428 478 524 565

190 233 269 329 380 425 466 503

171 209 242 296 342 383 419 452

137 167 194 237 274 306 335 362

114 140 162 198 228 255 280 302

15

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

3.42 4.19 4.83 5.92 6.84 7.64 8.37 9.04

1283 1571 1811 2220 2565 2865 3139 3390

855 1048 1208 1480 1710 1910 2093 2260

641 786 906 1110 1283 1433 1569 1695

513 629 725 888 1026 1146 1256 1356

428 524 604 740 855 955 1046 1130

366 449 518 634 733 819 897 969

321 393 453 555 641 716 785 848

285 349 403 493 570 637 698 753

257 314 362 444 513 573 628 678

205 251 290 355 410 458 502 542

171 210 242 296 342 382 419 452

7-27

20

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0

4.56 5.58 6.44 7.89 9.11 10.19 11.16 12.05

1710 2093 2415 2959 3416 3821 4185 4519

1140 1395 1610 1973 2278 2548 2790 3013

855 1046 1208 1479 1708 1911 2093 2259

684 837 966 1184 1367 1529 1674 1808

570 698 805 986 1139 1274 1395 1506

489 598 690 845 976 1092 1196 1291

428 523 604 740 854 955 1046 1130

380 465 537 658 759 849 930 1004

342 419 483 592 683 764 837 904

274 335 386 473 547 611 670 723

228 279 322 395 456 510 558 603

Verifying Calibration

Do not add chemicals until calibration is complete. Contact with chemicals may cause serious injury or death.

Calculating Spray Width

Number of Nozzles x Nozzle Spacing = Spray Section Width

7-28

Further Information

7-29

Remove all chemical residue from the work area before performing service/ maintenance.

Pump repair and replacement should be performed by qualified service personnel only. Replace with properly rated components. Refer to your parts manual for further information.

5 - DASH / AUTO

Hydraulic Oil

Hydraulic Oil Dipstick (Located on top of Hydraulic Oil Reservoir) -Typical View

Ensure area is clean before changing hydraulic oil and filters to avoid contamination, such as dirt and debris.

Failure to comply may result in severe hydraulic system damage.

Hydraulic Oil Sight Gauge (Located on the side of Hydraulic Oil Reservoir) -Typical View Ensure engine is off before filling hydraulic oil reservoir.

8-1

Filling the Hydraulic Oil Reservoir

Type

Wheel Hub Oil Torque Hub® Oil Level -Typical View

To check the oil level:

To change the oil:

8-2

General Maintenance

Failure to rotate the wheel hub and disperse oil may cause rusting and internal wheel hub damage.

Engine Oil Dipstick (Located on the left-hand side of engine) -Typical View

Capacity

Engine Oil Type

Never operate the engine with oil level below the “L” (low) mark or above the “H” (high mark) on the engine oil dipstick.

Engine Oil Fill

The engine must be level when checking the oil level to ensure accuracy.

8-3

• Engine Oil Fill Port

• Remote Engine Oil Fill Port

Checking Coolant Level/ Concentration

Allow engine and radiator to cool before removing radiator cap. Removing radiator cap while the engine is hot can cause coolant to spray out, resulting in serious injury.

Engine Oil Fill Ports (Located on the left-hand side of engine) -Typical View

Cooling System

Ethylene Glycol-based antifreeze and Propylene Glycol-based antifreeze should never be mixed.

Radiator Cap (Located behind cab - remove radiator screens to access) -Typical View

8-4

Further Information

Ethylene Glycol 40%

-23 C

-10 F

50%

-37 C

-34 F

60%

-54 C

-65 F

Engine Fuel

Changing Coolant

Type COOLING SYSTEM REQUIRES SPECIAL FILL PROCEDURE • Open cab heater water valve by turning the cab temperature selector knob to “Heat” with ignition on.

• Open both cab heater valves on engine.

• Fill radiator to bottom of fill neck using 50/50 EG coolant mixture.

• If radiator is drained completely and refilled faster than 3 gpm (11.4 l/min), radiator may need to be topped off.

• Run engine at operating temperature for 5 minutes.

• Shut off engine.

• Wait until coolant is below 122 F. before removing cap to check coolant level.

• Top off cooling system if required.

8-5

Priming

Filling the Fuel Tank

• Fuel Fill Cap

Engine Fuel Fill (Located on top of fuel tank on each side of machine) -Typical View

Air Conditioning A/C Charge Port -Typical View

Windshield Washer Fluid

DO NOT MIX REFRIGERANTS

Recharging the AC System

8-6

Engine Air Intake Filter (Located behind left-hand engine compartment) -Typical View

Windshield Washer Fluid Reservoir (Located toward front of machine behind center front shield) -Typical View

Removal

Engine Air Intake

Replacement ®

Cleaning Do not tap filter to remove dust. A crushed filter caused by tapping may result in engine damage. Remove and replace filter as recommended.

8-7

Filter Minder

Filter Minder (Located near the rear left-hand side of machine) -Typical View

Service

Radiator Screens (Located behind cab near the radiator) -Typical View

Cleaning

Radiator Screens

Failure to keep cooling systems clean can cause overheating and damage to the engine and hydrostatic systems.

Engine Oil Filter

Removal

8-8

Hydraulic Filters Hydraulic Suction Filter

Engine Oil Filter (Located on the right-hand side of machine - open hood to access) -Typical View

Fuel Filters Primary Fuel Filter (Water Separator) Hydraulic Suction Filter (Located behind right-hand engine compartment) -Typical View

Hydrostatic Charge Pressure Filter Secondary Fuel Filter

• Secondary Fuel Filter

• Primary Fuel Filter (Water Separator)

Primary and Secondary Fuel Filters (Located on left-hand side of engine - open hood to access) -Typical View

8-9

Tread Adjust Stack Valve -Typical View Hydrostatic Charge Pressure Filter (Located behind left-hand engine compartment) -Typical View

High Pressure In-Line Filters

-Typical View

Solution Line Strainer

Boom Stack Valve -Typical View

8-10

Charcoal Filter (2)

Recirculating Filter (3)

Solution Line Strainer (Located near front of machine behind the center front shield) -Typical View

Line Strainers (High-Pressure Pump)

Fresh Air Cab Filters (Refer to your Parts Manual for specific location and replacement part numbers)

Fresh Air Cab Filters • (1) - Paper Filter • (2) - Charcoal Filter • (3) - Recirculating Filter

-Typical View

Fresh Air Cab Filter Access (Located in cab headliner) -Typical View

Paper Filter (1) Failure to properly lubricate pivot and friction points may result in unnecessary wear and damage.

Leg Bearings

8-11

• (2) Lower Bearing Grease Points

• (1) Upper Bearing Grease Point • (1) Seal Boot Grease Point

Leg Bearing and Torque Hub Seal Boot Grease Points -Typical View

Torque Hub® Seal Boot

Hydraulic Tread Adjust Bearing Slide Path

Failure to inspect and lubricate the tread adjust bearing slide path may cause one of the legs to “hang up” while the other is still sliding during adjustment. Failure to comply may result in machine damage.

8-12

• Coat with grease approximately 30” (76 cm)

Boom Hinge and Breakaway Pivots

-Typical View

-Typical View

60/80/90’ Spray Booms

Transom, Lift Arm, and Lift Cylinders

80/90’ Spray Booms Only

-Typical View -Typical View

8-13

A/C Compressor Belt -If Equipped

Engine Drive Belt Removal

• Slide Bolt

• Pivot Bolt

-Typical View -Typical View

Inspection

Check lug nut torque immediately after receiving the machine and every 50 hours of operation thereafter.

Wheel Bolts -Typical View

8-14

To achieve even torque consistency, the tire should be completely off the ground.

To install wheel/tire assembly on the Torque Hub :

Leg Mounting Bolts

Never remove more than three leg mounting bolts from any single leg mount.

To torque leg mounting bolts:

8-15

Toe-In Adjustment

• Lock Collar Bolt and Nut

To Gauge Toe-In

• Swivel Assembly

• Steering Cylinder

• Cotter Pin • Lock Washer • Castel Nut

Steering Cylinder Assembly -Typical View

119.5” (303.5 cm)

120” (304.8 cm)

Example of correct Toe-In for a machine with 120” tread width

8-16

Wheel Bolts

Mounting

When inflating tire, use an extension with an in-line air gauge and air chuck.

This will allow the operator to stand clear of a possible tire sidewall explosion trajectory.

Tire Pressure -Typical View

Toe-In

-Typical View

8-17

Do not loosen the leg mounting bolts to obtain additional clearance for the leg to slide on the frame. Failure to comply may result in leg failure and serious injury.

If the leg mount bolts have been tightened to the proper torque and the mount is loose, the bearing may be worn and replacement is required. Check the bearing before shims are removed.

Tread Adjust Shim Adjustment

Speed Sensor (Located on the rear left-hand wheel motor) -Typical View

• .375” Shim • .250” Shim • .074” Shim • .025” Shim • .037” Shim

Tandem Hydrostatic Pumps • Nylon Bearings

-Typical View

Speed Sensor Adjustment (Left Rear Wheel Motor)

8-18

• Torque Hub

• Wheel Motor

Hydrostatic Pump Controller -Typical View -Typical View Repair/Replacement

Auxiliary Gear Pumps Repair/Replacement

Wheel Motors Repair/Replacement

Use care when removing the roof panel and place it in a safe location while servicing.

Torque Hubs® Repair/Replacement

To Remove the Roof Panel

8-19

Roof Panel Mounting Bolts/Washers (Located on top of cab roof) -Typical View Air Bag (Located on each leg) -Typical View

A/C System Receiver/Dryer

Roof Panel Removal -Typical View

A/C System Receiver/Dryer (Located behind cab near the radiator remove radiator screens to access) -Typical View

Air Bag Pressure

8-20

Air Tank/Wet Tank

Solution Pump

• Solution Plug

• Wet Tank

• Air Tank

Solution Pump (Located near front of machine) -Typical View

Nozzle Diaphragms Air and Wet Tanks (Located on the left-hand side of machine - open hood to access) -Typical View

Spray Tips

Never place a spray tip/nozzle to your mouth in an attempt to unplug it.

Tank Drain Valve -Typical View

8-21

Windshield Washer Fluid Spray Nozzle (Located near top of exterior cab) -Typical View

Washing the Machine Nozzle Diaphragms and Spray Tips -Typical View

Wiper Blade

Use a sturdy stationary ladder to safely access the wiper blade.

8-22

Service Point

Check Lug Nut Torque

Initial

Daily/ Before Each Use

As Required

X

Check Engine Oil Level

X

Check Radiator Coolant Level

X

Check Radiator Grille Screens

X

Check Engine Drive Belt

X

Check A/C Compressor Belt

X

Check Filter Minder® Level

X

Check Hydraulic Reservoir Level

X

Check Battery

X

Check for Leaks Around the Machine

X

Check Windshield Washer Fluid Level

X

Check and Drain Primary Fuel Filter (Water Separator)

X

Drain Wet Tank/Air Tank

X

Check Leg Mount Bolt Torque

X

Check Air Bags (visual)

X

Grease Leg Lubrication Zerks

X

Check Solution Line Strainer

X

Clean Solution Line Strainer

X

Check Spray Nozzle Diaphragms and Tips

X

Replace Windshield Wiper Blade

X

Fill Windshield Washer Fluid Reservoir

X

8-23

50 Hrs.

100 Hrs.

250 Hrs. **

500 Hrs. **

1000 Hrs.

Service Point

Initial

Daily/ Before Each Use

As Required

Clean Radiator Grille Screens

X

Change Engine Drive Belt

X

Change A/C Compressor Belt

X

Charge A/C Compressor *

X

Change Air Intake Filter (Filter Minder)

X

Replace High Pressure InLine Filter

X

Change Battery

X

Replace Fuses and Circuit Breakers

X

Replace Cab Charcoal Filter

X

Clean Cab Fresh Air (Paper) Filter

X

Clean Cab Recirculation Filter

X

Replace Cab Recirculation Filter

X

Check Tire Pressure

X

Lubricate Boom/Breakaway Grease Zerks

X

Lubricate Transom/Lift Arm/ Lift Cylinder Grease Zerks

X

Lubricate Hydraulic Tread Adjust Bearing Slide Path

X

50 Hrs.

Check Lug Nut Torque

X

Change Wheel Hub Oil (Break-in)

X

Lubricate Torque Hub® Grease Zerk/Seal Boot

X

100 Hrs.

Check Wheel Hub Oil Level

X

Clean Battery

X

250 Hrs. **

Change Engine Oil Filter

X

Change Engine Oil

X

500 Hrs. **

1000 Hrs.

8-24

Service Point

Initial

Daily/ Before Each Use

As Required

50 Hrs.

100 Hrs.

250 Hrs. **

Change Wheel Hub Oil

X

Change Hydrostatic Charge Pressure Filter

X

Change Hydraulic Suction Filter

X

500 Hrs. **

Change Primary Fuel Filter (Water Separator)

X

Change Secondary Fuel Filter

X

Check Radiator Coolant Concentration

X

Change Hydraulic Reservoir Oil

X

1000 Hrs.

Change Radiator Coolant

X

Change Spray Nozzle Diaphragms and Tips

X

Preparing For Storage

8-25

Removing From Storage

Protective compounds such as grease can harden under exposure to weather conditions. Be sure to remove any dried grease and reapply new, if necessary.

8-26

When transporting the sprayer, observe the following to avoid serious injury or death: • Check for adequate clearance before driving under any overhead obstructions.

• Contact with power lines may result in serious injury or death.

Hagie Manufacturing Company does not recommend any form of transportation other than driving the sprayer. Loading the sprayer onto a trailer may result in sprayer rollover.

Do not transport the machine without booms folded and in cradle. Failure to comply may result in injury or equipment damage.

5 - DASH / AUTO

• Never operate the sprayer on a public roadway with solution in the tanks.

• Never load or unload the sprayer with solution in the tanks.

• Stopping the sprayer on trailer ramps may cause the sprayer to tip over.

Cradling the Booms

DO NOT operate the machine at speeds exceeding 20 mph (32 km/h) with solution in the tanks. Operating speeds exceeding 20 mph (32 km/h) with fully loaded tanks may result in tire blow-out or wheel hub damage and will void the warranty.

Booms must be in FOLDED position when cradled. Failure to comply will result in property damage.

9-1

Loading

Keep all persons away from trailer when loading or unloading the sprayer. Failure to comply may result in serious injury or death.

Driving the Sprayer on a Public Roadway

Read and understand the trailer manufacturer’s operation manual. Hitch the trailer to the pulling vehicle according to their recommendations.

The loaded height and width of the trailer must conform to state law in which it is being used. Do not exceed the trailer manufacturer’s recommendations on loaded weight.

9-2

Unloading

(Non-Hydraulic Tread Adjust Machines)

Adjusting Tread Width Towing

Sprayer should never be towed under any circumstances. Machine damage will occur and will void the power train warranty.

9-3

Loosen leg mounting bolts only enough to allow for free movement of leg on mainframe. DO NOT remove bolts under any circumstances. Failure to comply will cause the machine to become unstable, resulting in serious injury or death.

Empty solution tanks before raising the machine.

To Adjust Tread Width Out

Rear Lock Nut (Located on leg brace) -Typical View

-Typical View

-Typical View

9-4

Keep hand wash tank full of fresh water at all times for immediate use should contact with hazardous chemicals occur.

Tread Width Indicator (Located on each leg) -Typical View

Fill hand wash tank with fresh water only.

To Adjust Tread Width In The Hand Wash System has been tested using RV-type antifreeze. Fill hand wash tank with fresh water and drain before initial use.

Filling the Hand Wash Tank

• Hand Wash Fill

The Hand Wash System is not a substitute for Personal Protective Equipment (PPE). Always use the proper PPE (safety eye wear, face shields, protective clothing, etc.) when handling agricultural chemicals.

9-5

• Fresh Water Outlet • Hand Wash Valve

Hand Wash Tank (Located near rear left-hand side of machine) -Typical View

To Dispense Fresh Water

9-6

Problem

Possible Cause

Suggested Remedy

Engine will not crank

• Dead battery • Poor battery connections

• Charge or replace battery • Clean and tighten battery connections • Adjust and/or replace, if necessary • Test, rebuild, or replace • Inspect switch

• Neutral Safety Switch • Starter or starter relay • Lock-out Switch in LOCKED position Engine will not start

• Fuel tanks empty • Clogged fuel filter • Cold weather

• Low starter speed

• Fill fuel tanks • Replace fuel filters • Refer to the engine manufacturer’s user guide for cold weather starting • Check starter and battery

Engine overheats

• Engine overload • Dirty radiator core/grille screens • Faulty radiator cap • Loose or faulty fan belt • Faulty thermostat • Low coolant level

• Reduce load • Remove all foreign material and clean all items • Replace cap • Tighten or replace fan belt • Replace thermostat • Refill to proper level with recommended coolant mixture

Engine misfires: runs uneven/low power

• Water in fuel

• Drain, flush, replace filter, fill system • Replace element • Drain system, change to a better grade fuel • Open fuel tank vent (in cap) • Replace fuel filter

• Dirty air cleaner element • Poor grade of fuel • Fuel tank vent clogged • Clogged fuel filter Engine knocks

9-7

• Low oil level in crankcase • Cold engine

• Add oil to full mark • Allow proper warm-up period refer to engine manufacturer’s user guide

Machine will not move in either direction

• Engine speed too low • Oil level in hydraulic reservoir low • Control linkage • Clogged filter • Faulty hydrostatic pump • Air leak in suction line • Low charge pressure

• Set engine at operating RPM before moving the machine • Fill hydraulic reservoir to proper level with approved oil • Repair or replace • Replace filter • Replace pump • Inspect and tighten all fittings on suction line • Refer to “Hydrostatic Charge Pressure Filter” elsewhere in this manual

Machine will move in only one direction

• Faulty Flow Divider Valve

• Replace valve

Hydrostatic System responding slowly

• Engine speed too low

• Set engine at operating RPM before moving the machine • Fill hydraulic reservoir to proper level with approved oil (see Service: Fluids elsewhere in this manual) • Allow adequate warm-up period • Check and replace filter • Inspect for collapsed suction hose • Replace hydrostatic pump or motor

• Oil in hydraulic reservoir low

• Cold oil • Plugged filter • Partially restricted suction line • Internal damage Noisy Hydrostatic System

• Cold oil

• Internal pump damage

• Allow adequate warm-up period • Increase engine speed • Fill hydraulic reservoir to proper level with approved oil (see Service: Fluids elsewhere in this manual) • Inspect and tighten all fittings on suction line • Replace pump

• Loose or faulty fittings • Damaged o-ring • Faulty hose

• Tighten or replace • Inspect, if damaged - replace • Replace hose

• Low engine speed • Oil level in hydraulic reservoir low

• Air in system

External oil leaks

9-8

Entire Hydraulic System fails to function

• Oil level in hydraulic reservoir low

• Oil not reaching pump

• Faulty hydraulic pump Noisy hydraulic pump

• Collapsed suction hose (caused by cold oil) • Oil level in hydraulic reservoir low

• Air leak in suction line

Solution pump will not prime

• Low water level in pump

• Air leak in suction line • Solution Tank Valve closed Erratic reading on pressure gauge

• Orifice in back of gauge clogged • Faulty gauge • Air leak in suction line • Solution Strainer plugged • Glycerin leaking from pressure gauge

9-9

• Fill hydraulic reservoir to proper level with approved oil (see Service: Fluids elsewhere in this manual) • Prime the pump by removing suction hose from reservoir.

Hold removed end higher than the pump. Hand-feed two quarts of approved oil through the suction hose by bumping engine with starter (ensuring NOT to start the engine).

Reinstall hose. Tighten all fittings.

• Replace hydraulic pump • Allow for adequate warm-up period • Fill hydraulic reservoir to proper level with approved oil (see Service: Fluids elsewhere in this manual) • Inspect and tighten all fittings on suction hose

• Ensure solution tanks are not empty (solution pump is selfpriming) • Inspect and tighten all fittings on suction line • Open Solution Tank Valve, allow air to leave the system • Remove pressure gauge, clean orifice, reinstall • Replace gauge • Inspect and tighten all fittings in suction line • Check/clean solution strainer • Replace gauge

Malfunction of electric solution valve

• Faulty ground • Dirty contact terminals • Separation in wire • Faulty switch • Short in solenoid coil • Bad valve

Solution pump not producing normal pressure

• Clogged line strainer screen

• Air leak in suction flow to pump • Restricted solution flow to pump • Suction hose collapsed

• Internal restriction of diaphragm (such as buildup of chemical) • Hydraulic failure

Entire electrical system is dead

• Dead battery • Poor battery connection • Low charging rate • No charging rate • Lockout Switch in LOCKED position

• Clean and tighten ground • Clean contact terminals • Check continuity and replace wire • Replace switch • Inspect, replace if necessary • Replace valve • Remove screen, clean thoroughly, tighten strainer cap to avoid air leak • Inspect and tighten all fittings on suction line • Ensure the Solution Tank Valves are completely open • Obstruction at inlet end of hose, causing high vacuum on hose - remove obstruction • Disassemble, inspect, clean, reassemble • Contact Hagie Customer Support for assistance

• Charge or replace battery • Clean and tighten battery connections • Tighten alternator belt • Replace alternator • Inspect switch

All gauges on instrument panel not working

• Blown fuse • Poor ground

• Replace fuse • Clean and tighten ground

Tachometer/MPH-km/h indicator not working

• Blown fuse • Loose connections at sensor/ alternator • Faulty sensor

• Replace fuse • Tighten or replace connectors

• Blown fuse • Burned out bulb • Separation or short in wire

• Clean and tighten ground • Replace bulb • Check continuity and replace wire • Replace fuse • Replace switch • Turn ignition switch to the ON position

Light system does not function

• Blown fuse • Faulty switch • Ignition switch is OFF

• Replace sensor

9-10

5 - DASH / AUTO © 2014-15 Hagie Manufacturing Company. Clarion, Iowa USA

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

Axial Piston Pumps and Motors Service Manual 250 - 61

Series 90

Introduction

Introduction Use of this Manual This manual includes information for the normal operation, maintenance, and servicing of the Series 90 family of hydrostatic pumps and motors.

The manual also includes the description of the units and their individual components, troubleshooting information, adjustment instructions, and minor repair procedures. Unit warranty obligations should not be affected if maintenance, adjustment, and minor repairs are performed according to the procedures described in this manual.

Many service and adjustment activities can be performed without removing the unit from the vehicle or machine.

However, adequate access to the unit must be available, and the unit must be thoroughly cleaned before beginning maintenance, adjustment, or repair activities.

Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, cleanliness requirements must be strictly adhered to. This is especially important when changing the system filter and during adjustment and repair activities.

For further information refer to Series 90 Technical Information. For information about fluid requirements refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No. 697581).

A worldwide network of SAUER-SUNDSTRAND Authorized Service Centers is available should repairs be needed. Contact any SAUER-SUNDSTRAND Authorized Service Center for details. A list of all Service Centers can be found in bulletin BLN-2-400527, or in brochure SAW (Ident. No. 698266).

Safety Precautions Observe the following safety precautions when using and servicing hydrostatic products.

Loss of Hydrostatic Braking Ability

Fluid under High Pressure

WARNING The loss of hydrostatic drive line power in any mode of operation (e.g., forward, reverse, or "neutral" mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

WARNING Use caution when dealing with hydraulic fluid under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This fluid may also be hot enough to burn. Serious infection or reactions can develop if proper medical treatment is not administered immediately.

S000 001E

S000 003E

Disable Work Function

Flammable Cleaning Solvents

WARNING Certain service procedures may require the vehicle/machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing them in order to prevent injury to the technician and bystanders.

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.

S000 004E

S000 005E

Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co. All rights reserved. Contents subject to change.

2

250 - 62

S90MVCTCD S90PVMFCD

Series 90

Contents

Contents Introduction ......................................................................................................................................................................... 2 Use of this Manual ........................................................................................................................................................................................ 2 Safety Precautions ........................................................................................................................................................................................ 2

Functional Description ....................................................................................................................................................... 5 General Description and Cross Sectional Views ......................................................................................................................................... 5 Variable Displacement Pumps ................................................................................................................................................................ 5 Fixed Displacement Motor ..................................................................................................................................................................... 5 Variable Displacement Motor .................................................................................................................................................................. 6 The System Circuit ....................................................................................................................................................................................... 7 The Basic Closed Circuit ........................................................................................................................................................................ 7 Case Drain and Heat Exchanger ........................................................................................................................................................... 7 Common Features of Pumps and Motors .................................................................................................................................................... 8 End Caps and Shafts ............................................................................................................................................................................. 8 Speed Sensors ....................................................................................................................................................................................... 8 Pump Features ............................................................................................................................................................................................. 9 Charge Pump .......................................................................................................................................................................................... 9 Charge Relief Valve ................................................................................................................................................................................. 9 Multi-Function Valves .............................................................................................................................................................................. 9 Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10 System Check Valves .................................................................................................................................................................... 10 Bypass Valves ................................................................................................................................................................................ 10 Displacement Limiters .......................................................................................................................................................................... 11 Auxiliary Mounting Pads ....................................................................................................................................................................... 11 Filtration Options ................................................................................................................................................................................... 11 Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12 Pump Control Options .......................................................................................................................................................................... 13 Manual Displacement Control (MDC) ........................................................................................................................................... 13 Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13 Electric Displacement Control (EDC) ............................................................................................................................................ 14 Automotive Control (FBA II B) ....................................................................................................................................................... 14 3-Position (FNR) Electric Control .................................................................................................................................................. 14 Motor Features ........................................................................................................................................................................................... 15 Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15 Variable Motor Displacement Limiters .................................................................................................................................................. 15 Variable Motor Controls ........................................................................................................................................................................ 16 Hydraulic 2-Position Control .......................................................................................................................................................... 16 Electric 2-Position Control .............................................................................................................................................................. 16

Technical Specifications .................................................................................................................................................. 17 General Specifications ................................................................................................................................................................................ 17 Circuit Diagrams ......................................................................................................................................................................................... 17 Hydraulic Parameters ................................................................................................................................................................................. 18 Size Specific Data ....................................................................................................................................................................................... 19

Pressure Measurement ................................................................................................................................................... 20 Required Tools ............................................................................................................................................................................................ 20 Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20 Variable Pump ....................................................................................................................................................................................... 20 Fixed Motor ........................................................................................................................................................................................... 23 Variable Motor ....................................................................................................................................................................................... 24

Initial Start-Up Procedure ................................................................................................................................................ 25 Fluid and Filter Maintenance ........................................................................................................................................... 26 Troubleshooting ................................................................................................................................................................ 27 "NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27 System Operating Hot ................................................................................................................................................................................ 27 Transmission Operates Normally in One Direction Only .......................................................................................................................... 28 System Will Not Operate in Either Direction .............................................................................................................................................. 28 Low Motor Output Torque ........................................................................................................................................................................... 29 Improper Motor Output Speed .................................................................................................................................................................... 29 Excessive Noise and/or Vibration .............................................................................................................................................................. 30 System Response is Sluggish .................................................................................................................................................................... 30

250 - 63

3

Series 90

Contents

Inspections and Adjustments ......................................................................................................................................... 31 Pump Adjustments ...................................................................................................................................................................................... 31 Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31 Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33 Engaging the Bypass Function ............................................................................................................................................................ 35 Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36 Displacement Limiter Adjustment ......................................................................................................................................................... 37 Pump Control Adjustments ......................................................................................................................................................................... 38 Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38 Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39 MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40 Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46 Motor Adjustments ...................................................................................................................................................................................... 48 Charge Relief Valve Adjustment ........................................................................................................................................................... 48 Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49 Displacement Control Adjustments ...................................................................................................................................................... 49 Speed Sensor Adjustment .......................................................................................................................................................................... 50

Minor Repair Instructions ................................................................................................................................................ 51 Pump and Motor Minor Repair .................................................................................................................................................................... 53 Pump / Fitting Torques .......................................................................................................................................................................... 53 Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54 Pump Minor Repairs ................................................................................................................................................................................... 56 Multi-Function Valve Cartridges ........................................................................................................................................................... 56 Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57 Charge Relief Valve ............................................................................................................................................................................... 57 Charge Pump - Remove ...................................................................................................................................................................... 58 Installing the Charge Pump .................................................................................................................................................................. 60 Auxiliary Pad Installation ....................................................................................................................................................................... 62 Auxiliary Pad Conversion ..................................................................................................................................................................... 63 Filtration Options ................................................................................................................................................................................... 64 Pump controls ....................................................................................................................................................................................... 65 Cover Plate ..................................................................................................................................................................................... 65 Manual Displacement Control (MDC) ........................................................................................................................................... 66 Solenoid Override Valve for MDC .................................................................................................................................................. 67 Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67 Hydraulic and Electric Displacement Controls ............................................................................................................................. 68 Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68 3-Position (FNR) Electric Control .................................................................................................................................................. 69 Displacement Control Components ............................................................................................................................................... 69 Minor Repair - Motor ................................................................................................................................................................................... 71 Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71 Variable Motor Displacement Limiters .................................................................................................................................................. 73 Variable Motor Controls ............................................................................................................................................................................... 74 Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74 Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74 Control Plugs ........................................................................................................................................................................................ 74 Variable Motor Control Orifices ............................................................................................................................................................ 75 Speed Sensor .............................................................................................................................................................................................. 77

Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78 Variable Pumps ........................................................................................................................................................................................... 78 Minor Repair Parts ................................................................................................................................................................................ 78 Parts List ............................................................................................................................................................................................... 79 Variable Pump Controls ........................................................................................................................................................................ 80 Control Parts List .................................................................................................................................................................................. 81 Filter and Options ................................................................................................................................................................................. 82 Parts List Filter and Options ................................................................................................................................................................. 83 Name Plates ......................................................................................................................................................................................... 83 Fixed Motor ................................................................................................................................................................................................. 84 Minor Repair Parts ................................................................................................................................................................................ 84 Parts List ............................................................................................................................................................................................... 85 Name Plates ......................................................................................................................................................................................... 85 Variable Motor .............................................................................................................................................................................................. 86 Minor Repair Parts ................................................................................................................................................................................ 86 Parts List ............................................................................................................................................................................................... 87 Name Plate ............................................................................................................................................................................................ 87

4

250 - 64

Series 90

Functional Description

Functional Description This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for readers unfamiliar with the functioning of a specific system.

General Description and Cross Sectional Views Variable Displacement Pumps The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power. The input shaft turns the pump cylinder which contains a ring of pistons. The pistons run against a tilted plate, called the swashplate. This causes the pistons to compress the hydraulic fluid which imparts the input energy into the hydraulic fluid. The high pressure fluid is then ported out to provide power to a remote function.

The swashplate angle can be varied by the control piston.

Altering the swashplate angle varies the displacement of fluid in a given revolution of the input shaft.

F000 539

Series 90 Variable Displacement Pump (PV) Slider Block Servo Arm Cradle Hold Down

Servo Valve Servo Piston Feed Back

Cradle Bearing

Cradle Leveler Charge Pump

Cradle Cradle Guide

P001 413E

Series 90 PV Cross Section

Fixed Displacement Motor The Fixed Displacement Motor (MF) is designed to convert an input of hydraulic power into an output torque.

It operates in the reverse manner of the pump. The high pressure hydraulic fluid enters through the input port. The fluid pressure builds behind the pistons causing them to move down the swashplate (the path of least resistance).

As the piston returns up the swashplate again, the fluid is allowed to exit through the exit port. The spinning pistons are housed in a cylinder which is connected to the output shaft. The output torque can be applied to a mechanical function.

90000347

Series 90 Fixed Displacement Motor (MF) 250 - 65

5

Series 90

Functional Description In the Fixed Displacement Motor the "swashplate" is fixed, so any variation in motor speed and torque must be made by the input mechanism, i.e. the pump.

Loop Flushing Valve Valve Plate

Piston Roller Bearing

Output Shaft

Fixed Swashplate End Cap

Cylinder Block 90000190E

Series 90 MF Cross Section

Variable Displacement Motor The Variable Displacement Motor (MV) operates in the same manner as the fixed motor. However, its swashplate is not fixed; it can be switched between minimum and maximum angle to amplify torque or speed like the Variable Displacement Pump.

90000348

Series 90 Variable Displacement Motor (MV)

End Cap

Minimum Angle Control Piston

Valve Plate Piston Roller Bearing Output Shaft

"A"

Cradle Swashplate

Partial Section "A-A" Cradle Swashplate in Full Displacement Position

"A"

Cradle Swashplate Cylinder Block

Maximum Angle Control Piston

Electric 2-Position Control (optional)

90000234E

Series 90 MV Cross Section

6

250 - 66

Series 90

Functional Description

The System Circuit

System loop (low pressure) Control Handle

Displacement Control Valve

Case drain fluid

Heat Exchanger Bypass Valve

System loop (high pressure) Reservoir

Orificed Check Valve

Control fluid Vacuum Gauge

Suction line

Heat Exchanger

Servo Control Cylinder

Variable Displacement Pump

Multi-Function Valve

Purge Relief Valve

Charge Pressure Relief Valve

Fixed Displacement Motor

to Pump Case Servo Pres.

Relief Valve Charge Pump Input Shaft

Output Shaft Multi-Function Valve

Pump Swashplate

Servo Control Cylinder

Motor Swashplate Loop Flushing Valve

Pump

Fixed Motor 90000800E

Circuit Diagram for Series 90 PV and 90 MF

The Basic Closed Circuit The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in either direction, from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. In pumping mode the position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow.

Case Drain and Heat Exchanger The pump and motor require case drain lines to remove hot fluid from the system. The motor should be drained from its topmost drain port to ensure the case remains full of fluid. The motor case drain can then be connected to the lower drain port on the pump housing and out the top most port. A heat exchanger, with a bypass valve, is required to cool the case drain fluid before it returns to the reservoir.

Reservoir Input

PV

MF

Output

Flow (Bi-directional)

Case Drain Line 90000803E

Basic Closed Circuit 250 - 67

7

Series 90

Functional Description

Common Features of Pumps and Motors End Caps and Shafts Series 90 pumps and motors can be supplied with a variety of end caps and shafts to allow for almost any configuration. For pumps, end caps are available with system ports on either side ("side ports") or both ports on one side ("twin ports"). Motors have end caps with ports on the face of the end cap ("axial ports") or both ports on one side ("twin ports"). See the Series 90 Technical Information manuals (BLN-10029 and BLN-10030) or the Series 90 Price Book (BLN-2-40588) for information on available options.

Removing the end cap will void the warranty on a Series 90 pump or motor.

Speed Sensors An optional speed sensor can be installed on Series 90 pumps and motors to provide unit speed information. The sensor reads a magnetic ring wrapped about the unit's cylinder. See the corresponding Section to locate, install and adjust the sensor.

Speed Sensor

8

250 - 68

90000810

Series 90

Functional Description

Pump Features Charge Pump The charge pump is necessary to supply cool fluid to the system, to maintain positive pressure in the main system loop, to provide pressure to operate the control system, and to make up for internal leakage. Charge pressure must be at its specified pressure under all conditions of driving and braking to prevent damage to the transmission.

The charge pump is a fixed-displacement, gerotor type pump installed in the variable displacement pump and driven off the main pump shaft. Charge pressure is limited by a relief valve.

The standard charge pump will be satisfactory for most applications. However, if the charge pump sizes available for the given main pump size are not adequate, a gear pump may be mounted to the auxiliary mounting pad and supply the required additional charge flow.

90000243

PV with Charge Pump Case Drain Line

Charge Relief Valve System Check Valves

Charge Relief Valve The charge relief valve on the pump serves to maintain charge pressure at a designated level. A direct-acting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1500 rpm. This nominal setting assumes the pump is in neutral (zero flow); in forward or reverse charge pressure will be lower. The charge relief valve setting is specified on the model code of the pump.

Input

PV

PF Charge Pump

Inlet Filter Tank 90000804E

Pump Charge System

Multi-Function Valves The multi-function valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve and the bypass valve in a replaceable cartridge.

These functions are described separately. There are two multi-function valve cartridges in each Series 90 pump to handle functions in either direction. See corresponding Sections for adjustments and repairs.

NOTE: Some multi-function valves do not include a pressure limiter valve.

250 - 69

90000243

Multi-Function Valve

9

Series 90

Functional Description Pressure Limiter and High Pressure Relief Valves

Pressure Limiter Housing Pressure Limiter Lock Nut

High Pressure Relief / check Valve Poppet

Check Valve Poppet

Pressure Limiter Adjustment Screw

Bypass Actuator

Pressure Limiter Valve Poppet

Bypass

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 so as to limit the system pressure. For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by cross-porting system flow to the low pressure side of the loop. The pressure limiter valve acts as the pilot for the high pressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar (500 psi) above the level that initiates the pressure limiter valve.

Both the pressure limiter sensing valves and relief valves are built into the multi-function valves (see above).

90000806E

Cross Section of Multi-Function Valve

NOTE: For some applications, such as dual path vehicles, the pressure limiter function may be defeated so that only the high pressure relief valve function remains.

System Check Valves The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level.

This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the multi-function valve assembly.

To Control

Multi-Function Valve

Bypass Adjustment

Servo Piston Port "A"

Bypass Valves

Servo Pres.

Relief Valve Port "B" Servo Piston Charge Pressure Relief Valve Multi-Function Valve

Circuit Diagram showing Pressure Control Mechanism

10

250 - 70

The bypass valves ("tow") can be operated when it is desired to move the vehicle or mechanical function when the pump is not running. The valve is opened by manually resetting the valve position.

The bypass valves are built into the multi-function valves.

90000801E

Series 90

Functional Description

Displacement Limiters All Series 90 pumps are designed for optional mechanical displacement (stroke) limiters. The maximum displacement of the pump can be limited in either direction.

The setting can be set as low as 0° in either direction.

For instructions on adjustment see corresponding Section.

Auxiliary Mounting Pads

90000244

PV with Displacement Limiters

Auxiliary mounting pads are available on all Series 90 pumps. SAE A through E mounts are available (availability varies by pump size). This pad is used for mounting auxiliary hydraulic pumps and for mounting additional Series 90 pumps to make tandem pumps. The pads allow for full through-torque capability.

Filtration Options

90000242

PV with Auxillary Mounting Pad

All Series 90 pumps are available with provisions for either suction or charge pressure filtration (integral or remote mounted) to filter the fluid entering the charge circuit.

Suction Filtration The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump. When suction filtration is used, a reducer fitting is placed in the charge pressure gauge port (M3). Filtration devices of this type are provided by the user.

90000243

PV with Suction Filtration (No filtration device attached)

Charge Pressure Filtration The pressure filter may be integrally mounted directly on the pump or a filter may be remotely mounted for ease of servicing.

A 125 µm screen, located in the reservoir or the charge inlet line, is recommended when using this filtration option.

90000246

PV with Integral Charge Pump 250 - 71

90000247

PV with Remote Charge Pump

11

Series 90

Functional Description Pressure Override (POR) - 180 Frame Size Only

To Control

Multi-Function Valve

Pressure Override Control Valve

Bypass Adjustment

The pressure override valve (POR) modulates the control pressure to the displacement control to maintain a pump displacement which will produce a system pressure level less than or equal to the POR setting. For unusually rapid load application, the high pressure relief valve function of the multifunction valves is available to also limit the pressure level.

Port "A" Shuttle Valve Port "B"

Multi-Function Valve

Charge Pressure Relief Valve

POR-Valve (180 Frame Size only)

12

250 - 72

90000802E

The pressure override consists of a three-way normally open valve which operates in series with the pump displacement control. Control supply pressure is normally ported through the pressure override valve to the displacement control valve for controlling the pump's displacement. If the system demands a pressure above the override setting, the POR valve will override the control by reducing the control pressure supplied to the displacement control. As the control pressure reduces, the internal forces tending to rotate the swashplate overcome the force of the servo pistons and allow the pump's displacement to decrease.

Series 90

Functional Description

Pump Control Options Manual Displacement Control (MDC) The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered fourway servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction.

The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input shaft.

Non-Linear MDC The non-linear manual displacement control operates in the same manner as the regular MDC except that it is designed so the change in the angular position of the pump swashplate progressively increases as the control input shaft is rotated toward its maximum displacement position.

Solenoid Override Valve for MDC A solenoid override valve option (not shown here) is available for MDC. This safety feature will return the swashplate to zero displacement position when activated. The valve may be set in either a normally open or normally closed mode.

90000237

PV with Manual Displacement Control

Neutral Start Switch (NSS) The neutral start switch is an optional feature available with MDC. When connected properly with the vehicle’s electrical system, the neutral start switch ensures that the prime mover can be started only when the control is in a neutral position.

90000239

Hydraulic Displacement Control (HDC)

PV with Manual Displacement Control and Neutral Start Switch

The hydraulic displacement control uses a hydraulic input signal to operate a spring-centered four-way servo valve.

This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The HDC is designed so the angular position of the pump swashplate is proportional to input pressure.

90000240

PV with Hydraulic Displacement Control 250 - 73

13

Series 90

Functional Description Electric Displacement Control (EDC)

90000241

PV with Electric Displacement Control

The electric displacement control is similar to the hydraulic displacement control with the input signal pressure controlled by a pressure control pilot (PCP) valve. The PCP valve converts a DC electrical input signal to a hydraulic signal which operates a spring- centered fourway servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement in one direction to full displacement in the opposite direction. The control is designed so the angular position of the swashplate is proportional to the EDC input.

Automotive Control (FBA II B) Automotive Control allows a vehicle to be driven in a manner similar to an automobile with an automatic transmission.

The Automotive Control includes a three-position electric control to provide direction control.

3-Position (FNR) Electric Control This control utilizes a 12 or 24 VDC electrically operated spool valve to port pressure to either side of the pump displacement control piston. Energizing one of the solenoids will cause the pump to go to its maximum displacement in the corresponding direction.

All functions of the three-position (FNR) electric control are preset at the factory.

PV with 3-Position (FNR) Electric Control

14

250 - 74

90000354

Series 90

Functional Description

Motor Features Motor Loop Flushing Valve and Charge Relief Valve All Series 90 motors are designed to accommodate a loop flushing valve. The loop flushing valve is used in installations which require additional fluid to be removed from the main hydraulic circuit because of transmission cooling requirements, or unusual circuits requiring additional loop flushing to remove excessive contamination in the high pressure circuit.

A shuttle valve and charge relief valve are installed in the motor end cap to provide the loop flushing function. The shuttle valve provides a circuit between the low pressure side of the closed loop and the charge relief valve in the motor end cap.

The motor charge relief valve regulates the charge pressure level only when there is a pressure differential in the main loop. The shuttle valve is spring centered to the closed position so that no high pressure fluid is lost from the circuit when reversing pressures.

90000248

Loop Flushing Valve (MF)

Top of Motor

Charge Relief Valve

For charge relief valve adjustment see corresponding Section.

Loop Flushing Shuttle Valve

End Cap

90000238E

Motor Charge Relief Valve and Loop Flushing Shuttle Valve

Variable Motor Displacement Limiters All Series 90 variable motors include mechanical displacement (stroke) limiters. Both the maximum and minimum displacement of the motor can be limited.

The range of the settings is as follows:

Minimum Displacement Maximum Displacement

055 MV

075 MV

19 - 40 cm3 1.2 - 2.4 in3

26 - 54 cm3 1.6 - 3.3 in3

65 - 100 %

65 - 100 %

90000352

MV Maximum Displacement Limiter (Minimum Displacement Limiters on opposite side)

T002 251E

250 - 75

15

Series 90

Functional Description

Variable Motor Controls

Hydraulic 2-Position Control This control utilizes a hydraulically operated three-way hydraulic valve to port system pressure to either of the motor displacement control pistons. The motor is normally held at its maximum displacement. Supplying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement.

90000350

MV with Hydraulic 2-Position Control

Electric 2-Position Control This control utilizes an electric solenoid operated threeway hydraulic valve to port system pressure to either of the motor displacement control pistons. The motor is normally held at its maximum displacement. Energizing the solenoid will cause the motor to go to its minimum displacement.

90000351

MV with Electric 2-Position Control

16

250 - 76

Series 90

Technical Specifications

Technical Specifications General Specifications Design

Port Connections (for details see chapter "Pressure Measurement")

Variable Pumps and Motors: Axial piston pump of variable displacement, cradle swashplate design.

Main pressure ports: SAE flange, Code 62, Remaining ports: SAE straight thread O-ring boss.

Fixed Motors: Axial piston motor with fixed displacement, fixed swashplate design.

Direction of Rotation

Type of Mounting (per SAE J744)

Clockwise or counterclockwise (motors are bi-directional)

SAE flange, Size "B", 2 bolts, SAE flange, Size "C and E", 4 bolts.

Recommended Installation Position Pump installation recommended with control position on the top or side. Consult SAUER-SUNDSTRAND for nonconformance guidelines. The housing must always be filled with hydraulic fluid.

Cartridge flange, 2 bolts (for motor only).

Circuit Diagrams

L2

M3 M1

A

M3 X5

Vg max

A M1

M5 M4

M2

B L1

M2 B L1

S

L2

MV with Electrohydraulic 2-Position Control

PV with Charge Pump and Manual Displacement Control

L2

M3

A

M1

B

M2

L1

MF

250 - 77

90000811 90000812 90000813

17

Series 90

Technical Specifications

Hydraulic Parameters S ystem Pressure Range

bar

R ated Pressure

420

6000

M aximum Pressure

480

6960 T002 252E

Charge Pump Inlet Vacuum (on pumps only)

bar abs

Temperature Range1)

psi Minimum R ated M aximum

°C -40 104 115

[°F] [ -40] [220] [ 240]

intermittent, cold start intermittent T002 006E

1)

At the hottest point, normally the case drain port.

Viscosity

in Hg

Minimum Vacuum (continuous)

0.7

10

Minimum Vacuum during Cold Start (Intermittent)

M inimum Recommended operating range

0.2

25

M aximum

mm2/s 7

[SUS] [49]

1 2-60

[70-278]

1600

[7500]

intermittent

intermittent, cold start T002 010E

T002 253E

C ase Pressure

bar

psi

M aximum (Continuous)

3

44

Maximum during Cold Start (Intermittent)

5

73 T002 254E

Cleanliness Level and β x -Ratio Required fluid cleanliness level Recommended βx -ratio for suction filtration Recommended βx -ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration

ISO 4406 Class 18/13 β 35-45 =75

(β10≥ 2)

β 15-20 =75

(β10≥ 10)

100 µ m-125 µm T002 007E

Hydraulic Fluid

Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No. 697581). Also refer to publication ATI-E 9101 for information relating to biogradable fluids.

Refer to SAUER-SUNDSTRAND Publications BLN 9887 or SDF (NO. 697581) and ATI-E 9201.

Refer to Series 90 technical information for definitions.

18

250 - 78

Series 90

Technical Specifications

Size Specific Data Variable Displacement Pumps D imension

030 PV

042 PV

055 PV

075 PV

100 PV

130 PV

180 PV

250 PV

Displacement (maximum)

cm in3

30 1.83

42 2.56

55 3.35

75 4.57

100 6.10

130 7.93

180 10.98

250 15.25

M inimum Speed

min-1 (rpm)

500

500

500

500

500

500

500

500

R ated Speed

min-1 (rpm)

4200

4200

3900

3600

3300

3100

2600

2300

M aximum Speed

min-1 (rpm)

4600

4600

4250

3950

3650

3400

2850

2500

Maximum attainable Speed at max. Displacement

min-1 (rpm)

5000

5000

4700

4300

4000

3700

3150

2750

Theoretical Torque at max. Displacement

Nm/bar lbf•in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 870

2.07 1260

2.87 1750

3.97 2433

kg lb

28 62

34 75

40 88

49 108

68 150

88 195

136 300

154 340

Weight (only base unit)

3

T002 257E

Fixed and Variable Displacement Motors E inheit

030 MF

042 MF

055 MF

075 MF

100 MF

130 MF

055 MV

075 MV

Displacement (maximum)

cm3 in3

30 1.83

42 2.56

55 3.35

75 4.57

100 6.10

130 7.93

55 3.35

75 4.57

Displacement (minimum)

cm3 in3

--

--

--

--

--

--

19

26

at maximum displacement

min-1 (rpm)

4200

4200

3900

3600

3300

3100

3900

3600

at minimum displacement

min-1 (rpm)

--

--

--

--

--

--

4600

4250

at maximum displacement

min-1 (rpm)

4600

4600

4250

3950

3650

3400

4250

3950

at minimum displacement

min-1 (rpm)

--

--

--

--

--

--

5100

4700

Max. attainable speed at max. displacement

min-1 (rpm)

5000

5000

4700

4300

4000

3700

4700

4300

Theoretical torque at max. displacement

Nm/bar lbf•in/1000 psi

0.48 290

0.67 380

0.88 530

1.19 730

1.59 970

2.07 1260

0.88 530

1.19 730

l/min gal/min

138 36.5

193 51

234 62

296 78

365 96

442 117

234 62

296 78

Max. corner power

kW hp

111 149

155 208

187 251

237 318

292 392

354 475

224 300

282 378

Weight SAE-Flange

kg lb

11 24

15 34

22 49

26 57

34 74

45 99

39 86

44 98

Weight Car tridge Motor

kg lb

--

21 46

26 57

33 72

--

--

40 88

46 101

Rated speed

Maximum speed

Maximum flow ar max. displacement

T002 258E

Refer to Series 90 technical information for definitions.

250 - 79

19

Series 90

Pressure Measurement

Pressure Measurement Required Tools The service procedures described in this manual for Series 90 pumps and motors can be performed using common mechanic's tools. Special tools, if required are shown.

Pressure gauges should be calibrated frequently to ensure accuracy. Snubbers are recommended to protect pressure gauges.

Port Locations and Pressure Gauge Installation The following sections list the ports for each type of hydraulic unit. The recommended pressure gauge and fitting are also specified.

Outline drawings showing port locations follow the tables below.

Variable Pump

Port

Function

Gauge Size and Fitting

M1

System Pressure Por t "A"

1000 bar or 10 000 psi 9/16-18 O-ring

M2

System Pressure Por t "B"

1000 bar or 10 000 psi 9/16-18 O-ring fitting

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

Servo Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3 (M6) M4 M5

Port

Function

L1 L2

Case Pressure

T002 259E

Gauge Size and Fitting 10 bar or 100 psi 030 042

7/8-14 O-ring

055 075 100

1-1/16-12 O-ring

130

1-5/16-12 O-ring

180 250

1-5/8-12 O-ring

X1 X2

HDC / EDC Control Pressure

50 bar or 1000 psi 7/16-20 O-ring or 9/16-18 O-ring

X3

External Control Pressure

50 bar or 1000 psi 9/16-18 O-ring

S

Charge Pump Inlet

Vacuum Gauge, Tee into Inlet Line 030 042

1-1/16-12 O-ring

055 075

1-5/16-12 O-ring

100 130 180

1-5/8-12 O-ring

250

1-1/2 SAE-Split Flange T002 260E

20

250 - 80

Series 90

Pressure Measurement

Servo / Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 System Pressure Port B

Servo / Displacement Cylinder Pressure Gauge Port M5 Top View

90000814E

System Pressure Gauge Port M2

System Pressure Port B

External Control Pressure Supply Port X3 Speed Sensor

Charge Inlet Pressure

System Pressure Gauge Port M1

Carge Pump Inlet Port S

System Pressure Port A

Case Drain Port L2

Left Side View

Charge Pressure Gauge Port M3 Right Side View

90000815E 90000816E

PV with Side Port End Cap and Manual Displacement Control

250 - 81

21

Series 90

Pressure Measurement

System Pressure Gauge Port M2

Case Drain Port L1

Servo / Displacement Cylinder Pressure Gauge Port M4

System Pressure Port B Charge Pump Inlet Port S System Pressure Port A System Pressure Gauge Port M1

Servo / Displacement Cylinder Pressure Gauge Port M5 Top View

Case Drain Port L2 Left Side View

90000819E 90000820E

PV with Twin Port End Cap and Manual Displacement Control

Charge Pressure Gauge Port M6 (before the filter)

Port E (from filter) Port D (to filter)

Charge Pressure Gauge Port M3 (after the filter) Rear View

Charge Pressure Gauge Port M3 (after the filter)

Rear View

90000817E 90000818E

PV with Side Port End Cap and Remote Pressure Filtration

22

250 - 82

PV with Side Port End Cap and Integral Pressure Filtration

Series 90

Pressure Measurement

Fixed Motor

Gauge Size and Fitting

Port

Function

Gauge Size and Fitting

Port

Function

M1

System Pressure Port "A"

1000 bar or 10 000 psi 9/16-18 O-ring

L1 L2

Case Pressure)

M2

System Pressure Port "B"

1000 bar or 10 000 psi 9/16-18 O-ring

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3

10 bar or 500 psi

T002 261E

030 042 055

7/8-14 O-ring

075 100 130

1-1/16-12 O-ring T002 262E

System Pressure Gauge Port M1 System Pressure Gauge Port M2

Charge Pressure Gauge Port M3

Case Drain Port L1

System Pressure Port B Case Drain Port L2 System Pressure Port A Rear View

Speed Sensor

Left Side View MF with SAE Flange System Pressure Gauge Port M1 System Pressure Gauge Port M2

Charge Pressure Gauge Port M3

Case Drain Port L1

Speed Sensor System Pressure Port B System Pressure Port A Rear View

Case Drain Port L2 Left Side View 90000821E

MF with Cartridge Flange

250 - 83

23

Series 90

Pressure Measurement

Variable Motor

Port

Function

Gauge Size and Fitting

M1

Systempressure Port "A"

1000 bar or 10 000 psi 9/16-18 O-ring

M2

Systempressure Port "B"

1000 bar or 10 000 psi 9/16-18 O-ring

Charge Pressure

50 bar or 1000 psi 9/16-18 O-ring

M3

T002 263E

Port

Function

Gauge Size and Fitting

M4

Control Cylinbder Pressure "Minimum Displacement"

1000 bar or 10 000 psi 7/16-20 O-ring

M5

Control Cylinbder Pressure"Maximum Displacement"

1000 bar or 10 000 psi 7/16-20 O-ring

L1 L2

Case Pressure

10 bar or 500 psi 1-1/16-12 O-ring T002 264E

Displacement Control Cylinder Pressure Gauge Port M4 Min. Displacement

System Pressure Gauge Port M2

Displacement Control Cylinder Pressure Gauge Port M5 Max. Displacement (Earlier Production Not available as gauge port with servo orifices)

Control Pressure Port X1 (Hydraulic 2-Position Control)

System Pressure Port B

Displacement Control Cylinder Pressure Gauge Port M5 Max. Displacement (Newer Production) Left Side View

MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)

Case Drain Port L1

System Pressure Gauge Port M1 charge Pressure Gauge Port M3 (Same position as in MF)

Speed Sensor System Pressure Port A Case Drain Port L2 Right Side View

90000823E

MV with SAE Flange (Cartridge Flange Version Similar)

24

250 - 84

Series 90

Initial Start-Up Procedure

Initial Start-Up Procedure

The following start-up procedure should always be followed when starting-up a new Series 90 installation or when restarting an installation in which either the pump or motor had been removed.

connections for EDC) be disconnected at the pump control until after initial start-up. This will ensure that the pump remains in its neutral position.

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

WARNING Do not start prime mover unless pump is in neutral position (0° swashplate angle). Take precautions to prevent machine movement in case pump is actuated during initial start up.

S000 008E

S000 007E

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

Fill the reservoir with recommended hydraulic fluid. This fluid should be passed through a 10 micron (nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage to the components, which may result in unexpected vehicle/machine movement. See the publications BLN-9887 and SDF 697581 for further related information.

The inlet line leading from the reservoir to the pump must be filled prior to start-up. Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks.

Be certain to fill the pump and/or motor housing with clean hydraulic fluid prior to start up.

Fill the housing by pouring filtered oil into the upper case drain port.

Install a 50 bar (or 1000 psi) pressure gauge in the charge pressure gauge port to monitor the charge pressure during start-up.

It is recommended that the external control input signal (linkage for MDC, hydraulic lines for HDC, or electrical

250 - 85

“Jog” or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at the lowest possible RPM until charge pressure has been established. Excess air may be bled from the high pressure lines through the high pressure system gauge port.

Once charge pressure has been established, increase speed to normal operating RPM. Charge pressure should be as indicated in the pump model code. If charge pressure is inadequate, shut down and determine cause for improper pressure. Refer to Troubleshooting.

WARNING Take necessary precautions that the motor shaft remains stationary during the adjustment procedure.

S000 010E

Shut down the prime mover and connect the external control input signal. Also reconnect the machine function if disconnected earlier. Start the prime mover, checking to be certain the pump remains in neutral. With the prime mover at normal operating speed, slowly check for forward and reverse machine operation.

Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly between forward and reverse for at least five minutes.

Shut down prime mover, remove gauges, and plug ports.

Check reservoir level and add filtered fluid if needed.

The transmission is now ready for operation.

25

Series 90

Fluid and Filter Maintenance

Fluid and Filter Maintenance

ManoVacuummeter

Check the reservoir daily for proper fluid level, the presence of water (noted by a cloudy to milky appearance, or free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat). If either of these conditions occur, change the fluid and filter immediately.

Hydraulic fluid reservoir Filter Charge pump

It is recommended that the fluid and filter be changed per the vehicle/machine manufacturer’s recommendations or at the following intervals:

Adjustable Charge pressure relief valve

to low pressure side and control

To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness while performing any service procedure.

First change

To pump case

500 operating hours after start up P000 797E

second and subsequent changes every 2000 operating hours or once a year.

Suction Filtration Schematic

This recommendation applies for the most applications.

High temperatures and pressures will result in accelerated fluid aging and an earlier fluid change may be required. At lower fluid loads longer change intervalls are possible. Therefore we suggest to check the fluid with the manufacturer for suitability. This should be done at latest half way between fluid changes.

Screen

Hydraulic fluid reservoir Adjustable Charge pressure relief valve

Charge pump

to low pressure side and control

To pump case

It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid has been subjected to temperature levels greater than the recommended maximum. Never reuse fluid.

The filter should be changed whenever the fluid is changed or whenever the filter indicator shows that it is necessary to change the filter.

Filter Cleanliness Level and β x -Ratio P000 798E

Charge Pressure Filtration Schematic (Partial flow)

Required fluid cleanliness level Recommended βx -ratio for suction filtration Recommended βx -ratio for charge pressure filtration Recommended inlet screen size for charge pressure filtration

ISO 4406 Class 18/13 β 35-45 =75

(β10≥ 2)

β 15-20 =75

(β10≥ 10)

100 µ m-125 µm T002 007E

26

250 - 86

Series 90

Toubleshooting

Troubleshooting This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your specific equipment.

"NEUTRAL" Difficult or Impossible to Find Check

Description

Action

1. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Adjust, repair, or replace control module as necessary.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Operating Hot Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid will not meet cooling demands of system.

Fill reservoir to proper level.

2. Heat exchanger.

Heat exchanger not sufficiently cooling the system.

Check air flow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger.

3. Charge pressure.

Low charge pressure will overwork system.

Measure charge pressure. Inspect and adjust or replace charge relief valve. Or repair leaky charge pump.

4. Charge pump inlet vacuum.

High inlet vacuum will overwork system. A dirty filter will increase the inlet vacuum. Inadequate line size will restrict flow.

Check charge inlet vacuum. If high, inspect inlet filter and replace as necessary. Check for adequate line size, length or other restrictions.

5. System relief pressure settings.

If the system relief settings are too low, the relief valves will be overworked.

Verify settings of pressure limiters and high pressure relief valves and adjust or replace multi-function valves as necessary.

Leakage will reduce low side system pressure and overwork the system.

Monitor motor case flow without loop flushing in the circuit (use defeat spool).

If flow is excessive, replace motor.

High system pressure will overheat system.

Measure system pressure. If pressure is high reduce loads.

6. For internal leakage in motor.

7. System pressure.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

250 - 87

27

Series 90

Toubleshooting

Transmission Operates Normally in One Direction Only Check

Description

Action

1. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary.

3. Interchange system pressure limiters, high pressure relief valves, and system check valves.

Interchanging the multi-function valves will show if the problem is related to the valve functions contained in the multifunction valves.

Interchange multi-function valves. If the problem changes direction, repair or replace the valve on the side that does not operate.

4. Charge pressure.

If charge pressure decays in one direction the loop flushing valve may be “sticking” in one direction.

Measure charge pressure in forward and reverse. If pressure decays in one direction, inspect and repair the motor loop flushing valve.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Will Not Operate in Either Direction Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid to supply system loop.

Fill reservoir to proper level.

2. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

3. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary.

4. Ensure bypass valve(s) are closed.

If bypass valve(s) is open, the system loop will be depressurized.

Close bypass valves. Replace multifunction valve if defective.

5. Charge pressure with pump in neutral.

Low charge pressure insufficient to recharge system loop.

Measure charge pressure with the pump in neutral. If pressure is low, go to step 6; otherwise continue with step 5.

6. Charge pressure with pump in stroke.

Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set.

Measure charge pressure with pump in stroke. If pressure is low, adjust or replace motor charge relief valve, otherwise go to step 9.

7. Pump charge relief valve.

A pump charge relief valve that is leaky or set too low will depressurize the system.

Adjust or replace pump charge relief valve as necessary.

8. Charge pump inlet filter.

A clogged filter will undersupply system loop.

Inspect filter and replace if necessary.

9. Charge pump.

A malfunctioning charge pump will provide insufficient charge flow.

Repair or replace the charge pump. If OK go to last step.

28

250 - 88

Series 90

Toubleshooting

10. Pump displacement control.

Control linkages are not secure, control orifices are blocked, etc.

Repair or replace control module as necessary.

11. System pressure.

Low system pressure will not provide power necessary to move load.

Measure system pressure. Continue with next step.

12. System multi-function valves.

Defective multi-function valves will cause system pressure to be low.

Repair or replace multi-function valve(s).

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

Low Motor Output Torque Check

Description

Action

1. System pressure at motor.

Low system pressure at the motor will reduce torque.

Measure system pressure at motor. If pressure limiter setting is low, increase setting.

2. Variable motor stuck at minimum displacement.

Minimum motor displacement yields low output torque.

Check control supply pressure or repair displacement control. Check motor control orifices.

3. For internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

Improper Motor Output Speed Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid will reduce motor speed.

Fill oil to proper level.

2. Pump output flow.

Incorrect outflow will affect output speed. Incorrect output flow indicates the swashplate is out of position.

Measure pump output and check for proper pump speed and see that the pump is in full stroke.

3. Variable motor displacement control.

If variable motor displacement control is not functioning correctly, variable motor swashplate may be in wrong position.

See if variable motor displacement control is responding. If not, repair or replace control.

4. For internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings. Repair unit as required, or replace leaky unit.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

250 - 89

29

Series 90

Toubleshooting

Excessive Noise and/or Vibration Check

Description

Action

1. Oil in reservoir.

Insufficient hydraulic fluid will lead to cavitation.

Fill reservoir to proper level.

2. Air in system.

Air bubbles will lead to cavitation.

Look for foam in reservoir. Check for leaks on inlet side of system loop. Afterwards, let reservoir settle until bubbles are gone. Run system at low speed to move system fluid to reservoir. Repeat.

3. Pump inlet vacuum.

High inlet vacuum will create noise. A dirty filter will increase the inlet vacuum.

Inspect and replace filter as necessary.

Check for proper suction line size.

4. Shaft couplings.

A loose shaft coupling will cause excessive noise.

Replace loose shaft coupling in charge pump or replace pump or motor.

5. Shaft alignment.

Unaligned shafts will create excessive frictional noise.

Align shafts.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

System Response is Sluggish Check

Description

Action

1. Oil level in reservoir.

Insufficient hydraulic fluid will reduce output pressure.

Fill reservoir to proper level.

2. Multi-function valves’ pressure settings.

Incorrect pressure settings will affect system reaction time.

Adjust or replace multi-function valves.

3. Pump inlet vacuum.

High pump inlet vacuum will reduce system pressure.

Measure charge inlet vacuum. If high replace inlet filter.

4. Prime mover speed.

Low engine speed will reduce system performance.

Adjust engine speed.

5. Charge and control pressures.

Incorrect charge or control pressures will affect system performance.

Measure charge and control pressures and correct if necessary.

6. System internal leakage.

Internal leakage will reduce system pressure.

Check for leakage in O-rings, gaskets, and other fittings.

If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center.

30

250 - 90

Series 90

Inspections and Adjustments

Inspections and Adjustments This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read through the entire related section before beginning a service activity. Refer to the corresponding section for location of gauge ports and suggested gauge size.

Pump Adjustments Charge Pressure Relief Valve Adjustment The following procedure explains how to check and adjust the charge pressure relief valve.

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

S000 007E

90000243

Charge Pressure Gauge Port (Reducer fitting shown - if filtration device attached)

1.

2.

To measure pump charge pressure, install a pressure gauge in the pump charge pressure gauge port (M3). Also install a gauge to measure case pressure (tee into L1 or L2 or use servo gauge port). Operate the system with the pump in “neutral” (zero displacement) when measuring pump charge pressure.

The table shows the acceptable pump charge pressure range for some nominal charge relief valve settings (see sample model code at right). These pressures assume 1500 pump rpm and a reservoir temperature of 50°C (120°F ), and are referenced to case pressure (see footnote on next page). Smaller displacement charge pumps will produce charge pressure readings in the lower portion of the range, while larger displacement charge pumps will produce readings in the higher portion of the range.

Nominal

90L055 EA 1 N Charge Pressure 6 S 3 C6 C 03 HNN 35 35 24 Model Code on Unit Name Plate (“24 bar”)

M odel Code

Measured Charge Pressure *

20

18.1 bis 21.7 bar (262 to 315 psi)

24

22.0 bis 26.9 bar (319 to 390 psi)

28

25.8 bis 30.7 bar (374 to 445 psi) T002 266E

* This is the actual charge pressure port gauge reading minus the case pressure port gauge reading.

Note:

These pressures assume a pump speed of 1450 - 1500 rpm. At higher pump input speeds (with higher charge flows) the charge pressure will rise over the rated setting.

* This is the actual charge pressure port gauge reading minus the case pressure port gauge reading.

250 - 91

31

Series 90

Inspections and Adjustments

3.

90000262

Shim Adjustable Charge Pressure Relief Valve (Pump)

Earlier production Series 90 pumps are equipped with a shim adjustable charge pressure relief valve.

Shim kits are available from SAUER-SUNDSTRAND. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring. The plug for this type of charge relief valve should be torqued to 68 Nm (50 lbf•ft).

Later production Series 90 pumps are equipped with an external screw adjustable charge pressure relief valve. Adjustment of the charge pressure is accomplished by loosening the lock nut -

90000264

Screw Adjustable Charge Pressure Relief Valve (Pump)

F rame Size 0 30 - 100 1 30 - 250

Wrench Size 1-1/16 inch 1-5/8 inch T002 267E

and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench.

Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 3.9 bar (50 psi) per turn).

The lock nut for this type of charge relief valve should be torqued to 52 Nm (39 lbf•ft).

4.

32

250 - 92

Once the desired charge pressure setting is achieved, remove the gauges.

Series 90

Inspections and Adjustments

Multi-Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simultaneously. The latter is automatically set approximately 35 bar (500 psi) above the former.

In order to adjust the pressure limiter setting, the motor output shaft must be locked so it does not rotate. This may be accomplished by locking the vehicle’s brakes or rigidly fixing the work function so it cannot rotate.

WARNING Take necessary precautions that the motor shaft remains stationary during the adjustment procedure.

S000 010E 90000258

Multi-Function Valves on PV

1.

Install two 1000 bar (or 10 000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 50 bar (or 1000 psi) pressure gauge in the pump charge pressure gauge port (M3).

2.

Start the prime mover and operate at normal speed.

3.

Loosen locking nut.

F rame Size early 042 - 100 newer 030 - 100 e arly 130 1 30 - 250

Wrench Size 10 mm 19 mm 13 mm 24 mm T002 268E

4.

Insert a internal hex wrench into the pressure adjusting screw.

F rame Size early 042 - 100 newer 030 - 100 e arly 130 1 30 - 250

Internal Hex Wrench Size 90000259

3 mm

Loosen Pressure Adjusting Screw Lock Nut

5 mm 4 mm 8 mm T002 269E

Note:

A plastic dust plug is installed in the adjusting screw on 030 and late 042 through 250 units.

250 - 93

33

Series 90

Inspections and Adjustments

90L055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24

5.

The factory preset pressure limiter setting is shown on the model code as at right. It is referenced to charge pressure, so the pressure limiter setting is the difference between the high and low pressure sides of the system loop. Activate or move the control input so that pressure increases in the high pressure side of the closed circuit to the pressure limiter pressure setting. The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level (as shown on the gauges).

6.

Return the pump to its “neutral” (zero flow) position and adjust the pressure limiter setting by rotating the pressure adjusting screw with the internal hex wrench.

Pressure Limiter Setting Ports A and B (differential pressure in 10s of bars, e.g. “35” = 350 bar)

Clockwise rotation of the pressure adjustment screw will increase the pressure setting, and counterclockwise rotation will decrease the pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure as shown in the following table.

Frame Size early 042 - 100 newer 030 - 100 1 30 - 250

90000260

Approx Change per Rev of the Adjusting Screw 80 bar (1157 psi) per Rev 90 bar (1300 psi) per Rev 80 bar (1157 psi) per Rev T002 270E

Rotate Pressure Adjusting Screw

7.

To verify the actual pressure setting, actuate or move the control input so that the pump again develops pressure in the high pressure circuit to the newly adjusted pressure limiter pressure setting, and read the high pressure gauge. Then allow the pump to return to its “neutral” position. The pressure in the high pressure circuit should return to the charge pressure setting.

8.

While holding the pressure adjusting screw stationary, tighten the pressure adjusting screw lock.

F rame Size early 042 - 100 newer 030 - 100 1 30 - 250

Torque 3 Nm (26 lbf•in) 20 Nm (15 lbf•ft) 4 0 Nm (30 lbf•ft) T002 271E

Do not overtorque.

90000261

Tighten Lock Nut

9.

Shut down the prime mover, remove the gauges and install the gauge port plugs. Replace the plastic dust plugs (if used).

The same procedure is used for setting the pressure limit of the other multi-function valve, but the control input signal must be activated or moved in the opposite direction so that high pressure develops in the opposite side of the closed circuit.

34

250 - 94

Series 90

Inspections and Adjustments

Engaging the Bypass Function The bypass function is performed by the multi-function valve cartridges. The prime mover should be shut down when opening or closing the bypass valves.

The bypass valves on both of the multi-function valves must be opened to engaged the bypass function.

1.

Using a F rame Size newer 030 - 100 1 30 - 250

Wrench Size 1-1/16 inch 1-3/8 inch T002 272E

wrench on the middle sized hex of the multi-function valve cartridge, and a F rame Size newer 030 - 100 1 30 - 250

Wrench Size

90000266

Loosening and Rotating Bypass Hex on Multi-Function Valve

1-1/4 inch 1-5/8 inch T002 273E

Bypass Actuator

Opening Bypass Valve allows flow to circuit through Multi-Function Valves

wrench on the large hex to prevent rotation of the cartridge assembly, rotate the middle hex three revolutions counterclockwise to open the bypass valve. Do not rotate more than 3-1/2 revolutions, as additional rotation will permit external leakage.

2.

For units with an MDC-type control, prior to moving the vehicle or otherwise causing the motor shaft to turn, move the control handle of the manual displacement control on the pump to the maximum full forward position. Hold the handle in this position during bypass valve operation.

90000827E

Multi-Function Valve with Bypass Function Engaged

Caution "Tow" at extremely low speeds and for short distances only.

S000 011E

3.

To close the bypass valve, rotate the middle hex clockwise until it is seated. Then torque the middle hex.

F rame Size newer 030 - 100 1 30 - 250

Torque 41 Nm (30 lbf•ft) 100 Nm (75 lbf•ft) T002 274E

250 - 95

35

Series 90

Inspections and Adjustments Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) The Pressure Override Valve is explained in the corresponding section.

Pressure Override Valve

1.

Install two 1000 bar (or 10 000 psi) pressure gauges in the high pressure gauge ports (M1 and M2). Install a 50 bar (or 1000 psi) pressure gauge in the pump charge pressure gauge port (M3).

2.

Start the prime mover and operate at normal speed.

3.

With the pump operating at approximately 20% displacement, load the work function and note the pressure as the POR valve operates (pump displacement reduces to “zero”).

4.

Adjustment of the pressure override setting is made by loosening the lock nut with a 9/16 inch hex wrench and turning the adjustment screw with a 3/16 inch internal hex wrench. The POR setting should be at least 50 bar (750 psi) below the high pressure relief valve setting of the multi-function valves for proper operation.

5.

Following the adjustment, torque the lock nut to 43 Nm (32 lbf•ft).

6.

Shut down the prime mover and remove the gauges and install the gauge port plugs.

Adjusting Screw Lock Nut

Right Side View 90000828E

Pressure Override Valve for 180 Frame Size

36

250 - 96

Series 90

Inspections and Adjustments

Displacement Limiter Adjustment The maximum displacement can be limited in either direction.

1.

Loosen the seal lock nut retaining the displacement limiter adjusting screw.

F rame Size 0 30 - 100 130 1 80 - 250

Wrench Size 13 mm 17 mm 19 mm T002 275E

2.

Rotate the adjusting screw.

F rame Size 0 30 - 100 130 1 80 - 250

Internal Hex Wrench Size 4 mm 5 mm 6 mm

90000267

Loosen Displacement Limiter Lock Nut

T002 276E

Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump while rotating the adjusting screw counterclockwise will increase the maximum displacement.

Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions.

The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

S000 012E 90000268

3.

After establishing the desired maximum displacement setting, tighten the lock nut on the adjusting screw as follows.

F rame Size 0 30 - 100 130 1 80 - 250

Rotate Adjusting Screw

Torque 24 Nm (18 lbf•ft) 48 Nm (35 lbf•ft) 125 Nm (92 lbf•ft) T002 278E

4.

One turn of the adjusting screw will change the maximum displacement approximately as follows.

Frame Size 030 042 055 075 100 130 180 250

Approx Change in Disp per Rev of Adjusting Screw 2.8 cm3 / Rev (0.17 in3 / Rev) 3.5 cm3 / Rev (0.21 in3 / Rev) 4.2 cm3 / Rev (0.26 in3 / Rev) 5.1 cm3 / Rev (0.31 in3 / Rev) 6.2 cm3 / Rev (0.38 in3 / Rev) 8.8 cm3 / Rev (0.53 in3 / Rev) 12.5 cm3 / Rev (0.76 in3 / Rev) 17.3 cm3 / Rev (1.06 in3 / Rev)

Tighten Lock Nut

90000269

T002 277E

250 - 97

37

Series 90

Inspections and Adjustments

Pump Control Adjustments Standard Manual Displacement Control (MDC) Adjustment There are no adjustable elements in the manual displacement control. The control spool is held in its “neutral” position by centering springs and washers on each end of the spool. Since there is no centering spring on the control input shaft, the shaft will automatically assume the appropriate position when the control is installed on the pump.

90000237

Variable Displacement Pump with Standard Manual Displacement Control

38

250 - 98

Series 90

Inspections and Adjustments

Non-Linear Manual Displacement Control (MDC) A centering spring, located on the control input shaft, locates the control shaft in its “neutral” position. A bias spring on the control spool maintains a force on the spool and the control linkage to eliminate looseness (“freeplay”) in the linkage.

The “neutral” adjustment is the only adjustment that can be made on the nonlinear manual displacement control.

All other functions are preset at the factory.

This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating.

90000829

Variable Displacement Pump with Non-Linear Manual Displacement Control

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

S000 007E

1.

Install two 50 bar (or 1000 psi) gauges in each of the displacement control cylinder gauge ports (M4 and M5). Disconnect the external control linkage from the control handle and make certain the control shaft is in its “neutral” position. Start the prime mover and operate at normal speed.

2.

Loosen the lock nut on the neutral adjusting screw with a 13 mm hex wrench.

3.

Using a 4 mm internal hex wrench, rotate the neutral adjusting screw clockwise until the pressure increases on one of the pressure gauges. Note the angular position of the wrench.

4.

Rotate the adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge. Note the angular position of the wrench.

5.

Rotate the adjusting screw clockwise half the distance between the locations noted above. The gauges should read the same pressure (case pressure), indicating that the control is in its “neutral” position.

6.

Hold the adjusting screw stationary and tighten the lock nut to 13.5 Nm (10 lbf•ft). Do not overtorque the nut.

7.

Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control linkage.

250 - 99

90000357

Rotate Neutral Adjusting Screw

90000358

Tighten Neutral Adjusting Screw Lock Nut

39

Series 90

Inspections and Adjustments MDC Neutral Start Switch (NSS) Adjustments

A

A Control Shaft

Switch Cam

Switch Lock Nut Neutral Start Switch Eccentric Plug Switch Pin Special Lock Nut for Eccentric Plug

The neutral start switch (NSS) provides a means to prevent the system prime mover from starting while the pump control handle and control input shaft are in a position which would command the pump to go “instroke” in either the “forward” or “reverse” direction.

When the control input shaft is in its “neutral” position, the inner end of the switch pin moves into a slot on the eccentric cam attached to the control shaft. This allows the spring loaded NSS to close, completing the electrical starting circuit for the prime mover.

When the control input shaft is NOT in its “neutral” position, the eccentric cam moves the switch pin out of the slot. This forces the NSS to open, breaking the electrical starting circuit for the prime mover.

MDC with Neutral Start switch

The neutral start switch is threaded into the special lock nut for the eccentric plug.

Orifice Check Valve Seat Control Spool Assembly Control Link Assembly View at Section A-A

90000830E

Components of the Standard Manual Displacement Control with Neutral Start Switch

Turning the NSS clockwise (CW) into the special nut will move the NSS closer to the switch cam on the control shaft, and will narrow the NSS deadband. Turning the NSS counterclockwise (CCW) out of the special nut will move the NSS farther from the switch cam on the control shaft, and will widen the NSS deadband.

The switch pin is located in an eccentric plug which is turned to move the center of the NSS deadband. (continued)

40

250 - 100

Series 90 The NSS must be adjusted to meet the following three requirements: i.

The distance the control handle can be turned without opening the NSS is called the “NSS Deadband.”

The distance the control handle can be moved without moving the control spool enough to port hydraulic fluid to the pump displacement control cylinders is called the “Control Deadband.” These deadbands must be centered in relation to each other.

Since the position of the control deadband cannot be adjusted, the position of the NSS deadband must be adjusted to match it.

ii.

Inspections and Adjustments NSS Deadband (Switch closed, "ON")

Control Shaft ("Free-Play")

Control Deadband ("Neutral") Total Control Shaft Rotation Control Shaft

The NSS deadband must be wide enough so the NSS will not open within the loose area of control handle movement caused by normal operating clearances in the control linkage (control shaft “free-play”).

By setting the NSS to open outside this area, the control spool springs or control shaft centering spring can always act to return the handle to “neutral” and re-close the NSS.

iii. The NSS deadband must be narrow enough so the NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction.

90000831E

(continued)

250 - 101

Neutral Start Switch Adjustment Requirements

41

Series 90

Inspections and Adjustments NSS Deadband Adjustment (Conditions ii & iii) The NSS deadband must be wide enough so the NSS will not open within the control shaft “free-play” area, and it must be narrow enough so the NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction.

1.

Install two 1000 bar (10 000 psi) pressure gauges in the system pressure gauge ports M1 and M2.

2.

Using two 1-1/8 inch wrenches, hold the neutral start switch from turning and loosen the locknut.

3.

Disconnect the external control linkage and make certain the control shaft is in its “neutral” position.

4.

Attach a continuity checker to the terminals of the switch. With the control shaft in its “neutral” position, turn the switch clockwise (CW) until electrical continuity is broken, then turn the switch counterclockwise (CCW) until electrical continuity is obtained. Turn the switch counterclockwise (CCW) an additional 1/4 turn (90°) after continuity has been obtained.

5.

Hold the switch in place and tighten the locknut to 27 Nm (20 lbf•ft) torque.

6.

With the continuity checker attached to the switch, rotate the control handle (or the control shaft) in each direction to assure continuity is broken when the control is not in the “neutral” position.

7.

If continuity is obtained in “neutral” and satisfactorily interrupted in each direction, proceed to check the switch with the prime mover running. The switch must open before the unit builds 7 bar (100 psi) differential system pressure in either direction.

90000253

Loosening the NSS Lock Nut

Control Shaft

Switch Lock Nut Switch Cam

Switch Pin

Neutral Start Switch

1-1/8 in. hex wrench Torque: 27 Nm (20 lbf•ft)

NSS

90000870

Checking Continuity of NSS (System Pressure Gauges installed on far side)

42

250 - 102

If the switch opens after the unit builds system pressure in either direction, loosen the switch lock nut and turn the switch clockwise (CW) 1/12 turn (30°). Tighten the switch lock nut and recheck the switch operation. Repeat this procedure if necessary.

90000832E

8.

If continuity is not interrupted with an equal movement of the control handle in each direction, turn off prime mover, remove the pressure gauges, and continue with the next section.

9.

If neutral start switch operation is satisfactory, turn off the prime mover, remove the pressure gauges, and reconnect the external control linkage.

Series 90

Inspections and Adjustments

Neutral Start Switch Eccentric Plug Adjustment (Condition i)

12.7 (0.5)

9.14 (0.36)

The NSS deadband and the control deadband must be centered in relation to each other.

Since the position of the control deadband cannot be adjusted, the position of the NSS deadband must be adjusted to match it. The switch pin is located in an eccentric plug which is turned to move the center of the NSS deadband.

The MDC should be installed on the pump and be in its “neutral” position when adjusting the neutral start switch eccentric plug.

3.175 (0.125)

1.52 (0.06)

25.4+ (1.0) 90000834E

Eccentric Plug Adjustment Tool

The accompanying drawing provides dimensions for an Eccentric Plug Adjustment Tool.

1.

Hold the switch and eccentric plug from turning and use two 1-1/8 inch wrenches to loosen the locknut.

Remove the neutral start switch.

WARNING Do not start the prime mover while the neutral start switch is removed from the control. Case pressure will force the pin out of the eccentric plug, causing oil loss.

Switch Lock Nut

Eccentric Plug

X

Switch Pin Special Lock Nut for Eccentric Plug

Neutral Start Switch

S000 032E

MDC with Neutral Start Switch Special Lock Nut for Eccentric Plug Eccentric Plug

Control Mounting Surface

Switch Pin

View in Direction X (Switch and lock nut removed) 90000833E

NSS with Eccentric Plug

2.

Note the slots on the eccentric plug for the adjustment tool. Hold the eccentric plug in place with the adjustment tool, and loosen the lock nut with a 1-1/8 inch wrench.

(continued)

90000256

Loosen Eccentric Lock Nut

250 - 103

NSS Removed

90000257

43

Series 90

Inspections and Adjustments

Switch Pin

3.

Position the eccentric plug so the switch pin is offset toward the control mounting surface. This will provide the best contact between the pin and the cam on the control shaft.

4.

Hold the control shaft in its “neutral” position (in the center of the control shaft “free-play” area). Locate the switch pin in the slot of the switch cam by turning the eccentric plug while checking the pin position (depth) in the plug. When the pin engages the cam slot, the pin will be at its maximum depth in the plug.

Hand tighten the plug lock nut to hold the eccentric plug in position.

5.

Turn the control shaft an equal amount in either direction from “neutral.” The switch pin should move out of the eccentric plug an equal distance when the control shaft is turned. Turn the eccentric plug to center the switch pin with the cam slot. Only a small amount of adjustment in either direction should be needed to center the pin.

6.

While holding the eccentric plug in place, tighten the eccentric plug lock nut to 27 Nm (20 lbf•ft). Reinstall and adjust the switch as outlined in the previous section.

Eccentric Plug

90˚

Control Mounting Surface

90˚

Eccentric Plug Adjustment Range

90000835E

Eccentric Plug Adjustment

Note:

Adjust the Eccentric Plug

The eccentric plug normally requires between 5-1/2 and 6-1/2 turns to install into the control housing .

90000256

Caution Do not turn the eccentric plug into or out of the housing beyond specifications.

S000 014E

7.

Once the switch is correctly adjusted, hold the switch in place and tighten the locknut to 27 Nm (20 lbf•ft) torque.

(continued)

44

250 - 104

Series 90

Inspections and Adjustments

Checking Switch Continuity Recheck switch continuity to determine whether additional adjustment of the eccentric plug is necessary.

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

S000 007E

1.

Install two 50 bar (or 1000 psi) gauges in each of the displacement control cylinder gauge ports (M4 and M5). Attach a continuity checker to the terminals of the neutral start switch.

2.

Energize the starter circuit, and start the prime mover.

3.

While operating at normal speed and with the pump in its “neutral” (zero flow) position, note the pressure reading on the gauges. This reading should be noted as the base pressure.

4.

Slowly move the control handle in one direction while observing the pressure gauges and the continuity checker. Continuity must be broken before the pressure on either gauge increases more than 1 bar (12 psi) from the base pressure obtained at “neutral.”

5.

Slowly move the control handle in the opposite direction. Again, continuity must be broken before the gauge pressure increases more than 1 bar (12 psi) from base pressure.

6.

Continuity must again be verified when the control is returned to neutral.

7.

If continuity is not broken at base pressure plus 0 to 1 bar (0 to 12 psi) in either direction, stop the prime mover and readjust the eccentric plug as described in the previous section. If the pressure difference is equal in each direction but greater than 1 bar (12 psi), loosen the switch locknut and turn the switch clockwise 1/12 turn (30°) to increase the sensitivity. Retighten the locknut and recheck pressure differences and continuity.

8.

After verifying proper control and switch operation, stop the prime mover. Remove the continuity checker and pressure gauges. Reinstall the servo pressure port plugs and reconnect the electrical leads from the machine starter circuit to the neutral start switch.

Install and adjust, if necessary, the external control linkage.

250 - 105

Checking Continuity of NSS (Gauges installed in Servo Gauge Ports)

90000255

45

Series 90

Inspections and Adjustments Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment The “neutral” adjustment is the only adjustment that can be made on hydraulic and electric displacement controls.

All other functions are preset at the factory.

This adjustment must be made on a test stand or on the vehicle/machine with the prime mover operating.

PV with Hydraulic Displacement Control

90000240

The neutral adjustment is performed by adjusting a neutral adjusting shaft (earlier production EDCs) or a neutral adjusting screw (HDCs and current production EDCs).

WARNING The following procedure may require the vehicle/ machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while performing the procedure in order to prevent injury to the technician and bystanders. Take necessary safety precautions before moving the vehicle/machine.

S000 007E

PV with Electric Displacement Control

90000241

90000249

Install Gauges in Displacement Control Cylinder Gauge Ports

46

250 - 106

1.

Install two 50 bar (or 1000 psi) gauges in each of the two displacement control cylinder gauge ports (M4 and M5). Disconnect the external control input (hydraulic or electronic) from the control. Start the prime mover and operate at normal speed.

2.

Loosen the lock nut with a 17 mm hex wrench for the neutral adjusting shaft or with a 10 mm or 13 mm hex wrench for the neutral adjusting screw.

Series 90 3.

Using a 5 mm internal hex wrench for the neutral adjusting shaft or a 3 mm or 4 mm internal hex wrench for the neutral adjusting screw, rotate clockwise until the pressure increases in one of the pressure gauges. Note the angular position of the wrench. Then rotate the neutral adjusting shaft or screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench.

4.

Rotate the neutral shaft or adjusting screw clockwise half the distance between the locations noted above.

The gauges should read the same pressure (case pressure), indicating that the control is in its “neutral” position.

5.

Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral shaft lock nut (early production controls) to 22 Nm (195 lbf•in.). Tighten the neutral adjusting screw lock nut (later production controls) to 7 Nm (62 lbf•in.) for the 6 mm screw or 13.5 Nm (120 lbf•in.) for the 8 mm screw. Do not overtorque the nut.

6.

Once the neutral position is set, stop the prime mover, remove the gauges, and install the gauge port plugs. Reconnect the external control input.

Inspections and Adjustments

90000250

Rotate Neutral Adjusting Shaft (Early production)

90000251

Rotate Neutral Adjusting Screw (Later production)

90000355

Rotate Neutral Adjusting Shaft (Current production HDC)

250 - 107

90000252

Tighten Neutral Adjusting Shaft Lock Nut (Early production)

90000318

Tighten Neutral Adjusting Screw Lock Nut (Later production)

90000356

Tighten Neutral Adjusting Shaft Lock Nut (Current production HDC)

47

Series 90

Inspections and Adjustments

Motor Adjustments Charge Relief Valve Adjustment

90000248

Charge Pressure Gauge Port (MF)

90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24

1.

To measure motor charge pressure, install a 50 bar (or 1000 psi) pressure gauge in the motor charge pressure gauge port (M3). Size 30 and 42 don’t have the M3 gauge port. Install pressure gauge in the motor system pressure gauge port. For this kind of measurement add 1 bar (14.5 psi) to the nominal values shown in the table. Also install a gauge to measure case pressure. Operate the system with the pump in stroke (forward or reverse) when measuring motor charge pressure.

2.

The following table shows acceptable motor charge pressures for some nominal charge relief valve settings (see model code at right). These pressures assume a reservoir temperature of 50°C (120°F).

They are referenced to case pressure and assume a one pump/one motor system.

3.

Earlier production Series 90 motors are equipped with a shim adjustable charge relief valve. Shim kits are available as service items. Adjustment of the charge pressure is accomplished by removing the plug (7/8 inch hex) and changing the shim thickness behind the spring. The plug for this type charge relief port should be torqued to 68 Nm (50 lbf•ft).

Nominal charge Pressure Setting

Model Code

Motor Charge Pressure (±1.4 bar [±20 psi])

10

8.1 bar (117 psi)

18

16.1 bar (233 psi)

20

18.1 bar (262 psi)

24

22.1 bar (320 psi)

28

26.1 bar (378 psi)

30

30.0 bar (435 psi)

Later production Series 90 motors are equipped with an external screw adjustable charge relief valve.

Adjustment of charge pressure is accomplished by loosening the lock nut, F rame Size 0 30 - 130

T002 279E

Wrench Size 1-1/16 inch T002 293E

Model Code at the Name Plate (24 bar)

and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 5.4 bar [78 psi] per turn). The lock nut for this type charge relief valve should be torqued to 52 Nm (38 lbf•ft).

4.

90000263

Shim Adjustable Charge Pressure Relief Valve (Motor)

48

250 - 108

90000343

Screw Adjustable Charge Pressure Relief Valve (Motor)

Once the desired charge pressure setting is achieved, remove the gauges.

Series 90

Inspections and Adjustments

Displacement Limiter Adjustment (MV) Both the maximum and minimum displacement may be limited.

1.

Remove the tamper resistant cap from the displacement limiter screw. Loosen the seal lock nut retaining the displacement limiter adjusting screw with a 19 mm wrench.

Tamper-Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw

Caution The displacement limiters act as travel stops for the swashplate. Do not turn the limiter screws counterclockwise beyond the point of contact with the swashplate for either the maximum or minimum displacement position.

S000 015E

2.

All adjustments can only be done when the motor is running and the pump is in neutral position. Steer the respective displacement limiter by the control.

Rotate the adjusting screw with a 6 mm internal hex wrench. Rotating the maximum displacement adjusting screw clockwise will decrease the maximum displacement of the motor. Rotating the minimum displacement adjusting screw clockwise will increase the minimum displacement of the motor.

Minimum Displacement Limiter Screw Seal Lock Nut Tamper-Resistant Cap SAE Flange Version shown (Cartridge Version similar) 90000837E

MV Displacement Limiters

Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions. See corresponding section for speed and pressure limits.

The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

S000 016E

3.

After establishing the desired displacement setting, tighten the lock nut on the adjusting screw to 54 Nm (40 lbf•ft). Install a new tamper resistant cap.

4.

One turn of the adjusting screw will change the maximum or minimum displacement according to the following chart.

Frame Size 055 075

90000359

Rotate Adjusting Screw for Minimum Displacement Limiter

90000360

Tighten Lock Nut for Minimum Displacement Limiter

Approx Change in Disp per Rev of Adjusting Screw 5.6 cm3 / Rev (0.34 in3 / Rev) 7.1 cm3 / Rev (0.43 in3 / Rev) T002 280E

Displacement Control Adjustments All variable motor displacement control settings do not require adjusting.

250 - 109

Maximum Displacement Limiter

90000352

49

Series 90

Inspections and Adjustments

Speed Sensor Adjustment When installing or adjusting the speed sensor on a pump or motor, it must be set at a specific distance from the speed ring on the unit’s cylinder. To locate the position of the speed sensor on the unit or description see the corresponding section.

Gap

Speed Sensor Magnetic Speed Ring 90000838E

Cross Section View of Speed Sensor in Variable Pump

1.

Loosen the sensor lock nut with an 1-1/16 inch hex wrench.

2.

Turn the sensor clockwise (CW) by hand until it contacts the speed ring.

3.

Turn the sensor counterclockwise (CCW) 1/2 turn (180°) to establish the nominal gap of 0.71 mm (0.028 inch).

4.

Then turn the sensor clockwise (CW) until the wrench flats on sensor body are positioned at a 22° angle to the pump shaft center line.

Gap

Magnetic Speed Ring Speed Sensor 90000839E

Note:

Cross Section View of Speed Sensor in fixed Motor

5.

The final sensor position should be between 1/2 (180°) and 1/4 turn (90°) counterclockwise (CCW) from the point where the sensor contacts the speed ring.

6.

Hold sensor in position with a 1/2 inch hex wrench while tightening the lock nut to 13 Nm (10 lbf•ft).

Gap

Speed Sensor Magnetic Speed Ring 90000840E

Cross Section View of Speed Sensor in Variable Motor

Shaft Centerline 1/2 in. Wrench Flats 22˚

22˚

Speed Sensor with Packard Connector

Speed Sensor with Turck Connector Shaft Centerline

1/2 in. Wrench Flats

22˚

22˚ Speed Sensor with Packard Connector

Speed Sensor with Turck Connector 90000841E

Positioning Speed Sensor relative to Pump or Motor Shaft

50

250 - 110

Many adjustable wrenches have a 22° handle offset.

Series 90

Minor Repair Instructions Minor Repair Instructions

Minor repairs may be performed, following the procedures in this section, without voiding the unit warranty.

Although specific models are shown, these procedures apply to all series and types of units in the Series 90 Family.

items must be kept free of foreign materials and chemicals.

Cleanliness is a primary means of ensuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a solvent wash and air drying is adequate, providing clean solvent is used. As with any precision equipment, the internal mechanism and related

It is recommended that all gaskets and O-rings be replaced when servicing. All gasket sealing surfaces must be cleaned prior to installing new gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

250 - 111

Protect all exposed sealing surfaces and open cavities from damage and foreign material.

51

Series 90

Minor Repair Instructions Hydrostatic Unit Outlines for Minor Repair Reference

Charge Pressure Relief Valve Filtration Options

Control Control Orifice Charge Pump

Shaft Seal

Main Shaft

(Auxiliary Pad)

Speed Sensor Right Side View

Left Side View

90000843E

SAE-Flange PV Charge Pressure Relief Valve

Charge Pressure Relief Valve Loop Flushing Valve

Loop Flushing Valve

Shaft Seal

Shaft Seal

(Speed Sensor)

(Speed Sensor) Left Side View

Left Side View

SAE Flange MF

Control Orifices Charge Pressure Relief Valve

Cartridge Flange MF

Maximum Angle Displacement Limiter

Loop Flushing Valve

Shaft Seal

Control Orifices Charge Pressure Relief Valve Loop Flushing Valve

Shaft Seal

Minimum Angle Displacement Limiter

Minimum Angle Displacement Limiter Left Side View

Cartridge Flange MV

250 - 112

Maximum Angle Displacement Limiter

Control

Control

52

90000844E

Left Side View

SAE Flange MV

90000845E

Series 90

Minor Repair Instructions

Pump and Motor Minor Repair Pump / Fitting Torques If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indicated in the accompanying table.

Always install new O-rings before reinstalling the plugs or fittings.

Caution Plugs or fittings installed into aluminum housings should always be torqued to the lower values specified for internal hex plugs of the same size.

S000 017E

D escription

Torque

7/16-20 O-ring 9/16 inch Hex Wrench

20 Nm (15 lbf•ft)

7/16-20 O-ring 3/16 inch Internal Hex Wrench

12 Nm (9 lbf•ft)

9/16-18 O-ring 11/16 inch Hex Wrench

37 Nm (27 lbf•ft)

9/16-18 O-ring 1/4 inch Internal Hex Wrench

23 Nm (17 lbf•ft)

3/4-16 O-ring 7/8 inch Hex Wrench

68 Nm (50 lbf•ft)

3/4-16 O-ring 5/16 inch Internal Hex Wrench

68 Nm (50 lbf•ft)

7/8-14 O-ring 1 inch Hex Wrench

95 Nm (70 lbf•ft)

7/8-14 O-ring 3/8 inch Internal Hex Wrench

68 Nm (50 lbf•ft)

1-1/16-12 O-ring 1 1/4 inch Hex Wrench

163 Nm (120 lbf•ft)

1-1/16-12 O-ring 9/16 inch Internal Hex Wrench

115 Nm (85 lbf•ft)

1-5/16-12 O-ring 1-1/2 inch Hex Wrench

190 Nm (140 lbf•ft)

1-5/16-12 O-ring 5/8 inch Internal Hex Wrench

129 Nm (95 lbf•ft)

1-5/8-12 O-ring 1-7/8 inch Hex Wrench

224 Nm (165 lbf•ft) T002 281E

250 - 113

53

Series 90

Minor Repair Instructions

Shaft Seal and Shaft Replacement Lip type shaft seals are used on Series 90 pumps and motors. These seals and/or the shafts can be replaced without major disassembly of the unit. However, replacement usually requires removal of the pump or motor from the machine.

1.

Position the pump with the shaft facing up.

Note:

2.

90000270

90000271

Remove Screws Holding Retainer Plate and Seal Carrier

Remove Seal Carrier

Remove the three or four screws holding the retainer plate and seal carrier to the housing, using a 10 mm hex wrench (030 and 042 units), a 5 mm internal hex wrench (055 through 100 units), or a 6 mm internal hex wrench (130 through 250 units). Remove the retainer plate.

Note:

90000272

Press Out Old Seal

If the unit is positioned horizontally when the shaft is removed, the cylinder block could move out of place, making shaft installation difficult.

Certain earlier production units use a one piece retainer plate and seal carrier.

3.

After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (1/4 inch). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet.

4.

Remove the O-ring from the seal carrier.

5.

Place seal carrier and seal in an arbor press and press out old seal.

6.

Inspect the seal carrier, the new seal and the O-ring for any damage or nicks.

7.

Using the arbor press, press the new seal into seal carrier. Be careful not to damage the seal.

90000273

New Seal Installed in Carrier

Screw Retaining Plate Seal Carrier Seal Seal Carrier (One Piece)

Screw

Seal O-ring

Series 90 Shaft Seal Components

54

250 - 114

90000846E

Note:

The outside diameter of the seal may be lightly coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

Series 90 8.

Minor Repair Instructions

Inspect the sealing area on the shaft for rust, wear, or contamination.

If the shaft is not being replaced proceed to step 12.

9.

Remove shaft and roller bearing assembly from pump or motor. The bearing assembly can be transferred to the new shaft.

10. Remove the retaining ring that secures roller bearing assembly with a snap ring pliers. Remove the roller bearing assembly.

11. Place roller bearing assembly on new shaft and secure with the retaining ring.

12. Wrap spline or key end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation.

Splined Shaft

Tapered Shaft

Roller Bearing Assembly Retaining Ring

OR

Roller Bearing

OR OR

Straight Key Shaft 90000866E

Fixed Motor Shaft Configuration Roller Bearing Assembly Splined Shaft

Retaining Ring OR

Rollen Bearing Tapered Shaft

OR OR

13. Prior to assembly, lubricate the O-ring on the O.D. of the seal carrier and the I.D. of the seal with clean petroleum jelly.

14. Assemble the seal carrier and seal over the shaft and into the housing bore. Install the retainer plate (if used).

Straigt Key Shaft

Variable Pump Shaft Configuration Roller Bearing Assembly

15. Install the screws and torque like the tables.

Retaining Ring

Splined Shaft

Pumps F rame Size 030 - 042 0 55 - 100 1 30 - 250

90000867E

Torque Pumps 12 Nm (9 lbf•ft) 16 Nm (12 lbf•ft) 32 Nm (24 lbf•ft)

OR

T002 282E

Tapered Shaft

Variable Motor Shaft Configuration

90000868E

Motors F rame Size 0 30 - 100 130

Torque Motors 9.5 Nm (7 lbf•ft) 22.5 Nm (16.6 lbf•ft) T002 283E

Note:

Torque the screws in a sequenced pattern then recheck.

90000274

Install Seal Carrier

250 - 115

90000275

Torque Retainer Screw

55

Series 90

Minor Repair Instructions

Pump Minor Repairs Multi-Function Valve Cartridges 1.

The multi-function valve cartridge is removed with a hex wrench on the largest hex on the cartridge.

F rame Size 0 30 - 100 1 30 - 250

Wrench Size 1-1/4 inch 1-5/8 inch T002 284E

2.

90000276

Remove Multi-Function Valve Cartridge

Inspect cartridge for damage to parts and O-rings.

The multi-function valve cartridge may be disassembled for cleaning. However, if the pressure limiter housing assembly is disassembled, the pressure settings must be readjusted. Usually, if there is contamination problem, it will be in the valve seat assembly. If it is not necessary to clean the interior of the cartridge, proceed to step 7.

90000277

Install and Torque Cartridge

Note: Multi-Function Valve Cartridge Components (Earlier production)

Multi-Function Valve Cartridge Components (Later production)

Multi-function valve components are not sold separately as service parts (except O-rings).

90000278

3.

On late versions, the valve seat section is pressed over a lip. Place the cartridge in a vise and pry the lower section off with an appropriate tool. Maintain sufficient control to prevent the contents from flying loose.

90000279

High Pressure Pressure Limiter Pressure Limiter Relief/Check Valve Spring Lock Nut Valve Poppet Pressure Limiter Spring Seat Housing Check Valve

4.

Remove pressure limiter lock nut and bypass actuator.

5.

Unscrew the pressure limiter adjustment screw from the bypass actuator. Clean and inspect all disassembled parts.

6.

Reassemble with new, lightly lubricated O-rings by reversing the above procedure. For early versions assemble with the retaining ring. For late versions, place the cartridge in a vise and press on lower assembly.

Poppet

Valve Seat Pressure Limiter Spring Valve Poppet Pressure Limiter Pressure Limiter Adjustment Screw Valve Poppet Bypass Actuator 90000869E

Multi-Function Valve Cartridge Sectional View

On early versions of the multi-function valves, the valve seat assembly is held by a retaining ring.

Remove retaining ring with a snap ring pliers.

Caution The pressure settings must be readjusted after disassembling the pressure limiter housing of the multi-function valve cartridge.

S000 018E

7.

Install cartridge in multi-function valve cavity and torque.

F rame Size 0 30 - 100 1 30 - 250

Torque 89 Nm (66 lbf•ft) 210 Nm (155 lbf•ft) T002 285E

Do not overtorque the multi-function valve cartridge.

56

250 - 116

Series 90

Minor Repair Instructions Screws

Pressure Override Valve (Option for 180 Frame Size) 1.

Pressure Override Valve

Remove the four screws attaching the pressure override valve to the pump end cap with a 5 mm internal hex wrench. Remove the O-rings.

2.

Inspect valve for damage to parts.

3.

Install new O-rings. Install the valve onto the pump end cap and torque the screws to 16 Nm (12 lbf•ft).

O-rings

Charge Relief Valve The pump charge relief valve may be shim adjustable (early models) or screw adjustable (late models).

1.

Remove the shim adjustable charge relief valve plug with a 1 inch hex wrench.

Pressure Override Valve Components

90000870E

Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to approximately maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a wrench.

F rame Size 0 30 - 100 1 30 - 250

Wrench Size 1-1/16 inch 1-5/8 inch T002 286E

Unscrew the plug with a large screwdriver or 1/2 inch hex wrench.

2.

Remove the spring and relief valve poppet.

3.

Inspect the poppet and mating seat in the end cap for damage or foreign material.

90000280

Remove Charge Relief Valve (Shim adjustable)

90000262

Shim Adjustable Charge Relief Valve

When inspecting shim adjustable valves, do not alter the shims or interchange parts with another valve.

4.

Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 lbf•ft).

For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 lbf•ft).

90000264

Check the charge pressure and adjust, if necessary.

250 - 117

Remove Charge Relief Valve (Screw adjustable)

90000265

Screw Adjustable Charge Relief Valve

57

Series 90

Minor Repair Instructions Charge Pump - Remove The following procedure shows how to remove and install a charge pump.

1.

For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end cap and remove the pad. Refer to the Auxiliary Mounting Pad Installation instructions (next section) for details.

Note:

At earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage.

90000303

90000281

Remove Auxiliary Pad Adapter

Remove Auxiliary Pad Adapter Screws

Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.

S000 019E

2.

90000282

Remove Retainer Screws

Remove the six screws holding the charge pump cover retainer.

F rame Size 0 30 - 100 1 30 - 250

90000284

Remove Charge Pump Cover

Wrench Size 10 mm 13 mm T002 287E

3.

Remove the retainer and the charge pump cover. For pumps with an auxiliary mounting pad, remove the auxiliary drive coupling. Note the orientation of the gerotor.

4.

Remove the charge pump shaft and charge pump drive key.

5.

Remove the spacer plate(s), if present (intermediate production pumps only).

90000297

Remove Drive Coupling

Discharge

Gerotor Assembly

Remove the charge pump outer port plate, if present (early and intermediate production pumps).

Remove the charge pump gerotor assembly.

Discharge

Alignment Pin

Inlet

Inlet

6.

Remove the outer eccentric ring and alignment pin.

7.

Remove the inner port plate.

8.

Inspect all parts for abnormal wear or damage.

Alignment Pin Gerotor Assembly Left Hand Rotation (Outside looking into pump)

Right Hand Rotation (Outside looking into pump)

Orienting Alignment Pin

58

250 - 118

90000871E

Series 90 Note:

Minor Repair Instructions

If a different displacement charge pump is being installed, the gerotor assembly, gerotor outer eccentric ring, and inner port plate (early and late production pumps) or outer spacer plate(s) (intermediate production pumps) must be replaced together. If different thickness port plates are used in an early production charge pump assembly, the thicker plate is the inner port plate (installed next to the pump end cap).

Standard End Cap Screws Alignment Pin Charge Pump Assembly Thin Port Plate Key

Thick Port Plate

Shaft

Eccentric Ring

O-ring

Gerotor Assembly

Cover

Each charge pump assembly includes a different quantity / types of port plates and spacer plates.

Journal Bearing Cover Retainer Retainer Screw

The charge pump kit "No Charge Pump" includes a spacer.

90000872E

Charge Pump Components (Early Production) Standard End Cap Screw Alignment Pin Thin Port Plate Charge Pump Assembly

Eccentric Ring

Key

Gerotor Assembly

Shaft

Thin Port Plate

O-ring

Spacer Plate(s)

Cover Journal Bearing Cover Retainer Retainer Screw

90000873E

Charge Pump Components (Intermediate Production)

Standard End Cap Screw Alignment Pin Charge Pump Assembly Key Shaft

Port Plate

O-ring

Eccentric Ring Gerotor Assembly

Cover

Journal Bearing Cover Retainer Retainer Screw

90000874E

Charge Pump Components (Late Production) Standard End Cap Screw Spacer Shaft O-ring Cover Plug Journal Bearing Cover Retainer Retainer Screw

90000875E

"No Charge Pump" Components 250 - 119

59

Series 90 Discharge

Minor Repair Instructions Gerotor Assembly

Installing the Charge Pump

Discharge

Alignment Pin

Inlet

Inlet

Be sure to install the charge pump in the proper orientation. If unsure of charge pump rotation, refer to the model code.

Note:

Alignment Pin Gerotor Assembly Left Hand Rotation (Outside looking into pump)

Right Hand Rotation (Outside looking into pump)

Orienting Alignment Pin

90000285

Install Inner Port Plate

90000287

Install Alignment Pin

90000289

Install Outer Port Plate (Early and intermediate production only)

60

250 - 120

Do not mix charge pump piece parts from different production periods. Always install as a complete assembly.

90000871E

90000286

Install Gerotor Assembly Outer Ring

90000288

Install Gerotor Assembly

90000290

Install Spacer Plate (Intermediate production only)

The charge pump rotation is determined by the orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap.

1.

Install the inner port plate and the gerotor assembly outer ring.

2.

Install the alignment pin to properly orient the port plates and outer eccentric ring for corresponding pump rotation.

3.

Prior to installation, apply a small quantity of petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly to provide initial lubrication.

4.

Install the gerotor assembly.

5.

Install the outer port plate (early production and intermediate production pumps only).

6.

Install the spacer plate, if present (intermediate production pumps).

7.

Install the charge pump drive key into the charge pump shaft and retain with petroleum jelly.

Series 90 Note:

8.

Intermediate production 75 cc and 100 cc pumps use the same charge pump drive shaft. Two keyways are provided in the drive shaft for the charge pumps used in these units. The rear keyway (with identifier groove) is used in 75 cc pumps. The front keyway (closest to the internally splined end of the shaft) is used in 100 cc pumps.

100 cc

75 cc

Install the charge pump shaft. The internally splined end of the shaft must engage the main pump shaft.

Note:

9.

Minor Repair Instructions

The outside diameter of the internally splined end of some early production charge pump shafts was chamfered. Early production end caps may not be machined to accept a nonchamfered shaft. Always use a chamfered charge pump shaft in pumps with the early end cap.

90000291

Keyways in Charge Pump Shaft (Intermediate Production 075 and 100)

90000292

Install Charge Pump Shaft

For pumps with an auxiliary mounting pad, install the auxiliary drive coupling.

10. Install a new O-ring onto the non-auxiliary pad charge pump cover. (If an auxiliary pad is installed, an O-ring is not used on the cover.)

11. Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the charge pump cover (see previous page for correct orientation) and retain with petroleum jelly. Install the cover (with alignment pin) into the end cap and aligned charge pump parts. (Take care not to damage the cover O-ring, if used.)

Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to the section „Auxiliary Pad Installation“ for details.

S000 020E

90000293

Alignment Pin Installed in Cover

90000294

Install Charge Pump Cover

12. Install the charge pump cover retainer and the six hex screws and torque the screws.

F rame Size 0 30 - 100 1 30 - 250

Torque 13.5 Nm (10 lbf•ft) 32 Nm (24 lbf•ft) T002 288E

13. For pumps with auxiliary mounting pads, install the O-ring and auxiliary mounting pad adaptor onto the end cap. Refer to the corresponding section for instructions on auxiliary pad installation.

250 - 121

90000283

Install Cover Retainer

90000295

Torque Retainer Screws

61

Series 90

Minor Repair Instructions Auxiliary Pad Installation 1.

Remove the six screws holding the charge pump cover retainer. Remove the retainer.

F rame Size 0 30 - 100 1 30 - 250

Wrench Size 10 mm 13 mm T002 287E

2.

Remove the charge pump cover and its O-ring.

Note: 90000282

The original charge pump cover will not be used when installing the auxiliary pad.

90000284

Remove Screws and Retainer

Remove Charge Pump Cover

3.

Remove the four large screws which fasten the end cap to the pump housing.

F rame Size 030 early 042 l ate 042 055 075 - 100 100 - 130 1 80 - 250

Wrench Sizes I nternal Hex External Hex 8 mm 10 mm 19 mm 24 mm 14 mm 17 mm T002 289E

90000296

Remove Large End Cap Screws

Note:

At earlier production frame size 75 pumps with twin ports secure the end cap to the pump housing with a clamp to avoid gasket damage.

Charge Pump Parts

Caution Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.

Cover Assembly Coupling (Typical) Journal Bearing

Special Washer End Cap Screw

O-ring auxiliary Pad (Typical) O-ring

Screw

Pad Cover

Auxiliary Pad Kit

S000 019E

Cover Retainer Retainer Screw

Auxiliary Pad Components (Typical)

62

250 - 122

90000876E

4.

Take care to assure the surfaces are clean and free of any foreign material or paint prior to installing the auxiliary pad.

5.

Install the auxiliary drive coupling onto the pump drive shaft spline (auxiliary drive spline must be toward the rear of the pump).

Series 90 6.

Minor Repair Instructions

Carefully remove the alignment pin from the charge pump parts. Install the pin in its hole in the new charge pump cover (with hole for the auxiliary coupling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts.

Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to the section "Auxiliary Pad Installation" for details.

S000 020E

90000297

Install Drive Coupling

7.

Install the charge pump cover retainer and the six hex screws and torque the screws.

F rame Size 0 30 - 100 1 30 - 250

90000298

Install Alignment Pin in Cover (CCW rotation shown)

Torque 13.5 Nm (10 lbf•ft) 32 Nm (24 lbf•ft) T002 288E

8.

Install O-ring on end cap pilot.

9.

Install the auxiliary mounting pad adapter on external pilot on rear of end cap.

10. Install four new large screws and washers through the mounting pad and end cap into the housing.

Torque per the accompanying table.

F rame Size 030 early 042 l ate 042 055 0 75 - 100 1 00 - 130 1 80 - 250

90000299

Install New Charge Pump Cover

90000300

Install Screws and Cover Retainer

Torque 58 Nm (43 lbf•ft) 122 Nm (90 lbf•ft) 122 Nm (90 lbf•ft) 256 Nm (189 lbf•ft) 298 Nm (220 lbf•ft) 580 Nm (429 lbf•ft) T002 290E 90000302

11. Install the O-ring and flange cover or auxiliary pump.

Install O-ring on End Cap Pilot

90000303

Install Auxiliary Pad Adapter

Auxiliary Pad Conversion To convert an auxiliary mounting pad to a different size mounting pad, use the above procedure with the following additions: After removing the charge pump cover (step 2), remove the old auxiliary drive coupling.

After removing the four end cap retaining screws, remove the old auxiliary mounting pad adapter.

90000281

Install Auxiliary Pad Adapter Screws

250 - 123

90000305

Torque Pad Adapter Screws

63

Series 90

Minor Repair Filtration Options Suction Filtration Installation 1.

Install the hydraulic fitting to connect the external suction filter to the charge pump inlet port.

2.

The reducer fitting (placed on the charge pressure gauge port) is installed as follows.

F rame Size 0 30 - 042 0 55 - 130 1 80 - 250

W rench Size 1 -1/4 inch 1 -1/2 inch 1 -1/2 inch

Torque 70 Nm (52 lbf•ft) 122 Nm (90 lbf•ft) 156 Nm (115 lbf•ft) T002 291E

90000310

Charge Pump Inlet

90000243

The gauge port plug takes a 1/4 inch internal hex wrench and is torqued to 27 Nm (20 lbf•ft).

Reducer Fitting and Gauge Port Plug

Remote Charge Pressure Filtration or Integral Charge Pressure Filtration Install either of these two filtration devices as follows.

90000311

remote Pressure Filter Manifold

90000312

Install Remote Pressure Filter Manifold

1.

Remove the reducer fitting, located at charge pressure gauge port, from pump end cap (this part will not be used).

2.

Install the filter manifold or filter head into the port.

The hydraulic tube should enter its mating bore in the pump end cap with a low force.

3.

After rotating the filter manifold or filter head clockwise so that the threads engage with the threads in the end cap, continue to rotate it clockwise between 6 and 7 revolutions. Face manifold or head to the desired position.

90000314

Integral Pressure Filter Head

90000315

Install Integral Pressure Filter Head

Caution Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore. This may allow unfiltered oil to bypass the filter and enter the charge system.

S000 021E

4.

While holding the filter manifold or filter head in the desired position, tighten the swivel lock nut.

F rame Size 0 30 - 042 0 55 - 130 1 80 - 250

W rench Size 1 -3/8 inch 1 -5/8 inch 1 -5/8 inch

Torque 70 Nm (52 lbf•ft) 122 Nm (90 lbf•ft) 156 Nm (115 lbf•ft) T002 292E

90000313

Tighten Remote Pressure Filter Manifold Lock Nut

64

250 - 124

90000316

Tighten Integral Pressure Filter Head Lock Nut

5.

After installing the integral pressure filter head assembly, install the filter canister per the instructions on the filter canister.

Series 90

Minor Repair

Pump controls Cover Plate 1.

Thoroughly clean external surfaces prior to removal of cover plate.

2.

Using a 5 mm internal hex wrench, remove the eight cover plate mounting screws. Remove the cover plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

3.

Pump with Cover Plate

90000361

In preparation for installing the cover plate, place a new gasket on the housing. Place the cover plate into position and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing.

S000 023E

250 - 125

65

Series 90

Minor Repair Manual Displacement Control (MDC) 1.

Thoroughly clean external surfaces prior to removal of control.

2.

Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E 90000319

Remove Mounting Screws

90000321

Inner Face of Control

90000320

Remove Control

3.

In preparation for installing the control, place a new gasket on the housing. Inspect to assure that the control orifice check valve and spring are in their proper position in the control.

4.

While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5.

With the control in position, move control lever both directions to check proper engagement of control linkage pin. Proper engagement will be indicated by centering torque as the lever is moved from center.

Non-engagement of control linkage pin is indicated by lack of centering torque as the lever is moved. In case of non-engagement remove the control and repeat the above procedure.

6.

Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

90000322

Assemble Control to Linkage

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing.

S000 023E

90000323

Assemble Control to Pump

90000324

Torque Mounting Screws

7.

If the control is equipped with a neutral start switch, refer to the "MDC Neutral Start Switch Adjustment" instructions.

WARNING The neutral start switch "neutral" must be readjusted after reassembling the MDC module.

S000 024E

66

250 - 126

Series 90

Minor Repair

Solenoid Override Valve for MDC 1.

Thoroughly clean external surfaces prior to removal of valve.

2.

Using a 5 mm internal hex wrench, remove the two screws and remove solenoid manifold from housing.

Remove the old gasket.

3.

The solenoid may be removed from the valve by removing the nut with a 3/4 inch hex wrench. The solenoid valve may be removed from the manifold with a 7/8 inch hex wrench.

4.

When installing the solenoid valve into the manifold, the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 lbf•ft). When installing the solenoid onto the valve, torque the nut to 6 Nm (53 ± 12 lbf•in).

5.

Components of Solenoid Override for MDC

90000363

In preparation for installing the solenoid manifold, place a new gasket on the control housing. Install the manifold onto the control housing, align the gasket, and install the screws. Torque the screws to 13.5 Nm (10 lbf•ft).

Solenoid Override Valve for MDC with Pressure Released Brake 1.

Thoroughly clean external surfaces prior to removal of valve.

2.

Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings) from the adapter plate.

3.

Using a 4 mm internal hex wrench, remove the four adapter plate mounting screws. Remove the adapter plate and O-rings from the control housing.

4.

Remove the check valve seat and O-ring from the control side of the adapter plate. Remove the check ball and spring.

5.

Install a new O-ring on the check valve seat and reassemble the check valve spring, ball, and seat into the adapter plate.

6.

Install new O-rings on the adapter plate. Place the adapter plate into position and install the screws.

Torque the screws to 5.4 Nm (48 lbf•in).

7.

90000364

Components of Solenoid Override with Brake Pressure Defeat for MDC

Install new O-rings onto the solenoid valve assembly and install the solenoid valve onto the adapter plate.

Install the screws and torque to 5.4 Nm (48 lbf•in).

250 - 127

67

Series 90

Minor Repair Hydraulic and Electric Displacement Controls 1.

Thoroughly clean external surfaces prior to removal of control.

2.

Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

90000325

Remove Mounting Screws

90000327

Inner Face of Control

90000326

3.

In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control.

4.

While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5.

With the control in position, move control assembly left and right to check engagement of pin in the link.

Proper engagement will be indicated by an increasing resistance as the control is moved away from center position. Non-engagement of pin will be indicated by lack of spring force. In case of non-engagement, remove control and repeat the above procedure.

6.

Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

Remove Control

90000328

Assemble Control to Linkage

Caution A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing.

S000 023E

90000329

Install Mounting Screws

90000332

PCP Components

68

250 - 128

90000330

Torque Mounting Screws

90000334

Torque PCP Valve Screws

Pressure Control Pilot (PCP) for Electric Displacement Control 1.

Thoroughly clean external surfaces of control.

2.

Using a 4 mm internal hex wrench, remove the four screws and remove the PCP.

3.

Check surfaces for nicks or damage. Clean internal screens.

4.

Install new O-rings in PCP Housing. Place PCP against EDC housing and install the screws. Torque to 5.4 Nm (48 lbf•in).

Note:

Do not remove black plastic cover from the aluminum plate. This is not a serviceable item and will void the product warranty.

Series 90

Minor Repair

3-Position (FNR) Electric Control 1.

Thoroughly clean external surfaces prior to removal of control.

2.

Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings and orifice) from the adapter plate.

3.

Using a 5 mm internal hex wrench, remove the eight adapter plate mounting screws. Remove the adapter plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

3-Position Electric Control Components

90000362

S000 022E

4.

Inspect the orifice installed between the valve and adapter plate. This orifice MUST be installed in the case drain passage for proper pressure limiter operation.

5.

In preparation for installing the adapter plate, place a new gasket on the housing. Place the adapter plate into position and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into „thru“ holes in the housing.

S000 023E

6.

Install new O-rings and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to 5.4 Nm (48 lbf•in).

Displacement Control Components Displacement Control Orifices 1.

Remove the control assembly as described in the instructions for the specific displacement control.

2.

Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove the orifice plugs with a 4 mm internal hex wrench. Note the location of each plug, do not interchange plugs.

Torque the orifice plugs to 3 Nm (26 lbf•in).

3.

Assemble the control onto the pump. Refer to the instructions for the specific control.

A B TA

P TB

Orifice Plugs Orifice Check Valve 90000849E

Underside of an HDC/EDC Module Showing Orifice Locations

250 - 129

69

Series 90

Minor Repair Displacement Control Orifice Check Valve

B

TA A

1.

Remove the control assembly as described in the instructions for the specific displacement control.

2.

The orifice check valve is located in the control assembly, at the surface of the pump housing face.

Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

3.

Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position.

4.

Assemble the control onto the pump. Refer to the instructions for the specific control.

TB

P

Orifice Plugs

Orifice check Valve 90000848E

Underside of an MDC Module Showing Orifice Locations

Displacement Control Adapter Plate (Early production 130 Pumps only) The screws fastening the control adapter plate to the housing have retaining compound on the threads. They are removed with a 6 mm internal hex wrench.

When installing the adapter plate, ensure the O-rings are in the proper position and torque the screws to 32 Nm (24 lbf•ft).

Displacement Control Filter Screens If the pump is equipped with control filter screens in the pump housing (late production), they should be pressed into position (with the rounded edge of the filter screens facing the control until they are flush to 2.0 mm (0.08 inch) below the surface of the housing.

90000847

Displacement Control Adapter Plate (Early production 130cc Pumps only)

70

250 - 130

Series 90

Minor Repair

Minor Repair - Motor Loop Flushing and Charge Relief Valves Loop Flushing Valve 1.

Using an 1-1/16 inch wrench, remove the hex plugs and O-rings from both sides of the valve. Remove the springs, shoulder washers, and flushing valve shuttle spool. Note orientation of the washers. Remove the flushing valve spool.

2.

Inspect parts for damage or foreign material.

Note:

3.

Early production motors used a small diameter shuttle valve spool. Late production motors use a larger diameter spool.

90000338

Remove Plugs Springs

90000339

Remove Flushing Shuttle Spool

Install flushing valve spool in end cap, then install the shoulder washers (with shoulders facing “out”) and springs on each end of the spool. Install the hex plugs with O-rings, and torque to 41 Nm (30 lbf•ft) on 030 through 100 motors or 68 Nm (50 lbf•ft) on 130 motors.

Motor Charge Relief Valve 1.

Remove the shim adjustable charge relief valve plug with a 7/8 inch hex wrench.

Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to be able to maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a 1-1/16 inch hex wrench for 030 through 100 units, or a 1-5/8 inch hex wrench for 130 units, and unscrewing the plug with a large screwdriver or 1/2 inch hex wrench.

2.

Remove the spring and valve poppet.

3.

Inspect the poppet and mating seat in the end cap for damage or foreign material. When inspecting shim adjustable valves, do not alter the shims or interchange parts with another valve.

250 - 131

90000340

Install Flushing Shuttle Spool

90000342

Torque Plugs

90000341

90000343

Remove Shim Charge Relief Remove Screw Charge Relief Valve Valve

71

Series 90

Minor Repair

90000344

Shim Adjustable Charge Relief Valve

Install the poppet and spring. For shim adjustable valves, install the plug and torque to 68 Nm (50 lbf•ft).

For screw adjustable valves, install the plug with its lock nut, aligning the marks made at disassembly, and torque the lock nut to 52 Nm (38 lbf•ft).

5.

Check and adjust the charge pressure.

90000345

Screw Adjustable Charge Relief Valve

Defeating the Loop Flushing Valve

Lock Nut Plug Plug

4.

O-ring

O-ring

Shims

Spring

Spring

Poppet

Poppet Plug with O-ring (defeat)

1.

Remove loop flushing valve components (these parts will not be used).

2.

Install defeating spool into spool bore in end cap.

3.

Install hex plugs provided and torque to 41 Nm (30 lbf•ft).

4.

Remove charge relief valve components (these parts are not necessary).

5.

Replace with the hex plug provided and torque to 41 Nm (30 lbf•ft).

Plug with O-ring (defeat)

Plug Spool (defeat)

O-ring Spring

Plug with O-ring (defeat)

Shoulder Washer

Note orientation of washers!

Shoulder OUT (toward spring).

Spool Shoulder Washer Spring O-ring Plug

90000850E

Motor charge Relief Valve and Loop Flushing Valve Parts

72

250 - 132

Series 90

Minor Repair

Variable Motor Displacement Limiters 1.

Remove the tamper-resistant cap from the displacement limiter. Measure and note the length of the adjustment screw up to the seal lock nut. Using a 19 mm hex wrench, loosen the seal lock nut and remove the nut. Remove the limiter screw from the motor housing with a 6 mm internal hex wrench.

2.

Install the limiter screw with the noted length between adjustment screw and the seal lock nut. Do not install a new tamper-resistant cap until the limiter has been adjusted.

3.

Final adjustment of the displacement limiters should be performed on a test stand.

Tamper-Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw

Do not turn the limiter screws counterclockwise beyond their initial adjustment positions.

Caution Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

Minimum Displacement Limiter Screw Seal Lock Nut Tamper-Resistant Cap SAE Flange Version shown (cartridge Version similar)

S000 026E

One full turn of the displacement limiter adjustment screw will change the displacement as follows: Frame Size 055 075

MV Displacement Limiters

90000851E

Approx Change in Disp per Rev of Adjusting Screw 5.6 cm3 / Rev (0.34 in3 / Rev) 7.1 cm3 / Rev (0.43 in3 / Rev) T002 295E

4.

Following the final adjustment, install new tamper resistant caps.

250 - 133

73

Series 90

Minor Repair

Variable Motor Controls Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND)

Note: Remove BEFORE removing control.

Install AFTER installing control.

Refer to "Control Orifices" Section

Hydraulic 2-Position Control Valve

Electric 2-Position Control Valve

MV Control components

90000852E

1.

Thoroughly clean external surfaces prior to removal of the control.

2.

Disconnect the external electrical signal connection.

3.

Remove the hex nut and solenoid from the control valve.

4.

Remove the orifice check valve for the maximum angle control cylinder, if equipped.

5.

Remove the control valve from the motor housing.

6.

Remove O-rings from the valve.

7.

Install new O-rings on the control valve.

8.

Install the valve into the motor housing and torque to 47 Nm (35 lbf•ft). Do not overtorque the control valve. Over-torquing may result in the valve spool sticking.

9.

Install the solenoid onto the valve and torque the hex nut to 5 Nm (44 lbf•in). Do not overtorque the nut.

10. If previously removed, reinstall the orifice check valve. Reconnect the external signal connection.

Hydraulic 2-Position Control (Type PT) Follow the steps above, except that in step 2 a hydraulic signal line will be disconnected, and steps 3 and 9 are not applicable.

1/8 in. int. hex wrench Torque: 5.4 Nm (48 lbf•in)

Control Plugs Remove the control plugs from the housings of earlier production motors, if necessary. Install new O-rings, reinstall, and torque.

9/16 in. hex wrench Torque: 34 Nm (25 lbf•ft)

7/8 in. hex wrench Torque: 68 Nm (50 lbf•ft)

MV Control Plugs

74

250 - 134

90000853E

Series 90

Minor Repair

Variable Motor Control Orifices Control Suply Orifice

Control Supply Orifice 1.

Remove the control supply orifice from the motor housing with an 1-1/16 inch hex wrench.

2.

Remove the O-rings and the backup washers. Check that the filter screen is secure in the orifice body and that the screen and the orifice are not plugged.

Screen (pressed in) O-ring Backup Washer

3.

Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf•ft).

Caution Do not interchange the control supply orifice with the minimum displacement orifice (next section).

O-ring Backup Washer

O-ring Backup Washer

Backup Washer

Screen (pressed in) Orifice Body

S000 027E

O-ring

Cross-section View of Control Supply Orifice Assembly 90000854E

MV Control Supply Orifice

Minimum Displacement Cylinder Orifice or Orifice Check Valve Orifice / Check Valve Assembly

Orifice

1.

2.

3.

Remove the minimum displacement cylinder drain orifice or the orifice check valve from the motor housing with an 1-1/16 inch hex wrench.

O-ring Backup Washer

Remove the O-rings and the backup washers. Check that the orifice is not plugged. Check that the check valve seat is secure in the body and that the check ball is free.

O-ring Backup Washer

Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf•ft).

Caution Do not interchange the control supply orifice (previous section) with the minimum displacement orifice.

S000 028E

O-ring

O-ring

Orifice Body

Orifice Body

Backup Washer

Spring Pin

O-ring Backup Washer

Backup Washer O-ring

Kugel

Backup Washer Orifice Seat (Spot welded)

Cross-Section View of Orifice Assembly

Cross-Section View of Orifice / Check Valve Assembly

MV Minimum Displacement Orifice

250 - 135

90000855E

75

Series 90

Minor Repair Maximum Displacement Cylinder Orifice Check Valve 1.

Remove the seal lock nut with a 3/4 inch hex wrench.

Remove the maximum displacement cylinder orifice check valve from the motor housing with a 1/4 inch end wrench. Remove the O-ring. The check ball in the valve must be free.

2.

Reinstall the check valve and torque to 15 Nm (11 lbf•ft). Install a new O-ring. Install the seal lock nut with the seal toward the motor housing.

Housing Plug Seal Lock Nut (seal toward housing)

O-ring Orifice / Check Valve Assembly

Seal Lock Nut (seal toward housing)

Hold the check valve from turning while torquing the seal lock nut to 34 Nm (25 lbf•ft).

O-ring

3.

Orifice Body Check Ball Spring Pin Cross-Section View of Orifice / Check Valve Assembly

MV Maximum Displacement Orifice

76

250 - 136

90000856E

If no orifice check valve is installed, the housing plug may be removed with a 9/16 inch hex wrench. Always install a new O-ring. Reinstall the plug and torque to 20 Nm (15 lbf•ft).

Series 90

Minor Repair

Speed Sensor 1.

Remove the speed sensor by disconnecting the electrical connector, loosening the lock nut, and unscrewing the speed sensor from the pump or motor housing.

Speed Sensor

2.

Always install a new O-ring before installing the sensor.

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf•ft) After adjustment!

3.

Reinstall the speed sensor (with lock nut and O-ring) into the housing. Adjust the gap between the sensor and the magnetic speed ring as instructed in Section "Speed Sensor Adjustment" and torque the sensor lock nut.

4.

If a speed sensor is not installed, the housing plug should be torqued as indicated in the accompanying figure.

Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf•ft)

or

Typical Location of Speed Sensor - PV

90000857E

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf•ft) After adjustment!

or Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf•ft)

Speed Sensor

90000858E

Typical Location of Speed Sensor - MF

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf•ft) After adjustment!

or Speed Sensor Housing Plug 1-1/16 in. hex wrench Torque: 37 Nm (27 lbf•ft)

90000859E

Typical Location of Speed Sensor - MV

250 - 137

77

Series 90

Exploded View Parts Drawings / Parts Lists Exploded View Parts Drawings / Parts Lists

Variable Pumps Minor Repair Parts

K90 B83 B83

OR

K10

B70 G532 G536

K50 K70

G542 G546 B82

P2B_

K018 bis K042

K80

L35 (Early Production 075 Frame Size)

(L70)

(L40)

L60

(B80)

(B90)

L30 (B70)

P30

P06 P13

L70

L40

B90 L50

P30 B71 P2A_

P06 P13

G512 G516 G502 G506 G522 G526

G172 G176

B80 (G502 G506)

(G63)

(G502 G506)

G63 (CODE 61 OPTION)

(G64)

G64 (CODE 61 OPTION) BOTH SIDES

(K018 THRU K042)

G531 G538

G501 G508 G511 G518

OR G541 G548

G63 (CODE 61 OPTION)

G521 G528 (G501 G508) (G501 G508)

(G63) (G64)

G64 (CODE 61 OPTION)

90000860E

78

250 - 138

Series 90

Exploded View Parts Drawings / Parts Lists

Parts List Item

Description

Qty

B70 ............... Plug ......................................................... 2 B71 ............... Plug ......................................................... 1 B80 ............... Plug ......................................................... 1 B82 ............... Plug ......................................................... 1 B90 ............... Filter screen ............................................ 3 G63 .............. Split flange clamp .................................... 4 G64 .............. Plug ......................................................... 4 G172 ............ Plug ......................................................... 1 G176 ............ O-ring ...................................................... 1 G501 ............ Plug ......................................................... 3 G502 ............ Plug ......................................................... 3 G506 ............ O-ring ...................................................... 3 G508 ............ O-ring ...................................................... 3 G511 ............ Plug ......................................................... 1 G512 ............ Plug ......................................................... 1 G516 ............ O-ring ...................................................... 1 G518 ............ O-ring ...................................................... 1 G521 ............ Plug ......................................................... 1 G522 ............ Plug ......................................................... 1 G526 ............ O-ring ...................................................... 1 G528 ............ O-ring ...................................................... 1 G531 ............ Plug ......................................................... 1

250 - 139

Item

Description

Qty

G532 ............ Plug ......................................................... 1 G536 ............ O-ring ...................................................... 1 G538 ............ O-ring ...................................................... 1 G541 ............ Plug ......................................................... 1 G542 ............ Plug ......................................................... 1 G546 ............ O-ring ...................................................... 1 G548 ............ O-ring ...................................................... 1 K10 ............... Plug assembly ......................................... 1 K50 ............... O-ring ...................................................... 1 K70 ............... Spring ...................................................... 1 K80 ............... Poppet ..................................................... 1 K90 ............... Nut ........................................................... 1 L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

79

Series 90

Exploded View Parts Drawings / Parts Lists

Variable Pump Controls

M1DC M1DD

M90D

M0DC M0DD OR

M11D

M9ME

M0MA M0ME M0MB M0MF M0MC M0MG M0MD M0M9 M74M M78M

M76M

M0CA M1CA M11C

M92M M97M

T001 THRU T009, T022 T050

M77M M98M

M95M M96M

M75M S40 M90M M1MA M880 M1MB M1MC M1MD M1ME M1MF M1MG

T201 THRU T209, T222 T250 T301 THRU T309, T322 T350

M90C M87C

T401 THRU T409, T422 T450

M72M M71M

OR

M7MA M7MB M7MC M7MD M7ME M7MF M7MG

M0EA M0EF M0EP

M91E

M87M M11M M90E M1EA M880 M860

M98E

M95E M97E

M1EF M1EP

M870

M96E M11E

M850 M840 M840 REF M830

M9EA M9EP

M87E M810 M840 REF

M820 (Early Production 130 cc Frame Size) OR

OR

M1HA, M1HC M1HF, M1HG M1HH, M1HJ M1HK, M1HL M1HM, M1HN M11H

M90H M880 M87H M0HA, M0HC M0HF, M0HG M0HH, M0HJ M0HK, M0HL M0HM, M0HN

90000861E

80

250 - 140

Series 90

Exploded View Parts Drawings / Parts Lists

Control Parts List Item

Description

Qty

Item

Description

Qty

M0CA ........... Cover plate kit ......................................... 1 M1CA ........... Cover plate .............................................. 1 M11C ........... Control gasket ......................................... 1 M11D ........... Control gasket ......................................... 1 M87C ........... Washer, seal (042) ................................. 1 M90C ........... Screw ...................................................... 6

M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1

M0DC ........... Control kit, 3-position FNR 12V .............. 1 M0DD ........... Control kit, 3-position FNR 24V .............. 1 M1DC ........... Control, 3-position FNR 12V ................... 1 M1DD ........... Control, 3-position FNR 24V ................... 1 M80 .............. Control gasket ......................................... 1 M87D ........... Washer, seal (042) ................................. 1 M90D ........... Screw ...................................................... 6

M0MC .......... Control MDC w/ sol. valve ...................... 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M74M ........... Solenoid valve ......................................... 1 M75M ........... Control manifold ...................................... 1 M77M ........... Manifold gasket ....................................... 1 M78M ........... Screw ...................................................... 2 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6

M0EA ........... Control kit, EDC with MS connector .......................................... 1 M0EP ........... Control kit, EDC with Packard connector .................................. 1 M1EA ........... Control, EDC with MS-connector .......................................... 1 M1EP ........... Control, EDC with Packard-connector .................................. 1 M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M80 .............. Control gasket ......................................... 1 M87E ............ Washer, seal (042) ................................. 1 M90E ............ Screw ...................................................... 6 M91E ............ Plastic cap (MS) ...................................... 1 M95E ............ O-ring ...................................................... 2 M96E ............ O-ring ...................................................... 1 M97E ............ O-ring ...................................................... 1 M98E ............ Screw ...................................................... 4 M1MA ........... Servovalve kit .......................................... 1 M0HA ........... Control kit, hydraulic, HDC ..................... 1 M0HC ........... Control kit, hydraulic, HDC ..................... 1 M1HA ........... Control, hydraulic, HDC .......................... 1 M1HC ........... Control, hydraulic, HDC .......................... 1 M11H ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1 M87H ........... Washer, seal (042) ................................. 1 M90H ........... Screw ...................................................... 6 M0MA ........... Control MDC w/o neutral start switch ........................... 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6

M0MD .......... Control MDC w/ sol. valve and neutral start switch .................................. 1 M7M ............. Control handle ......................................... 1 M71M ........... Washer .................................................... 1 M72M ........... Nut ........................................................... 1 M75M ........... Control manifold ...................................... 1 M76M ........... Solenoid valve ......................................... 1 M77M ........... Manifold gasket ....................................... 1 M78M ........... Screw ...................................................... 2 M80 .............. Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6 S40 ............... Neutral start switch ................................. 1 M810 ............ Adapter plate - Control (130 cc) ............. 1 M820 ............ O-ring (130 cc) ........................................ 1 M830 ............ O-ring (130 cc) ........................................ 1 M840 ............ O-ring (130 cc) ........................................ 2 M850 ............ Plug (130 cc) ........................................... 1 M860 ............ Screw (130 cc) ........................................ 6 M870 ............ Plug (130 cc) ........................................... 1 M9ME ........... 4/2 Way valve ......................................... 1 M92M ........... Screw ...................................................... 4 M95M ........... O-ring ...................................................... 1 M96M ........... O-ring ...................................................... 1 M97M ........... O-ring ...................................................... 1 M98M ........... Screw ...................................................... 4 T001-9 .......... Control orifice kit ..................................... 1 T201-9 .......... Orificed check valve ................................ 1 T301-9 .......... Spring ...................................................... 1 T401-9 .......... Spring retainer ......................................... 1

M0MB ........... Control MDC w/ neutral start switch ............................. 1 M7M ............. Control handle ......................................... 1 250 - 141

81

Series 90

Exploded View Parts Drawings / Parts Lists

Filter and Options

N40P

N40L

N00M

N00S

N35M REF N30R

N35M

N00R

N35S N10S Or

N10M N25M

N20M N15M N31R

N10R

N20R N15R N25R

N35R

OR

90000862E

H50L H50 H40 H05

OR H30 H60 H50

H40 OR H05

H30

(H30) J80N

H40 H05

H60 H50

OR H60 H50 H90L

J40N J15N H70

J15_ J10_

J30 J30 J70_

H80 OR

H70

J80_

J50_

J60_ J90_

H80 J00_

J92_ J95_

90000863E

82

250 - 142

Series 90

Exploded View Parts Drawings / Parts Lists

Parts List Filter and Options Item

Description

Qty

H05B-H ........ Kit - Charge pump ................................... 1 H50L ............ Spacer (No charge pump) ...................... 1 H30 .............. Port plate ................................................. 2 H40 .............. Pin ........................................................... 1 H50 .............. Charge pump shaft ................................. 1 H60 .............. Key .......................................................... 1 H70 .............. Retaining plate ........................................ 1 H80 .............. Screw ...................................................... 6 H90L ............ Plug ......................................................... 1 J00A ............. Aux. mtg. SAE A flange .......................... 1 J00B ............. Aux. mtg. SAE B flange .......................... 1 J00C ............. Aux. mtg. SAE C flange .......................... 1 J00D ............. Aux. mtg. SAE D flange .......................... 1 J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1 J00V ............. Aux. mtg. SAE B-B flange ....................... 1 J00N ............. Aux. mtg. flange - none .......................... 1 J10A-V ......... Coupling .................................................. 1 J15 ............... Charge pump cover assembly ................ 1 J15N ............. Charge pump cover assembly ................ 1 J30 ............... Bushing ................................................... 1 J50A-V ......... O-ring ...................................................... 1 J60A/T .......... Flange adaptor SAE A ............................ 1 J60B/V ......... Flange adaptor SAE B ............................ 1 J60C ............. Flange adaptor SAE C ............................ 1 J60D ............. Flange adaptor SAE D ............................ 1 J70A-V ......... Washer .................................................... 4

Item

Description

Qty

J80A-V ......... Screw ...................................................... 4 J80N ............. Screw ...................................................... 4 J90A-V ......... O-ring ...................................................... 1 J92A-V ......... Cover plate .............................................. 1 J95A-V ......... Screw ................................................... 2/4 N00M ........... Filtration manifold kit (Int) ....................... 1 N10M ........... Manifold ................................................... 1 N15M ........... O-ring ...................................................... 2 N20M ........... Nut ........................................................... 1 N25M ........... Tube ........................................................ 1 N35M ........... Plug ......................................................... 2 N40L ............ Filter ........................................................ 1 N40P ............ Filter ........................................................ 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1 N10R ............ Manifold ................................................... 1 N15R ............ O-ring ...................................................... 1 N20R ............ Nut ........................................................... 1 N25R ............ Tube ........................................................ 1 N30R ............ Plastic plug .............................................. 2 N35R ............ Plug ......................................................... 1 N00S ............ Filtration kit (Suction Flt) ......................... 1 N10S ............ Reducer fitting (Suction Flt) .................... 1 N35S ............ Plug ......................................................... 1

Name Plates

saue

Ames, Iowa, U.S.A. Model Code

90L055 EA 1 N 6 S 3 C6 C 03 Model Number

Model No.

94 – 2029

saue

Neumünster, Germany Typ

Ident Nr

Ames, Iowa, U.S.A. Model Code

Model Code Model Number

90L055 EA 1 N 6 S 3 C6 C 03 Model No.

Model Code

Ident Nr

687459

Serial Number

Serial Number Serial No. Fabr Nr MADE IN U.S.A.

Place of Manufacture

Name Plate (U.S.A. Production)

250 - 143

Neumünster, Germany Typ

Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture

Name Plate (German Production)

83

Series 90

Exploded View Parts Drawings / Parts Lists

Fixed Motor Minor Repair Parts

H68W L35 (Early Production 075 Frame Size)

H60W H62W H64W

(L70)

(L40)

H66W

L60

H60N L40

(B80)

(H50N)

L70

L30

(G50)

(H50W)

(H30W)

L50

(H40W) (H20W) G50 G70 H10N

(B80) H50N

H20W

(G63)

B80

H10W

G63 (CODE 61 OPTION) (G64)

H40W

H30W H50W

G64 (CODE 61 OPTION) B83

B83

OR

B80 G63 (CODE 61 OPTION) (G63) G64 (CODE 61 OPTION)

(G64)

(B83)

(B83)

90000864E

84

250 - 144

Series 90

Exploded View Parts Drawings / Parts Lists

Parts List Item

Description

Qty

B80 ............... Plug ......................................................... 2 B83 ............... Plug ......................................................... 1 B83 ............... Speed sensor .......................................... 1 G50 .............. Plug ......................................................... 2 G70 .............. Plug ......................................................... 1 G63 .............. Split flange screw .................................... 4 G64 .............. Screw - Shipping Cover .......................... 4 H10N ............ Loop flushing spool - defeat .................... 1 H50N ............ Plug ......................................................... 2 H10W ........... Shuttle valve spool .................................. 1 H20W ........... Spring guide ............................................ 2 H30W ........... Spring ...................................................... 2 H40W ........... O-ring ...................................................... 2

Item

Description

Qty

H50W ........... Plug ......................................................... 2 H60W ........... Charge relief valve plug .......................... 1 H62W ........... O-ring ...................................................... 1 H64W ........... Spring ...................................................... 1 H66W ........... Charge relief poppet ............................... 1 H68W ........... Lock nut ................................................... 1 L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

Name Plates

saue Ames, Iowa, U.S.A. Model Code

90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 Model No.

Model Number

Ident Nr

94 – 2029 A – 91 – 26 – 67890

Serial Number

saue

Neumünster, Germany Typ

Ames, Iowa, U.S.A. Model Code

Model Code Model Number Serial Number

Serial No. Fabr Nr MADE IN U.S.A.

Place of Manufacture

Name Plate (U.S.A. Production)

250 - 145

Neumünster, Germany Typ

90M055 NC 0 N 8 N 0 C6 W 00 NNN 00 00 24 Model No.

Model Code

Ident Nr

312918 N – 91 – 26 – 67890 Serial No. Fabr Nr MADE IN GERMANY

Place of Manufacture

Name Plate (German Production)

85

Series 90

Exploded View Parts Drawings / Parts Lists

Variable Motor Minor Repair Parts

Y100 Y101

Y102

Y40

E15

E35

E26

Y50 Y60 (Y50)

L35 (Early Production 075 Frame Size)

(L70) L60

(L40)

L70

L30 L40

B83

(B74) B80

B83

L50 B76 T100 T101 T30 T40 T50 T60 (T50)

H68W H60W (B74)

H62W H64W M1PT

H66W

Y80

M1NA, M1NB M1NC, M1ND

(G50)

P700 P702

G50

(H50N)

(B80)

(H50W)

E25

(B74)

(H40W)

E35

(H30W) (H20W)

Y71 Y72

B74

H60N

H10N

G70

E15 H50N

P601 P603

(P400) (P401) (P402) (P403)

Y70

(P400) (P401) (P402) (P403) P600 P602

H10W H20W (G63)

(G64)

H30W H40W G63 (CODE 61 OPTION) G64 (CODE 61 OPTION)

H50W

P800

90000865E

86

250 - 146

Series 90

Exploded View Parts Drawings / Parts Lists

Parts List Item

Description

Qty

B74 ............... Plug ......................................................... 4 B76 ............... Plug ......................................................... 1 B80 ............... Plug ......................................................... 2 B83 ............... Plug ......................................................... 1 B83 ............... Speed sensor .......................................... 1 E15 ............... Cap .......................................................... 1 E25 ............... Set screw ................................................ 1 E35 ............... Nut - Seal Lock ....................................... 1 G50 .............. Plug ......................................................... 2 G63 .............. Split flange clamp .................................... 4 G64 .............. Shipping cover screw .............................. 4 G70 .............. Plug ......................................................... 1 H10N ............ Loop flushing spool - defeat .................... 1 H50N ............ Plug ......................................................... 2 H60N ............ Plug ......................................................... 1 H10W ........... Shuttle valve spool .................................. 1 H20W ........... Spring guide ............................................ 2 H30W ........... Spring ...................................................... 2 H40W ........... O-ring ...................................................... 2 H50W ........... Plug ......................................................... 2 H60W ........... Charge relief valve plug .......................... 1 H62W ........... O-ring ...................................................... 1 H64W ........... Spring ...................................................... 1 H66W ........... Charge relief poppet ............................... 1 H68W ........... Lock nut ................................................... 1

Item

Description

Qty

L30 ............... Seal carrier .............................................. 1 L35 ............... Seal carrier .............................................. 1 L40 ............... Lip seal .................................................... 1 L50 ............... O-ring ...................................................... 1 L60 ............... Retainer ................................................... 1 L70 ............... Screw ...................................................... 3 M1N ............. Control valve - electric ............................ 1 M1P .............. Control valve - hydraulic ......................... 1 P400 ............. Plug ......................................................... 2 P600 ............. Plug ......................................................... 1 P601 ............. PCOR-Valve ............................................ 1 P700 ............. Special plug ............................................. 1 P800 ............. O-ring ...................................................... 1 T30 ............... Filter screen ............................................ 1 T40 ............... O-ring ...................................................... 1 T50 ............... Backup ring ............................................. 2 T60 ............... O-ring ...................................................... 1 T100 ............. Orifice plug .............................................. 1 Y40 ............... O-ring ...................................................... 1 Y50 ............... Backup ring ............................................. 2 Y60 ............... O-ring ...................................................... 1 Y70 ............... Orifice check valve .................................. 1 Y71 ............... Nut - Seal Lock ....................................... 1 Y72 ............... O-ring ...................................................... 1 Y80 ............... Plug ......................................................... 1 Y100 ............. Orifice plug .............................................. 1 Y102 ............. Orifice check valve .................................. 1

L8 ................. Key .......................................................... 1 L9 ................. Slotted nut ............................................... 1

Name Plate

saue Ames, Iowa, U.S.A. Model Code

Neumünster, Germany Typ

90S055 NB 2 0 8 N 4 S1 W 01 NNN 01 00 24 Model Number Serial Number

Model No.

Model Code

Ident Nr

94 – 4002 A – 91 – 26 – 67890 Serial No. Fabr Nr MADE IN U.S.A.

Place of Manufacture

Name Plate (U.S.A. Production) 250 - 147

87

Hydraulic Power Systems SAUER-DANFOSS Hydraulic Power Systems - Market Leaders Worldwide SAUER-DANFOSS is a world leader in the design and manufacture of Hydraulic Power Systems. Research and development resources in both North America and Europe enable SAUER-SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology.

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

SAUER-DANFOSS is Your World Source for Controlled Hydraulic Power Systems F000 691

F000 692

Heavy Duty Axial Piston Pumps and Motors

F000 686

Heavy Duty Bent Axis Variable Motors

Cartridge Motors/ Compact Wheel Drives

F000 685 F000 688

Medium Duty Axial Piston Pumps and Motors

F000 690

F000 684

Microcontrollers and Electrohydraulic Controls F000 717

Open Circuit Axial Piston Pumps

Hydrostatc Transmission Packages F000 693

F000 687

Gear Pumps and Motors

Genuine Service Parts

Worldwide Service Support SAUER-DANFOSS provides comprehensive worldwide service for its produkts through an extensive network of Authorized Service Centers strategically located in all parts of the world.

Look to SAUER-DANFOSS for the best in WORLDWIDE SERVICE.

Original Ersatzteile Genuine Parts

http://www.sauer-danfoss.com

SAUER-DANFOSS COMPANY 2800 East 13th Street Ames IA 50010 • U.S.A. Phone: (515) 239-6000 • Fax: (515) 239-6618

SAUER-DANFOSS GMBH & CO. Postfach 2460 • D-24531 Neumünster Krokamp 35 • D-24539 Neumünster • Germany Phone: (04321) 871-0 • Fax: (04321) 871 122

SM-SPV/SMF/SMV90-E • 10/98 • 300047G • BLN-9947 Revision G • Oct. 1998 250 - 148

M46 Variable Motors Service Manual

250 - 149

Service Manual

HISTORY OF REVISIONS

Table of Revisions Date

Page last

2

250 - 150

11026745

Changed

Rev.

Service Manual Contents INTRODUCTION

6 6 6 6 6 6 6 7 9 FLUID AND FILTER MAINTENANCE

INITIAL STARTUP PROCEDURES 3

PRESSURE MEASUREMENTS

250 - 151

3

11026745

3

Service Manual Contents TROUBLESHOOTING

4 4 4

6 6 6 INSPECTIONS AND ADJUSTMENTS

7 7

MINOR REPAIR

9

TORQUE CHART

3 3

4

250 - 152

11026745

Service Manual

OVERVIEW

520L0636

WARRANTY

GENERAL INSTRUCTIONS w Remove the unit

e Keep it clean

d Replace all O-rings and gaskets

t Secure the unit

250 - 153

11026745

5

Service Manual

SAFETY PRECAUTIONS

Unintended machine movement W Warning

Flammable cleaning solvents W Warning

Fluid under pressure W Warning

Personal safety W Warning

Hazardous material W Warning

SYMBOLS USED IN SAUER-DANFOSS LITERATURE









 

6

250 - 154

11026745

 

Service Manual

DESIGN

Cross section view Valve plate

Piston

Ball bearing Slipper Shaft Seal Shaft

Journal Bearing Swashplate bearing pin Needle bearing

Swashplate Servo piston

Cylinder block Sleeve Bearing P106 607E

250 - 155

11026745

7

Service Manual

THE SYSTEM CIRCUIT

The basic closed circuit

Case drain and heat exchanger

System circuit diagram

Heat exchanger bypass

Control handle

Reservoir

Filter

Displacement control valve

Heat exchanger Cylinder block assembly

Cylinder block assembly

Variable displacement motor

Charge relief valve Bypass valve

Output shaft Charge pump Input shaft

Variable displacement pump

Check valves w/ high pressure relief valve

Loop flushing module

Suction flow Charge pressure Servo pressure High pressure Case flow

8

250 - 156

11026745

P106 608E

Service Manual

MOTOR SCHEMATIC

Motor schematic MA

M5 (Top)

M5 (bottom)

A

L1 B MB

L2 P101 869

250 - 157

11026745

9

Service Manual

FLUID AND FILTER RECOMMENDATIONS

Fluid and filter change interval Reservoir type

CCaution

Hazardous material W Warning

10

250 - 158

11026745

Max oil change interval

Service Manual

GENERAL

W

START-UP PROCEDURE

W

250 - 159

11026745

11

Service Manual

STARTUP PROCEDURE (continued)

CCaution CCaution

12

250 - 160

11026745

Service Manual

REQUIRED TOOLS

PORT AND GAUGE INSTALLATION Port information Port identifier

Port size

Wrench size

Pressure obtained

Gauge size, bar [psi]

L1, L2 MA, MB M4 M5

System ports Port identifier A

Port size

B

Port locations M4

M5 (top)

M5 (bottom)

L2

B

A

L1 MA

MB Bottom View

End View

250 - 161

11026745

P106 598E

13

Service Manual

OVERVIEW

Introduction

SAFETY PRECAUTIONS

C Caution W Warning

W Warning

C Caution lines W Warning

SYSTEM OPERATING HOT

Item

14

11026745

250 - 162

Oil level in reservoir

Description

Action

Service Manual

SYSTEM WILL NOT OPERATE IN ONE DIRECTION

Item

Description

Action

Description

Action

valves

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

250 - 163

Item Oil level in reservoir

11026745

15

Service Manual

SYSTEM RESPONSE IS SLUGGISH

Item

NEUTRAL DIFFICULT OR IMPOSSIBLE TO FIND

SYSTEM NOISE OR VIBRATION

16

250 - 164

11026745

Description

Action

Service Manual

STANDARD PROCEDURES, INSPECTIONS, AND ADJUSTMENTS

C Caution lines

WARRANTY

250 - 165

11026745

17

Service Manual

MOTOR ADJUSTMENT Port and gauge locations

3

DISPLACEMENT LIMITER ADJUSTMENT

Displacement limiter adjustment

4513

4510 9/16 in

4509 4508

P106 614E

DISPLACEMENT LIMITER ADJUSTMENT DATA

18

250 - 166

Displacement Locknut wrench size and torque 46

11026745

Adjusting screw

Approximate displacement change

size

per revolution of adjusting screw

Service Manual

STANDARD PROCEDURES, REMOVING THE MOTOR C Caution

Removal

C Caution

C Inspection

Reassembly

250 - 167

11026745

19

Service Manual

SHAFT SEAL, BALL BEARING AND SHAFT REPLACEMENT Removal

Repair shaft

C Caution

C

Inspection

Reassembly

20

250 - 168

11026745

Service Manual

LOOP FLUSHING SPOOL Removal

Inspection

Reassemby

Replace loop flushing spool

250 - 169

11026745

21

Service Manual

DISPLACEMENT LIMITER Displacement limiter adjustment, Removal

Inspection

Reassemby

Repair displacement limiter

22

250 - 170

11026745

Service Manual

FASTENER SIZE AND TORQUE CHART

Item

Fastener

Wrench size

Torque

O-ring plug

Wrench size

Torque

4131 4115 4135 4618 4619

PLUG SIZE AND TORQUE CHART

Item 4127 4503 4604 4605 4606 4611

Hardware locations 4611

4619

4606 (2x)

4618

4604 4135 (6x)

4115 (1x)

4127 4131 (10x)

4503 (2 x)

4605

P106 600E

250 - 171

11026745

23

OUR PRODUCTS

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

Sensors

ünster ü

11026745

250 - 172

Series 40 - M46 Variable Pumps Service Manual

250 - 173

Series 40 M46 Variable Pumps Service Manual

HISTORY OF REVISIONS

Table of Revisions Date

Page

-

2

250 - 174

11026743

Changed

Rev.

Series 40 M46 Variable Pumps Service Manual

INTRODUCTION

6 6 6 6 6 6

0 FLUID AND FILTER MAINTENANCE

INITIAL STARTUP PROCEDURES PRESSURE MEASUREMENTS

4 4

TROUBLESHOOTING

6 6

250 - 175

11026743

3

Series 40 M46 Variable Pumps Service Manual

INSPECTIONS AND ADJUSTMENTS

0 0

3 4

MINOR REPAIR

30 3 33 34 3 36 3 3 3

TORQUE CHART

3 3

4

250 - 176

11026743

Series 40 M46 Variable Pumps Service Manual

OVERVIEW

WARRANTY

GENERAL INSTRUCTIONS w Remove the unit

e Keep it clean

d Replace all O-rings and gaskets

250 - 177

11026743

5

Series 40 M46 Variable Pumps Service Manual

SAFETY PRECAUTIONS

Unintended machine movement W Warning

Flammable cleaning solvents W Warning

Fluid under pressure W Warning

Personal safety W Warning

Hazardous material W Warning

6

250 - 178

11026743

Series 40 M46 Variable Pumps Service Manual

SYMBOLS USED IN SAUER-DANFOSS LITERATURE









    

    





















 

250 - 179



11026743

sleeve 

7

Series 40 M46 Variable Pumps Service Manual

DESIGN

Cross section view Gerotor

Valve plate

Ball bearing

Piston Slipper

Shaft

Shaft Seal

Journal Bearing Swashplate bearing pin Needle bearing

Servo piston Cylinder block

Swashplate Manual displacement Control

8

250 - 180

11026743

Sleeve Bearing

Series 40 M46 Variable Pumps Service Manual

THE SYSTEM CIRCUIT

The basic closed circuit

Case drain and heat exchanger

System circuit diagram

Heat exchanger bypass

Control handle

Reservoir

Filter

Displacement control valve

Heat exchanger Cylinder block assembly

Cylinder block assembly

Variable displacement motor

Charge relief valve Bypass valve

Output shaft Charge pump Input shaft

Variable displacement pump

Check valves w/ high pressure relief valve

Loop flushing module

Suction flow Charge pressure Servo pressure High pressure Case flow

250 - 181

11026743

P106 608E

9

Series 40 M46 Variable Pumps Service Manual

PUMP SCHEMATIC

Pump schematic

BNA E

M3

A

M4

M1 M5

L2

M2 B L1

10

250 - 182

11026743

S

P100 587E

Series 40 M46 Variable Pumps Service Manual

FLUID AND FILTER RECOMMENDATIONS

Fluid and filter change interval Reservoir type

Max oil change interval

C

Hazardous material W Warning

250 - 183

11026743

11

Series 40 M46 Variable Pumps Service Manual

GENERAL

W

START-UP PROCEDURE

W

12

250 - 184

11026743

Series 40 M46 Variable Pumps Service Manual

STARTUP PROCEDURE (continued)

C

250 - 185

11026743

13

Series 40 M46 Variable Pumps Service Manual

REQUIRED TOOLS

PORT LOCATIONS AND GAUGE INSTALLATION Port information Port identifier

Port size

Wrench size

Pressure obtained

Gauge size, bar [psi]

M3

System valves Port identifier

Relief

Port size

Wrench size

System ports Port identifier

Port size

Port locations MB

MA M3 RB

L1 M5

M4

R

B L2

BP

A

P106 604E

14

250 - 186

11026743

RA

S

Series 40 M46 Variable Pumps Service Manual

OVERVIEW

Introduction

SAFETY PRECAUTIONS

6

C Caution

C Caution lines SYSTEM NOISE OR VIBRATION

Item

Description

Action

vacuum

250 - 187

11026743

15

Series 40 M46 Variable Pumps Service Manual

SYSTEM OPERATING HOT

Item

Description

Action

Description

Action

Valves

SYSTEM WILL NOT OPERATE IN ONE DIRECTION

Item

valves

16

250 - 188

11026743

Series 40 M46 Variable Pumps Service Manual

SYSTEM WILL NOT OPERATE IN EITHER DIRECTION

Item

Description

Action

valves

NEUTRAL DIFFICULT OR IMPOSSIBLE TO FIND

a

250 - 189

11026743

17

Series 40 M46 Variable Pumps Service Manual

SYSTEM RESPONSE IS SLUGGISH

Item

Description

Action

Description

Action

valves

ELECTRICAL TROUBLESHOOTING

Item

18

11026743

250 - 190

Series 40 M46 Variable Pumps Service Manual

STANDARD PROCEDURES, INSPECTIONS, AND ADJUSTMENTS

C Caution

WARRANTY

250 - 191

11026743

19

Series 40 M46 Variable Pumps Service Manual

PUMP ADJUSTMENT Pressure measurements

CHARGE PRESSURE RELIEF VALVE

Charge pressure adjustment 103 102 1 in.

101 104 105

M3 11/16 in Charge pressure gage port

20

250 - 192

11026743

P106 634E

Series 40 M46 Variable Pumps Service Manual

ENGAGING THE BYPASS FUNCTION

C Caution

Using the bypass function Bypass check valve 5/8 in

P106 633E

250 - 193

11026743

21

Series 40 M46 Variable Pumps Service Manual

SYSTEM CHECK/RELIEF (SCR) VALVES

Installing the SCRs 166 1-1/4 in 176 Nm [130 ft 106

165 1103

1103 165 106 166 1-1/4 in 176 Nm [130 ft

22

250 - 194

11026743

Series 40 M46 Variable Pumps Service Manual

DISPLACEMENT LIMITER ADJUSTMENT

Displacement limiter adjustment

929 928 927 9/16 in 911

P106 626E

250 - 195

11026743

23

Series 40 M46 Variable Pumps Service Manual

SWASHPLATE NEUTRAL ADJUSTMENT

Measured data:

Pump Setup

Servo neutral adjustment

908 1/4 in Connect Ports M4 and M5 115 P106 630E

24

250 - 196

11026743

9/16 in

Series 40 M46 Variable Pumps Service Manual

MANUAL DISPLACEMENT CONTROL NEUTRALRETURN BRACKET ADJUSTMENT Swashplate neutral adjustment

Measured data

Procedure

Manual displacement control bracket adjustment 1210 3/8 in Neutral bracket

P106 631E

250 - 197

11026743

25

Series 40 M46 Variable Pumps Service Manual

ELECTRIC DISPLACEMENT CONTROL/HYDRAULIC DISPLACEMENT CONTROL NEUTRAL ADJUSTMENT

Measured data

Procedure

EDC / HDC control adjustment Adjustment screw 5/32 in Lock nut 1/2 in

P106 643

26

250 - 198

11026743

Series 40 M46 Variable Pumps Service Manual

STANDARD PROCEDURES, REMOVING THE PUMP C Caution

Removal

C Caution

C Inspection

Reassembly

Series 40 M46 Variable Pump Parts Manual BLN-2-41701

250 - 199

11026743

27

Series 40 M46 Variable Pumps Service Manual

DISPLACEMENT LIMITER

Removal

Inspection

Reassembly

Displacement limiter removal/installation 927

929

9/16 in

928

921

Servo neutral adjustment screw

3/8 in

911 115 9/16 in

936 902 P106 641E

28

250 - 200

11026743

Series 40 M46 Variable Pumps Service Manual

PRESSURE FILTRATION ADAPTER

Removal

Inspection

Reassembly

Pressure filtration adapter removal/installation

805 801

810 11/16 in

810A

250 - 201

11026743

806 1/2 in

P106 642E

29

Series 40 M46 Variable Pumps Service Manual

CHARGE PUMP

Removal

Charge pump removal/installation 1506 9/16 in 77Nm [57 f 1502 9/16 in 43Nm [32 f

1503

142

1505 1504

141 155 604 603 605

P106 636E

30

250 - 202

11026743

Series 40 M46 Variable Pumps Service Manual

CHARGE PUMP (continued)

Inspection

Reassemby

�

250 - 203

11026743

31

Series 40 M46 Variable Pumps Service Manual

SHAFT SEAL, ROLLER BEARING AND SHAFT REPLACEMENT

See Charge pump Removal

Shaft assembly 301 132

C Caution 131

C

C Caution

133

132

C

133 401

Inspection

P106 637E

Reassembly

Shaft seal installation tool

7 in

0.750 in

1.24 in

2.75 in

0.370 in

1.5 in 2.45 in 3 in

32

250 - 204

11026743

P106 652E

Series 40 M46 Variable Pumps Service Manual

SCR VALVES Removal

Inspection

Reassembly

SCR valves 166 1-1/4 in 176 Nm [130 ft 106

165 1103

1103 165 106 166 1-1/4 in 176 Nm [130 ft P106 635E

250 - 205

11026743

33

Series 40 M46 Variable Pumps Service Manual

CHARGE PRESSURE RELIEF VALVE

Charge pressure relief valve adjustment

Removal

Inspection

Reassemby

Charge pressure relief valve 102 1 in 103

101 104 105

P106 638E

34

250 - 206

11026743

Series 40 M46 Variable Pumps Service Manual

BYPASS VALVE

Removal

Inspection

Reassemby

Bypass valve

1002

1001 5/8 in 20 Nm [15 f

1003

P106 653E

250 - 207

11026743

35

Series 40 M46 Variable Pumps Service Manual

MANUAL DISPLACEMENT CONTROL

Removal

Inspection

Reassemby

MDC bracket adjustment

Manual displacement control 302

1208 1210 3/8 in

1402 1209 1207 303 1214

1235

1216 1215

1213 1/2 in

36

250 - 208

11026743

P106 639E

Series 40 M46 Variable Pumps Service Manual

ELECTRONIC DISPLACEMENT CONTROL/HYDRAULIC DISPLACEMENT CONTROL

Removal

Inspection When installing control, ensure that sleeve groove engages spring pin on swashplate.

Reassemby

EDC / HDC repair 1201

1220

304

1203 3/16 in 1220

EDC 1204 3/16 in

1220

1201

304 1203 3/16 in

1220 1227

HDC

P106 640E

1225 1204 3/16 in

1224 3/16 in 3-Position Control

250 - 209

11026743

1228

1223

1226 4 mm 1229 O-rings (1229) are supplied as part of control

37

Series 40 M46 Variable Pumps Service Manual

MDC ORIFICE REPAIR

Removal

MDC orifice repair

Inspection 1401 1/8 in

Reassemby

1219 3/16 in P106 654E

EDC/HDC orifice repair EDC/HDC ORIFICE REPAIR

934

Removal

920 3/8 in

Displacement limiter repair

901 2161

1403

Inspection

Reassemby

1404

Displacement limiter repair 936 902 921 3/8 in

115 9/16 in

38

250 - 210

11026743

P106 655E

Series 40 M46 Variable Pumps Service Manual

FASTENER SIZE AND TORQUE CHART

Item

Fastener

Wrench size

Torque

O-ring plug

Wrench size

Torque

920 921 130 163 1506 806 115 927 1213 1210

PLUG SIZE AND TORQUE CHART

Item 102 107 110 111 158 810 1001 1101 1102

Hardware locations 110 (2places)

1210

1213

Side 1506 (3 places)

806 (3 places)

Rear

810

163 (6 places)

111 (2 places)

Front

130

115 (2 places)

1102

927 (2 places)

1001

921 (5 places)

P106 604E

107 (2 places) 158

250 - 211

11026743

Bottom

920 (5 places)

1101 102

Top

39

OUR PRODUCTS

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

ü ü

11026743

250 - 212

– –

250 - 213

270 - 1

270 - 2

270 - 3

270 - 4

280 - 1

280 - 2

280 - 3

280 - 4

SCS 460 SERIAL INTERFACE

INSTALLATION AND SERVICE MANUAL 280 - 5

N O T I C E The use of the suspension type fertilizers and lime slurries will significantly reduce the life of the plastic parts in the Flow Meter and motorized Control Valve. Check the rotor and inlet hub assembly in the Flow Meter frequently for worn parts. Excessive wear can affect accuracy.

Do not attempt to modify or lengthen any of the three-wire Speed Sensor or Flow Meter cables. Extension cables are available from your Dealer.

W A R N I N G Disconnect console before jump starting, charging battery, or welding on equipment.

280 - 6

280 - 7

RAVEN INDUSTRIES LIMITED WARRANTY WHAT IS COVERED? This warranty covers all defects in workmanship or materials in your Raven Flow Control Product under normal use, maintenance, and service.

HOW LONG IS THE COVERAGE PERIOD? This warranty coverage runs for 12 months from the purchase date of your Raven Flow Control Product. This warranty coverage applies only to the original owner and is not transferrable.

HOW CAN YOU GET SERVICE? Bring the defective part, and proof of date of purchase, to your local dealer. If your dealer agrees with the warranty claim, he will send the part, and proof of purchase to his distributor or to Raven for final approval.

WHAT WILL RAVEN INDUSTRIES DO? When our inspection proves the warranty claim, we will, at our option, repair or replace the defective part and pay for return freight.

WHAT DOES THIS WARRANTY NOT COVER? Raven Industries will not assume any expense or liability for repairs made outside our plant without written consent. We are not responsible for damage to any associated equipment or product and will not be liable for loss of profit or other special damages. The obligation of this warranty is in lieu of all other warranties, expressed or implied, and no person is authorized to assume for us any liability. Damages caused by normal wear and tear, mis-use, abuse, neglect, accident, or improper installation and maintenance are not covered by this warranty.

280 - 8

280 - 9

Manual Rev. B, SCS 460 S.I. 11/00 #016-0159-823

016-0159-823 11/00

TABLE OF CONTENTS

SYMBOL DEFINITION .............................................................................................................................................. 2 INTRODUCTION ....................................................................................................................................................... 3 INSTALLATION ......................................................................................................................................................... 4 1. MOUNTING THE RAVEN RADAR SPEED SENSOR ............................. 4 2. MOUNTING THE FLOW METER ........................................... 5 3. MOUNTING THE CONTROL VALVE ........................................ 6 4. MOUNTING THE CONSOLE AND CABLING .................................. 7

BATTERY CONNECTIONS ...................................................................................................................................... 8 CONSOLE FEATURES............................................................................................................................................. 9 CONSOLE CALIBRATION ...................................................................................................................................... 10 1. CALCULATING "BOOM CAL" ........................................... 10 2. CALCULATING "SPEED CAL" .......................................... 10 3. CALCULATING "METER CAL" .......................................... 11 4. CALCULATING "VALVE CAL" .......................................... 12 5. CALCULATING "RATE 1 AND RATE 2 CAL" .............................. 13

CONSOLE PROGRAMMING .................................................................................................................................. 14 1. INITIAL CONSOLE PROGRAMMING ...................................... 14 2. OTHER DISPLAY FEATURES ........................................... 18 3. SELF TEST FEATURE ................................................ 18 4. VOLUME/MINUTE RATE FAULT ......................................... 19 5. VOLUME/AREA RATE ALARM ........................................... 19 6. LOW TANK FAULT ................................................... 19 7. AUTOMATIC RATE +/- ............................................... 20 8. CONTROL VALVE DELAY .............................................. 20 9. ZERO SPEED SHUT-OFF ............................................. 20 10. DATA MENU ........................................................ 20 11. DECIMAL SHIFT ................................................... 27

INITIAL SYSTEM SET-UP ...................................................................................................................................... 28 INITIAL SYSTEM FIELD TEST............................................................................................................................... 29 PREVENTIVE MAINTENANCE .............................................................................................................................. 29 TROUBLESHOOTING GUIDE ................................................................................................................................ 30

APPENDIXES 1. WHEEL DRIVE SPEED SENSOR INSTALLATION AND CALIBRATION ........................................................ 33 2. SPEEDOMETER DRIVE SPEED SENSOR INSTALLATION AND CALIBRATION ......................................... 36 3. ALTERNATE BY-PASS LINE PLUMBING SYSTEM ........................................................................................ 38 4. PROCEDURE TO TEST SPEED SENSOR EXTENSION CABLES ................................................................. 40 5. PROCEDURE TO TEST FLOW METER CABLES ............................................................................................ 41 6. FLOW METER MAINTENANCE AND ADJUSTMENT PROCEDURE .............................................................. 42 7. PROCEDURE TO RE-CALIBRATE FLOW METER .......................................................................................... 43 8. SERIAL INTERFACE .......................................................................................................................................... 44 9. SCS 460 COMMUNICATION STRINGS ............................................................................................................ 45 REPLACEMENT PARTS SHEETS

280 - 10

1

SYMBOL DEFINITION GPM lit/min dl/min PSI kPa GPA lit/ha ml/ha GPK mm

- Gallons per minute - Liters per minute - Deciliter per minute - Pounds per square inch - Kilopascal - Gallon per acre - Liter per hectare - Milliliter per hectare - Gallons per 1,000 sq. ft.

- Millimeters

cm dm m MPH km km/h US SI TU [] {}

- Centimeters - Decimeters - Meter - Miles per hour - Kilometers - Kilometers per hour - Volume per acre - Volume per hectare - Volume per 1,000 sq. ft.

- Metric numbers - 1,000 sq. ft. numbers

METER CAL CONVERSIONS To convert the METER CAL number simply divide the original number (number printed on Flow Meter label) by the desired conversion factor.

FOR EXAMPLE: Original METER CAL No. = METER CAL No. for displays in Fluid Ounces 128 Original METER CAL No. = METER CAL No. for displays in Liters 3.785 Original METER CAL No. = METER CAL No. for displays in Pounds Weight of one gallon LIQUID CONVERSIONS U.S. Gallons x 128 = Fluid Ounces U.S. Gallons x 3.785 = Liters U.S. Gallons x 0.83267 = Imperial Gallons U.S. Gallons x 8.34 = Pounds (Water) LENGTH 1 millimeter (mm) = 0.039 inch 1 centimeter (cm) = 0.393 inch 1 meter (m) = 3.281 feet 1 kilometer (km) = 0.621 mile 1 inch = 25.4 millimeters; 2.54 centimeters 1 mile = 1.609 kilometers PRESSURE 1 psi = 6.89 kPa 1 kPa = 0.145 psi AREA 1 square meter = 10.764 square feet 1 hectare (ha) = 2.471 acres; 10,000 square meters 1 acre = 0.405 hectare; 43,560 square feet 1 square mile = 640 acres; 258.9 hectares 280 - 11

2

INTRODUCTION The Raven SCS 460 (SPRAYER CONTROL SYSTEM) is designed to improve the uniformity of spray applications. Its performance relies on the installation and preventive maintenance of the complete sprayer. It is important that this Installation and Service Manual be reviewed thoroughly before operating the system. This manual provides a simple stepby-step procedure for installing and operating.

The SCS 460 system consists of a computer-based Control Console, a Speed Sensor, a turbine type Flow Meter and a motorized Control Valve. The Console mounts directly in the cab of the vehicle for easy operator use. The Radar Speed Sensor is mounted to the frame of the vehicle or implement (wheel drive and speedometer Drive Speed Sensors are also available.) The motorized Control Valve and Flow Meter mount to the framework supporting the boom valves. Appropriate cabling is furnished for field installation.

The operator sets the target volume per area to be sprayed and the SCS 460 automatically maintains the flow regardless of vehicle speed or gear selection. A manual override switch allows the operator to manually control flow for system check-out and spot spraying. Actual volume per area being applied is displayed at all times. The SCS 460 additionally functions as an area monitor, speed monitor and volume totalizer.

NOTE: The SCS 460 Control Console is designed to be used with external Boom switches.

In order for the Console to know when and which Boom is ON or OFF, Boom signal wires are provided.

280 - 12

3

INSTALLATION 1.

MOUNTING THE RAVEN RADAR SPEED SENSOR See Appendix 1 for Wheel Drive Speed Sensor installation instructions.

See Appendix 2 for Speedometer Drive Speed Sensor installation instructions.

For mounting the radar, the following guidelines will assure proper installation: It is suggested that a large heavy mounting bracket, (P/N 107-0159-693) be attached to the vehicle frame for mounting the radar.

1)

Park vehicle on level surface.

2)

Select mounting site by considering the following: a) The line of sight from the lens to the ground must not be obstructed by structures or tires. Obstructions must not come closer than 20 inches to the bottom of the radar. See Figures 1 and 2. b) The radar lens must be parallel to the ground from front to back. Radar can be tilted out 0-15 degrees to provide more clearance and miss obstructions. See Figure 2. c) The radar should be mounted so that the length of the radar is parallel with direction of vehicle travel.

3)

Use carpenters level to verify that mounting bracket is parallel to the ground.

4)

Bolt mounting bracket to implement.

5)

Bolt radar to mounting bracket using mounting hardware.

6)

Connect radar with Radar Interface Cable (P/N 115-0159-539), to the Console.

The Red wire should be connected to the Orange cable wire. The White wire should be connected to the White cable wire (See "BATTERY CONNECTIONS").

CAUTION:

The connection of the radar power in reverse polarity could result in damage to the Radar.

FIGURE 2

FIGURE 3

FIGURE 1 280 - 13

See Figure 3.

4

2.

MOUNTING THE FLOW METER AND OPTIONAL PRESSURE TRANSDUCER

FLOWMETER 1)

Mount Flow Meter in the area of the boom valves per Figure 4. All flow through Flow Meter must go to booms only, i.e., no return line to tank or pump after Flow Meter.

2)

Mount Flow Meter horizontal to the ground.

Meter.

3)

For best results, allow a minimum of 7 1/2 inches [20 cm] of straight hose on inlet of Flow Meter. Bend radius of hose on outlet of Flow Meter should be gradual.

4)

Flow must be in direction of arrow on Flow Meter.

Use the bracket to secure the Flow

NOTE:It is essential, when using suspensions, that the system be thoroughly rinsed out each day after use.

OPTIONAL PRESSURE TRANSDUCER 1)

Mount optional pressure transducer, part #422-0000-059, on desired location.

Use cables 115-0171-152 (or 115-0171-153)and 115-0171-151.

2)

With pump turned off and 0 PSI [kPa] on the lines, enter 0 for pressure calibration (cal pressure) under Data Menu Key.

3)

When system is operating, system PSI [kPa] will be displayed when the or

key is depressed.

FIGURE 4

280 - 14

5

3.

MOUNTING THE CONTROL VALVE

1)

Mount the motorized Control Valve in the main hose line between the Flow Meter and the booms, with motor in the upright position. (For flow less than 3 GPM [11 lit/min] the motorized Control Valve is mounted in a by-pass line. Refer to Appendix 3 for alternate plumbing diagram).

2)

Connect the Flow Control Cable connectors to boom valves, Flow Meter, and motorized Control Valve. (Black wire to boom valve #1, Brown wire to boom valve #2, Blue wire to boom valve #3, Blk/Wht wire to boom valve #4, Brn/Wht wire to boom valve #5, Blu/Wht wire to boom valve #6 and Wht/Blk to boom valve #7).

280 - 15

6

4.

MOUNTING THE CONSOLE AND CABLING

1)

Mount the Console to a secure support inside the cab of the vehicle.

2)

Connect the Console Control Cable to the plug in the back of the Console.

(Reference Figure 5). Route the Console Control Cable out of the vehicle cab and terminate. (Flow Meter extension cables are available from your Dealer).

3)

Turn POWER ON/OFF switch OFF and route the Red and White battery wires to a 12volt battery. Attach the White battery wires to the NEGATIVE (-) terminal and the Red battery wire directly to the POSITIVE (+) battery terminal. (See Figure 6 on page 8). (DO NOT CONNECT RED AND WHITE WIRES TO THE STARTER). Secure the battery wires with plastic cable ties. DO NOT tie the battery wires close to the existing battery leads or any other electrical wiring.

4)

Connect the Speed Sensor to the plug in the back of the Console.

5)

Secure and tie the Speed Sensor Cable and the Console Control Cable with plastic cable ties.

6)

Initial installation of the system is now complete.

FIGURE 5 NOTE: The SCS 460 Control Console is designed to be used with external boom switches.

In order for the Console to know when and which Boom is ON or OFF, boom signal wires are provided. The Console recognizes a boom ON whenever +12 VDC is applied to the boom signal wire. Connect the boom signal wire to the switched side of the boom valve.

280 - 16

7

BATTERY CONNECTIONS

FIGURE 6 NOTE: Disconnect SCS 460 battery wires if the system is not used for an extended period, (i.e. two weeks). With the POWER switch to OFF, the system draws .25 milliamps of current to maintain information stored in Console computer.

280 - 17

8

CONSOLE FEATURES IMPORTANT: This Console requires selection of US (Volume per acre), SI (Volume per hectare), or TU {1,000 sq. ft.} area; SP1 (wheel drive, etc.) or SP2 (radar) speed sensor; and C-SD (Standard Valve), C-F (Fast Valve), C-FC (Fast Close Valve), C-P (PWM Valve) or C-PC (PWM Close Valve). Hold SELF TEST key to view selections.

Console Revision can be determined by the letter stamped in REV box on label.

Console Program can be determined by the letter stamped in PGM box on label.

Selects manual or fully automatic control.

Manual override control provides capability for spot application.

CE -Use like you do the CE key on a calculator.

ENTER -Used only to enter data into the Console.

POWER-Selects POWER ON or OFF.

Displays actual rate of application, calibration, and function data.

CALIBRATION KEYS --

Used to enter data into the Console to calibrate the system.

FUNCTION KEYS

--

Used to Display Data

BOOM CAL

--

SPEED CAL METER CAL VALVE CAL RATE 1 CAL RATE 2 CAL TIME 280 - 18

-------

Length of Boom. Select Boom number by using the UP/DOWN arrow keys.

Determined by Speed Sensor Meter Calibration Number Valve Response Time Target Application Rate Target Application Rate 24 Hour Clock (Military Time)

TOTAL AREA TOTAL VOLUME FIELD AREA FIELD VOLUME DISTANCE SPEED VOLUME/MIN DATA MENU

---------

Total Area Applied Total Volume Applied Field Area Applied Volume Applied to Field Distance Traveled Speed of Vehicle Volume Per Minute Printer Option

9

CONSOLE CALIBRATION 1.

CALCULATING "BOOM CAL"

1)

Broadcast Spraying Calculate the width of each boom in inches [cm] by multiplying the number of tips times the spacing.

Write these boom widths down for future reference when programming the Console.

FIGURE 7

2)

Band Spraying Calculate the width of each boom in inches [cm] by multiplying the number of tips by the spacing. Calculate the Adjusted Applied Rate by multiplying the Broadcast Rate by Band Width in inches [cm] divided by Spacing in inches [cm].

EXAMPLE:

Broadcast Rate Spacing Band Width

Adjusted Applied Rate

2.

= 20 GPA [200 lit/ha] = 40 inches [100 cm] = 14 inches [40 cm]

=

GPA x Band Width Spacing

=

20 x 14 = 7 GPA 40

=

[200] x [40] = [80 lit/ha] [100]

CALCULATING "SPEED CAL" Initial SPEED CAL is 598 [152] when using the Raven radar. Complete Steps 1 thru 6 to refine this number after "INITIAL CONSOLE PROGRAMMING" has been completed.

1)

Set POWER switches to ON, all other switches to OFF.

2)

Enter "0" in

3)

Drive 1 mile [1 kilometer]. To achieve the most accurate calibration, accelerate and decelerate slowly.

CAUTION:

4)

.

Do not use vehicle odometer to determine distance. lines or highway markers.

Read DISTANCE by depressing

Use section

. DISTANCE should read a value of approximately

5280 [1000]. If it reads between 5260-5300 [990-1010], the SPEED CAL for the vehicle is 598 [152]. If the DISTANCE display reads any other value, perform the calculation: 280 -following 19

10

EXAMPLE:

Assume DISTANCE reads 5000 [980].

Corrected SPEED CAL = Old SPEED CAL x 5280 DISTANCE ENGLISH UNITS: = 598 x 5280 = 631.48 5000

METRIC UNITS: = [152] x [1000] = [155] [980]

The number to enter for SPEED CAL is 631 [155].

5)

Enter the number calculated for SPEED CAL.

6)

Recheck the new SPEED CAL derived in Step 5 by repeating Steps 2 thru 5.

3.

CALCULATING "METER CAL" The Flow Meter calibration number is stamped on the tag attached to each Flow Meter.

Write down this number for future reference when programming the Console.

280 - 20

11

4.

CALCULATING "VALVE CAL"

The initial recommended Control Valve calibration number for VALVE CAL is 2123 for C-SD (standard valve), 743 C-FC (fast close valve), 743 C-F (fast valve), 43 C-P (PWM valve) or 43 C-PC (PWM close valve). The VALVE CAL number is used to control response time of the control valve motor to the change in vehicle speed.

After operating the system, this number may be refined. See definitions below: For FAST VALVE (C-F) For PWM VALVE (C-P) For STANDARD VALVE (C-Sd): or FAST CLOSE VALVE (C-FC): or PWM CLOSE VALVE (C-PC):

Valve Backlash Digit

Controls the time of the first correction pulse after a change in correction direction is detected.

(INC to DEC -or- DEC to INC).

Range: 1 to 9

Valve Speed Digit

Controls response time of Control Valve motor.

CAUTION:

Running the Control Valve too fast will cause the system to oscillate.

C-Sd Valve Control

Range:

1 to 9

1-Slow 9-Fast

C-F, C-FC Valve Control

Range:

0 to 9

0-Fast 9-Slow

C-P, C-PC Valve Control

Range:

0 to 9

0-Slow 9-Fast

Brake Point Digit

Sets the percent away from target rate at which the Control Valve motor begins turning at a slower rate, so as not to overshoot the desired rate.

Range: 0 to 9

Dead-Band Digit

0 = 5% 1 = 10% 9 = 90%

Allowable difference between target and actual application rate, where rate correction is not performed.

Range: 1 to 9

280 - 21

1-Short Pulse 9-Long Pulse

12

1 = 1% 9 = 9%

5.

CALCULATING "RATE 1 AND RATE 2 CAL" Determine the application rate at which chemical is to be sprayed. Consult with a dealer to ensure these spray nozzles are capable of applying at this rate. In determining which spray nozzles to use with the sprayer the following must be known: 1) Nominal Application Pressure 2) Target Application Rate 3) Target Speed 4) Nozzle Spacing

___ PSI [kpa] ___ GPA [lit/ha] ___ MPH [km/h] ___ inches [cm]

From this information, calculate the volume per minute, per nozzle as follows: GPM [lit/min] = GPA [lit/ha] x MPH [km/h] x inches [cm] 5,940 [60,000] EXAMPLE:

1) 2) 3) 4)

Application Pressure Target Application Rate Target Speed Nozzle Spacing

GPM = 20 GPA x 5.2 MPH x 20 inches 5,940

= 30 PSI = 20 GPA = 5.2 MPH = 20 inches = .35

Using GPM .35 and pressure 30 select tip number XR8004 from the chart below, since it comes closest to providing the desired output.

VERIFYING FLOW RATE LIMITS: The flow rate of spraying must be within the range of that specified for the Flow Meter included.

FLOW METER MODEL RFM 5 RFM 15 RFM 60P RFM 100 RFM 200/200 Poly RFM 400 280 - 22

FLOW RANGE 0.05-5 GPM [0.2-18.9 lit/min] 0.3-15 GPM [1.1-56.8 lit/min] 1-60 GPM [3.8-210 lit/min] 3-100 GPM [11.4-380 lit/min] 15-200 GPM [56.8-760 lit/min] 25-400 GPM [94.6-1515 lit/min]

13

CONSOLE PROGRAMMING When entering data into the Console, the entry sequence is always the same.

NOTE: DATA MUST BE ENTERED FOR ALL BOOMS. ENTER "0" IF BOOM IS NOT USED. DATA MUST ALSO BE ENTERED IN KEYS 3 THRU 8.

1.

Depress the key in which you wish to enter data.

Depress the ENTER key. An "E" will illuminate in the display.

Depress the keys corresponding to the number you wish to enter (i.e. "2","1","2", "3").

The numbers will be displayed as they are entered.

Complete the entry by again depressing the ENTER key.

INITIAL CONSOLE PROGRAMMING When Console power is turned on, after all installation procedures have been completed, the Console will flash CAL and US VOLUME PER ACRE. This means the console must be "calibrated", or programmed, before it can be operated. This is a one-time operation which does not have to be repeated. Turning OFF the POWER ON/OFF switch does not affect the Console memory. All data is retained.

280 - 23

14

NOTE: If an entry selection error is made during steps 1-6, place the power ON/OFF switch to OFF. Depress and hold while placing the power ON/OFF switch to ON. This will reset the console.

1)

The display will show CAL US-VOLUME PER ACRE. The following steps must be followed: Display US-VOLUME PER ACRE, SI-VOLUME PER HECTARE , or TU-VOLUME PER 1000 SQ FT.

a)

Depressing momentarily

steps the display from

US-VOLUME PER ACRE to SI-VOLUME PER HECTARE.

b)

c)

Depressing momentarily

steps the display from SI-VOLUME PER HECTARE to TU-VOLUME PER 1000 SQ FT. Depressing momentarily

steps the display from

TU-VOLUME PER 1000 SQ FT to US-VOLUME PER ACRE.

2)

Selecting US, SI, or TU. a) b)

To select US, SI, or TU, press Momentarily depress

until the desired code is displayed.

, the display will now display

CAL SP1-WHEEL DRIVE.

3)

4)

Display SP1-WHEEL DRIVE or SP2-RADAR SPEED SENSOR. a)

Depressing momentarily

steps the display from SP1 to SP2.

b)

Depressing momentarily

steps the display from SP2 to SP1.

Selecting SP1 or SP2. a) b)

To select SP1 or SP2, press Momentarily depress

until desired code is displayed.

, the display will now display

CAL C-SD-STANDARD VALVE.

5)

Display C-SD-STANDARD VALVE, C-F-FAST VALVE, C-FC-FAST CLOSE VALVE, C-P-PWM VALVE or C-PC-PWM CLOSE VALVE. a)

Depressing momentarily

steps the display from C-SD to C-F.

b)

Depressing momentarily

steps the display from C-F to C-FC.

c)

Depressing momentarily

steps the display from C-FC to C-P.

d)

Depressing momentarily

steps the display from C-P to C-PC.

e)

Depressing momentarily

steps the display from C-PC to C-SD.

280 - 24

15

6)

Selecting C-SD, C-F, C-FC, C-P or C-PC. a)

To select C-Sd, C-F, C-FC, C-P, or C-PC, press displayed.

b)

Momentarily depress CAL

7)

until desired code is

, the DATA display will now display

SELF TEST 00.

Definition of Boom Calibration keys.

Depressing this key displays selected boom number in display.

EXAMPLE: Boom 1 will be displayed as CAL BOOM 1 CAL .

Depressing this key after selecting BOOM CAL changes the boom number.

EXAMPLE: CAL BOOM 1 CAL 0 to CAL BOOM 2 CAL 0.

Depressing this key after selecting BOOM CAL changes the boom number.

EXAMPLE: CAL BOOM 2 CAL 0 to CAL BOOM 1 CAL 0.

Enter Boom Data: a) Select boom 1 CAL . b) Use boom width as calculated under "CALCULATING BOOM CAL". c) If a boom is not needed, enter a "0" for the length.

8)

Enter SPEED CAL calibration number in

.

9)

Enter METER CAL calibration number in

.

10)

Enter appropriate VALVE CAL calibration number (2123, 743, or 43 in

11)

Enter the target RATE 1 (GPA) [lit/ha] {GPK} in

12)

Enter the target RATE 2 (GPA) [lit/ha] {GPK} in .

(If you do not use a second rate, enter the same rate as RATE 1 CAL).

.

.

NOTE: RATE 2 should not be more than 20% different from RATE 1 or else spray pattern may suffer.

PROGRAMMING THE CONSOLE IS NOW COMPLETED. The flashing "CAL" will now extinguish. If not, repeat procedure starting at Step 7.

After the console is programmed, if there is a need to change initial console programming (working units, speed sensor programs or valve drivers), hold The display will flash the current program setting.

Press

for 30 seconds. to switch to the de-

sired selection. Press to complete entry. Repeat procedure as necessary for speed (SP1, SP2) and valve driver selections (C-SD, C-F, C-FC, C-P, C-PC).

280 - 25

16

ENTERING ADDITIONAL DATA: Data may be entered in the

and

although it is not required for the

operation of the system.

1)

2)

ENTERING VOLUME: Enter the estimated VOLUME in the TANK in this number must be re-entered.

. Each time the tank is refilled,

ENTERING TIME, DATE, AND POWER DOWN: Definition of Time, Date, and Power Down Key: Depressing this key displays selected Time.

EXAMPLE: Display will display RATE 0.0 and TIME 0:00.

Depressing this key after selecting TIME toggles up through desired features.

EXAMPLE: TIME, MONTH, DAY, YEAR, and POWER DOWN DAY. Depressing this key after selecting TIME toggles down through desired features.

EXAMPLE: POWER DOWN DAY, YEAR , DAY , MONTH, and TIME.

3)

Enter TIME a) Select TIME b) Enter TIME when display shows RATE 0.0

TIME 0:00.

NOTE: This is a 24 hour clock. Therefore, all time after 12:59 p.m., add 12 hours. Thus, 8:30 a.m. is entered as 8:30, but 1:30 p.m. is entered as 13:30 in the keyboard.

4)

5)

6)

Enter MONTH a) Select MONTH b) Enter MONTH when display shows RATE 0.0

MONTH 1 .

Enter DAY a) Select DAY b) Enter DAY when display shows RATE 0.0

DAY 1.

Enter YEAR a) Select YEAR b) Enter YEAR when display shows RATE 0.0

YEAR 00 .

7)

POWER DOWN FEATURE If the Console is not used for 10 days, it will go into a power down (low power) mode of operation. In this mode, all data will be retained, but the time of day clock will reset to 0:00. The delay time is initially set at 10 days, but can be changed by the user. a) 280 - 26

Enter POWER DOWN 1) Select POWER DOWN 2) Enter POWER DOWN when display shows POWERDOWN DAY 10.

17

2.OTHER DISPLAY FEATURES 1)

To display TOTAL AREA covered, momentarily depress

.

To "zero out" this total at any time, enter a "0" in this key.

2)

To display TOTAL VOLUME sprayed, momentarily depress

.

To "zero out" this total at any time, enter a "0" in this key.

3)

To display FIELD AREA covered, momentarily depress

.

To "zero out" this total at any time, enter a "0" in this key.

4)

To display FIELD VOLUME sprayed, momentarily depress

.

To "zero out" this total at any time, enter a "0" in this key.

5)

To display DISTANCE (feet) [meters] traveled, momentarily depress

. To "zero

out" this total at any time, enter a "0" in this key.

6)

To display SPEED, momentarily depress

7)

To display VOL/MIN, momentarily depress

8)

To display AREA/HOUR, momentarily depress

. . .

This is an actual calculation

of AREA/HOUR at the present speed you are going. It is not an average over a period of time.

9)

To display US, SI, or TU; SP1 or SP2; and C-SD, C-F, C-FC, C-P or C-PC after being selected, depress

.

3.SELF TEST FEATURE SELF-TEST allows speed simulation for testing the system while vehicle is not moving.

Enter the simulated operating speed in

desired, enter 6.0 [10.0].

.

Verify SPEED by depressing

If 6 MPH [10 km/h] is .

The SELF-TEST

speed will clear itself when motion of vehicle is detected by the Speed Sensor.

A SPEED CAL value of 900 [230] or greater is recommended when operating in this mode.

NOTE: To prevent nuisance clearing of self-test speed, disconnect speed connector on back of Console when Radar Speed Sensors are used.

280 - 27

18

4.VOLUME/MINUTE RATE FAULT Depress until display shows SET LOW LIMIT 0. A low limit flow rate may now be entered. If the actual volume per minute falls below this limit, the Control Valve stops closing, an alarm sounds, and the display flashes LOW LIMIT . The low limit value should be determined with all booms ON. This value is automatically proportional to the percentage of booms that are ON. (i.e. If the entered low limit is 4 and half the total boom length is shut off, the Console automatically reduces the low limit to 2).

NOTE: Go to DATA MENU to silence alarm.

5.

VOLUME/AREA RATE ALARM Console alarm sounds if the application rate is 30% or more away from the target application rate for more than 5 seconds.

NOTE: Go to DATA MENU to silence alarm.

6.

LOW TANK FAULT This feature will sound the alarm when the volume in the tank drops below an entered value. The alarm will intermittently beep every 15 seconds and the display will flash LOW LEVEL. The alarm will stop when a value equal to or greater than the LOW TANK ALARM is entered into VOL/TANK or the booms are turned OFF. Entering "0" into LOW TANK ALARM disables it.

To select LOW TANK ALARM depress To enter value depress

until display shows SET LOW LEVEL 0.

,then LOW TANK ALARM value, and

.

NOTE: Go to DATA MENU to silence alarm.

7.

AUTOMATIC RATE +/This feature sets the increment at which flow is increased or decreased in RATE 1 or RATE 2 operation.

Enter rate change value by depressing

until display shows RATE +/- 0.0.

To enter a value depress

, then the increment value, and

.

EXAMPLE: If rate is to change by "1.0": Enter a value of 1.0 for RATE +/-. When in RATE 1 or RATE 2, each time the INC/DEC switch is positioned to INC the RATE CAL for that rate will increase by "1.0". Likewise, when positioned to DEC the RATE CAL will decrease by "1.0".

280 - 28

19

8.

CONTROL VALVE DELAY Depress

until display shows CONTROL VALVE DELAY.

The first digit,

( X 0 0 0 ), is the Control Valve delay digit. This feature allows the user to set a delay between the time the booms are turned ON and when the Console begins to control the flow rate. A value of 1-9 means a delay of 1-9 seconds respectively.

A value of 0 means no delay. This delay is active if the time between turning OFF and turning ON the booms is less than 30 seconds.

9.

ZERO SPEED SHUT-OFF This function will be active when C-FC (Fast Close Valve) or C-PC (PWM Close Valve) is selected. This function can not be disabled. When C-FC or C-PC has been selected, the valve will receive a decrease signal and run closed when the speed drops to .7 MPH or less. The only way the console can operate at .7 MPH or less is in the manual mode.

When a zero speed shut-off has occured, the MASTER switch must be turned OFF and then ON to restart the system. If a constant speed greater than .7 MPH is not attained within 10 seconds, the zero speed shut-off will be enacted again.

10. DATA MENU The following are brief descriptions of features available under the DATA MENU key.

DISPLAY

DESCRIPTION

PRINT FIELD BEGIN

Sends data through serial port to attached optional printer to print field begin and field end pages.

ALARM ON

Turns audible alarms ON or OFF for the following: 1) Volume/Area Rate Alarm 2) Volume/Minute Rate Fault 3) Low Tank Fault

DISPLAY SMOOTHING ON

Turns display smoothing ON or OFF. Selecting display smoothing ON means the window displays target rate when actual rate is within 10% of target rate.

RATE CHANGE ALARM ON

Turns rate change alarm ON or OFF. When rate change alarm is selected ON; alarm sounds 4 long beeps when the Rate 1 calibration number is changed via the serial port using a valid change request data string.

GPS FILE REF 1

Used only the Raven Grid Application System. See Grid Application System manual for more details.

GPS INACTIVE

Used only with Raven Grid Application System. See Grid Application System manual for more details.

280 - 29

20

DISPLAY

DESCRIPTION

FIELD REF 0

Allows user to enter up to a four-digit number to represent a field. Field reference is included in field begin and field end pages and the data logger time/date string.

BAUD RATE 9600

Used in GPS mode and data logging mode. Selectable between 1200 or 9600 baud.

DATA LOG TRIGGER VALUE 0

Used in data logging mode. The trigger determines how often actual rate data string (See Appendix 10 for Data Communication String Formats) is sent to the serial port. The trigger may be either feet [meters] or seconds.

DATA LOG TRIGGER UNITS FEET

Used in data logging mode. The trigger unit is selectable between feet [meters] or seconds.

DATA LOG OFF

Turns data logger ON or OFF.

PRESS ENTER TO CAL PRESSURE Used to set the zero point of the pressure

transducer for pressure display.

OFF RATE PERCENT 30

Used to set the percent of off target value. Alarm sounds when the actual rate is off from the target rate by a specified percent. The off target value is preset to 30%, but may be changed to a different number.

HIGH PWM OFFSET 253

Used to set the maximum desired RPM or hydraulic output of Pulse Width Modulated control valve.

LOW PWM OFFSET 1

Used to set the minimum desired RPM or hydraulic output of control valve. Used to set the zero point or shut-off point of Pulse Width Modulated control valve.

PWM FREQUENCY 122

Enter the coil frequency of the PWM type valve being used (default is 122 Hz).

PRESS ENTER FOR DATA-LOCK

Sequence to activate DATA-LOCK CODE (feature prohibits the entry of data without first entering the DATA-LOCK CODE). Enter 4-digit code within 15 seconds.

280 - 30

21

1)

Definition of Data Menu Key: Depressing this key displays selected Data Menu features.

EXAMPLE: Display will display options by name and default setting.

Depressing this key after selecting DATA MENU increments up through desired features.

EXAMPLE: PRINT FIELD BEGIN, ALARM ON, DISPLAY SMOOTHING ON, etc.

Depressing this key after selecting DATA MENU increments down through desired features.

EXAMPLE: PRINT FIELD BEGIN, DATA-LOG OFF, DATA LOG TRIGGER UNITS FEET, etc.

2)

CONSOLE DATA PRINTOUT a) Display will show PRINT FIELD BEGIN. 1) b)

To Print Field Begin, depress

Display will now show PRINT FIELD END. 1)

To Print Field End, depress

2)

While PRINT FIELD END is displayed, if Field Begin is required, depress

c) 3)

4)

.

.

to toggle the display to PRINT FIELD BEGIN.

Momentarily depress

to advance to AUDIBLE ALARM ON/OFF.

AUDIBLE ALARM ON/OFF a) Display will show ALARM ON. b)

Depressing

c)

Momentarily depress

momentarily changes the display between ALARM ON and ALARM OFF. A value of ALARM ON means the audible alarms are enabled; a value of ALARM OFF means the audible alarms are disabled. to advance to DISPLAY SMOOTHING ON/OFF.

DISPLAY SMOOTHING ON/OFF a) Display will show DISPLAY SMOOTHING ON. b)

Depressing

c)

Momentarily depress

280 - 31

momentarily changes the display between DISPLAY SMOOTHING ON and OFF. A value of ON means smoothing is enabled; a value of OFF means smoothing is disabled. Selecting DISPLAY SMOOTHING ON means the display shows target rate when actual rate is within 10% of the target rate. Selecting DISPLAY SMOOTHING OFF means the display shows actual target rate. to advance to RATE CHANGE ALARM ON/OFF.

22

5)

6)

7)

RATE CHANGE ALARM ON/OFF a) Display will show RATE CHANGE ALARM ON. b)

Depressing

c)

Momentarily depress

9)

to advance to GPS FILE REFERENCE.

GPS FILE REFERENCE a) Display will show GPS FILE REF 1 . b)

Enter the GPS file number

c)

Momentarily depress

to advance to GPS OPTIONS.

GPS OPTIONS a) GPS is inactive when the display shows GPS INACTIVE. The GPS features are explained further in the GRID APPLICATION SYSTEM MANUAL. b)

8)

momentarily changes the display between RATE CHANGE ARLAM ON and OFF . A value of ON means alarm is enabled; a value of OFF means alarm is disabled.

Momentarily depress

to advance to FIELD REFERENCE.

FIELD REFERENCE a) Display will show FIELD REF 0 . b)

Enter the field number.

c)

Momentarily depress

to advance to BAUD RATE.

BAUD RATE a) Display will show BAUD RATE 9600. b)

Depressing and 1200.

c)

Momentarily depress

momentarily changes the display between BAUD RATE 9600

to advance to DATA LOGGER TRIGGER VALUE.

NOTE: The TRIGGER VALUE default value is "zero". This value must be changed to a desired number ranging from 1-9999. The DATA LOGGER features will not work if this number is not changed.

10)

DATA LOGGER TRIGGER VALUE a) Display will show DATA LOG TRIGGER VALUE 0 . b)

Enter the TRIGGER VALUE.

c)

Momentarily depress

280 - 32

to advance to DATA LOGGER TRIGGER UNITS.

23

11)

12)

DATA LOGGER TRIGGER UNITS a) Display will show DATA LOG TRIGGER UNITS b)

Depressing

c)

Momentarily depress

FEET [METER].

momentarily changes the display between DATA LOG TRIGGER UNITS FEET [METER] and SEC. DATA LOGGER TRIGGER VALUE has been programmed previously. (SEC means seconds has been chosed as the unit of measure.) to advance to DATA LOGGER.

DATA LOGGER ON/OFF a) The DATA LOGGER uses the communications strings listed in Appendix 9 to pass data out through the serial port. The data is sent at a set time interval or a set distance traveled, as determined by the values entered in the DATA LOGGER TRIGGER VALUE and DATA LOGGER TRIGGER UNITS. Upon each trigger, the Actual Rate string, Data Strings 1, 2, and 3, and the Time/ date string are sent, in that order. When a Console calibration value is changed, the Console will automatically send out the Cal 1, 2, and 3 strings. When a Console switch is changed, the Data 1, 2, 3, Time/Date, and Cal 1, 2, 3 strings will be sent by the Console. The Data, (with Time/ Date string included) and Cal strings can also be requested by the data logger using the request strings shown in Appendix 9.

NOTE: Some options within the DATA MENU LISTINGS may be unavailable if certain features are on or active. The options affected are: CONSOLE DATA PRINTOUT: Console Data Printout will not be available when DATA LOGGER is ON or when GPS functions are active.

13)

GPS OPTIONS:

GPS options will not be available when DATA LOGGER is ON.

DATA LOGGER:

DATA LOGGER will not be available when GPS functions are active.

b)

Display will show DATA LOG OFF .

c)

Depressing momentarily changes the display between DATA LOG OFF and ON. A value of OFF means DATA LOGGER is disabled; a value of ON means DATA LOGGER is enabled.

d)

Momentarily depress

to advance to PRESSURE CALIBRATION.

PRESSURE CALIBRATION OF THE PRESSURE TRANSDUCER Used to set the zero point of the pressure transducer for pressure display. a)

Display will show PRESS ENTER TO CAL PRESSURE.

b)

Display will show ENTER SYSTEM PRESSURE.

c)

Enter actual system pressure and press

d)

Momentarily depress

280 - 33

Press

.

to advance to OFF RATE PERCENT 30.

24

.

14)

OFF RATE PERCENT 30 Used to set the percent of off target value. Alarm sounds when the actual rate is off from the target rate by a specified percent. The off target value is preset to 30%, but may be changed to a different number. a)

Display will show OFF RATE PERCENT 30 .

b)

Display will show OFF RATE PERCENT E. press

c) 15)

16)

17)

Press

.

Enter new off rate percent and

.

Momentarily depress

to advance to HIGH PWM OFFSET 253.

HIGH PWM OFFSET 253 Used to set the maximum desired RPM or hydraulic output of control valve. a)

Display will show HIGH PWM OFFSET 253.

b)

Place product switch on MAN, boom switches and master switch ON. Hold INC/DEC switch to increase. If motor exceeds desired RPM, decrease number by 10 and push INC again.

c)

Decrease the 253 number displayed until motor runs at desired maximum RPM, then enter a number of 10 more.

d)

Momentarily depress

to advance to LOW PWM OFFSET 1.

LOW PWM OFFSET 1 Used to set the minimum desired RPM or hydraulic ouput of control valve. to set the zero point or shut-off point of control valve.

Used

a)

Display will show LOW PWM OFFSET 1.

b)

Place product switch on MAN, boom switches and master switch ON. Hold INC/DEC switch to decrease until motor stops. Increase the number displaced until motor runs, then enter a number of 10 less.

c)

Hold INC/DEC switch to decrease. If motor does not stop, lower offset number by 10 and push DEC switch again.

d)

Momentarily depress

to advance to PWM FREQUENCY 122.

PWM FREQUENCY 122 a)

Display will show PWM FREQUENCY 122.

b)

Press

.

Enter the coil frequency of the PWM valve being used

(i.e. 180 Hz). c)

280 - 34

Press

Momentarily depress

, depress to advance to DATA-LOCK.

25

again.

18)

DATA-LOCK Sequence to activate DATA-LOCK CODE (feature prohibits the entry of data without first entering the DATA-LOCK CODE). a)

Display will show PRESS ENTER FOR DATA-LOCK.

b)

Display will show NEW CODE E.

c)

Enter 4-digit code within 15 seconds. (i.e. 1058, press

and

Press

.

).

Sequence to change DATA-LOCK CODE. a)

Press

until display shows PRESS ENTER FOR DATA-LOCK .

Press

. b)

Display will show OLD CODE E.

c)

Enter 4-digit old code within 15 seconds and press show NEW CODE E .

d)

Enter 4-digit new code within 15 seconds or 0 to clear data-lock.

. Display will

To enter mode sequence with activated DATA-LOCK CODE. a)

Depress the key in which data is to be entered. message will appear.

b)

Enter the DATA-LOCK CODE. If code is correct, E will appear. Now enter data normally. The data lock may be cleared by entering 0 or by resetting the console. To reset the console, place power ON/OFF switch to OFF, depress

Depress

.

Code

and hold while placing the power ON/OFF switch to ON.

NOTE: The DATA-LOCK feature prohibits the entry of data without first entering the DATA-LOCK CODE.

280 - 35

26

11. DECIMAL SHIFT The DECIMAL SHIFT feature is used to increase system accuracy at low application rates. Shifting of the decimal point is done during the entry of METER CAL. After entering METER CAL mode, depress the decimal shift

, enter the meter cali-

bration constant number, and depress . The sequence to unshift the decimals while in METER CAL is to enter the meter calibration constant number and depress . The following table illustrates how shifting the decimal point can increase system accuracy.

DECIMAL PLACE LOCATIONS US

METRIC

TURF

UNSHIFT

SHIFT

UNSHIFT

SHIFT

UNSHIFT

SHIFT

RATE DISPLAY

000.0

00.00

0000

000.0

00.00

00.00

RATE 1 CAL

000.0

00.00

0000

000.0

00.00

00.00

RATE 2 CAL

000.0

00.00

0000

000.0

00.00

00.00

TANK VOLUME

0000

000.0

0000

000.0

000.0

000.0

TOTAL AREA

000.0

000.0

000.0

000.0

0000

0000

TOTAL VOLUME

0000

000.0

0000

000.0

000.0

000.0

FIELD AREA

000.0

000.0

000.0

000.0

0000

0000

FIELD VOLUME

0000

000.0

0000

000.0

000.0

000.0

VOL/MINUTE

0000

000.0

0000

000.0

000.0

000.0

AREA/HOUR

000.0

000.0

000.0

000.0

0000

0000

RATE +/-

000.0

00.00

0000

000.0

00.00

00.00

LOW TANK LEVEL

0000

000.0

0000

000.0

000.0

000.0

LOW VOL/MIN

0000

000.0

0000

000.0

000.0

000.0

When entering RATE 1 CAL and RATE 2 CAL, remember that 2 GPA [20 lit/ha] is entered as 2.0 [20.0] when unshifted and 2.00 [20.00] when shifted.

280 - 36

27

INITIAL SYSTEM SET-UP 1)

Fill tank with water only. (If positive displacement pump is used, open pressure relief valve, PRV).

2)

Place MASTER ON/OFF switch to ON and BOOM ON/OFF switches to OFF.

3)

Place RATE 1/RATE 2/MAN switch to MAN.

4)

Place POWER ON/OFF switch to ON.

5)

Verify that Boom Widths, SPEED CAL, METER CAL, VALVE CAL, and RATE CALS have been entered correctly into the Console. In SELF TEST mode, enter the normal sprayer operating speed.

6)

Run pump at normal operating RPM.

7)

If centrifugal pump is used, proceed with Step 8. If positive displacement pump is used, set pressure relief valve (PRV) to 65 PSI [450 kPa].

8)

Verify that boom valves operate and that no nozzles are plugged by operating the BOOM ON/OFF switches.

9)

Place all BOOM ON/OFF switches to ON.

10)

Hold the FLOW CONTROL switch in INC position until pressure is at its maximum.

This assures that the motorized Control Valve is fully open. Verify maximum pressure and RATE. (Pressure gauge is not supplied).

NOTE: A pressure gauge MUST be installed to properly monitor the system.

11)

Adjust agitator line hand valve for desired agitation. is still present.

12)

Hold the FLOW CONTROL switch to DEC position until pressure is at its minimum.

This assures that the motorized Control Valve is fully closed. Verify minimum pressure and RATE. If minimum pressure and RATE can not be obtained, consider by-pass plumbing system in Appendix 3.

280 - 37

28

Verify maximum pressure

INITIAL SYSTEM FIELD TEST 1)

Drive down field or road at target speed with sprayer booms off, to verify SPEED readout on Console.

2)

Turn on sprayer and booms and place the RATE 1/RATE 2/MAN switch to RATE 1.

Increase or decrease speed by one MPH [2 km/h]. The system should automatically correct to the target application rate.

3)

If for any reason, the system is unable to correct to the desired RATE, check for an empty tank, a plugged line, a malfunctioning pump, improper vehicle speed, or a defect in the system.

4)

If the system does not appear to be correcting properly, first review INITIAL SYSTEM SET-UP, then refer to TROUBLESHOOTING GUIDE.

5)

At the end of each row, switch the MASTER ON/OFF to OFF to shut off flow. also shuts off the area totalizer.

6)

Verify area covered and volume used.

This

PREVENTIVE MAINTENANCE Preventive maintenance is most important to assure long life of the system. The following maintenance procedures should be followed on a regular basis: 1)

Flush entire system with water after use of suspension type chemicals. Failure to clean system can result in crystallization of chemicals which may plug the Flow Meter, lines, and/or tips.

2)

Flush and drain sprayer before storing.

METER IF WATER IS NOT DRAINED.

3)

Remove Flow Meter at the end of each spraying season. Clean Flow Meter turbine and inlet hub. Clean off all metal filings and wettable powders which have hardened on the plastic and metal parts. Check the inlet hub and turbine assembly for worn or damaged turbine blades and bearings. Flush Flow Meter with clear water and drain.

FREEZING TEMPERATURES MAY DAMAGE FLOW

KEEP FROM FREEZING

4)

Remove Console when not in use for extended periods.

280 - 38

29

TROUBLESHOOTING GUIDE PROBLEM 1)

NO DISPLAY LIGHTS WITH POWER ON.

CORRECTIVE ACTION 1) 2) 3) 4)

Check fuse on back of Console.

Check battery connections.

Check operation of POWER ON/OFF switch.

Return Console to your Dealer to replace Processor Board Assembly.

2)

ALL KEYBOARD LIGHTS ON AT SAME TIME.

1)

Return Console to your dealer to replace Face Plate Sub-assembly.

3)

A DIGIT CANNOT BE ENTERED VIA KEYBOARD.

1)

Return Console to your Dealer to replace Face Plate Sub-assembly.

4)

AN INDICATOR LIGHT ON A KEY WILL NOT ILLUMINATE.

1)

Return Console to your Dealer to replace Face Plate Sub-assembly and/or Processor Board Assembly.

5)

CONSOLE DISPLAYS FLASHING "CAL" WHENEVER VEHICLE ENGINE IS STARTED.

1)

Check battery voltage and battery connections.

6)

CONSOLE DISPLAYS FLASHING "CAL" WHENEVER MASTER SWITCH IS TURNED ON OR OFF.

1)

Check battery voltage and battery connections.

7)

CONSOLE DISPLAYS FLASHING "CAL" WHENEVER SPEED IS CHANGED.

1)

Check battery voltage and battery connections.

8)

"TIME" FUNCTION IS INACCURATE OR DRIFTING.

1)

Return Console to Dealer to replace Processor Board Assembly.

9)

ONE DISPLAY DIGIT HAS ONE OR MORE MISSING SEGMENTS.

1)

Return Console to Dealer to replace LCD Display Board Assembly.

10)

SPEED DISPLAY "0".

1)

Check Speed Sensor cable connector and plug on back of Console for loose pins.

Clean pins and sockets on Speed Sensor cable connectors.

If no extension cable is used, replace Speed Sensor Switch Assembly.

If Speed Sensor Extension Cable is used, see Appendix 4.

2) 3)

4)

11)

SPEED INACCURATE OR UNSTABLE (WHEEL DRIVE SPEED SENSOR).

280 - 39

1)

30

Run speed check on hard surface road. If SPEED is accurate, investigate Speed Sensor on different wheel. (Cont. next page)

2)

Remove one red magnet and one black magnet from the wheel. (Reposition remaining red and black magnets directly across from each other).

Enter a SPEED CAL number in the Console twice as large as the correct SPEED CAL number. Run speed check on hard surface road.

Remove these two magnets and replace with other two. Run speed check. If SPEED is in accurate with only one set of magnets, replace the bad set.

If SPEED is inaccurate with both sets, replace Speed Sensor Assembly.

NOTE: Re-enter original SPEED CAL number after testing is complete.

12)

SPEED INACCURATE OR UNSTABLE (SPEEDOMETER DRIVE SPEED SENSOR).

1)

2)

3) 4)

13)

RATE READS "0000".

1)

2)

14)

RATE INACCURATE OR UNSTABLE.

1)

2)

3)

280 - 40

31

Wiggle cable at the Speed Sensor connector. If speed is displayed, tighten connector or replace Transducer Assembly.

Check Speedometer Cable Adapter, Key, and Transducer Assembly for proper connections and engagement.

Check for kinks or sharp bends in speedometer cable.

Replace Speedometer Transducer Assembly.

Verify SPEED is registering accurately. If SPEED is zero, refer to Troubleshooting Problem 10.

Verify TOTAL VOLUME is registering flow. If not, refer to Troubleshooting Problem 17.

Verify that all numbers "keyed in" Console are correct. Verify SPEED is registering accurately. If SPEED is inaccurate, refer to Troubleshooting Problem 11 or 12.

In MAN (manual) operation, verify that RATE display (GPA) holds constant. If not, refer to Troubleshooting Problem 18.

In MAN (manual) operation, check low end and high end pressure range. Pressure range must be per initial system set-up on page 27.

If pressure cannot be adjusted manually, refer to Troubleshooting Problem 17. (Cont. next page)

15)

CAN NOT VARY RATE IN MANUAL OPERATION OR IN AUTO.

4)

If problem persists, return Console to Dealer to replace Processor Board Assembly.

1)

Check cabling to motorized Control Valve for breaks.

Check connections in cabling for cleanliness.

Verify that there is voltage at the valve connector by placing MASTER switch ON; RATE 1/RATE 2/MAN switch to MAN; and POWER switch to ON. Manually operate INC/DEC switch to verify voltage.

Verify that valve is turning, if not, replace motorized Control Valve.

2) 3)

4)

16)

SPRAYER PRESSURE IS CORRECT BUT RATE IS LOW.

1) 2) 3)

17)

TOTAL VOLUME DOES NOT REGISTER.

1)

2)

3)

Verify that nozzle strainer screens or check valves are not plugged.

Verify that pressure at each boom is the same.

Verify all nozzles are of proper and same orifice size. See Page 13 of Installation Manual.

Check Flow Meter Cable for breaks and shorts. See Appendix 5 for test procedure.

Check internals of Flow Meter; clean and adjust. See Appendix 6 for Flow Meter cleaning and adjustments.

Replace Flow Meter Transducer.

18)

TOTAL VOLUME REGISTERS FLOW INACCURATELY.

1)

Verify that arrow on Flow Meter is pointing in direction of flow. See Appendixes 6 and 7.

19)

MOTORIZED CONTROL VALVE ROTATES MORE THAN 1/4 TURN.

1)

Replace motorized Control Valve.

20)

WATER INSIDE COVER OF MOTORIZED CONTROL VALVE.

1)

Replace Isolation Flange Assembly and coupler shaft.

Replace entire motorized Control Valve, if PC board or motor is corroded and will not run.

2)

21)

BOOM SOLENOID(S) WILL NOT OPERATE.

1) 2) 3) 4)

280 - 41

32

Check cable for wires with breaks.

Check connectors for cleanliness.

Check BOOM switch and MASTER switch for operation.

Replace Boom Valves.

APPENDIX 1 WHEEL DRIVE SPEED SENSOR INSTALLATION AND CALIBRATION PROCEDURE 1.

MOUNTING WHEEL DRIVE SPEED SENSOR The Wheel Drive Speed Sensor consists of four magnets, a switch assembly with cable, and mounting hardware.

Sequence of mounting Speed Sensor: l)

Select a non-driven wheel (left front tractor wheel or implement wheel).

2)

Check for predrilled holes in rim.

If not predrilled, see "RIM DRILLING INSTRUCTIONS FOR WHEEL DRIVE SPEED SENSOR".

3)

Mount the four magnets to the inside of rim and tighten (See Figures below).

Magnets must be mounted in alternating red-black order.

4)

Mount switch assembly to stationary column with the hardware provided (See below).

The switch assembly need not pivot with the wheel.

SWITCH ASSEMBLY

MAGNET ASSEMBLY MAGNET LOCATION

5)

Position switch assembly so that as the wheel rotates the magnets pass across the center of the black, molded switch assembly.

6)

Clearance gap between magnets and switch assembly must be between 1/4 inch [6 mm] and 1 inch [25 mm]. With wheels pointed straight ahead, rotate wheel to ensure gap is correct. Make sure vehicle wheels can be turned to their extremes in each direction without the magnets hitting the switch assembly.

7)

Tighten switch assembly bracketry.

8)

Secure cable to column with plastic cable ties.

280 - 42

33

2.

RIM DRILLING INSTRUCTIONS FOR WHEEL DRIVE SPEED SENSOR MAGNETS

On wheels which do not have pre-punched mounting holes, proceed as follows: RIMS WITH FOUR OR EIGHT HOLE STUD PATTERN: Choose stud holes that are opposite each other as shown below. Using the center of opposite holes, scribe two lines on the rim web to divide the circumference into four equal parts. Measure in one inch from the outer edge of the web on each of the lines drawn. Mark this point as the center. Drill four 1/2" holes for mounting the magnets.

NOTE: Distance (D) between each set of drilled holes must be equal within 1/8 [3 mm] to ensure accuracy of system.

RIMS WITH SIX HOLE STUD PATTERN: Locate the center of the holes to be drilled by using the rim webbing as a guide.

Obtain a small piece of wood and cut to fit exactly over the web as shown. Measure the length of the piece of wood and mark the center on one edge. Using the center mark on the piece of wood, mark each of the four webs. Measure in one inch from the outer edge of the web on each of the lines drawn. Mark this point as center and drill four 1/2" holes for mounting the magnets.

NOTE: Distance (D) between each set of drilled holes must be equal within 1/8" [3 mm] to ensure accuracy of system.

EIGHT HOLE STUD PATTERN

280 - 43

SIX HOLE STUD PATTERN

34

3.

CALCULATING "SPEED CAL"

1)

Place a chalk mark or tape onto the vehicle tire that the Speed Sensor mounted to it as shown below.

2)

Mark the initial spot on the ground.

3)

Drive vehicle straight ahead counting 10 full revolutions of the wheel. The mark must stop at the same position it was in when the vehicle started.

4)

Measure the distance from the ground starting mark to stopping mark in inches [dm] (Round off fractions).

5)

Write down this distance as the SPEED CAL number; keep it for future reference when programming the Console.

NOTE: This measurement is critical to the performance of the Console. MEASURE CAREFULLY. Be sure tire is properly inflated before measuring. Measure tire in type of soil in which you will be spraying. Circumference of tire will vary when measured in soft soil versus hard packed soil. For best results, measure several times and average the results.

Large tires and very low speed applications may require additional magnets to insure accurate speed readings. Any even number of magnets may be used as long as they are of alternating color and equally spaced. After calculating "SPEED CAL", this number must be adjusted according to the number of magnets used.

Normal Number of Magnets Actual Number of Magnets Example:

4 6

x Speed Cal = Adjusted Speed Cal

x 1200 = 800

SCS 330, SCS 500 and SCS 550 normally use two magnets. All other consoles normally use four magnets.

280 - 44

35

APPENDIX 2 SPEEDOMETER DRIVE SPEED SENSOR INSTALLATION AND CALIBRATION PROCEDURE 1.

MOUNTING THE SPEEDOMETER DRIVE SPEED SENSOR

1)

Remove the existing speedometer cable from the back of the vehicle speedometer.

Pull cable through fire wall into engine compartment.

2)

Install adapter and key on speedometer cable and connect to Transducer Assembly.

(Some units do not use adapter and key).

3)

Connect Extension Cable to Transducer Assembly.

4)

Push Extension Cable through fire wall and re-install on speedometer.

5)

Connect the cable on the Transducer Assembly to the Console.

6)

Secure all cables with plastic cable ties.

You are now ready to calibrate the Speedometer Drive Speed Sensor.

280 - 45

36

2.

CALCULATING "SPEED CAL"

1)

Complete "INITIAL CONSOLE PROGRAMMING" before doing this procedure.

2)

Enter “0” in key labelled

3)

Enter a SPEED CAL of 612 [155] in key labelled

4)

Drive 1 mile [1 km].

CAUTION:

5)

Do not use vehicle odometer to determine distance. lines or Highway markers.

Use section

Read DISTANCE by depressing key labelled

a)

DISTANCE should read a value of approximately 5280 [1000]. If it reads between 5200-5350 [990-1010], the SPEED CAL for your vehicle is 612 [155].

b)

If the DISTANCE display reads any other value, perform the following calculation: Multiply the SPEED CAL by the target distance reading, then divide the sum by the actual value in DISTANCE display. This will give you the corrected value to enter for SPEED CAL. You must round off to the nearest 3 digit whole number.

EXAMPLE:

=

SPEED CAL = 612 [155] Target distance reading = 5280 [1000] Assume the actual DISTANCE display reads 5000 [980] ENGLISH UNITS: 612 x 5280 = 646.3 5000

METRIC UNITS: = [155] x [1000] = [158.1] [980]

The corrected number to enter for SPEED CAL is 646 [158].

6)

Enter the number calculated for SPEED CAL.

7)

Verify the corrected SPEED CAL number calculated above: a)

Zero out the DISTANCE display as in Step 2.

b)

Enter the corrected SPEED CAL number as in Step 3.

c)

Repeat Steps 4 and 5a.

Steps 5b, 6, and 7.

280 - 46

If DISTANCE value does not read correctly repeat

37

APPENDIX 3 ALTERNATE BY-PASS LINE PLUMBING SYSTEM

FIGURE 11

INITIAL SYSTEM SET-UP Plumb the system as shown in Figure 11. Adjust as follows: Install Polarity Reversal Jumper in motorized Control Valve Cable (P/N 115-0159-415).

1)

Fill tank with water only.

2)

Place MASTER ON/OFF switch to ON and BOOM ON/OFF switches to OFF.

3)

Place AUTO/MAN/OFF switch to MAN, and POWER ON/OFF to ON.

4)

Verify that Boom Widths, SPEED CAL, METER CAL, and RATE CALS have been entered correctly into the Console. In SELF TEST mode enter the normal sprayer operating speed.

5)

With pump not running, fully open main line hand valve, fully open by-pass #1 hand valve, and completely close agitator line hand valve.

If positive displacement pump is used, fully open pressure relief valve, PRV.

6)

Run pump at normal operating RPM.

7)

If centrifugal pump is used, proceed with Step 8. is used, proceed as follows: a) Place MASTER ON/OFF switch to OFF. b) Close by-pass #1 hand valve. c) Set PRV to 65 psi [450 kPa]. d) Open by-pass #1 hand valve. e) Place MASTER ON/OFF switch to ON. 280 - 47

38

If positive displacement pump

8)

Verify that each boom valve operates and that no nozzles are plugged by operating the BOOM ON/OFF switches.

9)

Place all BOOM ON/OFF switches to ON.

10)

Hold the FLOW CONTROL switch to INC position for approximately 12 seconds. This assures motorized Control Valve is fully closed. (Pressure gauge is not supplied).

11)

Adjust agitator line hand valve for desired agitation.

12)

Close the main line hand valve, if necessary, to set the desired maximum operating pressure. Maximum pressure should be approximately 10 psi [70 kPa] above normal spraying pressure.

EXAMPLE: If normal spraying pressure is 30 psi [210kPa], set maximum pressure at approximately 40 psi [280 kPa].

13)

Hold the MAN ADJ switch to DEC position for approximately 12 seconds. This assures motorized Control Valve is fully open.

14)

Close by-pass #1 hand valve to set the desired minimum operating pressure. Minimum pressure should be approximately one half the normal spraying pressure.

EXAMPLE: If normal spraying pressure is 30 psi [210 kPa], set minimum pressure at approximately 15 psi [105 kPa].

15)

Verify maximum and minimum pressures and RATE by repeating Steps 11 and 14.

INITIAL SYSTEM FIELD TEST 1)

Drive down field or road at target speed with sprayer booms OFF, to verify SPEED readout on Console.

2)

Turn on sprayer and booms and place the MAN/AUTO switch to AUTO. Increase or decrease speed by one (1) MPH [2 km/h]. The system should automatically correct to the target application rate.

3)

If for any reason, the system is unable to correct to the desired RATE, check for an empty tank, a plugged line, a malfunctioning pump, improper vehicle speed or a defect in the system.

4)

If the system does not appear to be correcting properly, first review INITIAL SYSTEM SET-UP, then refer to TROUBLESHOOTING GUIDE.

5)

At the end of each row, switch the MASTER ON/OFF to OFF to shut off flow. also shuts off the area totalizer.

6)

Verify area covered and volume used.

280 - 48

39

This

APPENDIX 4 PROCEDURE TO TEST SPEED SENSOR EXTENSION CABLES Verify that the Console is in the SP1 Speed Sensor mode while testing the cable.

Disconnect extension cable from Speed Sensor Assembly cable. Hold extension cable connector so that keyway is pointing in the 12 o’clock position.

PIN DESIGNATIONS 2 o’clock socket location is power.

10 o’clock socket location is ground.

6 o’clock socket location is signal.

VOLTAGE READINGS 1) 10 o’clock socket to 6 o’clock socket = +5 VDC. 2) 10 o’clock socket to 2 o’clock socket = +5 VDC. If a +5 VDC voltage reading is not present, disconnect the Flow Sensor cable.

If the Speed reading is restored, Test the Flow Sensor cable per Appendix "PROCEDURE TO TEST FLOW METER CABLES".

PROCEDURE TO CHECK CABLE: l)

Enter SPEED CAL number of 1000 in key labelled

2)

Depress key labelled

3)

With small jumper wire (or paper clip), short between the 10 o’clock and 6 o’clock sockets with a "short-no short" motion. Each time a contact is made, the DISTANCE total should increase by increments of 1 or more counts.

4)

If DISTANCE does not increase, remove the section of cable and repeat test at connector next closest to Console. Replace defective cable as required.

5)

Perform above voltage checks.

6)

If all cables test good, replace Speed Sensor.

NOTE: After testing is complete, re-enter correct SPEED CAL number before application.

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APPENDIX 5 PROCEDURE TO TEST FLOW METER CABLES Disconnect cable from Flow Sensor. Hold Flow Sensor cable so that the keyway is pointing in the 12 o’clock position:

PIN DESIGNATIONS 2 o’clock socket location is ground.

10 o’clock socket location is power.

6 o’clock socket location is signal.

VOLTAGE READINGS 1) 2 o’clock socket to 6 o’clock socket = +5 VDC. 2) 2 o’clock socket to 10 o’clock socket = +5 VDC. If a +5 VDC voltage reading is not present, disconnect the Speed Sensor cable.

If the Flow reading is restored, Test the Speed Sensor cable per Appendix "PROCEDURE TO TEST SPEED SENSOR EXTENSION CABLES".

PROCEDURE TO CHECK CABLE: 1)

Enter a METER CAL number of one (1) in key labelled

2)

Depress key labelled

3)

Place BOOM switches to ON.

4)

With small jumper wire (or paper clip), short between the 2 o’clock and 6 o’clock sockets with a "short-no short" motion. Each time a contact is made, the TOTAL VOLUME should increase by increments of 1 or more counts.

5)

If TOTAL VOLUME does not increase, remove the section of cable and repeat test at connector next closest to Console. Replace defective cable as required.

6)

Perform above voltage checks.

7)

If all cables test good, replace Flow Sensor.

NOTE: After testing is complete, re-enter correct METER CAL numbers before application.

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APPENDIX 6 FLOW METER MAINTENANCE AND ADJUSTMENT PROCEDURE 1)

Remove Flow Meter from sprayer and flush with clean water to remove any chemicals.

NH3 WARNING: Thoroughly bleed nurse tank hose and all other system lines prior to disassembling the Flow Meter, fittings, and hoses.

2)

Remove flange bolts or clamp from the Flow Meter.

3)

Remove the turbine hub and turbine from inside Flow Meter.

4)

Clean turbine and turbine hub of metal filings or any other foreign material, such as wettable powders. Confirm that the turbine blades are not worn. Hold turbine and turbine hub in your hand and spin turbine. The turbine should spin freely with very little drag inside the turbine hub.

5)

If transducer assembly is replaced or if turbine stud is adjusted or replaced, verify the turbine fit before reassembling. Hold turbine hub with turbine on transducer. Spin turbine by blowing on it. Tighten turbine stud until turbine stalls. Loosen turbine stud 1/3 turn. The turbine should spin freely.

6)

Re-assemble Flow Meter.

7)

Using a low pressure (5 psi) [34.5 kPa] jet of air, verify the turbine spins freely.

If there is drag, loosen hex stud on the bottom of turbine hub 1/16 turn until the turbine spins freely.

8)

If the turbine spins freely and cables have been checked per Appendix "PROCEDURE TO TEST FLOW CABLES", but Flow Meter still is not totalizing properly, replace Flow Meter transducer.

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APPENDIX 7 PROCEDURE TO RE-CALIBRATE FLOW METER 1)

Enter a METER CAL number of 10 [38] in the key labelled

2)

Enter a TOTAL VOLUME of 0 in the key labelled

3)

Switch OFF all booms.

4)

Remove a boom hose and place it into a calibrated 5 gallon [19 liter] container.

5)

Switch ON appropriate boom switch (for the hose that was just placed into the 5 gallon container) and the MASTER switch. Pump exactly 10 gallons [38 liters].

6)

Readout in TOTAL VOLUME is the new METER CAL number. This number should be within +/- 3% of the calibration number stamped on the tag of the Flow Meter.

7)

Repeat this procedure several times to confirm accuracy. (Always "zero out" the TOTAL VOLUME display before retesting).

NOTE: For greatest precision, set METER CAL to 100 and pump 100 gallons (378 liters) of water.

8)

To verify Flow Meter calibration, fill applicator tank with a predetermined amount of measured liquid (i.e. 250 gallons). DO NOT RELY ON GRADUATION NUMBERS MOLDED INTO APPLICATOR TANK. Empty the applicator tank under normal operating conditions. If the number displayed under TOTAL VOLUME is different from the predetermined amount of measured liquid by more than +/- 3%, complete the following calculation: EXAMPLE: METER CAL TOTAL VOLUME Predetermined amount of measured liquid Corrected METER CAL

=

METER CAL x TOTAL VOLUME Predetermined amount of measured liquid

ENGLISH UNITS: = 720 x 260 = 749 250 Corrected METER CAL 9)

= 720 [190] = 260 [984] = 250 [946]

METRIC UNITS: = [190] x [984] = [198] [946]

= 749 [198]

Enter corrected METER CAL before resuming application.

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APPENDIX 8 SERIAL INTERFACE 1) Cable pinout (P/N 115-0159-624), supplied with Thermal Printer Kit (P/N 117-0159-529).

RAVEN CONSOLE 9 PIN

DSR 6 CTS 8 DTR 4 TXD 3 RXD 2 GND 5

5 Printer 25 Pin

6 2 3 7

2) Changing RATE 1 CAL by remote computer. a) Configuration of RS-232C serial port: 1200 or 9600 Baud Rate NO Parity 8 Data Bits 2 Stop Bits b) Data stream to Raven Console.

EXAMPLE: Change RATE 1 to 123.4 $R,RC,1234<CR><LF> Line Feed Com munication string Rate Cal

RATE 1 = 123.4

Carriage Return

Decimal point is not sent from Remote Computer to Raven Console.

3) Optional 9 pin to 9 pin cable pinout (P/N 115-0159-822).

RAVEN CONSOLE 9 PIN

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DSR 6 CTS 8 DTR 4

4 6 8 2 3 5

TXD 3 RXD 2 GND 5

44

COMPUTER/ GPS 9 Pin

APPENDIX 9 SCS 460 COMMUNICATION STRINGS REMOTE COMPUTER TO SCS 450/460 CONSOLE All request strings begin with $R, to indicate a Raven communication string.

Rate 1 Change Request: $R,RC,<rate_1_cal><CR><LF> Calibration String Values Request: $R,CR<CR><LF> Data String Request: $R,DR<CR><LF>

SCS 450/460 CONSOLE TO REMOTE COMPUTER All console output strings begin with $R124F, the $R indicates a Raven communication string, the 124 is the last three digits of the current SCS 450/460 programmed chip part number and F is the software revision number.

Calibration Strings: $R124F,C1,<switch_byte_1>,<switch_byte_2>,<boom_1_cal>, <boom_2_cal>,<boom_3_cal>,<boom_4_cal>,<boom_5_cal>, <boom_6_cal>,<speed_cal> <CR><LF> $R124F,C2,<meter_cal>,<CR><LF> $R124F,C3,<valve_cal>,<rate_1_cal>,<rate_2_cal><CR><LF> Bit 0 1 2 3 4 5 6 7

Switch Byte 1 boom 1 boom 2 boom 3 boom 4 boom 5 boom 6 0 1

Switch Byte 2 0 0 0 rate 1 rate 2 0 0 1

NOTE: If rate 1 and rate 2 are both zero, the console is in Manual. For switch Byte Bits; 0 = off and 1 = on.

Data Strings: $R124F,D1,<total_area>,<field_area><CR><LF> $R124F,D2,<total_volume>,<field_volume><CR><LF $R124F,D3,<tank_volume>,<distance><CR><LF> Actual Rate: $R124F,AR,<actual_rate><CR><LF> Time/Date: $R124F,TD,<hr:min>,<month/day/year>,<field_reference><CR><LF>

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