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Axial Piston Pumps and Motors Service Manual

1. 81 PGS AN ONS NE RE o T c 82 Pans SU Filier aid COINS cree aes T T cas Tt mU Tr 83 allen de E 83 Se Ree 84 PVM F lt FR OUI Parte E 84 Sei 85 Klee 85 VE de e EE 86 KNOR GDA F RENE TEE CO TO T DEEST toc 86 mcum em RE 87 POE A ac ees cin ae ee een ed E gece ce cee ie snc as ee a cesta pinot eset Vacate GE bn Ge E 87 SAUER DANFOSS 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 FOOO 539 Series 90 Variable Displacement Pump PV Slider Block Servo Arm Servo Va
2. ee 1 M1DC Control 3 position FNR 12V 1 M71M Washer eene 1 M1DD Control 3 position FNR 24V 1 M72M NT PR 1 M80 Control gasket eesssssese 1 M74N Solenoid valve a 1 M 7D egen Washer seal 042 1 M75M Control manifold aaeeea 1 MOOD ce ERRORI THREE 6 MI77M Manifold gasket EEN 1 M78M OE W en ee E 2 MOEA Control kit EDC with M n Control gasket ee ee ee 1 MS connector see ese SEE ge Re Ke Se EE Ee ge ee 1 M87M Washer seal 042 eee 1 MOEP Control kit EDC with M90M Sef RA AE OE M EE N 6 Packard connector 1 MIEA Control EDC with MOMD Control MDC w sol valve and MS connector EEN 1 neutral start switch Ee 1 MIEP Control EDC with M7M Control handle eee 1 Packard connector sssssss 1 M74M EE TEE 1 MOEA PCP type 3 oil filled MS 1 M72M NUt ee ee ee ee ee ee ee ee ee ee 1 M9EA casi PCP type 3 oil filled Packard 1 M75M Control manifold eeese 1 M80 Control gasket ENEE 1 M76
3. System ui Check Y Valves Input f Charge i Pump e Inlet Filter C3 Tank 90000804E Pump Charge System 90000243 Multi Function Valve SAUER DANFOSS Series 90 Pressure Limiter Housing High Pressure Relief check Check Valve Valve Poppet Poppet Pressure Limiter Lock Nut uo Dra I NY SS 7 Pressure Limiter Adjustment Screw Bypass Actuator Valve Poppet 90000806E Cross Section of Multi Function Valve To Control Multi Function Valve Bypass Servo Piston J Adjustment Port A Port B Servo Piston Charge Pressure Relief Valve Multi Function Valve 90000801E Circuit Diagram showing Pressure Control Mechanism 10 Functional 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 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 ini ti
4. KOS SE Roller Bearing Output Shaft D Ie MME ae We d Ym TT AS SSS CG IDDIE E cA DD JB DED SS i Electric 2 Position Control optional Cradle Swashplate 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 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 Minimum Angle Control Piston Cradle Swashplate p SS 7 st Partial Section A A Cradle Swashplate in Full Displacement Position lt TI D N 4 Ai 90000234E Series 90 MV Cross Section SAUER DANFOSS Series 90 The System Circuit i d LZ FC Control Handle Displacement Control Valve S Heat Exchanger ZEN Bypass Valve HH CES ul SL SUR SES i SZ FEN Orificed Check Valve Heat Exchanger Servo Control Variable Cylinder Displacement Pump 7 OSS ZZ _ EAN EE AL EE LA Ee G N TS o m T F NR sd NE VW Pump Swashplate Servo Control Cylinder Pump Charge Pressure Multi F
5. 1 Orienting Alignment Pin ent production periods Always install as a com plete assembly 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 petro leum jelly to the I D O D and side faces of the gerotor assembly to provide initial lubrication 4 Install the gerotor assembly 790000285 90000286 5 Install the outer port plate early production and Install Inner Port Plate Install Gerotor Assembly intermediate production pumps only Outer Ring 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 90000288 n Install Gerotor Assembly 0000287 i 90000290 Install Spacer Plate Early and intermediate Intermediate production production only only 99000289 Install Outer Port Plate 60 SAUER DANFOSS Series 90 Note 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 inter nally splined end of the shaft is used in 100 cc pumps 8 Install the charge pump shaft T
6. H20W 7 N CODE 61 OPTION G63 CODE 61 OPTION G64 CODE 61 OPTION 4 A 7 G64 NS P 90000864E 84 SAUER DANFOSS Series 90 Parts List Exploded View Parts Drawings Parts Lists Item Description Qty Item Description Qty BOO E gis EE EE OE EE EE HQ 2 H50W se EE 2 B83 de ERK 1 H60W Charge relief valve plug 1 BE CREER Speed Sensor ee ee EE RR Ee ee EE 1 H62W ene NER E EE 1 H64W visio E 1 G50 sccuietanncse SL U 2 H66W Charge relief poppet 1 ET uocis x t EO AE TN 1 H68W Were dU AAR EER EO 1 363 MK nes Split flange screw ssssss 4 G64 Screw Shipping Cover 4 BC c Seal Gamer 1 Bo eet ese Seal Gamer 1 H10N Loop flushing spool defeat 1 L40 Biet Meer rU pH 1 H50N aU TRENT 2 LBO MT UE erg ge Tr A 1 L60 Retainer esses enne 1 H10W Shuttle valve spool 1 bie EE oet AE AE a S 3 H20W Spring guide sese 2 H30W IMIG EO OR HA cR 2 LE TNR VEN EE A 1 H40W erg E 2 f o Slotted Bn E 1 Name Plates SAUER S SUNDSTRAND Ames lowa U S A Neum nster Germany Model Code
7. 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 S000007E 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 a 90000358 with a 13 mm hex wrench Rotate Neutral Adjusting Tighten Neutral Adjusting Screw Screw Lock Nut 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 Rotatethe 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 dis tance 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 Ibfeft Do not overtorque the nut 7 Once the neutral position is set stop the prime mover remove the gauges and install the gauge port plu
8. 65 SAUER DANFOSS Series 90 Minor Repair Manual Displacement Control MDC 1 Thoroughly clean external surfaces prior to removal of control 2 Usinga5 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 000 022E 90000319 90000320 Remove Mounting Screws 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 90000321 90000322 Non engagement of control linkage pin is indicated Inner Face of Control Assemble Control to Linkage by lack of centering torque as the lever is moved In case of non engagement remove the control and repeat the above procedure 6 Alignthe control gasket and install the screws Torque the screws to 16 Nm 12 Ibfeft NOTE Asealing washer mustbe installed under the head of any mounting screws that
9. 90M055 NC O N SAUER S SUNDSTRAND Ames lowa U S A Neum nster Germany Typ Model Code Typ 90M055 NC 0 N 8 N O C6 W 00 i 8 NO C6 W 00 Geen NNN OO OO 24 NNN OO OO 24 Model No Ident Nr Model No Ident Nr Model Number 94 2029 Model Number T 312918 Serial Number T A 91 26 67890 Serial Number N 91 26 67890 Serial No Fabr Nr Serial No Fabr Nr MADE IN U S A MADE IN GERMANY L place of Manufacture m Place of Manufacture Name Plate U S A Production Name Plate German Production 85 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Variable Motor Minor Repair Parts Y100 Y102 vor L35 Y40 Early Production 1 yso 079 Frame Size A L70 Y60 reo E L30 A d f H60N L wer x M1NA M1NB Ee M1NC MIND P702 Ka ak G50 SO Ca H50N gl ei P401 H50W A M P402 AIM B74 L E p H40W Sa de e 8 P603 Q og GP E35 H30w J g R H10N P400 ee H20W aS EN P401 P602 G70 x H50N P402 cC P403 TEA veld re H30W V N G63 GED i CODE 61 OPTION pean _ G64 CODE 61 OPTION 90000865E 86 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Parts List Item Description Qty Item Description Qty B74 ies PG EE M 4 o M Seal carrier MuR PP AD EE eind B76 aw e 1 Bolo PE Seal carrier ee
10. Pressure Override Valve Option for 180 Frame Size 1 Remove the four screws attaching the pressure override valve to the pump end cap with a 5mm 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 Ibfeft 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 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 030 100 1 1 16 inch 130 250 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 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 Ibfeft 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 Ibfeft Check the charg
11. 50 Ibfeft Later production Series 90 pumps are equipped with an external screw adjustable charge pressure relief valve Adjustment of the charge pressure is accom plished by loosening the lock nut 030 100 1 1 16 inch 130 250 1 5 8 inch TOO2 267E and turning the adjustment plug with a large screw driver 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 Ibfeft Once the desired charge pressure setting is achieved remove the gauges SAUER DANFOSS Series 90 Multi Function Valve Pressure Adjustment Adjustment of the pressure limiter setting and the high pressure relief valve setting is accomplished simulta neously 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 S000010E 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 pu
12. 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 WARNING The loss of hydrostatic drive line power in any mode of operation e g 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 S000 001E Disable Work Function WARNING Certain service procedures may require the ve hicle 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 S000 005E Copyright 1987 1998 SAUER SUNDSTRAND GmbH amp Co All rights reserved Contents subject to change 2 Fluid under High Pressure 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 treat ment is not administered immediately S000 003E Flammable Cleaning Solvents WARNIN
13. Displacement Control MDC ss ERNS ER SG Ee ese Eau ed ictu we d cdi td ko de n ge d GE ER 66 Solenoid Override Valve for RE 67 Solenoid Override Valve for MDC with Pressure Released Brake sess enne enne nnn nnne 67 Hydraulic and Electric Displacement Controls cccccccsseeseeeeeeceeeeeeeeeeeeeeeeeaeseesaeeeeeeesaaaaaaeeeeeseseaesaedeeeeeeeesessasaassseeeeeessesannaeess 68 Pressure Control Pilot PCP for Electric Displacement Control 68 POSTON FINA El elrie Control icp ese nwo ea Eege deen 69 Displacement Control Components EN 69 elei ee e TEE 71 Loop Flushing and Charge Relief Valves E 71 Variable Motor Displacement LIMIterS E 73 variable Moir CONTOS EEN 74 Electrohydraulic 2 Position Control Types NA NB NC andNlDk ee Ee ee RR EE Ee ee AR EE ee ee ee ee Re RR EE ee ee ee ee ee RR Re nnns nnns 74 Hydraulic 2 Position Control Type PT W 74 og ea Ee ENE EE EE N ET RE 74 Variable Motor euer 75 Soeke ie RE RE N OR T TE 77 Exploded View Parts Drawings Parts Lists sees kk ke RR RR KEER ERK RE ERK RR RARR RR KEER RR RR KEER RR RR Ra ERK RR EER RR RR EER RR RR Rae RR nhan nnn nnn 78 EI le E ab eN A AE EE OE NT ER 78 MOREDA an OO AA EE EE EO N EE EE ER OE IE 78 EURE e ORN EE EE EE EE M 79 Varisble Pine E Sie aluo ON TNT T DE 80 Gee de acca Al rM X
14. ExemalHek early 042 late 042 om IT 05 II 190mm 075 10 1 24mm 100 130 10 250 7mm 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 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 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 SAUER DANFOSS Series 90 Minor Repair Instructions 6 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 cou pling 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 lo cated 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 n 90000298 Install Drive Coupling Install Alignment Pin in Co
15. G SAUER Series 90 Axial Piston Pumps and Motors Service Manual SAUER DANFOSS Series 90 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 manual 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 if 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 Introduction Since dirt and contamination are the greatest enemies of any type of hydraulic equipment cleanliness require ments 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 Autho rized Service Centers is available should repairs be needed
16. Place PCP against EDC housing and install the screws Torque to 5 4 Nm 48 Ibfein Note Do not remove black plastic cover from the aluminum plate This is not a serviceable item and will void the product warranty SAUER DANFOSS 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 sole noid 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 90000362 3 Position Electric Control Components and foreign material S000022bE 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 op eration 5 n 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 Ibfeft NOTE A sealing washer mustbe installed under the head of any mounting screws that are installed into thru holes in the housing S000023E 6 Install new O rings and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter pl
17. Position Control 9000081 1 MF 90000812 90000813 17 SAUER DANFOSS Series 90 Hydraulic Parameters Rated Pressure 6000 T002 252E Charge Pump Inlet Vacuum bar abs on pumps only Minimum Vacuum 0 7 10 continuous Minimum Vacuum during Cold Start Intermittent T002 253E Wem e t Maximum during Cold Start 5 73 Intermittent T002 254E Hydraulic Fluid Refer to SAUER SUNDSTRAND BLN 9887 or SDF ld No 697581 Also refer to publication ATI E 9101 for information relating to biogradable fluids Refer to Series 90 technical information for definitions 18 Technical Specifications Temperature Range ee 0 O 40 40 toa iz20 O SSS 115 1240 intermittent D At the hottest point normally the case drain port i mes ius operating range Maximum 1600 pzsoop eertse cold start TOO2 O10E Cleanliness Level and B Ratio Required fluid cleanliness ISO 4406 Class 18 13 level Recommended fB ratio u for suction filtration D ci B052 Recommended ratio for charge pressure filtration Bisse 75 B 1 O Recommended inlet screen size for charge pressure filtration TOO2 OO7E 100 um 125 um Cleanliness Refer to SAUER SUNDSTRAND Publications BLN 9887 or SDF NO 697581 and ATI E 9201 SAUER DANFOSS Series 90 Technical Specifications Size Specific Data Variable Displacement Pumps muli 30 55 75 100 130 180 25
18. RE EE ee EE ee BED ves POG AA N EE EE EE 2 L40 M ME EER N EE EE BES semis t EE EE NE OE IE N 1 Es o erm BE EE Speed Sensor eie ee EE RR Ee ee EE 1 LOO EN tone Retainer o c EN Eie m sei ER EI EE e CAD PO 1 E29 eese Set SCI eW cccccsssececceseeeceeeeeeceseneeeeenees 1 MAN Control valve electric ES N Nut Seal Locke 1 MIP Suis ties Control valve hydraulic ELE x ec E TATE 2 P400 ode EL TORRES GBS PA Split flange clamp 4 P600 lie N G64 Shipping cover screw 4 P601 PCGOR ValVe enne P700 Special plug ccccccseseeeeeeseseeeeeeeeeeeens GIO er ae ET EE EE EE N 1 P800 RE ne RE H10N Loop flushing spool defeat 1 jp 0 S Filter screen iese ee ee EE ER ER ee Ee ee EE ee H50N le 2 T40 OO il SE H60N x prem 1 TOU EA BACKUP TING sr T60 snas rq m H10W Shuttle valve spool 1 T100 see Orifice plug WEE H20W Spring guide ccecceeeeeeceeeeeeeseaeeeesenees 2 H30W DING eke tues VPE 2 EE eegene 6 EE TE RE EE EE H4OW TIN E 2 iss EE BackUp Bn H50W ae 2 YOO c
19. Remove the sole noid valve with O rings from the adapter plate 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 Remove the check valve seat and O ring from the control side of the adapter plate Remove the check ball and spring Install a new O ring on the check valve seat and reassemble the check valve spring ball and seat into the adapter plate 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 Ibfein 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 Ibfein Minor Repair 90000363 Components of Solenoid Override for MDC 90000364 Components of Solenoid Override with Brake Pressure Defeat for MDC 67 SAUER DANFOSS Series 90 t 90000325 90000326 Remove Mounting Screws Remove Control 90000327 90000328 Inner Face of Control Assemble Control to Linkage 90000330 90000329 m Torque Mounting Screws Install Mounting Screws 90000332 90000334 PCP Components Torque PCP Valve Screws 68 Minor Repair Hydraulic and Electric Displacement Controls 1 Thoroughly clean external surfaces prior to removal of control 2 Usinga 5 mm internal hex wrench remove the eight control m
20. SAUER DANFOSS Series 90 Common Features of Pumps and Motors Speed Sensor 90000810 Functional Description 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 SAUER DANFOSS Series 90 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 transmis sion The charge pump is a fixed displacement gerotor t
21. are installed into thru holes in the housing S000023E 90000323 90000324 7 If the control is equipped with a neutral start switch Assemble Control to Torque Mounting Screws refer to the MDC Neutral Start Switch Adjustment Pump instructions WARNING The neutral start switch neutral must be read justed after reassembling the MDC module S000 024E 66 sy SAUER DANFOSS Series 90 Solenoid Override Valve for MDC 1 Thoroughly clean external surfaces prior to removal of valve Using a 5 mm internal hex wrench remove the two screws and remove solenoid manifold from housing Remove the old gasket 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 When installing the solenoid valve into the manifold the valve should be torqued to 24 2 4 Nm 17 7 x 1 8 Ipfeft When installing the solenoid onto the valve torque the nut to 6 Nm 53 12 Ibfein 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 Ibfeft Solenoid Override Valve for MDC with Pressure Released Brake 1 Thoroughly clean external surfaces prior to removal of valve Using a 4 mm internal hex wrench remove the four solenoid valve mounting screws
22. control To pump case Filter P000 798E Charge Pressure Filtration Schematic Partial flow 26 Fluid and Filter Maintenance To ensure optimum service life of Series 90 products regular maintenance of the fluid and filter 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 daily for proper fluid level the pres ence 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 It is recommended that the fluid and filter be changed perthe vehicle machine manufacturer s recommenda tions or at the following intervals First change 500 operating hours after start up second and subsequent changes 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 mat
23. 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 acti vated The valve 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 ensures that the prime mover can be started only when the control is in a neutral position Hydraulic Displacement Control HDC 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
24. 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 Remove the charge pump outer port plate if present early and intermediate production pumps Remove the charge pump gerotor assembly Gerotor Discharge Assembly Discharge 6 Remove the outer eccentric ring and alignment pin Inlet i i 7 Remove the inner port plate Alignment Pin 8 Inspect all parts for abnormal wear or damage Gerotor Assembly Left Hand Rotation Right Hand Rotation Outside looking into pump Outside looking into pump 90000871E Orienting Alignment Pin 58 SAUER DANFOSS Series 90 Note If a different displacement charge pump is be ing 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 re placed 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 Each charge pump assembly includes a different quan tity types of port plates and spacer plates The charge pump kit No Charge Pump includes a spacer Minor Repair Instructions Standard End Cap Screws Ali
25. replace if necessary Repair or replace the charge pump If OK go to last step SAUER DANFOSS Series 90 10 Pump displacement control 11 System pressure 12 System multi function valves Control linkages are not secure control orifices are blocked etc Low system pressure will not provide power necessary to move load Defective multi function valves will cause system pressure to be low Toubleshooting Repair or replace control module as necessary Measure system pressure Continue with next step 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 1 System pressure at motor 2 Variable motor stuck at minimum displacement 3 For internal leakage Description Low system pressure at the motor will reduce torque Minimum motor displacement yields low output torque Internal leakage will reduce system pressure Action Measure system pressure at motor If pressure limiter setting is low increase setting Check control supply pressure or re pair displacement control Check mo tor control orifices Check for leakage in O rings gaskets and other fittings Repair unit as re quired 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 1
26. system pressure in either direction continued Inspections and Adjustments Control Shaft Free Play NSS Deadband Switch closed ON Control Deadband Neutral Total Control Shaft Rotation Control Shaft 90000831E Neutral Start Switch Adjustment Requirements 41 SAUER DANFOSS Series 90 Inspections and Adjustments NSS Deadband Adjustment Conditions ii amp 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 2 3 4 Loosening the NSS Lock Nut Si D i T Swen an Neutral Start Switch Switch Pin 1 1 8 in hex wrench Torque 27 Nm 20 Ibfeft 90000832E NSS 8 9 90000870 Checking Continuity of NSS System Pressure Gauges installed on far side 42 de either direction Install two 1000 bar 10 000 psi pressure gauges in the system pressure gauge ports M1 and M2 Using two 1 1 8 inch wrenches hold the neutral start switch from turning and loosen the locknut Disconnect the external control linkage and make certain the control shaft is in its neutral position 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 conti nuity is broken then turn the switch counterclockw
27. 0 maximum SR 1 ETE M ER E 35 4 rs EJ 10 y rs E 98 EE 25 Minimum Speed min mme Rated Speed min rpm 4200 4200 3900 3600 3300 3100 2600 2300 Maximum Speed 4600 4600 4250 3950 3650 3400 2850 2500 m Maximum attainable Speed wo rpm 5000 5000 4700 4300 4000 3700 3150 2750 at max Displacement Theoretical Torque at Nm bar 0 48 0 67 0 88 1 19 1 59 2 07 2 87 3 97 max Displacement Ibfein 1000 psi 290 380 530 730 870 1260 1750 2433 Weight kg 28 34 40 49 68 88 136 154 only base unit Ib 62 75 88 108 150 195 300 340 T002 257E Fixed and Variable Displacement Motors C eem use oni anre sor ar Displacement maximum is 29 We Wal Vi e We p 1 83 SE 3 35 4 57 6 10 7 93 3 35 4 57 MEEN ENE p lle Te i 4200 4200 3900 3600 3300 3100 3900 3600 AE 4600 4600 4250 3950 3650 3400 4250 3950 ann min rpm 5100 4700 displacement van ene aeons min rpm 5000 5000 4700 4300 4000 3700 4700 4300 max displacement Theoretical torque at max Nm bar 0 48 0 67 0 88 1 19 1 59 2 07 0 88 1 19 displacement Ibfein 1000 psi 290 380 530 730 970 1260 530 730 Maximum flow ar max l min 138 193 234 296 442 234 296 displacement gal min 36 5 51 62 78 117 62 78 Niece COME COWON KW 111 155 187 237 292 354 224 282 P hp 149 208 251 318 392 475 300 378 Weight kg 11 15 22 26 34 39 44 SAE Flange Ib 24 34 49 57 74 86 98 Weight kg 21 26 33 40 46 Cartridge Motor Ib 46 5 72 88 101 T002 258E Refer to Series 90 technical information for definition
28. 00269 Tighten Lock Nut 37 SAUER DANFOSS Series 90 Pump Control Adjustments 38 90000 Variable Displacement Pump with Standard Manual Displacement Control 237 Inspections and Adjustments Standard Manual Displacement Control MDC Adjustment There are no adjustable elements in the manual dis placement 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 appro priate position when the control is installed on the pump SAUER DANFOSS 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 free play 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
29. 00837E MV Displacement Limiters 90000359 90000360 Tighten Lock Nut for Minimum Displacement Minimum Displacement Limiter Limiter 90000352 Maximum Displacement Limiter 49 SAUER DANFOSS Series 90 Speed Sensor Adjustment Speed Sensor Magnetic Speed Ring 90000838E Cross Section View of Speed Sensor in Variable Pump s Gap Magnetic Speed Ring Speed Sensor 90000839E Cross Section View of Speed Sensor in fixed Motor Speed Sensor Magnetic Speed Ring 90000840E Cross Section View of Speed Sensor in Variable Motor Shaft Centerline 1 2 in Wrench Flats Speed Sensor with Packard Connector Speed Sensor with Turck Connector Shaft Centerline 1 2 in Wrench Flats Speed Sensor with Packard Connector Speed Sensor with Turck Connector 90000841E Positioning Speed Sensor relative to Pump or Motor Shaft 50 Inspections and Adjustments 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 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 clock
30. 1 MOOH SOEN RS ee ie DE Re Se N 6 M92M SCIeW EE lil 4 M95M 8 io rc 1 MOMA Control MDC M96M OUI EE 1 w o neutral start switch 1 M97M ENG ERR ET 1 M7M Control handle sno kes GR 1 M98M SCIEW ee ee ee ee ee 4 M71M Washer E 1 M72M RU MP 1 TOO1 9 Control orifice ki EE 1 M80 Control gasket VENDER EE 1 T201 9 Orificed check vahve aaa 1 M87M Washer seal 042 sess 1 T301 9 Spring 1 M90M SCIQGW oo ccccececccecececececcceccacccacecscececececeaeaeas 6 T401 9 Spring retalner EG 1 MOMB Control MDC w neutral start switch 1 M7M Control handle eene 1 81 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Filter and Options LWJ NS idc N40L e A y p i 90000862E 90000863E 82 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Parts List Filter and Options Item Description Qty Item Description Qty HO5B H Kit Charge pump iese esse ee ee ee EE ee 1 J80A V Eege H5OL Spacer No charge pump 1 J80N nil P PIS eegent FOWL elim 2 J90A V 8de RR H40 mer
31. 1 J92A V Cover plate ee Ee Ee H50 Charge pump shaft 1 J95A V SG OW M 2 4 H60 ll ER P 1 FAZO cum Retaining plate ssseeusssss 1 NOOM Filtration manifold kit Int H8O elders 6 N10M Manifold cccccsseeeeceeseeeeeeeeeeeeseeeeeeens PISOL isses ss M N 1 N15M S MOT N20M pl A HO JOOA Aux mtg SAE A flange 1 N25M im JOOB Aux mtg SAE B flange 1 N35M alie ER JOOC Aux mtg SAE C flange 1 NAOL gae AE EA EE JOOD Aux mtg SAE D flange 1 NAOP mac JOOT Aux mtg SAE A flange 11 T 1 JOOV Aux mtg SAE B B flange 1 NOOR Filtration manifold kit Imt JOON Aux mtg flange none 1 N10R Manifold WP J10A V COUDIING ME 1 NTR iussis Sip ME du EL ENE Charge pump cover assembly 1 N2OR x ge EO EE J15N Charge pu
32. 3 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 Ibfeft on 030 through 100 motors or 68 Nm 50 Ibfeft on 130 motors Motor Charge Relief Valve 1 Remove the shim adjustable charge relief valve plug with a 7 8 inch hex wrench SEES M Install Flushing Shuttle Torque Plugs Before removing the screw adjustable relief valve Spool plug mark the plug lock nut and housing so as to be able to maintain the original adjustment when assem bling 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 Inspectthe poppet and mating seat in the end cap for damage or foreign material When inspecting shim 90000342 90000343 adjustable valves do not alter the shims or inter Remove Shim Charge Relief Remove Screw Charge Relief change parts with another valve Valve Valve 71 SAUER DANFOSS Series 90 EAR A H Sch Y 0000344 90000345 9 Shim Adjustable Charge Screw Adjustable Charge Relief Valve Relief Valve Lock Nut Plug 2 I D N Plug N O ring SE Shims Spring S B jg P i Ge Poppet oppet IW gy
33. 5 1 2 and 6 1 2 turns to install into the control housing 90000256 Adjustthe Eccentric Plug Caution Do not turn the eccentric plug into or out of the housing beyond specifications S000014E 7 Oncethe switch is correctly adjusted hold the switch in place and tighten the locknut to 27 Nm 20 Ibfeft torque continued 44 SAUER DANFOSS Series 90 Inspections and Adjustments Checking Switch Continuity Recheck switch continuity to determine whether addi tional 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 S000007E 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 p
34. 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 Q 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 SAUER DANFOSS Series 90 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 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 S000007E Priorto 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 reservoi
35. C Current production HDC 90000356 47 SAUER DANFOSS Series 90 Motor Adjustments Charge Pressure Gauge Port MF 90M055 NC 0 8 N O C6 W OO NNN OO OO 24 Lo ee ME o T002 279E Model Code at the Name Plate 24 bar N Nominalcharge Pressure Setting 90000343 90000263 Shim Adjustable Charge Screw Adjustable Charge Pressure Relief Valve Pressure Relief Valve Motor Motor 48 1 Inspections and Adjustments Charge Relief Valve Adjustment 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 The following table shows acceptable motor charge pressures for some nominal charge relief valve set tings 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 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 p
36. Control Cylinder Gauge Ports 46 Inspections and Adjustments Hydraulic Displacement Control HDC and Electric Displacement Control EDC Adjust ment 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 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 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 hy draulic 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 SAUER DANFOSS Series 90 Inspections and Adjustments 3 Using a 5mm internal hex wrench for the neutral adjusting shaft or a 3mm o
37. DANFOSS Series 90 Parts List Exploded View Parts Drawings Parts Lists Item Description Qty Item Description Qty B EK sie EE N EE ED 2 2592 eise le E M 1 zy te ai e 1 2590 iiis erg 1 BED vase POG AA N EE OE 1 25938 ass DS OR EE OE EE 1 B82 xl 1 Q544 sd 1 eeben Filter screen WEE 3 Q542 uo PER RE EE AR EE 1 G546 Bid M PET cpm 1 30 eee N Split flange clamp 4 G548 ORE ebe 1 G64 xl N EO EE EE EE N 4 21272 erisin ER En 1 ITO EE Plug assembly ek 1 3170 see Si e p 1 SO sees Sog o 1 G501 gx pw H Q 3 3 40 MENS Sade AE RE THEMES 1 G502 ale 3 K80 Poppet EE EE N 1 G506 ino PETRO EE 3 KOO xp vm EE 1 G508 ej M 3 G511 ul ER N Ne 1 E ORE Seal carrier RE ER IE RE 1 Q512 ul AE 1 Bo TN Seal carrier ee RE RR EE 1 GST G crises OSTIBI E EE EE EN 1 L40 EE ie U c PH 1 518 El e EE ON 1 BR OG EE EE EE H 1 Q521 ae EE E 1 LOO IEEE Retainer RERO 1 G522 xo OE 1 Tr orm vier e gie 3 2520 EEN is PHP EU P 1 528 Sr P EE 1 E c MI EM E
38. E ee es mee eee m 1 G531 x tcm 1 Rc Slotted nut P ee ie SS eg Ee Ge 1 79 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Variable Pump Controls a 7 N MODC M90D MIDGC MODD 1 M1DD E 80 MOMA MOME MOMB MOMF MOMC MOMG MOMD MOM9 2 MOCA M90C M1CA M87C NS lt S Early Production 130 cc Frame Size 2 KI OR aN E M1HF M1HG M1HH M1HJ M1HK MIHL amp M1HM M1HN MOHA MOHC MOHF MOHG MOHH MOHJ MOHK MOHL MOHM MOHN 90000861E SAUER DANFOSS Series 90 Control Parts List Exploded View Parts Drawings Parts Lists Item Description Qty Item Description Qty MOCA Cover Plate E 1 M71M Washer eene 1 MICA COVED plate X Ae 1 M72M OI 1 M11C Sei No c s cccstenaatanctinchenestiensiensonearaes 1 M80 Control gasket useisiin 1 M11D Control gasket cccccceecseeeeeeeeeeeeeeeeees 1 M87M Washer seal 042 ne 1 MOTO iuis Washer seal 042 E 1 M90M SCIEW ee ee ee ee ee 6 M90C SEE deeg EE 6 SAO Neutral start switch kit 1 MODC Control kit 3 position FNR 12V 1 MOMC Control MDC w sol valve ee 1 MODD Control kit 3 position FNR 24V 1 M7M Control handle
39. G 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 S90MVCTCD S90PVMFCD SAUER DANFOSS Series 90 Contents Contents dg OCC ite EE 2 Uce orms e EE 2 Ny PIOC e E 2 Funcuonal DESCriIPOT E 5 General Description and Cross Sectional Views 5 vanable Displacement PUMPS EER NE N a EE 5 Fred Displacement Oe EE 5 vanable Bie cler qz ni ee EE 6 EA cU M t m PET 7 The Basie Closed Eie me t T 7 Case Dran and Heat EXC Le EE 7 Common Features f Pumps and MOEOFS ass sees esse aua eh auda rada GR ts ANN Ge Ra ld d rd n d C Rd Md d iR 8 Eiid as NS T m m mmm 8 SO OO RE N t w I 8 Seiler 9 EE lee CA un EE 9 Charge sis ii EE 9 EE COW E 9 Pressure Limiter and High Pressure Relief Valves AANEREN 10 VISUM Me mU ERN NCC 10 ByDSSS Eege 10 Reien leet 11 Auxiliary MOUNINO WE e EE 11 FORO o m ie GE dee RE n EE EG ae OE OM we ee ER od ee AE EG N 11 Pressure Override POR 180 Frame Size Only es ee ee EE Ee RE EE Ee ee ee ee nennen ee ee ee ER EE ee ee ee ee ee ee ER ee ee ee ee ee ee EER EE ee ee ee ee 12 Pil CODON DUO so RE ES pe ENE RD G Ne ee SE EG 13 Manual Displacement Control MDC ass dis Es cas AE iN ee NG wi al ag aaa i ra REG rai iss dial 13 Hydraulic Displacement Control HDC sai
40. M Solenoid valve ee 1 MO E ss Washer seal 042 ee 1 M77M Manifold gasket eene 1 MOOE SCIEW c cccccccccccccececececececcacccacecececececeaeacs 6 M78M Crew 2 MOVE ies Plastic cap ME 1 M80 Control gasket ee ee ee ee ee 1 M95E O ring ORE EE 2 M87M Washer seal 042 EN OER KS 1 M96E BEE 1 M90M SCIEW ee ee ee ee ee ee 6 Mot O ring TE OE EE EE EE en rer Te 1 SAO Neutral start switch e 1 M98E e 4 M1MA Servovalve kit enn 1 M810 Adapter plate Control 130 CC MUS 1 M820 CO nmmgO O 20ec RR EE 1 MOHA Control kit hydraulic HDC 1 M830 O ring 130 CC ee ee 1 MOHC Control kit hydraulic HDC 1 M840 O ring 130 ee ee ee 2 MIHA ais Control hydraulic HDC 1 M850 Plug 130 c6 EE 1 M1HC Control hydraulic HDC 1 M860 Screw 130 ec 6 M11H Control gasket ccccceecseeeeeeeeeeeeeeeeees 1 M870 Plug 130 cc ee ee ee ee 1 M80 Control gasket ee ee RE ee 1 M87H uices Washer seal 042 sess 1 M9ME 4 2 Way valve ee ee ee ee ee ee
41. Oil level in reservoir 2 Pump output flow 3 Variable motor displacement con trol 4 For internal leakage Description Insufficient hydraulic fluid will reduce motor speed Incorrect outflow will affect output speed Incorrect output flow indicates the swashplate is out of position If variable motor displacement control is not functioning correctly variable motor swashplate may be in wrong position Internal leakage will reduce system pressure Action Fill oil to proper level Measure pump output and check for proper pump speed and see that the pump is in full stroke See if variable motor displacement con trol is responding If not repair or re place control Check for leakage in O rings gaskets and other fittings Repair unit as re quired or replace leaky unit If the above actions do not remedy the problem contact a SAUER SUNDSTRAND Authorized Service Center 29 SAUER DANFOSS Series 90 Excessive Noise and or Vibration Check 1 Oil in reservoir Description Insufficient hydraulic fluid will lead to cavitation 2 Air in system Air bubbles will lead to cavitation 3 Pump inlet vacuum High inlet vacuum will create noise A dirty filter will increase the inlet vacuum 4 Shaft couplings A loose shaft coupling will cause exces sive noise 5 Shaft alignment Unaligned shafts will create excessive frictional noise Toubleshooting Action Fill reserv
42. Repair Instructions 7 16 20 O ring 20 Nm 9 16 inch Hex Wrench 15 Ibfeft 7 16 20 O ring 12 Nm 3 16 inch Internal Hex Wrench 9 Ibfeft 9 16 18 O ring 3 Nm 11 16 inch Hex Wrench 27 lbfeft 9 16 18 O ring 23 Nm 1 4 inch Internal Hex Wrench 17 Ibfeft 3 4 16 O ring 68 Nm 7 8 inch Hex Wrench 50 Ibfeft 3 4 16 O ring 68 Nm 5 16 inch Internal Hex Wrench 50 Ibfeft 7 8 14 O ring 95 Nm 1 inch Hex Wrench 70 Ibfeft 7 8 14 O ring 68 Nm 3 8 inch Internal Hex Wrench 50 Ibfeft 1 1 16 12 O ring 163 Nm 1 1 4 inch Hex Wrench 120 Ibfeft 1 1 16 12 O ring 115 Nm 9 16 inch Internal Hex Wrench 85 Ibfeft 1 5 16 12 O ring 190 Nm 1 1 2 inch Hex Wrench 140 Ibfeft 1 5 16 12 O ring 129 Nm 5 8 inch Internal Hex Wrench 95 Ibfeft 1 5 8 12 O ring 224 Nm 1 7 8 inch Hex Wrench 165 Ibfeft T002 281E 53 SAUER G DANFOSS Series 90 Shaft Seal and Shaft Replacement Remove Screws Holding 54 90000270 Retainer Plate and Seal Carrier 90000272 Press Out Old Seal New Seal Installed in Carrier Screw Retaining Plate Seal Carrier N A Seal yo Series 90 Shaft Seal Components 90000271 Remove Seal Carrier 90000273 Screw Seal Carrier One Piece 90000846E Minor Repair Instructions 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 replace ment usually requires removal of the p
43. S Series 90 10 11 12 13 14 15 Inspect the sealing area on the shaft for rust wear or contamination If the shaft is not being replaced proceed to step 12 Hemove shaft and roller bearing assembly from pump or motor The bearing assembly can be trans ferred to the new shaft Remove the retaining ring that secures roller bearing assembly with a snap ring pliers Remove the roller bearing assembly Place roller bearing assembly on new shaft and secure with the retaining ring Wrap spline or key end of shaft with plastic film to prevent damage to the sealing lip on the seal during installation Prior to assembly lubricate the O ring on the O D of the seal carrier and the D of the seal with clean petroleum jelly Assemble the seal carrier and seal over the shaft and into the housing bore Install the retainer plate if used Install the screws and torque like the tables Pumps Frame Size Torque Pumps 030 042 12 Nm 9 Ibfeft 055 100 16 Nm 12 Ibfeft 130 250 32 Nm 24 Ibfeft T002 282E Motors FrameSize TorgueMotors 030 100 9 5 Nm 7 lbfeft 22 5 Nm 16 6 Ibfeft T002 283E Note Torque the screws in a sequenced pattern then recheck Minor Repair Instructions Roller Bearing Assembly Retaining Ring Tapered Shaft Splined Roller Bearing Shaft 90000866E Fixed Motor Shaft Configuration Roller Bearing SC l _ Retain
44. a SAUER SUNDSTRAND Authorized Service Center System Operating Hot 1 Check Oil level in reservoir Heat exchanger Charge pressure Charge pump inlet vacuum System relief pressure settings For internal leakage in motor System pressure Description Insufficient hydraulic fluid 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 filter will increase the inlet vacuum Inadequate line size will re strict flow If 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 Action Fill 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 filter 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 multi function valves as nec essary Monitor motor case flow without loop flushing in the circuit use defeat spool If flow is excessive replace motor Measure system pr
45. aaa quus Si ae N Se aad uad ARE cU RC d GR N RS oe Ge Ge ay 13 Electric Displacement Control EDE ss ei ER GR ARE od ea ee de UM Vat un ia ee Ge Gui oe ee NE 14 Automotive Control FBA MB ss asses SR Has a ei Ge AS RD ea Me ae ei 14 o Position FNR Electric C ODLIFO sissies die SE as N RE RS dd We Pr oe es Ge cu ae RU FR ok aid ne NA WE N 14 MOr SNS EO OO EE ERLA E EER EE EE OE EO NO 15 Motor Loop Flushing Valve and Charge Relief Valve EEN 15 Variable Motor Displacement LIMITErS sis Es RR ie Fuse apad n ER asd ED OE Ga Te RE Ee De EE ed Ee ee oe Ee S 15 Variable Meier Eon Ole si EE DE E mos 16 ek del t e RE e nde WEE 16 See Ee ie Cor e EE 16 Technical SOG CINCO mec M 17 EE e ee Tu E 17 eres de Le el E 17 AYO le En EA EE EE ese ciel sc E N OG OE N EE OE cacao 18 dodesel OE OE EE N EE EE Ee 19 Pressure pill E 20 Perur ad ae E 20 Port Locations and Pressure Gauge Installation AER 20 lg ele uU apio E 20 gioi P OG 23 Elle EN eo Me 24 Initial Start Up Procedure fm 25 F luid and Fiter MaAINICNANCE e 26 Troubleshoot O ER EE EE 0 O 27 NEUTRAL Diricult or impossible io Find iss Ee n
46. ackup Washer Orifice Seat Spot welded Cross Section View of Cross Section View of Orifice Assembly Orifice Check Valve Assembly 90000855E MV Minimum Displacement Orifice 19 SAUER DANFOSS Series 90 Minor Repair Maximum Displacement Cylinder Orifice Check Valve A Housing Plug od Seal Lock Nut EN 7 seal toward housing O ring Orifice Check Valve Assembly Seal Lock Nut seal toward housing O ring Orifice Body Check Ball Spring Pin Cross Section View of Orifice Check Valve Assembly 90000856E MV Maximum Displacement Orifice 76 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 Reinstall the check valve and torque to 15 Nm 11 Ibfeft Install a new O ring Install the seal lock nut with the seal toward the motor housing Hold the check valve from turning while torquing the seal lock nut to 34 Nm 25 Ibfeft 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 Ibfeft SAUER DANFOSS Series 90 Minor Repair Speed Sensor Remove the speed sensor by disconnecting the electrical connector loosening the lock nut and unscrewing the speed sensor from the pump or mot
47. ate Install the screws and torque to 5 4 Nm 48 Ibfein Displacement Control Components Displacement Control Orifices D C E Ch 1 Hemove the control assembly as described in the e 77 9 B instructions for the specific displacement control Laf J w P eg 9 TE 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 Ibfein Assemble the control onto the pump Refer to the instructions for the specific control 8 C BS 9 9 LIU Orifice Plugs E BI NT N Orifice Check Valve 90000849E Underside of an HDC EDC Module Showing Orifice Locations 69 SAUER DANFOSS Series 90 Minor Repair Displacement Control Orifice Check Valve 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 8 B e Orifice Plugs NY j 9 g 4 Assemble the control onto the pump Refer to the B instructions for the
48. ates the charge pres IN ee EAN sure level only when there is a pressure differential in the A main loop The shuttle valve is spring centered to the A iS closed position so that no high pressure fluid is lost from ur the circuit when reversing pressures 4 LLLI 7 S PE ET PA Er E l For charge relief valve adjustment see corresponding Section aw av AV 4p EN Zo End Cap Loop Flushing Shuttle Valve 90000238E Motor Charge Relief Valve and Loop Flushing Shuttle Valve Variable Motor Displacement Limiters All Series 90 variable motors include mechanical dis placement stroke limiters Both the maximum and mini mum displacement of the motor can be limited The range of the settings is as follows Minimum 19 40 cm 26 54 cm Displacement 1 2 2 4 in 1 6 3 3 in Maximum o MV Maximum Displacement Limiter Displacement pa GE Minimum Displacement Limiters on opposite side T002 251E 15 SAUER DANFOSS Series 90 Variable Motor Controls K 9000035 d 0 MV with Hydraulic 2 Position Control 90000351 MV with Electric 2 Position Control 16 Functional Description 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 hydr
49. ates 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 dual 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 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 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 valve is opened by manually resetting the valve position The bypass valves are built into the multi function valves SAUER DANFOSS Series 90 Displacement Limiters All Series 90 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 Mount
50. aulic pressure to the valve will cause the motor to go to its minimum displacement Electric 2 Position Control This control utilizes 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 will cause the motor to go to its minimum displacement SAUER DANFOSS Series 90 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 J744 SAE flange Size B 2 bolts SAE flange Size C and E 4 bolts Cartridge flange 2 bolts for motor only Circuit Diagrams ai EE I Me air PV with Charge Pump and Manual Displacement Control Technical Specifications 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 fluid MV with Electrohydraulic 2
51. bar or 500 psi System Pressure Port B 7 8 14 O ring Charge Pressure 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 System Pressure Port A Case Drain Port L2 BEES Rear View Left Side View MF with SAE Flange System Pressure Gauge Port M1 System Pressure Gauge Port M2 Charge Pressure Case Drain Port L1 Gauge Port M3 Speed Sensor System P Port B E EER Case Drain Port L2 System Pressure Port A Rear View Left Side View 90000821E MF with Cartridge Flange 23 SAUER DANFOSS Series 90 Pressure Measurement Variable Motor Gauge Size Gauge Size and and Fitting Fitting Systempressure 1000 bar or 10 000 psi Control Cylinbder Port A 9 16 18 O ring Pressure Minimum WE EE ES n 7 16 20 O ring NM Systempressure 1000 bar or 10 000 psi Displacement ss ong l Ad 1000 bar or 10 000 psi ar or si S ri ES Charge Pressure 9 16 18 on Displacement 7 16 20 O ring T002 263E L1 10 bar or 500 psi T002 264E Displacement Control Cylinder Pressure Gauge Port M4 Min Displacement System Pressure Gauge Port M2 Control Pressure Port X1 Hydraulic 2 Position Control Displacement Control Cylinder Pressure Gauge Port M5 Max Displacement Earlier Production Not available as gauge port with servo orifices System Pressure Port
52. 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 Note Multi function valve components are not sold separately as service parts except O rings 3 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 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 4 Remove pressure limiter lock nut and bypass actuator 5 Unscrew the pressure limiter adjustment screw from the bypass actuator Clean and inspect all disas sembled 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 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 FrameSie Torque 030 100 89 Nm 66 lbfeft 130 250 210 Nm 155 Ibfeft T002 285E Do not overtorque the multi function valve cartridge SAUER DANFOSS Series 90
53. control Rotate the adjusting screw with a 6 mm internal hex wrench Rotating the maximum displacement adjust ing 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 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 andto prevent external leakage during unit operation S000016E 3 After establishing the desired displacement setting tighten the lock nut on the adjusting screw to 54 Nm 40 Ibfeft 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 Approx Change in Disp per Rev of Adjusting Screw 055 5 6 cm Rev 0 34 in Rev 075 7 1 cm Rev 0 43 ir Rev T002 280E Displacement Control Adjustments All variable motor displacement control settings do not require adjusting Rotate Adjusting Screw for Inspections and Adjustments Tamper Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw Minimum Displacement Limiter Screw Seal Lock Nut Tamper Resistant Cap SAE Flange Version shown Cartridge Version similar 900
54. e ee ee ee ee EER EE ee ee nnn dee 39 MDC Neutral Start Switch NSS Adjustments ees ee RR EE Ee ee AR RR EE ee ee ee ee RR EE ee ee ee ee RR EE ee ee ee ee AA RR EE ee ee ee ee ne rennen ee ee ee nnn nnn 40 Hydraulic Displacement Control HDC and Electric Displacement Control EDC Adjustment esse ese ee ee ee RE Ee ee ee ee 46 Motor AUS E 48 Charge Relief Valve c NNS De EK Bee EE EE EER de ER RE ks ee oek ee eo ei ER Ge en Oe OE Re Ge N De GES Ee SR Dee ee 48 Displacement Limiter Adjustment MV 49 Displacement Control Adjustments us send Ad ee oe vu ie GE d e d ee wa ued ed ee Ge Du EU d uu Ge adil 49 Speed sensor el EEU IR Nee 50 Minor REDall TE lede RR EE AE E N Ea Eai 51 Pump and Motor Minor AS BE ss ses SE has EE ED SA ce sete nis caste ER ee GE ES EE N GE GE sas EE eN GE ER EE 53 Pie td LR leie cA RE RE m 53 Shaft Seal and Shaft Replacement ss SEA Pa atu raa tds onu du og OR SG c ie tp N GE a do Re ande td US dd 54 arie ke se EE EE N EE EN EE N EN EE EE ER EI EE EN N N 56 AU GE Sa Lidl die EE Si ig ele SE OO EK EE EE EE EE N EE N OR EE N EE ENE EN 56 Pressure Override Valve Option for 180 Frame Size EE ee EE EE ee ee ee EE ee ee ee ee EE Ee ee nens ee ee nnn nn ee ee ee ee ee ren EE rennen nns 57 Be sd SUC Wal Caso EE N EE EE EE EE EL EE EE RE EE EE EE 57 Charge Pump Ee 58 Hsiang ie Charge PUMP E 60 ADA Pad STAO E 62 Away Pad CONVEN EE 63 SIE ei OPON EE 64 Sie CU S RE OE nae ea E T Em 65 Be Aa ME OE I EE T TT 65 Manual
55. e pressure and adjust if necessary Minor Repair Instructions 7 Screws Pressure Override Valve O rings 90000870E Pressure Override Valve Components 90000280 90000262 Remove Charge Relief Valve Shim Adjustable Charge Shim adjustable Relief Valve EM 90000264 2 90000265 Remove Charge Relief Valve Screw Adjustable Charge Screw adjustable Relief Valve 57 SAUER DANFOSS 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 90000281 90000303 Remove Auxiliary Pad Remove Auxiliary Pad Adapter Screws Adapter 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 SOOOO19E 2 Remove the six screws holding the charge pump cover retainer ner Sc Re 99900284 090 100 Remove Retainer Screws Remove Charge Pump Cover 190 250 3 Remove the retainer and the charge pump cover For pumps with an auxiliary mounting
56. ed Service Center 30 Cs SAUER DANFOSS 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 We J The following procedure explains how to check and adjust the charge pressure relief valve WARNING The following procedure may require the vehicle machineto be disabled wheels raised offthe 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 S000007E e 90000243 Charge Pressure Gauge Port Reducer fitting shown if filtration device attached 1 To measure pump charge pressure install a pres sure 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 displace er omina ment when measuring pump charge pressure 90L055 EA 1 N BEE sie 6 S 3 C6 C 03 2 The table shows the acceptable pump charge pres sure range for some nominal charge relief valve HNN 35 35 24 settings see sample m
57. ee O ring L lt j Plug with O ring defeat Ne Spool defeat N 7 Plug with O ring aor Note orientation of washers Shoulder OUT toward spring Spool Shoulder Washer Spring 90000850E Motor charge Relief Valve and Loop Flushing Valve Parts 72 Minor Repair 4 Install the poppet and spring For shim adjustable valves install the plug and torque to 68 Nm 50 Ibfeft 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 Ibfeft 5 Check and adjust the charge pressure Defeating the Loop Flushing Valve 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 Ibfeft 4 Remove charge relief valve components these parts are not necessary 5 Replace with the hex plug provided and torque to 41 Nm 30 Ibfeft sy SAUER DANFOSS Series 90 Variable Motor Displacement Limiters 1 Remove the tamper resistant cap from the displace ment 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 Install the limiter screw with the noted length between adjustment screw and the seal lock nut Do not i
58. elation 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 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 oilloss 000 032E Inspections and Adjustments 12 7 9 14 0 5 0 36 52 E 3 175 1 0 125 0 06 SS 1 0 90000834E Eccentric Plug Adjustment Tool Switch Lock Nut x Neutral Start Switch d MDC with Neutral Start Switch Eccentric Plug Switch Pin Special Lock Nut for Eccentric Plug Special Lock Nut for Eccentric Plug Control Eccentric Plug 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 adjust ment tool Hold the eccentric plug in place with the adjustment tool and loosen the lock nut wi
59. ement control 4 Ensure bypass valve s are closed 5 Charge pressure with pump in neu tral 6 Charge pressure with pump in stroke 7 Pump charge relief valve 8 Charge pump inlet filter 9 Charge pump 28 Description Insufficient hydraulic fluid to supply system loop Input to control module is operating improperly Control linkages are not secure control orifices are blocked etc If bypass valve s is open the system loop will be depressurized Low charge pressure insufficient to re charge system loop Low charge pressure with the pump in stroke indicates a motor charge relief valve or system pressure relief valve may be improperly set A pump charge relief valve that is leaky or set too low will depressurize the system A clogged filter will undersupply system loop A malfunctioning charge pump will pro vide insufficient charge flow Action Fill reservoir to proper level Check control input and repair or re place as necessary Repair or replace control module as necessary Close bypass valves Replace multi function valve if defective Measure charge pressure with the pump in neutral If pressure is low go to step 6 otherwise continue with step 5 Measure charge pressure with pump in stroke If pressure is low adjust or replace motor charge relief valve oth erwise go to step 9 Adjust or replace pump charge relief valve as necessary Inspect filter and
60. essure If pressure is high reduce loads If the above actions do not remedy the problem contact a SAUER SUNDSTRAND Authorized Service Center 27 SAUER DANFOSS Series 90 Transmission Operates Normally in One Direction Only Check 1 Input to pump control 2 Pump displacement control 3 Interchange system pressure limit ers high pressure relief valves and system check valves 4 Charge pressure Description Input to control module is operating improperly Control linkages are not secure control orifices are blocked etc Interchanging the multi function valves will show if the problem is related to the valve functions contained in the multi function valves If charge pressure decays in one direc tion the loop flushing valve may be sticking in one direction Toubleshooting Action Check control input and repair or re place as necessary Repair or replace control module as necessary Interchange multi function valves If the problem changes direction repair or replace the valve on the side that does not operate 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 1 Oil level in reservoir 2 Input to pump control 3 Pump displac
61. gnment Pin Charge Pump Assembly Thin Port Plate Ke y N Thick Port Plate SU Ne Eccentric Ring Gerotor Assembly N Retainer Screw 90000872E Charge Pump Components Early Production Standard End Cap Screw Alignment Pin Thin Port Plate N am Eccentric Ring N Gerotor Assembly RO Port Plate Spacer Plate s e Cover Retainer Retainer Screw 90000873E Charge Pump Components Intermediate Production Standard End Cap Screw Alignment Pin Charge Pump Assembly Port Plate N Eccentric Ring Cover Gerotor Assembly oN Cover Retainer Retainer Screw 90000874E Charge Pump Components Late Production Standard End Cap Screw Spacer Cover Retainer ed Retainer Screw 90000875E No Charge Pump Components 59 SAUER DANFOSS Series 90 Minor Repair Instructions Installing the Charge Pump Discharge Gerotor Discharge Assembly TA Alignment Pin WA sR 7 RAN KI Be sure to install the charge pump in the proper orienta tion If unsure of charge pump rotation refer to the model code a d Note The charge pump rotation is determined by the orientation of the gerotor assembly outer ec centric ring and the location of the alignment pin Left Hand Rotation Right Hand Rotation in the end cap Outside looking into pump Outside looking into pump Alignment P Gerotor Assembly Do not mix charge pump piece parts from differ 90000871E
62. gs Reconnect the external control linkage 39 SAUER DANFOSS Series 90 Switch Lock Nut Neutral Start Switch Switch Pin Special Lock Nut for Eccentric Plug MDC with Neutral Start switch ISS Er NET TREIN CA N N RSS Z 7 ON Orifice Check Valve Seat Control Spool Assembly View at Section A A LE Control Link Assembly 90000830E Components of the Standard Manual Displacement Control with Neutral Start Switch 40 Inspections and Adjustments MDC Neutral Start Switch NSS Adjustments 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 in stroke 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 The neutral start switch is threaded into the special lock nut for the eccentric plug Turning the NSS clockwise CW into the special nut will
63. he 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 lbfeft 6 Shut down the prime mover and remove the gauges and install the gauge port plugs SAUER DANFOSS Series 90 Displacement Limiter Adjustment The maximum displacement can be limited in either direction 1 Loosen the seal lock nut retaining the displacement limiter adjusting screw 030 100 180 250 T002 275E 2 Rotate the adjusting screw Frame Size Internal Hex Wrench Size T002 276E Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump while rotat ing the adjusting screw counterclockwise will in crease 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 S000012E 3 After establishing the desired maximum displace ment setting tighten the lock nut on the adjusting screw as follows Frame Size Torge T002 278E 4 One turn of the adjusting screw will change the maximum displacement approximately as follows ree a ail Adjusting Screw Inspections and Adjustments 90000268 Rotate Adjusting Screw 900
64. he internally splined end of the shaft must engage the main pump shaft Note 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 non chamfered shaft Always use a chamfered charge pump shaft in pumps with the early end cap 9 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 orienta tion 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 S000020E 12 Install the charge pump cover retainer and the six hex screws and torque the screws FrameSize Torque 030 100 13 5 Nm 10 lbfeft 130 250 32 Nm 24 Ibfeft T002 288E 13 For pumps with auxiliary mounting pads instal
65. he middle hex Frame Size Torque newer 0502208 41 Nm 30 Ibfeft 130 250 100 Nm 75 Ibfeft T002 274E Inspections and Adjustments 90000266 Loosening and Rotating Bypass Hex on Multi Function Valve Opening Bypass Valve allows flow to circuit Bypass through Multi Function Valves Actuator APASA Y N eN J N EXC 90000827E Multi Function Valve with Bypass Function Engaged 35 SAUER DANFOSS Series 90 Pressure Override Valve Adjusting Screw Lock Nut Right Side View 90000828E Pressure Override Valve for 180 Frame Size 36 Inspections and Adjustments Pressure Override POR Valve Pressure Adjustment Option for 180 Frame Size The Pressure Override Valve is explained in the corre sponding section 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 dis placement load the work function and note the pressure as the POR valve operates pump displace ment 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 t
66. ing 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 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 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 um screen located in the reservoir or the charge inlet line is recommended when using this filtration option Functional Description La WB PV with Displacement Limiters 90000244 90000242 90000243 PV with Suction Filtration No filtration device attached r 90000246 90000247 PV with Integral Charge PV with Remote Charge Pump Pump 11 SAUER DANFOSS Series 90 To Control Multi Function Valve Pressure Override Control Va
67. ing Ring Rollen Bearing Tapered Shaft Straigt Key Shaft 90000867E Variable Pump Shaft Configuration Roller Bearing Assembly Q _ Retaining Ring Splined Shaft N Shaft 90000868E Variable Motor Shaft Configuration 90000274 90000275 Install Seal Carrier Torque Retainer Screw 55 SAUER DANFOSS Series 90 Pump Minor Repairs 90000276 90000277 Remove Multi Function Install and Torque Cartridge Valve Cartridge 90000278 Multi Function Valve Cartridge Components Earlier production 90000279 Multi Function Valve Cartridge Components Later production High Pressure Relief Check Valve Poppet Pressure Limiter Pressure Limiter Valve Spring Lock Nut Pressure Limiter Housing Spring Seat Check Valve Poppet E A LSS San ET Pressure Limiter Pressure Limiter Valve Poppet Adjustment Screw Bypass Actuator Pressure Limiter Valve Poppet 90000869E Multi Function Valve Cartridge Sectional View 56 Minor Repair Instructions Multi Function Valve Cartridges 1 The multi function valve cartridge is removed with a hex wrench on the largest hex on the cartridge 030 100 1 1 4 inch 130 250 1 5 8 inch 2 Inspect cartridge for damage to parts and O rings The multi function valve cartridge may be disas sembled for cleaning However if the pressure limiter housing assembly is disassembled the pressure settings must
68. iox Ges Ak oe RD n S aD Re ae wash ae vdd ama rpm o dta p acc ei oe Rap dd ond 27 Sy Ste ial OOS FU ele NEN mmm 27 Transmission Operates Normally in One Direction Only ees ee EE EE EE ee AE EE Ee ee ee Re RR EE Ee ee ee ee ee ee RE ee ee ee ee ee RR ee ee ee ee ee EER EE 28 System Will Not Operate in Either Deep suis si ss ss td de RR es da san De N ng cb ae eN hiked Ve SE da RR EG uaa da Rma au ik eeh 28 LOW Meier Output orde Ge BE AE hci OR GE ae ie ER Ra Re RR AR oe RSG Ee we REED EG Ge oo ei P 29 improper Motor Output SOC E 29 Excessive Noise And Or Vibratu OR ss se oo Omm 30 System Response ee 30 SAUER DANFOSS Series 90 Contents Inspections and Adjustments c m 31 atipiese Sa oa ORE EE EE RE ER OE EE UTE 31 Charge Pressure Relief Valve Adjustment AANEREN EE ee nennen ener nennen nnn 31 Multi Function Valve Pressure Adjustment uk 33 Engaging Me Bypass FUNCION sesse 35 Pressure Override POR Valve Pressure Adjustment Option for 180 Frame Gei 36 Displacement Limiter al E E 37 PIM Contor CS IERE aas Me GE neat De GE N Gie AE Ge EE EED E N EE ge Ge Gras E ie n Ge 38 Standard Manual Displacement Control MDC Adjustment ii ee Ee RR EE Ee ee ee AA RR EE ee ee ee ee ee RR ee ee ee ee ee ee RR EE ee ee ee ee dee RR EE 38 Non Linear Manual Displacement Control MDC ee ee RR EE RR EE EE ee ee nennen nennen nnn ee ee ee ee RR EE e
69. ise CCW until electrical continuity is obtained Turn the switch counterclockwise CCW an additional 1 4 turn 90 after continuity has been obtained Hold the switch in place and tighten the locknut to 27 Nm 20 Ibfeft torque 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 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 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 neces sary If continuity is not interrupted with an equal move ment of the control handle in each direction turn off prime mover remove the pressure gauges and continue with the next section If neutral start switch operation is satisfactory turn off the prime mover remove the pressure gauges and reconnect the external control linkage SAUER DANFOSS Series 90 Neutral Start Switch Eccentric Plug Adjustment Con dition i The NSS deadband and the control deadband must be centered in r
70. l the O ring and auxiliary mounting pad adaptor onto the end cap Refer to the corresponding section for instructions on auxiliary pad installation Minor Repair Instructions 100 cc 75 cCc 90000291 90000292 Keyways in Charge Pump Shaft Intermediate Produc tion 075 and 100 Install Charge Pump Shaft 90000293 0293 90000294 Alignment Pin Installed in Install Charge Pump Cover Cover 90000283 90000295 Install Cover Retainer Torque Retainer Screws 61 SAUER DANFOSS Series 90 90000282 90000284 Remove Screws and Remove Charge Pump Cover Retainer E s d Au AM m E Petr I r e UNES E AURAS E P p 8 90000296 Remove Large End Cap Screws K Coupling Special Washer N N Typical CH N 6 OT N Journal Bearing N pA o ring S M d D d o SC gt Est Nauxiliary Pad 8 Typical N O ring Cover Retainer Pad bur Ts P d lt N Retainer Screw Auxiliary Pad Kit 90000876E Auxiliary Pad Components Typical 62 Minor Repair Instructions Auxiliary Pad Installation 1 Remove the six screws holding the charge pump cover retainer Remove the retainer 030 100 130 250 2 Remove the charge pump cover and its O ring Note The original charge pump cover will not be used when installing the auxiliary pad 3 Remove the four large screws which fasten the end cap to the pump housing Wrench Sizes Hand Hex
71. lug 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 Ibfeft 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 030 130 1 1 16 inch and turning the adjustment plug with a large screw driver 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 approxi mately 5 4 bar 78 psi per turn The lock nut for this type charge relief valve should be torqued to 52 Nm 38 Ibfeft Once the desired charge pressure setting is achieved remove the gauges SAUER DANFOSS Series 90 Displacement Limiter Adjustment MV Both the maximum and minimum displacement may be limited 1 Remove the tamper resistant cap from the displace ment limiter screw Loosen the seal lock nut retaining the displacement limiter adjusting screw with a 19 mm wrench 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 S000015E 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
72. lve Cradle Hold Down Servo Piston Feed Back Cradle Bearing F O ed Cradle Leveler Cradle Guide Charge Pump 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 Series 90 Fixed Displacement Motor MF SAUER DANFOSS Series 90 Loop Flushing Valve Piston Valve Plate NL TT 7 A y AL AX On Al E rel E AAG Hi Jg SSS SSS SS LU Em m CREARE E Fixed Swashplate End Cap Cylinder Block 90000190E Series 90 MF Cross Section 90000348 Series 90 Variable Displacement Motor MV
73. lve Bypass Adjustment Charge Pressure Relief Valve Multi Function Valve 90000802E POR Valve 180 Frame Size only 12 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 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 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 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 SAUER DANFOSS Series 90 Pump Control Options Manual Displacement Control MDC Functional Description The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring centered four way servo valve This valve ports
74. 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 SAUER DANFOSS Series 90 The NSS must be adjusted to meet the following three requirements The distance the control handle can be turned with out opening the NSS is called the NSS Deadband The distance the control handle can be moved with out 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 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 The NSS deadband must be narrow enough so the NSS will open before the unit builds 7 bar 100 psi differential
75. mp charge pressure gauge port M3 2 Start the prime mover and operate at normal speed 3 Loosen locking nut early 130 130 250 T002 268E 4 Inserta internal hex wrench into the pressure adjust ing screw Frame Size Internal Hex Wrench Size early newer 5 mm 030 100 early 130 130 250 T002 269E Note A plastic dust plug is installed in the adjusting screw on 030 and late 042 through 250 units Inspections and Adjustments 90000258 Multi Function Valves on PV 90000259 Loosen Pressure Adjusting Screw Lock Nut 33 SAUER DANFOSS Series 90 90LO055 EA 1 N 6 S 3 C6 C 03 HNN 35 35 24 d Pressure Limiter Setting Ports A and B differential pressure in 10s of bars e g 35 350 bar Rotate Pressure Adjusting Screw le oe t e f hi m di ae Tighten Lock Nut 34 Inspections and Adjustments 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 sho
76. mp cover assembly 1 N25H TUDE J30 uem BUSANO EE 1 NSOR SE ioo Tro RE EE AE J50A V eg e EE 1 N35H xo EE EE IE EE J60A T Flange adaptor SAE A 1 J60B V Flange adaptor SAE B 1 NOOS Filtration kit Suction FIt J60C Flange adaptor SAE C 1 N10S Reducer fitting Suction FIt J60D Flange adaptor SAE D 1 N35S aile N N J70A V Washer EE EE EE EE Fi 4 Name Plates SAUER S SUNDSTRAND SAUER S SUNDSTRAND Ames lowa U S A Neum nster Germany Ames lowa U S A Neum nster Germany Model Code Typ Model Code Tvp 90L055 EA 1 N 90L055 EA 1 N 6 S 3 C6 C 03 Mode 6 S 3 C6 C 03 Model Code Code Model No Ident Nr Model No Ident Nr Model Number 94 2029 Model Number 687459 Serial Number _ Serial Number Serial No Fabr Nr Serial No Fabr Nr MADE IN U S A MADE IN GERMANY p Place of Manufacture L Place of Manufacture Name Plate U S A Production Name Plate German Production 83 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Fixed Motor Minor Repair Parts H68W 89 H6OW L35 H62W Early Production O 075 Frame Size HON 2 H50W d amp usw am WA
77. nor Repair Instructions Hydrostatic Unit Outlines for Minor Repair Reference Charge Pressure Relief Valve Control S Control Orifice Auxiliary Pad Left Side View Shaft Seal Main Shaft Filtration Options Speed Sensor Right Side View 90000843E SAE Flange PV Charge Pressure Relief Valve Loop Flushing Valve Bi Shaft Seal Speed Sensor Left Side View SAE Flange MF Control Orifices Charge Pressure Relief Valve Maximum Angle Displacement Limiter Loop Flushing Valve Control Minimum Angle Displacement Limiter Left Side View Cartridge Flange MV 52 Charge Pressure Relief Valve Loop Flushing Valve Speed Sensor Left Side View 90000844E Cartridge Flange MF Control Orifices Charge Pressure Maximum Angle Relief Valve Displacement Limiter Loop Flushing Valve Shaft Seal Control Minimum Angle Displacement Limiter Left Side View 90000845E SAE Flange MV SAUER DANFOSS Series 90 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 indi cated 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 S000017E Minor
78. nstall a new tamper resistant cap until the limiter has been adjusted Final adjustment of the displacement limiters should be performed on a test stand 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 S000026E One full turn of the displacement limiter adjustment screw will change the displacement as follows Approx Change in Disp per Rev of Adjusting Screw 5 6 om Rev 0 34 in Rev 7 1 cm Rev 0 43 in Rev T002 295E Following the final adjustment install new tamper resistant caps Minor Repair Tamper Resistant Cap Seal Lock Nut Maximum Displacement Limiter Screw Minimum Displacement Limiter Screw Seal Lock Nut Tamper Resistant Cap SAE Flange Version shown cartridge Version similar 90000851E MV Displacement Limiters 73 SAUER DANFOSS Series 90 Variable Motor Controls 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 8 in int hex wrench 9 16 in hex wrench Torq
79. odel code at right These l pressures assume 1500 pump rpm and a reservoir Model Code on Unit Name Plate 24 bar 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 18 1 bis 21 7 z readings in the higher portion of the range 25 8 bis 30 7 bar 374 to 445 psi 22 0 bis 26 9 SS 319 to 390 psi 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 31 SAUER S DANFOSS Series 90 32 90000262 Shim Adjustable Charge Pressure Relief Valve Pump 90000264 Screw Adjustable Charge Pressure Relief Valve Pump Inspections and Adjustments 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
80. 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 displace ment 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 PV with Manual Displacement Control 90000239 PV with Manual Displacement Control and Neutral Start Switch PV with Hydraulic Displacement Control SAUER DANFOSS Series 90 90000241 PV with Electric Displacement Control i 7 A BW Alb 90000354 PV with 3 Position FNR Electric Control 14 Functional Description Electric Displacement Control EDC The electric displacement control is similar to the hydrau lic 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 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 control is designed so the angular position of the swashplate is proportional to the EDC input Automotive Cont
81. oir to proper level Look for foam in reservoir Check for leaks on inlet side of system loop After wards let reservoir settle until bubbles are gone Run system at low speed to move system fluid to reservoir Repeat Inspect and replace filter as necessary Check for proper suction line size Replace loose shaft coupling in charge pump or replace pump or motor Align shafts If the above actions do not remedy the problem contact a SAUER SUNDSTRAND Authorized Service Center System Response is Sluggish Check Description Insufficient hydraulic fluid will reduce output pressure 1 Oil level in reservoir Incorrect pressure settings will affect system reaction time 2 Multi function valves pressure set tings 3 Pump inlet vacuum High pump inlet vacuum will reduce system pressure 4 Prime mover speed Low engine speed will reduce system performance Incorrect charge or control pressures will affect system performance 5 Charge and control pressures 6 System internal leakage Internal leakage will reduce system pressure Action Fill reservoir to proper level Adjust or replace multi function valves Measure charge inlet vacuum If high replace inlet filter Adjust engine speed Measure charge and control pressures and correct if necessary Check for leakage in O rings gaskets and other fittings If the above actions do not remedy the problem contact a SAUER SUNDSTRAND Authoriz
82. olled technology Hydraulic Power Systems Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors Pumps and Motors Variable Motors Compact Wheel Drives 3 Se 7 ae Medium Duty Axial Piston Microcontrollers and Hydrostatc Transmission Pumps and Motors Electrohydraulic Controls Packages Worldwide Service Support _ m SAUER DANFOSS provides comprehensive worldwide service for its y 4 Bs V An Ra ON produkts through an extensive network of Authorized Service Centers N strategically located in all parts of the world O Y y Z Look to SAUER DANFOSS for the best in WORLDWIDE SERVICE ME Original Ersatzteile http www sauer danfoss com Genuine Parts SAUER DANFOSS COMPANY SAUER DANFOSS GMBH amp CO 2800 East 13th Street Postfach 2460 e D 24531 Neum nster D Ames IA 50010 e U S A Krokamp 35 e D 24539 Neum nster e Germany DAN FOSS Phone 515 239 6000 Fax 515 239 6618 Phone 04321 871 0 e Fax 04321 871 122 SM SPV SMF SMV90 E 10 98 e 300047G BLN 9947 Revision G Oct 1998
83. on 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 Frame Size WrenchSize Torque 030 042 1 1 4 inch 70 Nm 52 Ibfeft 055 130 1 1 2 inch 122 Nm 90 Ibfeft 180 250 1 1 2 inch 156 Nm 115 Ibfeft 90000310 90000243 The gauge port plug takes a 1 4 inch internal hex Charge Pump Inlet Reducer Fitting and Gauge Port Plug wrench and is torqued to 27 Nm 20 lbfeft Remote Charge Pressure Filtration or Integral Charge Pressure Filtration Install either of these two filtration devices as follows 1 Remove the reducer fitting located at charge pres sure 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 _ 90000311 90000314 remote PressureFilter Integral Pressure Filter Head Manifold 3 After rotating the filter manifold or filter head clock wise 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 Caution Failure to install the filter manifold or filter head to a sufficient depth inthe end cap will result in insufficient engagement ofthe tube in the end cap bo
84. or housing Always install a new O ring before installing the sensor 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 If a speed sensor is not installed the housing plug should be torqued as indicated in the accompanying figure Housing Plug Speed Sensor 1 4 in int hex wrench Co Torque 23 Nm 17 Ibfeft 1 1 16 in hex wrench Torque 13 Nm 10 Ibfeft After adjustment 90000857E Typical Location of Speed Sensor PV 1 1 16 in hex wrench Torque 13 Nm 10 Ibfeft After adjustment v a or Housing Plug S Speed Sensor 1 4 in int hex wrench Torque 23 Nm 17 Ibfeft 90000858E Typical Location of Speed Sensor MF 1 1 16 in hex wrench Torque 13 Nm 10 Ibfeft After adjustment Speed Sensor J a Housing Plug 1 1 16 in hex wrench Torque 37 Nm 27 Ibfeft 90000859E Typical Location of Speed Sensor MV T7 SAUER DANFOSS Series 90 Exploded View Parts Drawings Parts Lists Exploded View Parts Drawings Parts Lists Variable Pumps Minor Repair Parts L35 KO18 Early Production bis 075 Frame Size L70 K042 Gy L40 5 L60 Lag A 3 L40 y i G506 G502 G506 G64 9 CODE 61 OPTION K018 BOTH SIDES OR s CODE 61 OPTION 90000860E 78 sy SAUER
85. oruri oj Met N EE EO H60W Charge relief valve plug 1 KR EE Orifice check valve sees ees ee ee ee ee ee ee H62W BE Le 9 1 pfo Nut Seal LOCK eeeuusss H64W sj eT o o OE HEN 1 LOA EE CN E H66W Charge relief poppet 1 WOO OD se MEE EE ER H68W Were dil fmt Cc N 1 b o o Orifice DIG ME ale E Orifice check valve ees esse ee ee ee ee Ee B RR af 1 Wo E ER Slotied NUT E 1 Name Plate SAUER S SUNDSTRAND Ames lowa U S A Neum nster Germany Model Code Typ 90S055 NB 2 0 8 N 4 S1 W O01 Model Code NNN 01 00 24 Model No Ident Nr Model Number 7 94 4002 Serial Number L 21 26 67890 ona OMADE NUSA E Name Plate U S A Production Place of Manufacture 87 SAUER Hydraulic Power Systems SAUER DANFOSS Hydraulic Power Systems Market Leaders Worldwide SAUER DANFOSS is a world leader in the design SAUER DANFOSS specializes in integrating a full and manufacture of Hydraulic Power Systems Research range of system components to provide vehicle designers and development resources in both North America and with the most advanced total design system Europe enable SAUER SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system SAUER DANFOSS is Your World Source for Contr
86. ounting 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 S000022bE 3 n 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 increas ing resistance as the control is moved away from center position Non engagement of pin will be indi cated by lack of spring force In case of non engage ment remove control and repeat the above proce dure 6 Alignthe control gasket and install the screws Torque the screws to 16 Nm 12 Ibfeft 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 Pressure Control Pilot PCP for Electric Displace ment 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
87. r The use of contaminated fluid will cause damage to the components which may result in unexpected vehicle machine move ment 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 Initial Start Up Procedure 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 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 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 estab lished Excess air may be bled from the high pressure lines through the high pressure s
88. r 4mm internal hex wrench for the neutral adjusting screw rotate clock wise 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 90000250 90000252 half the distance between the locations noted above Rotate Neutral Adjusting Tighten Neutral Adjusting The gauges should read the same pressure case Early Geet Eet 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 Ibfein Tighten the neutral adjusting screw lock nut later production controls to 7 Nm 62 Ibfein for the 6 mm screw or 13 5 Nm 120 Ibfein for the 8 mm screw Do not overtorque the nut 6 Once the neutral position is set stop the prime F 4 S P d d ek p i 2 2 mover remove the gauges and install the gauge wm 90000251 90000318 port plugs Reconnect the external control input Rotate Neutral Adjusting Tighten Neutral Adjusting Screw Screw Lock Nut Later production Later production i 90000355 Rotate Neutral Adjusting Tighten Neutral Adjusting Shaft Shaft Lock Nut Current production HD
89. re This may SCC allow unfiltered oil to bypass the filter and enter the RE 90000312 90000315 charge system Install Remote Pressure Install Integral Pressure S000021E Filter Manifold Filter Head D x a D ah BS kW Zb A E D Ce te ENEE ee ER SE N EN 4 While holding the filter manifold or filter head in the desired position tighten the swivel lock nut Frame Size Wrench Size Torque 030 042 1 3 8 inch 70 Nm 52 Ibfeft 055 130 1 5 8 inch 122 Nm 90 Ibfeft 180 250 1 5 8 inch 156 Nm 115 Ibfeft KA d s x 90000313 90000316 Filter Manifold Lock Nut Filter Head Lock Nut sembly install the filter canister per the instructions on the filter canister 64 sy SAUER DANFOSS Series 90 Pump controls Cover Plate Te Thoroughly clean external surfaces prior to removal of cover plate 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 S000022bE 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 Ibfeft NOTE A sealing washer mustbe installed under the head of any mounting screws that are installed into thru holes in the housing S000023E Minor Repair Pump with Cover Plate
90. res sure 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 morethan 1 bar 12 psi from base pressure 6 Continuity must again be verified when the control is returned to neutral Checking Continuity of NSS Gauges installed in Servo Gauge Ports 90000255 7 If continuity is not broken at base pressure plus O 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 clock wise 1 12 turn 30 to increase the sensitivity Re tighten 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 45 SAUER DANFOSS Series 90 mg S b7 A P LT sA PV with Hydraulic Displacement Control 90000240 90000241 PV with Electric Displacement Control 90000249 Install Gauges in Displacement
91. rol FBA II B Automotive Control allows a vehicle to be driven in a manner similar to an automobile with an automatic trans mission 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 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 SAUER DANFOSS 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 instal lations which require additional fluid to be removed from the main hydraulic circuit because of transmission cool ing requirements or unusual circuits requiring additional loop flushing to remove excessive contamination in the dE high pressure circuit ne N oase SOP Loop Flushing Valve MF 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 regul
92. s 19 SAUER DANFOSS Series 90 Pressure Measurement Pressure Measurement Required Tools The service procedures described in this manual for Pressure gauges should be calibrated frequently to en Series 90 pumps and motors can be performed using sure accuracy Snubbers are recommended to protect common mechanic s tools Special tools if required are pressure gauges shown Port Locations and Pressure Gauge Installation The following sections list the ports for each type of Outline drawings showing port locations follow the tables hydraulic unit The recommended pressure gauge and below fitting are also specified Variable Pump Gauge Size Gauge Size and and Fitting Fitting om stem Pressure 1000 bar or 10 000 psi Lom CUR Pressure 1000 bar or 10 000 psi M6 9 16 18 O ring 055 9 16 18 O ring E 100 T002 259E 1 5 16 12 O ring 180 i 1 5 8 12 O ring 50 bar or 1000 psi HDC EDC 7 16 er O ring Control Pressure 9 16 ia m ring External Control 50 bar or 1000 psi Pressure 9 16 18 O ring Charge Pump Inlet Vacuum Gauge Tee into Inlet Line 030 1 1 16 12 O ring 055 l 1 5 16 12 O ring 1 5 8 12 O ring 1 1 2 SAE Split T002 260E 20 SAUER DANFOSS Series 90 Pressure Measurement Servo Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 N System Pressure Port B Servo Displacement Cylinder Pressure Gauge Port M5 Top View 90000814E Sys
93. specific control e N Orifice check Valve 90000848E Underside of an MDC Module Showing Orifice Locations Displacement Control Adapter Plate Early produc tion 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 Ibfeft 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 SAUER DANFOSS 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 Early production motors used a small diameter GE E shuttle valve spool Late production motors use Remove Plugs Springs Remove Flushing Shuttle a larger diameter spool Spool
94. ssure limit of the other multi function valve but the control input signal must be activated or moved in the opposite direc tion so that high pressure develops in the opposite side of the closed circuit SAUER DANFOSS Series 90 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 Usinga 1 1 16 inch 130 250 1 3 8 inch T002 272E wrench on the middle sized hex of the multi function valve cartridge and a newer 030 100 1 1 4 inch 130 250 1 5 8 inch T002 273E 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 leak age 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 displace ment control on the pump to the maximum full forward position Hold the handle in this position during bypass valve operation Caution Tow at extremely low speeds and for short distances only S000011E 3 To close the bypass valve rotate the middle hex clockwise until it is seated Then torque t
95. tem Pressure Port B External Control Pressure System Pressure Supply Port X3 Gauge Port M2 Charge Inlet Pressure System Pressure Gauge Port M1 Carge Pump or Inlet Port S System Pressure Case Drain Port L2 Charge Pressure Port A Gauge Port M3 Left Side View Right Side View 90000815E 90000816E PV with Side Port End Cap and Manual Displacement Control 21 SAUER DANFOSS Series 90 System Pressure Gauge Port M2 System Pressure Port B Charge Pump Inlet Port S System Pressure Port A System Pressure Gauge Port M1 Case Drain Port L2 Left Side View Pressure Measurement Servo Displacement Cylinder Pressure Gauge Port M4 Case Drain Port L1 Servo Displacement Cylinder Pressure Gauge Port M5 Top View 90000819E 90000820E PV with Twin Port End Cap and Manual Displacement Control Port E from filter Port D to filter Charge Pressure Gauge Port M3 after the filter Rear View PV with Side Port End Cap and Remote Pressure Filtration 22 Charge Pressure Gauge Port M6 before the filter Charge Pressure Gauge Port M3 after the filter Rear View 90000817E 90000818E PV with Side Port End Cap and Integral Pressure Filtration SAUER DANFOSS Series 90 Pressure Measurement Fixed Motor Gauge Size Gauge Size and and Fitting Fitting System Pressure 1000 bar or 10 000 psi Case Pressure Port A 9 16 18 O ring 10
96. ter dirt water grease etc or if the fluid has been subjected to temperature levels greater than the recommended maximum Never reuse fluid Thefilter should be changed wheneverthe fluid is changed or whenever the filter indicator shows that it is necessary to change the filter Cleanliness Level and B Ratio Required fluid cleanliness ISO 4406 Class 18 13 level Recommended ratio Pn uem Recommended fB ratio for charge pressure filtration Beer se O Recommended inlet screen size for charge pressure filtration TOO2 OO7E 100 um 125 um sy SAUER DANFOSS Series 90 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 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 1 2 Check Input to pump control Pump displacement control Description Input to control module is operating improperly Control linkages are not secure control orifices are blocked etc Action Check control input and repair or re place as necessary Adjust repair or replace control mod ule as necessary If the above actions do not remedy the problem contact
97. th a 1 1 8 inch wrench continued 90000256 90000257 Loosen Eccentric Lock Nut NSS Removed 43 SAUER DANFOSS Series 90 Inspections and Adjustments 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 Switch Pin Eccentric Plug 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 Adjustment Range on plug in position Control Mounting Surface 90000835E 5 Turn the control shaft an equal amount in either Eccentric Plug Adjustment 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 Ibfeit Reinstall and adjust the switch as outlined in the previous section Note The eccentric plug normally requires between
98. trol supply orifice from the motor SEET housing with an 1 1 16 inch hex wrench 2 Remove the O rings and the backup washers Check 3 E N d O ring that the filter screen is secure in the orifice body and Gei that the screen and the orifice are not plugged 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 Ibfeft Backup Washer Caution Do notinterchangethe control supply orifice with the EE minimum displacement orifice next section 000027E Orifice Body Cross section View of Control Supply Orifice Assembly 90000854E MV Control Supply Orifice Minimum Displacement Cylinder Orifice or Orifice Check Valve Orifice s 7 Orifice Check Valve 1 Remove the minimum displacement cylinder drain i P SR orifice or the orifice check valve from the motor 4 housing with an 1 1 16 inch hex wrench pu nd A Backup Washer 2 Remove the O rings and the backup washers Check O ring that the orifice is not plugged Check that the check 3 valve seat is secure in the body and that the check ball is free 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 Ibfeft O ring Orifice Body Orifice Body Caution Do notinterchangethe control supply orifice previous oo AR Backup Washer section with the minimum displacement orifice O ring O ring Oe OBIE Backup Washer SES B
99. ue 34 Nm 25 Ibfeft 7 8 in hex wrench Torque 68 Nm 50 Ibfeft 90000853E MV Control Plugs 74 Minor Repair Electrohydraulic 2 Position Control Types NA NB NC and ND 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 Ibfeft 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 Ibfein 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 Control Plugs Remove the control plugs from the housings of earlier production motors if necessary Install new O rings reinstall and torque SAUER DANFOSS Series 90 Minor Repair Variable Motor Control Orifices Control Suply Orifice Control Supply Orifice P 1 Remove the con
100. ump or motor from the machine 1 Position the pump with the shaft facing up Note If the unit is positioned horizontally when the shaft is removed the cylinder block could move out of place making shaft installation difficult 2 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 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 Note The outside diameter of the seal may be lightly coated with a sealant such as Loctite High Performance Sealant 59231 prior to installa tion This aids in preventing leaks caused by damage to the seal bore in the seal carrier SAUER G DANFOS
101. unction Relief Valve Multi Function Valve Functional Description System loop low pressure Case drain fluid System loop high pressure Reservoir Control fluid Vacuum Gauge Suction line JEN C Purge Relief Valve Fixed Displacement Motor Ly 1 Sew WZ el Wy SE d d D Jr m SC Shaft 77 Motor Swashplate Loop Flushing Valve 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 L Reservoir Flow Bi directional N Case Drain Line 90000803E Basic Closed Circuit
102. ver CCW rotation shown 7 nstall the charge pump cover retainer and the six hex screws and torque the screws FrameSize Torque 030 100 13 5 Nm 10 Ibfeft 130 250 32 Nm 24 Ibfeft 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 0000299 90000300 10 Install four new large screws and washers through Install New Charge Pump Install Screws and Cover the mounting pad and end cap into the housing Cover Retainer Torque per the accompanying table FrameSie Torque 030 early 042 58 Nm 43 Ibfeft late 042 122 Nm 90 Ibfeft 055 122 Nm 90 Ibfeft 075 100 256 Nm 189 Ibfeft 100 130 298 Nm 220 Ibfeft 180 250 580 Nm 429 lbfeft T002 290E 90000302 90000303 Install O ring on End Cap Install Auxiliary Pad Adapter 11 Install the O ring and flange cover or auxiliary pump Pilot 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 90000305 Install Auxiliary Pad Adapter Torque Pad Adapter Screws Screws 63 SAUER DANFOSS Series 90 Minor Repair Filtration Options Suction Filtrati
103. wise CW until the wrench flats on sensor body are positioned at a 22 angle to the pump shaft center line Note Many adjustable wrenches have a 22 handle offset 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 Ibfeft SAUER DANFOSS Series 90 Minor Repair Instructions Minor Repair Instructions Minor repairs may be performed following the proce dures 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 Cleanliness is a primary means of ensuring satisfactory transmission life on either new or repaired units Clean ing 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 items must be kept free of foreign materials and chemi cals Protect all exposed sealing surfaces and open cavities from damage and foreign material 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 51 SAUER DANFOSS Series 90 Mi
104. wn 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 Clockwise rotation of the pressure adjustment screw will increase the pressure setting and counterclock wise rotation will decrease the pressure setting Each complete rotation of the pressure adjusting screw changes the pressure as shown in the following table Approx Change per Rev of the Adjusting Screw early 042 100 80 bar 1157 psi per Rev newer 030 100 90 bar 1300 psi per Rev 130 250 80 bar 1157 psi per Rev 7 Toverify 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 station ary tighten the pressure adjusting screw lock FrameSie Torque early 042 100 3 Nm 26 Ibfein newer 030 100 130 250 40 Nm 30 Ibfeft Do not overtorque 20 Nm 15 Ibfeft 9 Shutdown 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 pre
105. ype 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 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 sur passes a certain level This level is nominally set refer 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 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 Functional Description 90000243 PV with Charge Pump Case Drai ah Charge Relief Valve
106. ystem 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 S000010E 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 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 filtered fluid if needed The transmission is now ready for operation 25 SAUER DANFOSS Series 90 Fluid and Filter Maintenance Mano Ed E RR Vacuummeter H Li D Hydraulic fluid reservoir EE SH Filter NY Charge pump d h lt SOS SS EEN Adjustable to low N Charge pressure relief valve pressure side and Ll To pump case control POOO 797E Suction Filtration Schematic Adjustable Charge pressure relief valve to low pressure side and

Axial Piston Pumps and Motors Service Manual

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