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    142 views364 pages

    Manual de Serviços - CA250

    Uploaded by

    Cesar Augusto

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    © All Rights Reserved
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    DYNAPAC ROLLERS WORKSHOP MANUAL STEERING HITCH W1051EN2 Replaces W10235 DYNAPAC Vibratory and Combination Rollers CA/CC Work Shop Manual, Cross Type Steering Hitch W1051EN2 Replaces W10235 We reserve the right to change specications without notice. inlod in Swede CONTENTS General . seamen Steering hitch field checks/adjustment Exploded view . Hitch disassembly/pre-assembly/assembly Installing the upper bearing cup Shimming the tractor frame Torque specifications SAFETY PRECAUTIONS ™&“* ANY WORK PERFORMED IN THE HITCH AREA MUST BE DONE WITH THE ENGINE "OFF". WHEN IT BECOMES NECESSARY TO SEPA- RATE THE MACHINE IN THE HITCH AREA SPECIAL PRECAUTIONS MUST BE TAKEN. SUPPORT BOTH FRAME SECTIONS IN THE FRONT AND BEHIND THE DRUM AND TIRES. BY STRONG SAFETY SUPPORT AS THERE IS A DANGER OF TIPPING OVER. IN ADDITION EACH SECTION MUST BE PRE- VENTED FROM ROLLING BY CHOCKING THE DRUM AND TIRES. 2 - DYNAPAC CAICC W1051EN2 STEERING HITCH FIELD CHECKS/ADJUSTMENT General Steering Pivot Pitch Fig. 1 Checking bearing clearance tack 2. Dial indicator Oscillation Pivot Check The two halves of the compactor are joined together at the articulated steering hitch. The hitch consists of a "cross" fitted with adjustable bearings at the pivot points, see fig. 2 and 3. The hitch allows steerings at the vertical pivots of up to +40° and oscillation at the horizontal pivots up to +12°. Hitch bearings are shimmed at the factory to provide the correct bearing preload. As the bearings wear, adjustment is required to remove excess clearance in the bearings. If Clearance is not removed, the dynamic behavior of the machine may be affected causing heavy vibration of the frames and operator platform. Damage to the hitch can also bee result. The hitch should be checked periodically for looseness at the hitch bearings. 1. Place a hydraulic jack of sufficient capacity under the tractor section at the rear part of the plate holding the lower vertical bearing of the steering link, see fig. 1. 2. While jacking up and down look for movement between the rear frame plate and the bottom of the steering link in the bearing area. A dial indicator can be used to precisely measure movement. 3. When observable movement develops, in excess of 004 inch (0.1 mm), shims must be removed to eliminate clearance in the bearings. Another indication of excessive clearance is chattering noise at the pivot points. Clearance between the cup and cone of the bearing should be .000. 1. With the engine running at low idle speed, turn the steering wheel from side to side just enough to start the frame turing in each direction. 2. Watch for excessive movement between the front frame plates and the horizontal pivots of the steering link in the bearing area. Excessive movement indicates excessive clearance. A chattering noise may also be heard. 3. When observable movement develops, in excess of .004 inch (0.1 mm), shims must be removed to eliminate clearance in the bearings. Clearance between the cup and cone of the bearing should be 000. DVWAPAC CACC W1051EN2 STEERING HITCH FIELD CHECKS/ADJUSTMENT (continue) Steering hitch - Adjustment procedure Before supporting the machine with heavy duty jackstands The instructions in this section cover complete disassemly, shimming and assembly procedures for the hitch. Before proceeding with the disassembly these instructions should be studied in order to become familiar with proper sequence and parts nomenclature. Disassemble only as far as necessary to re-shim or replace damaged bearings. 1. Start the engine, and tum the steeringwhee! fully in the anti-clockwise direction 2. Stop the engine, and loosen the screws at the right side of the rear coverplate, item 7 in fig. 2, about one halfturn. 3. Start the engine, and turn the steeringwheel fully in the clockwise direction. 4. Stop the engine, and loosen the screws at the left side of the rear coverplate, about one half turn. 5. Start the engine, and turn the steeringwheel until the machine comes to a stright position. 6. STOP the engine. DYNWAPAC CACC Wi051EN2 EXPLODED VIEW Rear Frame Ref. Drum Frame Ref. Mem Qty Description 1 Hitch 3° Locking Screw 4 Lubricant Nipple 4 Sealing 2 Bushing AIR Shim, 1.0mm AR AR 1 ‘Shim, 0.35 mm ‘Shim, 0.10 mm Rear Bearing Cover B12 Screw 9 ft Cover 10 2 ToprBottom Bearing Cover 11 12° Screw 12 12. Washer ig.2. Steering hitch ass 1212 Washer Fig.2. Steering hitch assembly = AR Shim, 0.35 mm = AIR Shim, 0.10 mm 14 1 Serow AUR = As Required DYMIAPAC CACC Wi051EN2 HITCH DISASSEMBLY/PRE-ASSEMBLY/ASSEMBLY Hitch disassembly (refer to fig. 2-3) Pre-assembly of the link in the drum frame Fig.2 Shimming the drum frame Remove hydraulic motor(s) from the drum, release clamps and move hoses away from the hitch area. Do not disconnect hose unless necessary. . Disconnect steering cylinders by removing pins from the hitch. . Block machine as described in "SAFETY PRECAUTIONS", . Remove the capscrews (8) from the cover plate (7). . Using a fork lift or some other suitable machine, such as a jack on wheels, pull the front frame for- ward to provide sufficient clearance to work in the hitch area. . Remove the capscrews (11) and lockwashers (12) from the top cover (10) and remove the plate and shims (13). . Place hydraulic jack on each side between the lower plate of the tractor frame and the steering hitch and Jack uniformly until bearing cup (part of 5) comes out on top. Remove the steering link (1) from the tractor frame, . Inspect the bearing surfaces of the steering link (1), inside the drum frame and inside the cover plate (7) Remove any dirt, paint or grease using a solvent. If any bearing surface is damaged replace both parts of the bearing (5). Ifit is necessary to replace the bushing inside the cover plate (7) remove the locking screws (2). Apply a light coat of grease, SKF LGEM2 P/N 904354, to the bearing surfaces and fit the link (1) to the drum frame using four screws (8) in the cover plate (7). Tighten the screws alternately and evenly to 22 lb-ft. (30 Nm). Use a feeler gauge to measure clearance at the cover plate (fig. 3). Clearance should be equal at four corners. Note dimensions. IDYMAPAC CACC W1051EN2 HITCH DISASSEMBLY/PRE-ASSEMBLY/ASSEMBLY (cont ue) Assembly of the link in the tractor frame without the plattform mounted Fig. 4 Installing the link in the tractor frame 4. Loosen the four screws (8) in the cover plate and insert the necessary shims (6) to compensate for the clearance. (Shims available: 0.10 mm, 0.35 mm and 1.0 mm) NOTE: Adding or subtracting down to 0.05 mm is possible by replacing a 0.35 mm shim with 3 pes or 4 pos of the 0.10 shim. 5. Install the capscrews (8), and tighten alternately and evently to spec. torque, see page 10. 6. It should be possible to move the link from side to side by hand, however, a high force should be required. An extension bar clamped to the link may be used when checking tightness. If the link moves easily, REDUCE the amount of shims. If it cannot be moved, ADD shims. THE BEARING SHOULD BE FULLY SEATED AND ALL CLEARANCE MUST BE ELIMINATED. 1. Inspect the bearing surfaces of the link and inside the tractor frame. Remove any dirt, paint or grease using a solvent. If any bearing surface is damaged replace both parts of the bearing (5). 2. Apply a light coat of grease, SKF LGEM2 P/N 904354, to the bearing surfaces of the vertical pin and install the link into the tractor frame (fig. 4). DVYMAPAC CACC W1051EN2 INSTALLING THE UPPER BEARING CUP. Fig. 5 Installing the upper bearing cup without the plattform mounted Assembly of the link in the tractor frame with the platform mounted Fig. 6 Installing the upper bearing cup with the plattform mounted 3, Install a bearing cup into the upper tractor frame bore (fig. 5) and install the upper cover. Inspect the bearing surfaces of the link and inside the tractor frame. Remove any dirt, paint or grease using a solvent. If any bearing surface is damaged replace both parts of the bearing (5). Apply a light coat of grease, SKF LGEM2 PIN 904354, to the bearing surfaces of the vertical pin and install the link into the tractor frame (fig. 4). Install a bearing cup on top of the tractor frame bore. Place the upper cover upside down, on top of the cup. Install three long screws (M12x50) in the upper cover, 120° apart from each other. Press the cup into the bore by tightening the screws evenly, until they reaches the bottom of the threads (fig. 6). . Remove the long screws, and tum around the cover in its right position . Continue the pressing by tighten three screws of the proper length, until the bearing is fully seated, and there is no play at all. DYMWAPAC CACC W1051EN2 SHIMMING THE TRACTOR FRAME 4, Install 3 capscrews in the upper cover, alternately spaced and tighten screws evenly to 11 Ib. ft. (15 Nm) 2. Use a feeler gauge to measure clearance at the upper cover (fig. 7). Clearance should be equal at points 120° apart. Note dimensions. 3. Remove the screws in the upper cover and insert the necessary shims (13) to compensate for the clearance (Shims available: 0.10 mm, 0.35 mm and 1.0 mm) Note: Adding or subtracting down to 0.05 mm is possible by replacing a 0.35 mm shim with 3 pes or Fig.7 Shimming the tractor frame 4 pes of the 0.10 shim. 4. Install all 6 screws (11) and lockwashers (12) and tighten alternately and evently to 75 Ib. ft. (100 Nm). 5. It should be possible to move the link from side to side by using both hands (see fig. 7), however, a high force should be required. An extension bar clamped to the link may be used when checking tightness. If the link moves easily, REDUCE the amount of shims. If it cannot be moved, ADD shims. THE BEARING SHOULD BE FULLY SEATED AND ALL CLEARANCE MUST BE ELIMINATED. 7. Make the final tightening of the cover screw(s) to specified torque. Proceed as in section: BEFORE SUPPORTING THE MACHINE WITH HEAVY DUTY JACKSTANDS (page 2) Note: Retorque the cover screws after first 50 hours of operation. Assembly of the drum frame to the tractor frame 1, Move the drum frame to the tractor frame and line up with the link horizontal bearings (fig. 8). 2. Install the cover plate (7) and shims (6) selected during the Pre-assembly procedure. 3. Install screws (8), and tighten altemately and evently. 4. Lubricate all four fittings until grease is forced out at each bearing. 5. Replace hydraulic motor(s), clamp hoses properly and replace steering cylinder pins. Fig. 8 Assembly of the drum frame to the tractor frame 6. Remove all safety supports and wheel and drum, chocks. DVMAPAC CACC Wi051EN2 SHIMMING THE TRACTOR FRAME (continue) 7. Make the final tightening of the rear cover screw(s) to specified torque. Proceed as in section: BEFORE ‘SUPPORTING THE MACHINE WITH HEAVY DUTY JACKSTANDS (page 2). Note: Retorque the rear cover screws after first 50 hours of operation, TORQUE SPECIFICATIONS: TOP/BOTTOM COVER SCREWS Note: Oiled threads. Use SHELL ONDINA 32 oil all. SHELL RETINAX 15. fr Type of vibratory roller Nm tb. ft. CA 151, CA 251, CA 301 70 52 A282 70 82 CA 511, CA 551 70 52 CA 512, CA 602 70 52 CC 501, CC 722 70 52 TORQUE SPECIFICATIONS: REAR COVER SCREWS Note: Oiled threads. Use SHELL ONDINA 32 oil alt, SHELL RETINAX 15. Type of vibratory roller CA 151, CA 251, CA 301 CA 252 CA511, CA 551 CA 512, CA 602 CC 501, CC 722 Nm 470 470 800 800 800 Ib. ft. 346 346 589 589 589 10 DYNAPAC CAICC WI051EN2 J DYNAPAC Série W Bomba Hidraulica de Engrenagens & Motor de Engrenagens DYNAPAC Série W Bomba Hidraulica de Engrenagens & Motor de Engrenagens Inspegdo / Manuten¢ao Codigo: 197.012 Manual de Manutengao — BeBe | ms | ‘On. DYNA: ic jombas de Engrenage: Ferramentas exigidas * Conjunto de Chaves de Boca Métrico * Afcate para Trava Interia ‘© Luva para montagem do Retentor Torquimetro — capacidade de 100 b-f Desmontagem Nota: As instrugdes gerais seguintes também se aplicam para bombas de engrenagem de segdes miltiplas, as Unicas partes extras so 0 acoplamento entre o eixo motriz e 0 centro da placa de separagdo que divide as duas sees da bomba. Este procedimento de conserto ‘também se aplica a série “W" de Motores de Engrenagem. 1.£ muito importante trabathar numa area fmpa quando consertamos _produtos hidraulcos. Tampe todos os furos e lave 0 exterior com sovente apropriado antes de continuar. 2.Remova todos os tampées e escoe todo bleo da bomba, 3.Use uma caneta marcadora permanente para marcar uma linha através da flange de montagem, caixa de engrenagem e tampa fraseira. Isto assegurara uma montagem correta e a rotagdo da bomba. 4Remova a chaveta do eixo motriz se necessario. 5.Prenda a flange de montagem numa morsa com 0 eixo da bomba dirigido para baixo 8.Sole os quatro parafusos com cabecas hexagonais. 7.Remova a bomba da morsa e colque-a numa bancada fmpa, remova os quatro parafusos de cabegas hexagonais e os espacadores se houverem. ®.Cuidadosamente remova a cata de engrenagens e a coloque sobre a bancada. Tenha certeza que 0 bloco de rolamentos iraseiro permaneca sobre os eixos de engrenagens 10.Remova 0 bloco de rolamentos traseiro dos eixos de engrenagens. ‘Série W Bombas de Engrenagem rolamento 12.Remova o eixo motriz da flange de montagem, N&o ha necessidade de proteger o retentor ja que sera trocado por um novo. 14.Vire a flange de montagem, com o retentor para cima, € remova o anel retentor com o alicate de trava. 15.Remova o sel de blo da flange de montagem, seja cuidadoso para ndo danificar ‘ou arranhar 0 furo do seb. 16.Remova as cavilhas da calva de engrenagens. Néo perca 05 pinos. 17.Remova os retentores de ambos os blocos de rolamentos ¢ descarte Inspecao das Pecas ~ Desgaste tlimpe e seque todas as _pecas cuidadosamente antes da inspe¢do. No ¢ necessario inspecionar os selos ja que serdo trocades por novos. Veritque estes pontos PVN \ \ 2Merifique as ranhuras do eixo motriz a procura de denies torcidos ou quebrados, verifique © rasgo de chavela se nfo estd quebrado ou lascado, Ndo pode haver marcas ou arranhées no eixo na area do retentor, akuma descoloracdo do eixo € permitida, DYWwAPACc 3.inspecione ambas as engrenagens no local dos rolamentos e retentores a procura de superficies Asperas ou desgastadas erm fe da engrenagem Vertque o canto do dente \ a engrenagem 4inspecione a procura de marcas ou desgaste na face das engrenagens.Se o canto dos dentes da face da engrenagem estiverem afiados, eles irdo fresar os blocos do rolamento. Se houver desgaste, as pecas nao sdo ulilzaveis Verinque aface Espesaura do bloco ters que ser igual 5. Inspecione os blocos de rolamentos a procura de marcas ou desgaste nas superficies que estéo em contato com as engrenagens. Também inspecione os rolamentos para ver se ndo hd marcas nem desgaste G.Inspecione a area dentro da caia de engrenagens. E normal mostrar um faixa ustrosa na parte interna da caixa de engrenagens, na superficie interna do lado de entrada. N4o pode haver desgaste excessivo ‘ou arranhées € estrias, Informagao Geral E importante que a conexéo entre a flange de montagem, blocos de rolamento e caia de engrenagens esteja correta. Faha na montagem desta bomba resultara em pouco ou nenhum furxo na pressdo ajustada, Reverter o Elxo de Rotacao da Bomba (Nota: Esta bomba nfo & bi-rotacional, se 0 eixo de rotagao precisa ser mudado, 0 procedimento seguinte precisa ser seguido.) Revertendo o eixo de rotagdo da bomba de engrenagens da série “W" serd feito girando, como um conjunto, os dois blocos de rolamento © a caixa de engrenagens 180° em relagéo as partes restantes da bomba. Este procedimento colecaré 0 furo de pressdo no lado ‘oposto da bomba da posiedo original. Remontagem (Nota: Novos retentores deverdo ser instalados na remontagem da bomba ou motor. Consulte a pagina 8 para os numeros dos conjuntos necessérios para as bombas e motores W-600, W-200 e W- 4500.) Linstale 0 nove retentor montagem com 0 nimero da peca voRado para fora, Pressione o retentor para dentro do furo do retentor aé que atinja © fundo do furo, Deverd ser usada press4o uniforme para evitar desalinhamento ou dano no retentor. na flange de 2.Instale 0 anel de trava no suko do furo do tetentor da flange de montagem: 3.Posione os blocos de rolamentos, dianteiro € traseiro, numa superficie impa com os sukcos dos retentores-€ virados para cima. Apique uma leve camada de graxa nos suicos. Também passe graxa nos retentores-E © no anel de seguranca, isto ajudara a manter os Tetentores no lugar durante a montagem. Série W Bombas de Engrenagem 4.Coloque os retentores-E, lado chalo para fora, dentro dos suicos em ambos os blocos de’ rolamentos. — Prossiga_ _colocando cuidadosamente 0 anel de seguranca, lado chalo para fora, no suko feito pelo retentor-E € 0 suko no bloco de rolamentos. (Nota: Na bomba série W-900, no centro do anel de seguranga e retentor-E existe um chanfro, tenha certeza que estes chanfros estejam alinhados assim 0 anel de seguranca se nivelard com o retentor-£). O anel de seguranca na bomba W-1500 ¢ simétrica. 5.Coloque a flange de montagem, com o lado do retentor para baixo, numa superficie impa e tsa 6.Apique uma leve camada de graxa na face dianteira exposta do bloce de rolamentos Z.insira a ponta do eixo motriz através do bloco de rolamentos com o lado do retentor para baixo, e 0 lado aberto do retentor-£ ‘apontando para o lado de entrada da bomba 8.instale a ka para montagem do relentor sobre o eixo motriz e cuidadosamente desize © exo motriz através do retentor. Remova a luva do eixo. B.Instale 0 eixo da engrenagem na posi¢ao remanescente no bloco de rolamentos. Aplque uma leve camada de éleo impo nas faces das engrenagens. 10.Pegue © bleco de rolamentos traseiro, com 0 lado do retentor para cima e o lado aberto do retentor-E apontando para 0 lado de entrada da bomba, coloque os eixos motriz e de engrenagem. U1.instale duas cavihas nos buracos da flange de montagem ou duas cavihas longas através da caixa de engrenagens se bomba de secdo mutipla. 12.Para instalar_ 05 anéis-O na caixa de engrenagem, apique uma feve camada de graxa nos sulcos em ambos os lados da caixa de engrenagens. Também aplque graxa nos noves antis-O e instale-os nos suleos. pywapac Série W Bombas de Engrenagem 13.Delicadamente desize a caixa de engrenagens — 17.Coloque a flange de montagem da bomba sobre o bloco montada de rolamentos traseiro, desfze a _novamente na morsa e alemadamente aperte caixa para baixo alé a caica conectar-se com as 0s parafusos. com 0 torquimetro nas cavilhas. Pressione firmemente com as méos, ndo force, _especificagées de torque na tabela da pagina nem use ferramentas. Verifique, para ter certeza, que 0 9. Todos os numeros de torque s40 para furo de entrada da catra esta do mesmo lado aberto do _parafusos de torque seco felentor-E e que a inha marcada na flange de ‘montagem e n caixa de engrenagens estdo afnhadas. 18. Remova a bomba da morsa 14A superficie do bloco de rolamentos traseira dever’. —_19,Coloque uma pequena quantidade de dleo estar ligeiramente abaixo da face da caixa de impo na entrada da bomba e gire 0 exo engrenagens. Se o bloco de rolamentos estiver mais motriz uma revohigdo. Se o eixo motriz travar, ako que a face traseira da caixa de engrenagens, enldo — desmonte a bomba e verifique se houve © retentor-£ ou o anel-O movimentou-se para fora do problemas de montagem, entéo remonte a sulco. Se este ¢ 0 caso remova a caixa de engrenagens —_bomba. € relaga a instalagdo do retentor o = oe 15.Instale as duas chavetas remanescentes na traseira 20 etiqueta locaizada na tampa traseira da caixa de engrenagens, se apkcavel, ¢ colque a — conlém a dala de fabricagdo e o numero do tampa lraseira sobre a tampa traseira da bomba. modelo Favor mencionar esta informagdo quando entrar_em —contalo como departamento de manutengdo da J.S.Bares. Cédigo de Identificagao de Data a Més Ano x = ‘Semana do Més 16.instale 05 quatro espagadores, se apicavel, e os parafusos de cabecas hexagonais através dos furos da a tampa traseira, aperte com amido. Série W Bombas de Engrenagens Colocando a bomba novamente em funcionamento, 1.Se bancada de teste est4 dispontvel, 0 procedimento a seguir para testar bombas reformadas ¢ recomendado: A. Monte a bomba na bancada de teste verificando se 0 nivel de dleo impo no reservatério esta correto. Verifique se a linha de sucg4e tem vazamento ou obstrugées B. Ligue a bomba e funcione-a por trés minutos a pressdo zero. De forma intermitente carregue a bomba para 34 bar (500 psi) por trés minutos. D. De forma intermitente carregue a bomba para 68 bar (1000 psi) por trés minutos E, De forma intermitente carregue a bomba para 138 bar (2000 psi) por trés minutos F, Remova a bomba da bancada de teste € verifique se ha folga no elxo motriz. Procure sinais de vazamento. 2. Se no houver bancada de testes. A. Para bombas acopladas a motor, monte a bomba no equipamento ¢ funcione a meia (1/2) velocidade do motor a presso zero, por trés minutos B. Operando a vaWula de controle, aumente a pressdo de forma intermitente por trés minutos €. Aumente a velocidade do motor para velocidade total e aumente a presséo de forma intermitente por trés minutos. D. Pare o motor e verifique se ha vazamentos na bomba E, Para bombas acopladas a motor elétrico, funcione a pouca ou nentuma carga por trés minutos, aumente graduammente a carga na bomba ¢ tlle cada carga sucessiva por trés minutos. Verifique se hd vazamentos na bomba Bomba / Motor Tabela do Conjunto de Retentores DESCRIGAO | SERIEW-600 | SERIE W-000 | SERIEW-1500 | CONJ.SERIEW.-1500 BOMBAMOTOR |X CONJUNTO | NPCONJUNTO | N’CONJUNTO | RETENTOR W/35VM Bomea simples | 5400042 5000100 5200001 200015 BOMBA DUPLA 400044 so0ot01 5200002 5200018 jaomenTRiPiA | 40004 | sooot02 | 5200003 | ©—=—«szocory— | BOMBA QUADR. | 5400046 5000103, 5200004 5200018 MOTOR 5400043 5000234 5200020 ND [BI-ROTACIONAL = — - — — MOTOR 5400047 5000233 200018 ND UNL-DIRECIONAL Bombas da Série W-1500 fabricadas desde 1996 usam retentores 0.D. 35mm. Motores da Série 1500 no so afetados DYwApac Tabela de Torque de Parafuso ‘Série W Bombas de Engrenagem | SERIE BOMEA] MEDIDADAROSCA] VALORES DE TORQUE | VALORES DE TORQUE TAVPA TRAZEIRANEGRA | TAVPA TRASEIRA ZINCADA OU ESTATOR ovestaton | w-00 BX125METRICO | 18-21 b-R/24-30Nm 18-18 B.R/ 217-244 Nm ~ W-800 10x15 METRICO | 50-55 b-f'/ 68-75 Nm 38-43 b-f/51,5.58,3 Nm | we1500 | 12x1,75METRICO | 80-85BR/108-115Nm | 68-73-N/92.2-00,0Nm | Parafusos e 0 furo rosqueado de flange precisem ester secos, nfo podem ser lubriticados, ‘Solugdes de Problemas para Bombas Simples ou Duplas PROBLEMA DA BOMBA CAUSA PROVAVEL soLUGAO 1.Bomba nao atinge Pressdo total @. Valvula do sistema auxitar regulada muito baixa ou vazamento. b. Viscosidade baixa do 6leo ¢. Bomba esta gasta a. Verifique a regulagem da vatvula do sistema auxitar b. Troque 0 dteo para viscosidade correta. c. Conserte ou troque a bomba, 2.Bomba ndo bombeia dleo, a. Reservatério vazio ou baixo b. Peneira do sugador entupida a. Encha o reservatério no nivel correto. b. Limpe a peneira do sugador 3.Bomba Ruidosa causada por cantagao ‘a. Oleo muito espesso, b. Fitro de dleo entupido. . Tubo de éleo entupido ou muto pequeno a. Troque o éieo para viscosidade cometa. b. Limpe os fitros. c. Limpe 0 tubo e verifique © tamanho correto. 4 Aquecimento do deo, a. Suprimento baixo de dleo. b. Oleo sujo . Regulagem da valvula auxi- far muito ala ou baixa. d. Viscosidade do Oleo muito baixa, a. Encha 0 reservatério no nivel correto. b. Esvazie o reservatério e encha com éleo impo. ¢. Regule na pressdo correta. d. Esvazie 0 reservatério e encha com éleo na viscosidade correla 5.6leo espumando a. Nivel de dleo baixo. b. Ar entrando no tubo de dleo. ©. Tipo de 6leo errado, a. Encha 0 reservatério no nivel correto, b. Aperte os encaixes e verifique a condigdo do tubo. c. Esvazie 0 reservatério e encha com dleo ndo espumante. 6 Vazamento pelo retentor a. Retentor gasto b. Eixo gasto na area do retentor a. Troque o retentor. b. Troque 0 eixo motriz ¢ 0 relentor. ‘Série W Bombas de Engrenagem NOTAS Strie W Bombas de Engrenagem NOTAS " Série W Bombas de Engrenagem DISTRIBUIDOR AUTORIZADO PUMPS & SYSTENS 2 SPARE PARTS LIST W9A1-26-R-5-K -01-B2BU-E588 _/— Someta pa Fang de Montage "2. 19" TENt DESCRICAO. = QUANT. + Teava 4 2 Retentor \ 4 Flange de Montagem 4 a Anwide Seguranga” 2 5 Retentore 2 6 BlocodoRolamento 2 7 Ane 2 8 areapa 4 8 aviha 3 0 Engrenagem Moti 4 co Ensrenagem 1 2 ‘Tampa de Valvula 3 a Paratuso 2 % Tampte ‘ 18 4 7 ‘ 8 4 8 artuela 4 JOGO DE RETENTORES Ne 000100 INe_DEscRIGAO i Retentor " ‘nel ce Sepuranga 5 Retentore 7 Bnet 7 ‘nel =O 4 Anal 20 + Veja desenho 2880138 para nformagao edielonal ADICIONAL Pigg 6 Anal -0 zosorons 1 “oe 24.9. a6 Series 90 Axial Piston Pumps and Motors Service Manual Series 90 Introduction Introduction, Use of this Manual ‘This manual includes information for the normal opera: tion, maintenance, and servicing of the Series 90 family of hydrostatic pumps and motors. ‘The manusl also includes the description of the units and their individual components, troubleshooting informa. tion, adjustment instructions, and minor repair proce: dures, Unit warranty obligations should not be affected it maintenance, adjustment, and minor repairs are per formed 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. Safety Precautions Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, cleanliness require- ments must be striclly adhered to. This is especially Important when changing the system filer 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 SOF (Id No. 697581), ‘A worldwide network of SAUER-SUNDSTRAND Autho- rized Service Centers is avallable should repairs be needed. Contact any SAUER-SUNDSTRAND Autho- rized 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). Observe the following safety precautions when using and servicing hydrostatic products. Loss of Hydrostatic Braking Ability Fluid under High Pressure WARNING The loss of hydreaaler drive line power in any mode of operation (e.9,, forward, reverse, or “neu tral" 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 See Use caution when dealing with hydraulic fluid under pressure, Escaping hydraulle fluld und 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 treat- iment is not administered immediately, hicle/machine to bi aa id (wh the ground, work function disconnected, etc.) while performing them in order to, Prevent Injury to the technician and bystanders, om oe Disable Work Function Flammable Cleaning Solvents WARNING ch WARNING | : Certain service procedur ire the ve- Some cleaning solvents are tlammable, To avoid possible fire, do not use cleaning solvents in an. area where a sour Use of this Manual : . eee Safety Precautions vom : Functional Description.. Fixed Displacement Motor : Variable Dgplacement Motor. = oo a ‘The System Cir... co . - “The Basic Closed Circuit Case Drain and Heat Exchanger Common Features of Pumps and Motors End Caps and Shatts Speed Sensors Pump Features Gharge Pump Charge Rolie Valve Muit-Function Valves erotmenerentennstam bi Pressure Limiter and High Pressure Relist Valves ‘System Check Valves. Bypass Valves o Displacement Liters : ‘Auxitary Mounting Pads a oo Fitration Optons. Toe. Pressure Ovarie (POA) ~ 180 Frame Size Only : : Pump Control Option. - : ‘Manual Displacement Contol (\0C) beeen Hydraulic Displacement Contiol (HOC) Electne Displacement Control (EDO)... wo ‘Automatve Contiol(FBA IB) : = : ‘Position (FNA) Electric Control. Motor Features - is ret Motor Loop Flushing Valve and Charge Relief Valve Variable Motor Displacement Uimiters. Vatlabie Motor Contos, Hydaulle 2-Positon Conta Electric 2Positon Control ‘Technical Specifications... General Specitcations | Circuit Diagrams Hydraulic Parameters Size Specific Data Pressure Measurement... Required Tools... Port Locations and Pressure Gauge Installation Viable Pump Fheed Motot 0 Vanabie Mota: - Initial Start-Up Procedure ms “NEUTRAL! Diffeuit or Impossible fo Find ‘System Operating Hot ‘Tansmission Operates Normally in On@ Direction Only Systam Wil Not Oporto in Ethor Ditocton Low Motor Output Torque Improper Motor Output Spee Excessive Noise and/or Vib System Response is Sluggish ee Inspections and Adjustments Pump Adusiments : CChaige Pressure Relief Valve Adjustment ‘MuitsFunction Valve Pressure Adjustment. Engaging the Bypass Function ressuro Override (POR) Valve Prossure Adjustment (Option for 180 Frame Sze) Displacement Limtor Adjustment Pump Contal Adjustments ‘Standard Manual Displacement Gontial (MDG) Adjustrent ‘Non-Linear Marval Displacement Control (MOC) MDC Neuital Start Switch (NSS) Adjustment... oo ‘Hycrauic Displacement Control (HDC) and Electic Displacement Control (EDC) Adustment 46 Motor Adjustments ‘Charge RelietVaive Adjustment... Displacement Limiter Agusiment (MV) Displacement Control Adustnents ‘Speed Sensor Adjustment ‘Minor Repair Instructions ..., Pump and Motor Minor Repait Pump / Fiting Torques ‘Shaft Seal and Shaft Replacement Pump Minor Repalrs ‘Muli-Functon Valva Cartidges Pressure Over Valve (pte fr “80 Frama Size) ‘Charge Ree! Valve... ‘Charge Pump - Remove .. Instaling the Cnarge Pump Auxllaty Pad instalation Awiliary Pad Conversion Filtration Options Pump contole so ‘Cover Pate — Manual Displacement Contol (MOC) ‘Salonoid Override Vale for MOC. ‘Solenoid Override Valve for MOG with Pressure Released Brake Hydraulic and Electic Displacement Controls. Rss Cel Pt (RP) fate Depart Cal ‘Poston (FNR) Eloctic Contot Displacement Contal Components Minor Repair - Motor Loop Flushing and Charge Fist Valves YYanable Motor Displacement Linvters. Variable Motor Contils. su Electrohydraullc 2-Posion Control (Types NA, NB, NG. and ND) Iya 2 Poston Conte ype Pt) Control Plugs | : Variable Motor Conti Off'c28 sv ssso - Speed Sensor. Exploded View Parts Drawings/ Pans Lists. Vatiable PUMPS soe ‘Minor Repait Parts Pans List Vatiable Purp Contois : Conteol Pars List| oo ° iter and Options Par ist ia and Ons Name Plates Fred Motor. : : ‘Minor Repair Parts oo Pars Uist - Name Plates oe 2 woo - Vanable Motor ‘Minor Repair Pars Parts Ust Name Prata 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 Displ ment Pumps ‘The Variable Displacement Pump (PV) is designed to convert an input torque into hydraulic power. The input shaft tums the pump cylinder which contains a ring of pistons. The pistons run against a tited 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 Serles 00 Voriable Displacement Pump (PV) Serles 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. Noperates 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 ext 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. Serles 90 Fixed Displacement Motor (MF) Series90 Functional Description In the Fixed Displacement Motor the “swashplate” is, Fasting Va fixed, 80 any variation in motor speed and torque must be vaio Pe made by the input mechanism, Le. the pump. ites Sasi Cyne 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. Series 90 Variable Displacement Motor (MV) rio te scm _ ppg Sabon KZ Dal carat ZA Zi EG Z re Sno oyrom B00 cru Arle xo Poon Corr cna) Contre Serles 90 MV Cross Section Series90 é Functional Description The System Circuit ‘System loop ow pres) Conte Maree Deplacomert Corset Vahe ‘Case drain fluid ‘System loop heh pecs) Control tld Suction line Fees Dupacomoet Woe yori eer Cantoh Pump Fixed Motor Circult Diagram for Series 60 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 {rom 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 coolthe case drain fluid before itreturns tothe Flow (Bidirectional) case brain Line ed Basle Closed Clreult Series90 Common Features of Pumps and Motors Functional Description TOOT ‘Speed Sensor 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 con 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, instal and adjust the sensor. | Series 90 Pump Features Functional Description Charge Pump ‘The charge pump is necessary to supply coo! 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 ‘and braking to prevent damage to the transmis: ‘The charge pump is a fixed-displacement, gerotor type pump installed in the variable displacement pump and riven off the main pump shaft. Charge pressureis imited by a relief valve. The standard charge pump will be satistactory for most applications. However, ifthe charge pump sizes available for the given main pump size are not adequate, a gear ump may be mounted to the auxiliary mounting pad and ‘Supply the required additional charge flow. Charge Reliet 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 sur- passes a certain level. This level Is nominally set reter- encing 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. Multi-Function Valves ‘The multifunction valve incorporates the system check valve, the pressure limiter valve, the high pressure relief valve and the bypass valve ina replaceable cartridge. ‘These functions are described separately. There are two ‘mul-unction 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, aon08o4e Pump Charge System Mult-Funetion Valve aBEeR: Pressure Liter Housing gh Pressure elt cnees Pressure Liner agusimen See nee ll = ween Vahe 7 (a Pajares _,_linesy"e Circutt Diagram showing Pressure Control Mechanism ional Description” Pressure Limiter and High Pressure Relief Valves Series 90 pumps are designed with a sequenced pres: sure 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 tolimit 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 ini tiates the pressure limiter valve Both the pressure limiter sensing valves and relief valves are built into the multi-function valves (see above). NOTE: For some applications, such as cual path ve- hicles, the pressure limiter function may be de- feated 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 wil generally lose system Pressure due to leakage and other factors. Since the pump can operate in either ditection, two system check valves are used to direct the charge supply into the ow Pressure lines. The system check valves are poppet valves located in the multifunction valve assembly. Bypass Valves 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 vaive is opened by manually resetting the valve postion, ‘The bypass vaives are built into the multi-function valves. 10 Series 90° * Displacement Limiters AllSeries 80 pumps are designed for optional mechanical displacement (stroke) limiters. The maximum displace ‘ment 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 Sec: tion, Auxiliary Mounting Pads Auxiliary mounting pads are available on all Series 90 pumps. SAE A through E mounts are available (availabil ity 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 All Series 90 pumps are available with provisions for either suction or charge pressure fitration (integral or remote mounted) to filer the fluid entering the charge circut. ‘Suction Filtration The suction fiter 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, Charge Pressure tion The pressure filter may be integrally mounted directly on the pump or a fier may be remotely mounted for ease of servicing, ‘A 125 um screen, located in the reservoir or the charge inlet line, is recommended when using this filtration option. _ Functional Description PY with Suetion Filtration (otiltration device attached) PVwhthintegralcharge PY with Remote Charge Pump Pump i Series 90 as aL Fone vo ‘etree POR-Valve (160 Frame Size only) secon Functional Description Pressure Override (POR) - 180 Frame Size Only ‘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 tothe 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. ‘The pressure override consists of a three-way normally ‘open valve which operates in series with the pump displacement control. Control supply pressure is nor mally ported through the pressure override valve to the displacement control valve for controlling the pump's displacement. I the system demands a pressure above the override setting, the POR valve wil 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. 12 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 four: way servo valve. This valve ports hydraulic pressure to elther side of a dual-acting servo piston. The servo piston rotates the cradle swashplate through an angular rotation of +179, 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, shat. NomLinear MDC The non-linear manual displacement control operates in the same manner as the regular MDC except that itis designed so the change in the angular position of the pump swashplate progressively increases as the control input shaft is rotated toward ts 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 act vated. The vaive may be set in either a normally open or normally closed mode. 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 ensuresthat the prime mover can be started only when the control is ina neutral position PV with Manual Displacement Control and Hydraulic Displacement Control (HDC) Neutral Start Switch The hydraulic displacement control uses a hydraulic input signal to operate a spring-centered four-way servo valve. This vaive 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 trom full displace: ment in one direction to full displacement in the opposite direction, The HDG Is designed so the angular position of the pump swashplate Is proportional to input pressure. PV with Hydraulle Diaplacement Control 13 Series 90 PV with Electric Displacement Control PV with 3-Position (FNA) Electric Control Functional Description Electric Displacement Control (EDC) ‘The electric displacement controls similar to the hydrau: lic displacement control with the input signal pressure controlled by a pressure control pilot (PGP) valve. The PCP valve converts a OC electrical input signal to a hydraulic signal which operates a spring- centered four- way servo valve. This valve ports hydraulic pressure to elther side of a dual-acting servo piston. The servo piston rolates the cradle swashplate through an angular rotation of 17°, thus varying the pumps displacement from full displacement in one direction to full displacement in the opposite direction. The controls designed so the angular position of the swashplate is proportional to the EDC. input Automotive Control (FBA 1 B) Automotive Control allows @ vehicle to be driven in a manner similar to an automobile with an automatic trans- ‘The Automotive Control includes a three: position electric control to provide direction control 3-Position (FNR) Electric Control This control utlizes a 12 of 24 VDC electrically operated spool valve to port pressure to either side of the pump displacement control piston. Energizing one of the sole- noids will cause the pump to go to its maximum displace- ment in the corresponding direction, All functions of the three-position (FNR) electric control are preset at the factory. 14 Series 90 Motor Features Motor Loop Flushing Valve and Charge Relief Valve AllSeries 90 motors are designed to accommodates loop flushing valve. The loop flushing valve is used in instal: lations which require additional fluid to be removed from the main hydraulic citcult because of transmission coo! ing requirements, or unusual circus requiring additional loop flushing to remove excessive contamination in the high pressure circuit. A shutlle 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 reliet valve regulates the charge pres sure 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 (ost from the circuit when reversing pressures, For charge relief valve adjustment see corresponding Section. Vai ble Motor Displacement Limiters All Series 90 variable motors include mechanical dis placement (stroke) imiters. Both the maximum and min: mum displacement of the motor can be limited. The range of the settings is as follows: 055 MV o7s av Minimor 18 a0 en? | 28-84 on? Displacement ia-24m | 16-490" Maximum 00% a 65-10% | 65-10% Toe IE Functional Description Loop Flushing Valve (MF) Motor Charge Rellet Valve and Loop Flushing Shuttlevaive MY Maximum Displacement Limiter (Minimum Displacement Limiters on opposite elde) 15 Series 90 Variable Motor Controls /Funetional Description MY with Hydraulic 2-Position Control MV with Electric 2-Position Control 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 nor- mally held at its maximum displacement. Supplying pilot hydraulic pressure to the valve will cause the motor to go to its minimum displacement. Electric 2-Position Control This control utlizes an electric solenoid 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. Energizing the solenoid wil cause the motor to go to iis minimum displacement. 16 Technical Specifications “Technical Specifications General Specifications Design Variable Pumps and Motors: Axial piston pump of vari able displacement, cradle swashplate design Fixed Motors: Axial piston motor with fixed displacement, fixed swashplate design, ‘Type of Mounting (per SAE 1744) SAE flange, Size °B", 2 bolts, SAE flange, Size °C and E*, 4 bolts Cartridge flange, 2 bolts (for motor only). Circuit Diagrams ad AE PV with Charge Pump ana Manual placement Control Port Connections: (for details see chapter *Pressure Measurement") Main pressure ports: SAE flange, Code 62, Remaining ports: SAE straight thread O-ring boss. Direction of Rotation Clockwise or counterclockwise (motors are bi-directional) Recommended Installation Position Pump installation recommended with control position on the top or side. Consult SAUER-SUNDSTRAND for non: conformance guidelines. The housing must always be filled with hydraulic fui, Control MF Hydraulic Parameters fons syatem Pressure Range | bar pal aaa! ated Presare yo so Tainiana | =ad— Ea [rere Ta Rated Toa 13207 aru Pressure “80 yo Maxim [113 (349) [inserter Tea TAC Ghe HORST POINT ROVTAT The Cae ‘Charge Pump Infet Vacuum iscoaiy, (on pumps only) bar abs int mmen7= [_(SUST Tiiniar Vaca 7 fai [h 7 1 (Continous) . ° 12-60 | 170-2761 Minimum Vacuum dung interment Cold Start 02 2s 2600 | 17500) | org stare (interttent) 02 61s Gaus Procure ray = ER aR RSIS ane RR Hydraulic Fluid Refer to SAUER-SUNOSTRAND BLN 9887 of SOF (Id No, 697581), Also refer to publication ATLE 9101 for information relating to biogradable fluids. ries 90 technical information for definitons Mann (Continous) “ Tramtameeer | Snr Ome Wax dung Gal Stat Pac 7# (Bute) nteritent) . 7” Bes = Cleanliness Refer to SAUER-SUNDSTRAND Publications BLN9887 (or SDF (NO. 697581) and ATE 9201, 18 Size Specitic Data ‘Technical Specifications Variable Displacement Pumps Dinensin | ooopv | oszev | osspv | orsev | wom] iaoev | veoev | asopv oo oF sa ase a ane \resrary ts | 260 | aos | cer | cto | za | soe | oes tearm Spo mney | | so | sm | soo | sm | 0 | sm | soo sted Spend mem | eo | «ono | amo | aco | om | ovo | am | m0 Naaru Spe romp | ao | sooo | ao | oso | ono | ooo | amo | m0 ase Sve | sooo | sooo | ammo | sooo | woo | svoo | amo | a0 Hie Toepe a Wer | eae ar | ase ate] ag} 207 | aa a7 Ire Optra vernon | oo | so | a | v0 | ow | tao | iso | oan Famer rs = | | @ | | 6 | oo | 106 | 158 Jon base nt) ® = | % | © | i | wm | ww | oo | oe Fixed ond Variable Displacement Motors cnet | ooomr | oF | oss | arse | toomr | taowr| ossuv | ovo uv oF | as] se] a0] 8 [Displacement (maximum) iw 1,83 256 335 457 6.10 7983 335 AST rs ~--t|-)-1-)- >» pe awe a wanton | a0 | a200 | ao | sooo | sao | sioo | amo | sooo feet enna : ler oem | - | - | - aeoo | samo a a om vemy | emo | oo sexo | 200 | suo | caso | amo poet” ater va —T lees om om - woo | ara ve ieee a = min* (rpm) ‘5000 5000, 4700 4300, 4000 3700 A700 4300 Harta ove atm | —Twotar [as | oer] as | ie] a0] aa] oa | a0 Liocorart tenttoons | 20 | fw | so | ro | oo | iw | So | tae xara ow oma tin tse} tea ase 206 aes] ma} ae \acorart om |x| s |e | «| es || @ | % vw [ast ass | aarp za] ana ase] 220 an fi. comer power hp 149 208 251 318 392 475 300 378 Inmet ‘9 ups | @ pa] a ps | a fae Senge é ee ee haar rn a] me] ae wo] a8 Toes Reterto Serios 90 tachnicalinformation or dotinvtons 19 Pressure Measurement Required Tools ‘The service procedures described in this manual for Series 30 pumps and motors can be performed using common mechanic's tools. Special tools, if required are shown, Port Locations and Pressure Gauge Installation ‘The following sections list the ports for each type of Pressure gauges should be calibrated frequently to en- sure accuracy. Snubbers are recommended to protect pressure gauges. Outline drawings showing pot locations follow the tables hyeraulie unt, The recommend pressure gauge end below. Ming are also spectied Variable Pump Googe Sa Gauge Sie Port Function and Port Function and 7 a a Fitting a we [Pee pee EE [Gases sonar or 0p a Baton Pesare | —T00Dbar oo BT fore | ‘se womgiey | yeuowe oe 7 cee Sober aD (ute | Marge Pr ‘96-18 Ong Os a Wear or 1000p oe | sanssz0mg MS ‘Servo Pressure 916-18 O-ring: 100 aay ST 700 : 100 | ssse-2.0009 GObaro TOS x | tecrens | “thes Ooms 2 | swap a 11618" ng ve | Bear conva | 80 or o 105 resure ones Ow 3 |@taipe Pure it] Vacuum Gavoe, oe io inate oo 8 | sanerz0me ss 65 |v ner2omy 100 199 | +5829 fe TaERH 2am Flange Tone 20 ‘seriéso0 ‘Servo / Displacement (Cylinder Pressure ‘Gaugg Port Ma Case Drain Pott? ‘System Pressure Pon B ‘Servo Displacement (ylinder Pressure Gauge Port MS. Top View System Pressure system Pressure Pot Gauge Port M2 Extomal Control Pressure Supply Port x3 Charge inlet Pressure System Pressure ‘Gauge Por Mi Carge Pump Inlet Port S ‘System Pressure zase Drain Pot Shaadi Pot Case Drain Pork Gauge Port Ms Left Side View Right Side View PV with Side Port End Cap and Manual Displacement Control, 2 Pon S ‘System Pressure Post A System Pressure ‘Gauge Port Mt Left Side View ‘Servo / Displacement Gylinder Pressure yinder Pressure Gauge Port MS Top view PV with Twin Port End Cap and Manual Displacement Control Port E (trom fer) Port D (to fiter) Charge Pressure Gauge Pot M3 (after the titer) Rear View PV with Side Port End Cap and Remote Pressure Fikration Charge Pressure Gauge Port M6 (before the tte) Charge Pressure, Gauge Port M3 (attor the fter) PV with Side Port End Cap and Integral Pressure Filtration 22 Series 90 — Gauge Sze Gauge Size Port Funetion ‘and Port Function and iting iting System Pressure | _ TOGO bar or 10 000 pal Tt | Case Prosanay ut Port ‘AY 916-18 O-ring BR 1b oF SCO psi wz) Sytem Pressure | —1000 bar or 10 000 pat = = Pon's ce on | 714 08g cige Proseue 0100 ps 055, Charge Pr 916-18 Ong = Toate 11612 Ong Tour ee System Pressure Gauge Port Mt ‘System Pressure ‘Gauge Pont M2 Charge Pressure ‘Gauge Port M3 Case Drain Port Lt System Presaute Por B System Prosure Pot Case brain Pod t2 Speed Sensor Rear View Let Side View MF with SAE Flange system Pressure ‘Gauge Port Mt ‘System Pressure Gauge Poa M2 Charge Pressure Case Drain Port La ‘Gauge Port M3 Sensor System Pressure Port B System Pressure Port A (Case Drain Port L2 ear View Lett Side View nen MF with Cartridge Flange 23 Variable Motor | Préssiire Meastirement Gouge Gauge Sze pon | Fimcton ona port Function me ig rng Srenprase | —1000bar or 10 REO Conta Opretar - “ mon one owg wwe | crocs chiirarn | *8@ 01000 wa | SiStempressure | ~ 7000 bar or 10.000 ps Displacement” ron 0-18 Ong ve Sat 3 sn oro we Pr "BO bar or 1000 pst ressure’ Maximum 76-20 Ong Charge Pressure | SOBRE GHD plone ood ae u ‘Case Pressure TO bar or 500 pal a Tneteorg To Displacement Control Gyinder Pressure Gauge Port Mi ‘System Pressure Min, Displacement Gauge Pon Me > Canto! Pressure Dieplacement Control Pot x1 \f Gylinder Pressure (Hydraulic 2-Postion Contr) ‘System Pressure Pott B Hi C4 4B Left Side View ‘Gauge Port MS Max. Displacement (Eater Production Not avaliabe as gauge pon with servo ortices) Deplacement Control ‘Gylinder Pressure ‘Gauge Port MS Max Displacement (Newer Production) MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar) (Case Drain Port Lt System Pressure ‘Gauge Pon Mt charge Pressure Gauge Port MB (Game position as in MF) ‘Speed Sensor ‘System Pressure Post A (Cove Drain Port L2 Right Side View woootese MY with SAE Flange (Cartridge Flange Version Similar) 24 Series 90 Initial Start-Up Procedure Initial Start-Up Procedure ‘The following start-up procedure should always be fol lowed 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 inital start-up. This will ensure that the: pump remains in its neutral position, WARNING The following procedure may require the vehicle/ machinetobedisabled whaels raisedoffthe ground, ‘work function disconnected, ete.) while performing the procedure in order to prevent injury to the technician and bystanders, Take necessary safety precautions before moving the vehicle/machine. Someone 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 filing 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 vehiclefmachine move: ment. See the publications 8LN-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 i 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 ftered oil into the upper case drain port Install a 50 bar (cr 1000 psi) pressure gauge in he charge Pressure gauge port to monitor the charge pressure during start-up. Itis recommended that the external control input signal (linkage for MDC, hydraulic lines for HDC, or electrical WARNING z Do not start prime mover uniess pump is in neutral position (0° swashplate angle), Take precautionsto preventmachinemovementincase pumpis aetucted during initialstartup, socom "Jog" or slowiy 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 estab: lished. 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 shatt remains stationary during the adjustment procedure, eT 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 tobe certain the pump remains in neutral. With the prime mover at normal operating speed, siowly check for for ward 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 fiteres fluid if needed The transmission is now ready for operation. 25 Fluid and Filter Maintenance ‘Suction Filtration Schematic Aegsttle Charge presse Topmpeaco Charge Pressure Fittration Schematic (Partial flow) To ensure optimum service life of Series 90 products, regular maintenance of the fluid and fier must be per- formed. Contaminated fluid is the main cause of unit failure. Care should be taken to maintain fluid cleanliness while performing any service procedure. Check the reservoir daly for proper ud level, the pres- ence of water (noted by a cloudy to milky appearance, oF free water in bottom of reservoir), and rancid fluid odor (indicating excessive heat). If either of these conditions occur, change the fluid and iter immediately. is recommended that the fluid and filter be changed per the vehicie/machine manufacturer's recommenda- tions or at the following intervals: First change 500 operating hours atter start up second and subsequent chenges ‘every 2000 operating hours or once a year This recommendation applies for the most applications. High temperatures and pressures will result in acceler ated 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. It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes contami: nated with foreign matter (dit, water, grease, etc.) or if the fluid has been subjectedto temperature levels greater than the recommended maximum. Never reuse fluid. ‘The ter should be changed whenever the fluidis changed (or whenever the filer indicator shows that tis necessary to change the fiter.. aaa BRS Pues ea) Bree? 5, 26 Troubleshooting Toubleshooting 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 ofthe items willbe system specific. For ares covered in this manual, a section |s 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 2. Input to pump control Pump displacement control System Operating Hot Input to control module is operating improper Controllinkages are not secure, control orifices are blocked, etc. ‘Check control input and repair or re place as necessary. Adjust, repair, or replace control mod. ule as necessary. Ifthe above actions do not remedy the problem ‘contact a SAUER-SUNDSTRAND Authorized Service Center. Check Description Action Oil level in reservar, Heat exchanger Charge pressure. Charge pump inlet vacuum. ‘System relief pressure settings. For internal leakage in motor. System pressure, Insufficient hydraulic fuld will not meet cooling demands of system. Heat exchanger not sufficiently cooling the system, Low charge pressure will overwork sys- tem. High inlet vacuum will overwork sys: tem. A dirty fiter will increase the inlet vacuum. Inadequate ine size will re strict flow. the system relief settings are too low, the relief valves will be overworked, Leakage will reduce low side system pressure and overwork the system, High system pressure will overheat system, Fil reservoir to proper level Check air flow and input air tempera: ture for heat exchanger. Clean, repair or replace heat exchanger. Measure charge pressure. Inspect and adjust or replace charge relief valve. Or repair leaky charge pump. Check charge inlet vacuum. If high, inspect inlet fter and replace as neces: sary. Check for adequate line size, length or other restrictions. Verify settings of pressure limiters and high pressure relief valves and adjust or replace mult-function valves as nec- essary, Monitor motor ease flow without loop flushingin the crcutt (use defeat spool) flow is excessive, replace motor. Measure system pressure. If pressure is high reduce loads. If the above actions do not remedy the problem contact a SAUER-SUNDSTRAND Authorized Service Center. 27 Transmission Operates Normally in One Direction Only Toubleshooting Check Description Action 1. Input to pump control 2. Pump displacement control 3, Interchange system pressure limit: cers, high pressure relief valves, and system check valves. 4. Charge pressure. Taput to control module 1s operating improperiy. Control linkages are not secure, control orifices are blocked, ete. Interchanging the mult-function valves will show if the problem is related to the valve functions contained in the multi- function valves. {charge pressure decays in one direc- tion the loop flushing valve may be “sticking” in one direction. ‘Check control input and repair or re place as necessary. Repair or replace control module as necessary. Interchange multi-function valves. ithe problem changes direction, repair o replace the valve on the side that does not operate. Measure charge pressure in forward and reverse. If pressure decays in one

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