Danfoss Axial Piston 90 Service guide

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Series 90

Axial Piston

Pumps and Motors

Service Manual

Series 90 Introduction

Introduction

Use of this Manual

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

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

The manual also includes the description of the units and

adjustment and repair activities. their individual components, troubleshooting information, adjustment instructions, and minor repair procedures. Unit warranty obligations should not be affected if maintenance, adjustment, and minor repairs are performed according to the procedures described in this

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).

manual.

A worldwide network of SAUER-SUNDSTRAND AuthoMany 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.

rized Service Centers is available should repairs be

needed. Contact any SAUER-SUNDSTRAND Autho-

rized Service Center for details. A list of all Service

Centers can be found in bulletin BLN-2-400527, or in

brochure SAW (Ident. No. 698266).

Safety Precautions

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 "neutral" mode) may cause the loss of hydrostatic braking capacity. A braking system, redundant to the hydrostatic transmission must, therefore, be provided which is adequate to stop and hold the system should the condition develop.

S000 001E

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 treatment is not administered immediately.

S000 003E

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

S000 005E

Flammable Cleaning SolventsDisable Work Function

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

S000 004E

S90MVCTCD S90PVMFCD

Series 90 Contents

Contents

Introduction ......................................................................................................................................................................... 2

Use of this Manual ........................................................................................................................................................................................ 2

Safety Precautions ........................................................................................................................................................................................ 2

Functional Description ....................................................................................................................................................... 5

General Description and Cross Sectional Views ......................................................................................................................................... 5

Variable Displacement Pumps................................................................................................................................................................ 5

Fixed Displacement Motor ..................................................................................................................................................................... 5

Variable Displacement Motor.................................................................................................................................................................. 6

The System Circuit ....................................................................................................................................................................................... 7

The Basic Closed Circuit ........................................................................................................................................................................ 7

Case Drain and Heat Exchanger ........................................................................................................................................................... 7

Common Features of Pumps and Motors .................................................................................................................................................... 8

End Caps and Shafts ............................................................................................................................................................................. 8

Speed Sensors ....................................................................................................................................................................................... 8

Pump Features ............................................................................................................................................................................................. 9

Charge Pump .......................................................................................................................................................................................... 9

Charge Relief Valve................................................................................................................................................................................. 9

Multi-Function Valves .............................................................................................................................................................................. 9

Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10

System Check Valves .................................................................................................................................................................... 10

Bypass Valves ................................................................................................................................................................................ 10

Displacement Limiters .......................................................................................................................................................................... 11

Auxiliary Mounting Pads ....................................................................................................................................................................... 11

Filtration Options ................................................................................................................................................................................... 11

Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12

Pump Control Options .......................................................................................................................................................................... 13

Manual Displacement Control (MDC) ........................................................................................................................................... 13

Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13

Electric Displacement Control (EDC) ............................................................................................................................................ 14

Automotive Control (FBA II B) ....................................................................................................................................................... 14

3-Position (FNR) Electric Control .................................................................................................................................................. 14

Motor Features ........................................................................................................................................................................................... 15

Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15

Variable Motor Displacement Limiters.................................................................................................................................................. 15

Variable Motor Controls ........................................................................................................................................................................ 16

Hydraulic 2-Position Control .......................................................................................................................................................... 16

Electric 2-Position Control .............................................................................................................................................................. 16

Technical Specifications ..................................................................................................................................................17

General Specifications ................................................................................................................................................................................ 17

Circuit Diagrams ......................................................................................................................................................................................... 17

Hydraulic Parameters ................................................................................................................................................................................. 18

Size Specific Data ....................................................................................................................................................................................... 19

Pressure Measurement ................................................................................................................................................... 20

Required Tools ............................................................................................................................................................................................ 20

Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20

Variable Pump ....................................................................................................................................................................................... 20

Fixed Motor ........................................................................................................................................................................................... 23

Variable Motor ....................................................................................................................................................................................... 24

Initial Start-Up Procedure ................................................................................................................................................25

Fluid and Filter Maintenance ........................................................................................................................................... 26

Troubleshooting ................................................................................................................................................................ 27

"NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27

System Operating Hot ................................................................................................................................................................................ 27

Transmission Operates Normally in One Direction Only .......................................................................................................................... 28

System Will Not Operate in Either Direction .............................................................................................................................................. 28

Low Motor Output Torque ........................................................................................................................................................................... 29

Improper Motor Output Speed .................................................................................................................................................................... 29

Excessive Noise and/or Vibration .............................................................................................................................................................. 30

System Response is Sluggish .................................................................................................................................................................... 30

Series 90 Contents

Inspections and Adjustments .........................................................................................................................................31

Pump Adjustments ...................................................................................................................................................................................... 31

Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31

Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33

Engaging the Bypass Function ............................................................................................................................................................ 35

Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36

Displacement Limiter Adjustment ......................................................................................................................................................... 37

Pump Control Adjustments ......................................................................................................................................................................... 38

Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38

Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39

MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40

Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46

Motor Adjustments ...................................................................................................................................................................................... 48

Charge Relief Valve Adjustment ........................................................................................................................................................... 48

Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49

Displacement Control Adjustments ...................................................................................................................................................... 49

Speed Sensor Adjustment .......................................................................................................................................................................... 50

Minor Repair Instructions ................................................................................................................................................ 51

Pump and Motor Minor Repair .................................................................................................................................................................... 53

Pump / Fitting Torques .......................................................................................................................................................................... 53

Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54

Pump Minor Repairs ................................................................................................................................................................................... 56

Multi-Function Valve Cartridges ........................................................................................................................................................... 56

Pressure Override Valve (Option for 180 Frame Size)....................................................................................................................... 57

Charge Relief Valve ............................................................................................................................................................................... 57

Charge Pump - Remove ...................................................................................................................................................................... 58

Installing the Charge Pump .................................................................................................................................................................. 60

Auxiliary Pad Installation ....................................................................................................................................................................... 62

Auxiliary Pad Conversion ..................................................................................................................................................................... 63

Pump controls ....................................................................................................................................................................................... 65

Cover Plate ..................................................................................................................................................................................... 65

Manual Displacement Control (MDC) ........................................................................................................................................... 66

Solenoid Override Valve for MDC .................................................................................................................................................. 67

Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67

Hydraulic and Electric Displacement Controls ............................................................................................................................. 68

Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68

3-Position (FNR) Electric Control .................................................................................................................................................. 69

Displacement Control Components ............................................................................................................................................... 69

Minor Repair - Motor ................................................................................................................................................................................... 71

Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71

Variable Motor Displacement Limiters.................................................................................................................................................. 73

Variable Motor Controls............................................................................................................................................................................... 74

Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74

Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74

Control Plugs ........................................................................................................................................................................................ 74

Variable Motor Control Orifices ............................................................................................................................................................ 75

Speed Sensor .............................................................................................................................................................................................. 77

Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78

Variable Pumps ........................................................................................................................................................................................... 78

Minor Repair Parts ................................................................................................................................................................................ 78

Parts List ............................................................................................................................................................................................... 79

Variable Pump Controls ........................................................................................................................................................................ 80

Control Parts List .................................................................................................................................................................................. 81

Filter and Options ................................................................................................................................................................................. 82

Parts List Filter and Options ................................................................................................................................................................. 83

Name Plates ......................................................................................................................................................................................... 83

Minor Repair Parts ................................................................................................................................................................................ 84

Variable Motor.............................................................................................................................................................................................. 86

Minor Repair Parts ................................................................................................................................................................................ 86

Name Plate ............................................................................................................................................................................................ 87

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.

Series 90 Variable Displacement Pump (PV)

Slider Block

Cradle Hold Down

Servo Arm

Servo Piston

Servo Valve

F000 539

Feed Back

Cradle Bearing

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.

Charge Pump

Cradle Leveler

Cradle

Cradle Guide

Series 90 PV Cross Section

Series 90 Fixed Displacement Motor (MF)

P001 413E

90000347

Series 90 Functional Description

In the Fixed Displacement Motor the "swashplate" is

Loop Flushing Valve

Valve Plate

Piston

Roller Bearing

Output Shaft

fixed, so any variation in motor speed and torque must be made by the input mechanism, i.e. the pump.

End Cap

Cylinder Block

Fixed Swashplate

Series 90 MF Cross Section

Series 90 Variable Displacement Motor (MV)

End Cap

Valve Plate

Piston

Roller Bearing

90000190E

90000348

Output Shaft

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

"A"

Cylinder Block

Cradle Swashplate

Electric 2-Position Control (optional)

"A"

Series 90 MV Cross Section

Maximum Angle Control Piston

Partial Section "A-A"

Cradle Swashplate in Full

Displacement Position

90000234E

Series 90 Functional Description

The System Circuit

Control Handle

Variable Displacement Pump

Input Shaft

Pump Swashplate

Displacement Control Valve

Heat Exchanger Bypass Valve

to Pump

Case

Reservoir

Vacuum Gauge

Purge Relief Valve

Motor Swashplate

Loop Flushing Valve

Orificed Check Valve

Servo Control Cylinder

Heat Exchanger

Multi-Function Valve

Servo Pres. Relief Valve

Charge Pressure Relief Valve

Charge Pump

Multi-Function Valve

Pump Fixed Motor

Circuit Diagram for Series 90 PV and 90 MF

System loop

Case drain fluid

System loop

Control fluid

Suction line

Fixed Displacement Motor

Output Shaft

(low pressure)

(high pressure)

90000800E

The Basic Closed Circuit

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

Case Drain and Heat Exchanger

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

Reservoir

Input

Flow (Bi-directional)

Basic Closed Circuit

Output

Case Drain Line

90000803E

Series 90 Functional Description

Common Features of Pumps and Motors

End Caps and Shafts

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

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

Speed Sensors

Speed Sensor

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.

90000810

Series 90 Functional Description

Pump Features

Charge Pump

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

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

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

Charge Relief Valve

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

Multi-Function Valves

Case

Drain

Input

Line

90000243

PV with Charge Pump

Charge Relief Valve

System Check Valves

PV PF

Charge Pump

Inlet Filter

Tank

90000804E

Pump Charge System

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.

90000243

Multi-Function Valve

Series 90 Functional Description

Pressure Limiter and High Pressure Relief Valves

Pressure Limiter Housing

Pressure Limiter

Lock Nut

Pressure Limiter

Adjustment Screw

Bypass

Actuator

Cross Section of Multi-Function Valve

Servo Piston

Port "A"

Port "B"

Servo Piston

Pressure Limiter

Valve Poppet

To Control

Multi-Function Valve

Servo Pres. Relief Valve

High Pressure

Relief / check Valve Poppet

Bypass

Bypass Adjustment

Check Valve

Poppet

90000806E

Charge Pressure Relief Valve

Series 90 pumps are designed with a sequenced pressure limiting system and high pressure relief valves. When the preset pressure is reached, the pressure limiter system acts to rapidly destroke the pump so as to limit the system pressure. For unusually rapid load application, the high pressure relief valve acts to immediately limit system pressure by cross-porting system flow to the low pressure side of the loop. The pressure limiter valve acts as the pilot for the high pressure relief valve spool. The high pressure relief valve is sequenced to operate at approximately 35 bar (500 psi) above the level that initiates the pressure limiter valve.

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

NOTE: For some applications, such as dual path ve-

hicles, the pressure limiter function may be defeated so that only the high pressure relief valve function remains.

System Check Valves

The system check valves allow pressurized flow from the charge pump to enter the low pressure side of the loop whenever system pressure dips below a certain level. This is needed as the pump will generally lose system pressure due to leakage and other factors. Since the pump can operate in either direction, two system check valves are used to direct the charge supply into the low pressure lines. The system check valves are poppet valves located in the multi-function valve assembly.

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.

Multi-Function Valve

Circuit Diagram showing Pressure

Control Mechanism

90000801E

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

Series 90 Functional Description

Displacement Limiters

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

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

For instructions on adjustment see corresponding Section.

Auxiliary Mounting Pads

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

Filtration Options

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

90000244

PV with Displacement Limiters

90000242

PV with Auxillary Mounting Pad

90000243

PV with Suction Filtration

(No filtration device attached)

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

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

PV with Integral Charge

90000246

Pump

PV with Remote Charge

90000247

Pump

Series 90 Functional Description

To Control

Pressure Override Control Valve

Port "A"

Shuttle Valve

Port "B"

Multi-Function Valve

POR-Valve (180 Frame Size only)

Multi-Function Valve

Charge Pressure

Relief Valve

Bypass Adjustment

90000802E

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 normally ported through the pressure override valve to the displacement control valve for controlling the pump's displacement. If the system demands a pressure above the override setting, the POR valve will override the control by reducing the control pressure supplied to the displacement control. As the control pressure reduces, the internal forces tending to rotate the swashplate overcome the force of the servo pistons and allow the pump's displacement to decrease.

Series 90 Functional Description

Pump Control Options

Manual Displacement Control (MDC)

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

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

Non-Linear MDC

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

Solenoid Override Valve for MDC

progressively

increases as the control

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

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

90000237

PV with Manual Displacement Control

90000239

PV with Manual Displacement Control and

Neutral Start Switch

PV with Hydraulic Displacement Control

90000240

Series 90 Functional Description

Electric Displacement Control (EDC)

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

90000241

PV with Electric Displacement Control

opposite direction. The control is designed so the angular position of the swashplate is proportional to the EDC input.

Automotive Control (FBA II B)

Automotive Control allows a vehicle to be driven in a manner similar to an automobile with an automatic transmission.

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

PV with 3-Position (FNR) Electric Control

3-Position (FNR) Electric Control

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

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

90000354

Series 90 Functional Description

Charge Relief Valve

Loop Flushing Shuttle Valve

End Cap

Top of Motor

Motor Features

Motor Loop Flushing Valve and Charge Relief Valve

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

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

90000248

For charge relief valve adjustment see corresponding Section.

Variable Motor Displacement Limiters

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

The range of the settings is as follows:

muminiM

tnemecalpsiD

mumixaM

tnemecalpsiD

VM550VM570

mc04-91

ni4.2-2.1

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mc45-62

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E152200T

90000238E

Motor Charge Relief Valve and Loop Flushing

Shuttle Valve

90000352

MV Maximum Displacement Limiter

(Minimum Displacement Limiters on opposite side)

Series 90 Functional Description

Variable Motor Controls

Hydraulic 2-Position Control

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

90000350

MV with Hydraulic 2-Position Control

Electric 2-Position Control

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

90000351

MV with Electric 2-Position Control

Series 90 Technical Specifications

Technical Specifications

General Specifications

Design

Variable Pumps and Motors: Axial piston pump of variable 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

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 nonconformance guidelines. The housing must always be filled with hydraulic fluid.

M5 M4

A M1

M2 B

MV with Electrohydraulic 2-Position

Control

max

PV with Charge Pump and Manual

Displacement Control

90000811 90000812 90000813

Series 90 Technical Specifications

Hydraulic Parameters

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Hydraulic Fluid

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

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Cleanliness

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

Refer to Series 90 technical information for definitions.

Series 90 Technical Specifications

Size Specific Data

Variable Displacement Pumps

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Refer to Series 90 technical information for definitions.

Series 90 Pressure Measurement

Pressure Measurement

Required Tools

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

Port Locations and Pressure Gauge Installation

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

Variable Pump

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4M 5M

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gnir-O81-61/9

isp0001rorab05

gnir-O81-61/9

E952200T

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

Outline drawings showing port locations follow the tables below.

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550 570 001

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550 570

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E062200T

Series 90 Pressure Measurement

Servo / Displacement

Cylinder Pressure

Gauge Port M4

Case Drain

Port L1

System Pressure

Port B

Servo / Displacement

Cylinder Pressure

Gauge Port M5

Top View

System Pressure

Gauge Port M2

Charge Inlet Pressure

System Pressure

Gauge Port M1

Carge Pump

Inlet Port S

System Pressure

Port B

System Pressure

Port A

Left Side View

Case Drain Port L2

90000814E

External Control Pressure

Supply Port X3

Speed Sensor

Charge Pressure

Gauge Port M3

Right Side View

PV with Side Port End Cap and Manual Displacement Control

90000815E 90000816E

Series 90 Pressure Measurement

Servo / Displacement Cylinder Pressure

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 L1

Case Drain Port L2

Top View

Left Side View

Gauge Port M4

Servo / Displacement Cylinder Pressure Gauge Port M5

Port E

(from filter)

Port D

(to filter)

Charge Pressure

Gauge Port M3

(after the filter)

PV with Twin Port End Cap and Manual Displacement Control

Charge Pressure

Gauge Port M3

Rear View

(after the filter)

Charge Pressure Gauge Port M6 (before the filter)

Rear View

90000819E 90000820E

90000817E 90000818E

PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Integral Pressure Filtration

Series 90 Pressure Measurement

Fixed Motor

troPnoitcnuF

Charge Pressure

Gauge Port M3

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erusserPmetsyS

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System Pressure Gauge Port M1

System Pressure Gauge Port M2

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E162200T

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570 001 031

Case Drain Port L1

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gnir-O41-8/7

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E262200T

Charge Pressure

Gauge Port M3

System Pressure Port A

Rear View

System Pressure Gauge Port M1

System Pressure Gauge Port M2

System Pressure Port A

Rear View

System Pressure Port B

MF with SAE Flange

System Pressure Port B

MF with Cartridge Flange

Case Drain Port L2

Left Side View

Speed Sensor

Case Drain Port L1

Speed Sensor

Case Drain Port L2

90000821E

Series 90 Pressure Measurement

Variable Motor

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(Hydraulic 2-Position Control)

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System Pressure

Gauge Port M2

Control Pressure

Port X1

System Pressure Port B

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isp0001rorab05

E362200T

Left Side View

troPnoitcnuF

1L 2L

Displacement Control Cylinder Pressure Gauge Port M4 Min. Displacement

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

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

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E462200T

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

Case Drain Port L1

Case Drain Port L2

Right Side View

MV with SAE Flange (Cartridge Flange Version Similar)

System Pressure Gauge Port M1

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

Speed Sensor

System Pressure Port A

90000823E

Series 90 Initial Start-Up Procedure

Initial Start-Up Procedure

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

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

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

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

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

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

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

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

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

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 established. Excess air may be bled from the high pressure lines through the high pressure system gauge port.

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

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

S000 010E

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

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

Shut down prime mover, remove gauges, and plug ports. Check reservoir level and add filtered fluid if needed.

The transmission is now ready for operation.

Series 90 Fluid and Filter Maintenance

Fluid and Filter Maintenance

To ensure optimum service life of Series 90 products, regular maintenance of the fluid and filter must be performed. Contaminated fluid is the main cause of unit

ManoVacuummeter

failure. Care should be taken to maintain fluid cleanliness while performing any service procedure.

to low pressure side and control

Suction Filtration Schematic

Hydraulic fluid reservoir

to low pressure side and control

Hydraulic fluid reservoir

Adjustable Charge pressure relief valve

To pump case

Screen

Charge pump

Filter

P000 797E

Adjustable Charge pressure relief valve

To pump case

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

It is recommended that the fluid and filter be changed per the vehicle/machine manufacturer’s recommendations 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 accelerated fluid aging and an earlier fluid change may be required. At lower fluid loads longer change intervalls are possible. Therefore we suggest to check the fluid with the manufacturer for suitability. This should be done at latest half way between fluid changes.

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

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

Filter

Charge Pressure Filtration Schematic

(Partial flow)

P000 798E

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E700200T

Series 90 Toubleshooting

Troubleshooting

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

specific equipment.

"NEUTRAL" Difficult or Impossible to Find

Check Description Action

1. Input to pump control.

2. Pump displacement control.

contact a SAUER-SUNDSTRAND Authorized Service Center.

System Operating Hot

Check Description Action

1. Oil level in reservoir.

2. Heat exchanger.

3. Charge pressure.

4. Charge pump inlet vacuum.

Input to control module is operating improperly.

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

If the above actions do not remedy the problem

Insufficient hydraulic fluid will not meet cooling demands of system.

Heat exchanger not sufficiently cooling the system.

Low charge pressure will overwork system.

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

Check control input and repair or replace as necessary.

Adjust, repair, or replace control module as necessary.

Fill reservoir to proper level.

Check air flow and input air temperature 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 necessary. Check for adequate line size, length or other restrictions.

5. System relief pressure settings.

6. For internal leakage in motor.

7. System pressure.

contact a SAUER-SUNDSTRAND Authorized Service Center.

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.

If the above actions do not remedy the problem

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

Monitor motor case flow without loop flushing in the circuit (use defeat spool). If flow is excessive, replace motor.

Measure system pressure. If pressure is high reduce loads.

Series 90 Toubleshooting

Transmission Operates Normally in One Direction Only

Check Description Action

1. Input to pump control.

Input to control module is operating improperly.

Check control input and repair or replace as necessary.

2. Pump displacement control.

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

4. Charge pressure.

contact a SAUER-SUNDSTRAND Authorized Service Center.

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 multifunction valves.

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

If the above actions do not remedy the problem

System Will Not Operate in Either Direction

Check Description Action

1. Oil level in reservoir.

2. Input to pump control.

3. Pump displacement control.

Insufficient hydraulic fluid to supply system loop.

Input to control module is operating improperly.

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

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.

Fill reservoir to proper level.

Check control input and repair or replace as necessary.

Repair or replace control module as necessary.

4. Ensure bypass valve(s) are closed.

5. Charge pressure with pump in neutral.

6. Charge pressure with pump in stroke.

7. Pump charge relief valve.

8. Charge pump inlet filter.

9. Charge pump.

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

Low charge pressure insufficient to recharge 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 provide insufficient charge flow.

Close bypass valves. Replace multifunction 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, otherwise go to step 9.

Adjust or replace pump charge relief valve as necessary.

Inspect filter and replace if necessary.

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

Series 90 Toubleshooting

10. Pump displacement control.

11. System pressure.

12. System multi-function valves.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

Low Motor Output Torque

Check Description Action

1. System pressure at motor.

2. Variable motor stuck at minimum displacement.

3. For internal leakage.

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.

Low system pressure at the motor will reduce torque.

Minimum motor displacement yields low output torque.

Internal leakage will reduce system pressure.

Repair or replace control module as necessary.

Measure system pressure. Continue with next step.

Repair or replace multi-function valve(s).

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

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

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

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

Improper Motor Output Speed

Check Description Action

1. Oil level in reservoir.

2. Pump output flow.

3. Variable motor displacement control.

4. For internal leakage.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

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.

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 control is responding. If not, repair or replace control.

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

Series 90 Toubleshooting

Excessive Noise and/or Vibration

Check Description Action

1. Oil in reservoir.

Insufficient hydraulic fluid will lead to cavitation.

Fill reservoir to proper level.

2. Air in system.

3. Pump inlet vacuum.

4. Shaft couplings.

5. Shaft alignment.

If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.

System Response is Sluggish

Check Description Action

1. Oil level in reservoir.

Air bubbles will lead to cavitation.

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

A loose shaft coupling will cause excessive noise.

Unaligned shafts will create excessive frictional noise.

Insufficient hydraulic fluid will reduce output pressure.

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

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.

Fill reservoir to proper level.

2. Multi-function valves’ pressure settings.

3. Pump inlet vacuum.

4. Prime mover speed.

5. Charge and control pressures.

6. System internal leakage.

contact a SAUER-SUNDSTRAND Authorized Service Center.

Incorrect pressure settings will affect system reaction time.

High pump inlet vacuum will reduce system pressure.

Low engine speed will reduce system performance.

Incorrect charge or control pressures will affect system performance.

Internal leakage will reduce system pressure.

If the above actions do not remedy the problem

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.

Series 90 Inspections and Adjustments

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Inspections and Adjustments

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

Pump Adjustments

Charge Pressure Relief Valve Adjustment

The following procedure explains how to check and adjust the charge pressure relief valve.

S000 007E

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

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

Charge Pressure Gauge Port (Reducer fitting shown - if

filtration device attached)

90L055 EA 1 N

90000243

Nominal

Charge Pressure

6 S 3 C6 C 03

HNN 35 35 24

Model Code on Unit Name Plate (“24 bar”)

* 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.

Series 90 Inspections and Adjustments

3. Earlier production Series 90 pumps are equipped with a shim adjustable charge pressure relief valve. Shim kits are available from SAUER-SUNDSTRAND. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the shim thickness behind the spring. The plug for this type of charge relief valve should be torqued to 68 Nm (50 lbf•ft).

Later production Series 90 pumps are equipped with

Shim Adjustable Charge

90000262 90000264

Pressure Relief Valve

(Pump)

Screw Adjustable Charge

Pressure Relief Valve

(Pump)

an external screw adjustable charge pressure relief valve. Adjustment of the charge pressure is accomplished by loosening the lock nut -

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001-030hcni61/1-1 052-031hcni8/5-1

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

E762200T

Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 3.9 bar (50 psi) per turn). The lock nut for this type of charge relief valve should be torqued to 52 Nm (39 lbf•ft).

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

Series 90 Inspections and Adjustments

Multi-Function Valve Pressure Adjustment

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

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

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

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).

S000 010E

90000258

Multi-Function Valves on PV

2. Start the prime mover and operate at normal speed.

3. Loosen locking nut.

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001-240

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001-030 031ylraemm31 052-031mm42

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E862200T

4. Insert a internal hex wrench into the pressure adjusting screw.

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E962200T

Note: A plastic dust plug is installed in the adjusting

screw on 030 and late 042 through 250 units.

90000259

Loosen Pressure Adjusting Screw Lock Nut

Series 90 Inspections and Adjustments

90L055 EA 1 N

6 S 3 C6 C 03

HNN 35 35 24

Pressure Limiter Setting

Ports A and B (differential

pressure in 10s of bars,

e.g. “35” = 350 bar)

Rotate Pressure Adjusting Screw

90000260

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

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

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

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E072200T

Tighten Lock Nut

90000261

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

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

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Do not overtorque.

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

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

Series 90 Inspections and Adjustments

Engaging the Bypass Function

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

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

1. Using a

eziSemarFeziShcnerW

rewen

001-030 052-031hcni8/3-1

wrench on the middle sized hex of the multi-function valve cartridge, and a

eziSemarFeziShcnerW

rewen

001-030 052-031hcni8/5-1

hcni61/1-1

E272200T

90000266

Loosening and Rotating Bypass Hex on Multi-Function

hcni4/1-1

E372200T

Bypass

Actuator

Valve

Opening Bypass Valve

allows flow to circuit

through Multi-Function Valves

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

as additional rotation will permit external leakage.

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

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

S000 011E

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

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rewen

001-030 052-031)tf•fbl57(mN001

)tf•fbl03(mN14

E472200T

90000827E

Multi-Function Valve with Bypass Function Engaged

Series 90 Inspections and Adjustments

Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size)

The Pressure Override Valve is explained in the corresponding section.

Pressure Override Valve

Right Side View

Pressure Override Valve for 180 Frame Size

Adjusting Screw

Lock Nut

90000828E

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

2. Start the prime mover and operate at normal speed.

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

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

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

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

Series 90 Inspections and Adjustments

Displacement Limiter Adjustment

The maximum displacement can be limited in either direction.

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

eziSemarFeziShcnerW

001-030mm31

031mm71

052-081mm91

E572200T

2. Rotate the adjusting screw.

eziSemarFeziShcnerWxeHlanretnI

001-030mm4

031mm5

052-081mm6

E672200T

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

Loosen Displacement Limiter Lock Nut

90000267

Caution Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed conditions. The seal lock nut must be retorqued after every adjustment to prevent an unexpected change in operating conditions and to prevent external leakage during unit operation.

S000 012E

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

eziSemarFeuqroT

001-030)tf•fbl81(mN42

031mN84)tf•fbl53(

052-081)tf•fbl29(mN521

E872200T

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

eziSemarF

030mc8.2 240mc5.3 550mc2.4 570mc1.5 001mc2.6 031mc8.8 081mc5.21 052mc3.71

ni71.0(veR/

ni12.0(veR/

ni62.0(veR/

ni13.0(veR/

ni83.0(veR/

ni35.0(veR/

ni67.0(veR/

ni60.1(veR/

wercSgnitsujdA

foveRreppsiDniegnahCxorppA

)veR/ )veR/ )veR/ )veR/ )veR/ )veR/

)veR/ )veR/

E772200T

90000268

Rotate Adjusting Screw

90000269

Tighten Lock Nut

Series 90 Inspections and Adjustments

Pump Control Adjustments

Standard Manual Displacement Control (MDC) Adjustment

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

Variable Displacement Pump with Standard Manual

Displacement Control

90000237

Series 90 Inspections and Adjustments

Non-Linear Manual Displacement Control (MDC)

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

The “neutral” adjustment is the only adjustment that can be made on the nonlinear manual displacement control. All other functions are preset at the factory.

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

S000 007E

Variable Displacement Pump with Non-Linear Manual

Displacement Control

90000829

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

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

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

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

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

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

the nut.

Rotate Neutral Adjusting

90000357

Screw

Tighten Neutral Adjusting

90000358

Screw Lock Nut

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

Series 90 Inspections and Adjustments

MDC Neutral Start Switch (NSS) Adjustments

Control Shaft

Eccentric Plug

Switch Pin

Special Lock Nut

for Eccentric Plug

MDC with Neutral Start switch

View at Section A-A

Components of the Standard Manual Displacement Control

with Neutral Start Switch

Switch Cam

Switch Lock Nut

Neutral Start Switch

Orifice Check Valve Seat

Control Spool Assembly

Control Link Assembly

90000830E

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

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

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

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 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)

Series 90 Inspections and Adjustments

The NSS must be adjusted to meet the following three requirements:

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

NSS Deadband

(Switch closed, "ON")

Control Deadband

("Neutral")

Total Control

Shaft Rotation

Control Shaft ("Free-Play")

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

ii. The NSS deadband must be wide enough so the NSS

will not open within the loose area of control handle movement caused by normal operating clearances in the control linkage (control shaft “free-play”).

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

iii. The NSS deadband must be narrow enough so the

NSS will open before the unit builds 7 bar (100 psi) differential system pressure in either direction.

(continued)

Control Shaft

90000831E

Neutral Start Switch Adjustment Requirements

Series 90 Inspections and Adjustments

NSS Deadband Adjustment (Conditions ii & iii)

The NSS deadband must be wide enough so the NSS will not open within the control shaft “free-play” area, and it

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

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

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

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

4. Attach a continuity checker to the terminals of the switch. With the control shaft in its “neutral” position,

Loosening the NSS Lock Nut

90000253

turn the switch clockwise (CW) until electrical continuity is broken, then turn the switch counterclockwise (CCW) until electrical continuity is obtained. Turn the switch counterclockwise (CCW) an additional 1/4 turn (90°) after continuity has been obtained.

Switch Cam

Switch Pin

Control Shaft

Switch Lock Nut

Neutral Start Switch

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

NSS

90000832E

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

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

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

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

8. 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.

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

Checking Continuity of NSS (System Pressure Gauges

installed on far side)

90000870

Series 90 Inspections and Adjustments

Neutral Start Switch Eccentric Plug Adjustment (Condition i)

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

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

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

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

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

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

S000 032E

12.7

(0.5)

Eccentric Plug Adjustment Tool

Eccentric Plug

Switch Pin

Special Lock Nut

for Eccentric Plug

MDC with Neutral Start Switch

3.175 (0.125)

1.52

(0.06)

Neutral Start Switch

Special Lock Nut for Eccentric Plug

9.14 (0.36)

25.4+ (1.0)

90000834E

Switch

Lock Nut

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

(continued)

Control

Mounting

Surface

View in Direction X

(Switch and lock nut removed)

NSS with Eccentric Plug

90000256

Eccentric Plug

Switch Pin

90000833E

90000257

NSS RemovedLoosen Eccentric Lock Nut

Series 90 Inspections and Adjustments

3. Position the eccentric plug so the switch pin is offset

Switch Pin

Control Mounting Surface

Eccentric Plug

90˚90˚

Eccentric Plug Adjustment Range

90000835E

Eccentric Plug Adjustment

toward the control mounting surface. This will provide the best contact between the pin and the cam on the control shaft.

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

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

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

Adjust the Eccentric Plug

Note: The eccentric plug normally requires between

5-1/2 and 6-1/2 turns to install into the control housing .

90000256

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

S000 014E

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

(continued)

Series 90 Inspections and Adjustments

Checking Switch Continuity

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

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.

S000 007E

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

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

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

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

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

Checking Continuity of NSS

(Gauges installed in Servo Gauge Ports)

90000255

Series 90 Inspections and Adjustments

Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment

The “neutral” adjustment is the only adjustment that can be made on hydraulic and electric displacement controls. All other functions are preset at the factory.

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

The neutral adjustment is performed by adjusting a neutral adjusting shaft (earlier production EDCs) or a

PV with Hydraulic Displacement Control

90000240

neutral adjusting screw (HDCs and current production EDCs).

S000 007E

PV with Electric Displacement Control

90000241

90000249

Install Gauges in Displacement Control Cylinder Gauge

Ports

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

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

Series 90 Inspections and Adjustments

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

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

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

the nut.

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

Rotate Neutral Adjusting

Shaft

(Early production)

Rotate Neutral Adjusting

Screw

(Later production)

90000250 90000252

90000251 90000318

Tighten Neutral Adjusting

Shaft Lock Nut

(Early production)

Tighten Neutral Adjusting

Screw Lock Nut

(Later production)

Rotate Neutral Adjusting

Shaft

(Current production HDC)

90000355

Tighten Neutral Adjusting

Shaft Lock Nut

(Current production HDC)

90000356

Series 90 Inspections and Adjustments

Motor Adjustments

Charge Relief Valve Adjustment

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

Charge Pressure Gauge Port (MF)

90M055 NC 0 N

8 N 0 C6 W 00

NNN 00 00 24

edoCledoM

01)isp711(rab1.8

81)isp332(rab1.61

02)isp262(rab1.81

42)isp023(rab1.22

82)isp873(rab1.62

03)isp534(rab0.03

Model Code at the Name Plate (24 bar)

90000248

Nominal charge Pressure Setting

erusserPegrahCrotoM

)]isp02±[rab4.1±(

2. The following table shows acceptable motor charge pressures for some nominal charge relief valve settings (see model code at right). These pressures assume a reservoir temperature of 50°C (120°F). They are referenced to case pressure and assume a one pump/one motor system.

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

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,

eziSemarFeziShcnerW

E972200T

031-030hcni61/1-1

E392200T

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

Shim Adjustable Charge

Pressure Relief Valve

(Motor)

90000263 90000343

Screw Adjustable Charge

Pressure Relief Valve

(Motor)

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

Series 90 Inspections and Adjustments

Displacement Limiter Adjustment (MV)

Both the maximum and minimum displacement may be limited.

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

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

S000 015E

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

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

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)

90000837E

MV Displacement Limiters

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

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

S000 016E

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

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

eziSemarF

550mc6.5 570mc1.7

wercSgnitsujdA

ni43.0(veR/

ni34.0(veR/

foveRreppsiDniegnahCxorppA

)veR/

E082200T

Rotate Adjusting Screw for

90000359

Minimum Displacement

Limiter

Tighten Lock Nut for

90000360

Minimum Displacement

Limiter

Displacement Control Adjustments

All variable motor displacement control settings do not require adjusting.

Maximum Displacement Limiter

90000352

Series 90 Inspections and Adjustments

Speed Sensor Adjustment

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

Gap

the speed sensor on the unit or description see the corresponding section.

Speed Sensor Magnetic Speed Ring

90000838E

Cross Section View of Speed Sensor in Variable Pump

Gap

Magnetic Speed Ring

Speed Sensor

90000839E

Cross Section View of Speed Sensor in fixed Motor

Gap

Speed Sensor

Magnetic Speed Ring

90000840E

Cross Section View of Speed Sensor in Variable Motor

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

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

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

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

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 lbf•ft).

Shaft Centerline

1/2 in. Wrench Flats

22˚

Speed Sensor with

Packard Connector

1/2 in. Wrench Flats

22˚

Speed Sensor with

Packard Connector

Positioning Speed Sensor relative to Pump or Motor Shaft

22˚

Speed Sensor with

Turck Connector

Shaft Centerline

22˚

Speed Sensor with

Turck Connector

90000841E

Series 90 Minor Repair Instructions

Minor Repair Instructions

Minor repairs may be performed, following the procedures in this section, without voiding the unit warranty. Although specific models are shown, these procedures apply to all series and types of units in the Series 90 Family.

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

items must be kept free of foreign materials and chemicals.

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.

Series 90 Minor Repair Instructions

Hydrostatic Unit Outlines for Minor Repair Reference

Charge Pressure

Relief Valve

Control

Control Orifice

Filtration Options

Charge Pump

(Auxiliary Pad)

Loop Flushing

Valve

Left Side View

Charge Pressure

Relief Valve

(Speed Sensor)

Left Side View

Shaft Seal

SAE-Flange PV

Shaft Seal

Main Shaft

Loop Flushing

Valve

Right Side View

Charge Pressure

Relief Valve

(Speed Sensor)

Left Side View

Cartridge Flange MFSAE Flange MF

Speed Sensor

90000843E

Shaft Seal

90000844E

Control Orifices

Charge Pressure

Relief Valve

Loop Flushing

Valve

Control

Minimum Angle Displacement Limiter

Left Side View

Cartridge Flange MV

Maximum Angle Displacement Limiter

Shaft Seal

Control Orifices

Charge Pressure

Relief Valve

Loop Flushing

Valve

Control

Left Side View

SAE Flange MV

Maximum Angle Displacement Limiter

Shaft Seal

Minimum Angle Displacement Limiter

90000845E

Series 90 Minor Repair Instructions

Pump and Motor Minor Repair

Pump / Fitting Torques

If any plugs or fittings are removed from the pump or motor during servicing, they should be torqued as indicated in the accompanying table.

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

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

S000 017E

noitpircseDeuqroT

gnir-O02-61/7

hcnerWxeHhcni61/9

gnir-O02-61/7

hcnerWxeHlanretnIhcni61/3

gnir-O81-61/9

hcnerWxeHhcni61/11

gnir-O81-61/9

hcnerWxeHlanretnIhcni4/1

gnir-O61-4/3

hcnerWxeHhcni8/7

gnir-O61-4/3

hcnerWxeHlanretnIhcni61/5

gnir-O41-8/7

hcnerWxeHhcni1

gnir-O41-8/7

hcnerWxeHlanretnIhcni8/3

gnir-O21-61/1-1

hcnerWxeHhcni4/11

gnir-O21-61/1-1

hcnerWxeHlanretnIhcni61/9

gnir-O21-61/5-1

hcnerWxeHhcni2/1-1

gnir-O21-61/5-1

hcnerWxeHlanretnIhcni8/5

gnir-O21-8/5-1

hcnerWxeHhcni8/7-1

mN02

)tf•fbl51(

mN21

)tf•fbl9(

mN73

)tf•fbl72(

mN32

)tf•fbl71(

mN86

)tf•fbl05(

mN86

)tf•fbl05(

mN59

)tf•fbl07(

mN86

)tf•fbl05(

mN361

)tf•fbl021(

mN511

)tf•fbl58(

mN091

)tf•fbl041(

mN921

)tf•fbl59(

mN422

)tf•fbl561(

E182200T

Series 90 Minor Repair Instructions

Shaft Seal and Shaft Replacement

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

1. Position the pump with the shaft facing up.

Note: 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

90000270 90000271

Retainer Plate and Seal

Carrier

Remove Seal CarrierRemove Screws Holding

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.

Press Out Old Seal New Seal Installed in Carrier

90000272 90000273

Retaining Plate

Seal Carrier

Seal

Screw

Seal Carrier (One Piece)

O-ring

Screw

Seal

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 installation. This aids in preventing leaks caused by damage to the seal bore in the seal carrier.

Series 90 Shaft Seal Components

90000846E

Series 90 Minor Repair Instructions

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

If the shaft is not being replaced proceed to step

12.

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

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

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

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

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

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

15. Install the screws and torque like the tables.

Pumps

eziSemarFspmuPeuqroT

240-030mN21)tf•fbl9( 001-550mN61)tf•fbl21( 052-031)tf•fbl42(mN23

E282200T

Roller Bearing

Assembly

Tapered

Splined

Shaft

Fixed Motor Shaft Configuration

Roller Bearing

Assembly

Splined

Shaft

Variable Pump Shaft Configuration

Roller Bearing

Assembly

Splined

Shaft

Variable Motor Shaft Configuration

Retaining Ring

Roller Bearing

Straight Key Shaft

Retaining Ring

Straigt Key

Shaft

90000866E

Rollen Bearing

Tapered Shaft

90000867E

Retaining Ring

Tapered Shaft

90000868E

Motors

eziSemarFsrotoMeuqroT

001-030mN5.9)tf•fbl7(

031)tf•fbl6.61(mN5.22

E382200T

Note: Torque the screws in a sequenced pattern then

recheck.

Install Seal Carrier

90000274 90000275

Torque Retainer Screw

Series 90 Minor Repair Instructions

Pump Minor Repairs

Multi-Function Valve Cartridges

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

eziSemarFeziShcnerW

001-030hcni4/1-1 052-031hcni8/5-1

2. Inspect cartridge for damage to parts and O-rings.

E482200T

Remove Multi-Function

Valve Cartridge

Multi-Function Valve Cartridge Components

Pressure Limiter

Lock Nut

Pressure Limiter

90000276 90000277

(Earlier production)

(Later production)

Pressure Limiter

Housing

Install and Torque Cartridge

Valve Spring

Spring Seat

High Pressure

Relief/Check

Valve Poppet

Check Valve

Poppet

90000278

90000279

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

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 disassembled parts.

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

Pressure Limiter

Adjustment Screw

Multi-Function Valve Cartridge Sectional View

Valve Poppet

Bypass

Actuator

Valve Seat

Spring

Pressure Limiter

Valve Poppet

90000869E

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

S000 018E

Install cartridge in multi-function valve cavity and torque.

eziSemarFeuqroT

001-030)tf•fbl66(mN98

052-031)tf•fbl551(mN012

Do not overtorque the multi-function valve cartridge.

E582200T

Series 90 Minor Repair Instructions

Pressure Override Valve

O-rings

Screws

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 5 mm internal hex wrench. Remove the O-rings.

2. Inspect valve for damage to parts.

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

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.

eziSemarFeziShcnerW

001-030hcni61/1-1 052-031hcni8/5-1

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

Check the charge pressure and adjust, if necessary.

Pressure Override Valve Components

E682200T

Remove Charge Relief Valve

(Shim adjustable)

Remove Charge Relief Valve

(Screw adjustable)

Shim Adjustable Charge

Relief Valve

Screw Adjustable Charge

Relief Valve

90000870E

9000026290000280

9000026590000264

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.

Remove Auxiliary Pad

90000281

Adapter Screws

Remove Auxiliary Pad

Adapter

Remove Retainer Screws Remove Charge Pump Cover

Remove Drive Coupling

90000297

90000303

9000028490000282

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

S000 019E

2. Remove the six screws holding the charge pump cover retainer.

eziSemarFeziShcnerW

001-030mm01 052-031mm31

E782200T

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

4. Remove the charge pump shaft and charge pump drive key.

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

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

Discharge

(Outside looking into pump)

Gerotor Assembly

Left Hand Rotation

Orienting Alignment Pin

Alignment Pin

Inlet

Alignment Pin

Gerotor Assembly

Discharge

Right Hand Rotation

(Outside looking into pump)

Inlet

90000871E

Remove the charge pump gerotor assembly.

6. Remove the outer eccentric ring and alignment pin.

7. Remove the inner port plate.

8. Inspect all parts for abnormal wear or damage.

Series 90 Minor Repair Instructions

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 replaced together. If different thickness port plates are used in an early production charge pump assembly, the thicker plate is the inner port plate (installed next to the pump end cap).

Cover

O-ring

Standard End Cap Screws

Charge Pump Assembly

Thin Port Plate

Key

Shaft

Alignment Pin

Thick Port Plate

Eccentric Ring

Gerotor Assembly

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

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

Journal Bearing

Cover Retainer

Retainer Screw

Charge Pump Components (Early Production)

Standard End Cap Screw

Alignment Pin

Thin Port Plate

Charge Pump Assembly

Eccentric Ring

Gerotor Assembly

Cover

Key

Shaft

O-ring

Journal Bearing

Cover Retainer

Retainer Screw

Thin Port Plate

Spacer Plate(s)

Charge Pump Components (Intermediate Production)

Standard End Cap Screw

Alignment Pin

Charge Pump Assembly

Key

Cover

Shaft

O-ring

Gerotor Assembly

Port Plate

Eccentric Ring

90000872E

90000873E

Journal Bearing

Cover Retainer

Retainer Screw

Charge Pump Components (Late Production)

Standard End Cap Screw

Spacer

Shaft

O-ring

Cover

Plug

Journal Bearing

Cover Retainer

Retainer Screw

"No Charge Pump" Components

90000874E

90000875E

Series 90 Minor Repair Instructions

Discharge

Left Hand Rotation

(Outside looking into pump)

Gerotor Assembly

Orienting Alignment Pin

Discharge

Alignment Pin

Inlet

Alignment Pin

Gerotor Assembly

Inlet

Right Hand Rotation

(Outside looking into pump)

90000871E

Installing the Charge Pump

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

Note: The charge pump rotation is determined by the

orientation of the gerotor assembly outer eccentric ring and the location of the alignment pin in the end cap.

Do not mix charge pump piece parts from different production periods. Always install as a complete 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 petroleum jelly to the I.D., O.D., and side faces of the gerotor assembly to provide initial lubrication.

4. Install the gerotor assembly.

Install Inner Port Plate

Install Alignment Pin

Install Gerotor Assembly

Outer Ring

Install Gerotor Assembly

9000028690000285

9000028890000287

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

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

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

Install Outer Port Plate (Early and intermediate

production only)

Install Spacer Plate

(Intermediate production

only)

9000029090000289

Series 90 Minor Repair Instructions

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 internally splined end of the shaft) is used in 100 cc pumps.

8. Install the charge pump shaft. The 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 nonchamfered 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.)

100 cc

Keyways in Charge Pump

Shaft (Intermediate Produc-

tion 075 and 100)

75 cc

90000291 90000292

Install Charge Pump Shaft

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

Caution In order to avoid loss of charge pressure in pumps with an auxiliary mounting pad, always install the charge pump cover with the pad drain hole located on the same side of the end cap as the charge inlet port. Refer to the section „Auxiliary Pad Installation“ for details.

S000 020E

12. Install the charge pump cover retainer and the six hex screws and torque the screws.

eziSemarFeuqroT

001-030)tf•fbl01(mN5.31 052-031)tf•fbl42(mN23

E882200T

Alignment Pin Installed in

Cover

90000293

Install Charge Pump Cover

90000294

13. For pumps with auxiliary mounting pads, install the O-ring and auxiliary mounting pad adaptor onto the end cap. Refer to the corresponding section for instructions on auxiliary pad installation.

90000283 90000295

Torque Retainer ScrewsInstall Cover Retainer

Series 90 Minor Repair Instructions

Auxiliary Pad Installation

1. Remove the six screws holding the charge pump cover retainer. Remove the retainer.

eziSemarFeziShcnerW

001-030mm01 052-031mm31

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.

Remove Screws and

Retainer

Remove Charge Pump Cover

9000028490000282

3. Remove the four large screws which fasten the end cap to the pump housing.

eziSemarFseziShcnerW

xeHlanretnIxeHlanretxE

-030 240ylrae

240etalmm01

550mm91

001-570mm42 031-001mm41 052-081mm71

mm8

E782200T

E982200T

Screw

Remove Large End Cap Screws

Charge Pump Parts

Cover

Assembly

Special Washer

End Cap

Screw

O-ring

Pad Cover

O-ring

auxiliary Pad (Typical)

Auxiliary Pad Kit

Auxiliary Pad Components (Typical)

Coupling (Typical)

Journal Bearing

Cover Retainer

Retainer Screw

90000296

90000876E

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).

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 coupling) and retain with petroleum jelly. Install the new charge pump cover with alignment pin into the end cap and the aligned charge pump parts.

7. Install the charge pump cover retainer and the six hex screws and torque the screws.

eziSemarFeuqroT

001-030)tf•fbl01(mN5.31 052-031)tf•fbl42(mN23

8. Install O-ring on end cap pilot.

S000 020E

Install Drive Coupling Install Alignment Pin in

Cover (CCW rotation shown)

E882200T

9000029890000297

9. Install the auxiliary mounting pad adapter on external pilot on rear of end cap.

10. Install four new large screws and washers through the mounting pad and end cap into the housing. Torque per the accompanying table.

eziSemarFeuqroT

-030 240ylrae

240etal)tf•fbl09(mN221

550)tf•fbl09(mN221 001-570)tf•fbl981(mN652 031-001)tf•fbl022(mN892 052-081)tf•fbl924(mN085

)tf•fbl34(mN85

E092200T

11. Install the O-ring and flange cover or auxiliary pump.

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.

Install New Charge Pump

Cover

Install O-ring on End Cap

Pilot

90000299

Install Screws and Cover

Retainer

Install Auxiliary Pad Adapter

90000300

9000030390000302

After removing the four end cap retaining screws, remove the old auxiliary mounting pad adapter.

Install Auxiliary Pad Adapter

Screws

90000281

Torque Pad Adapter Screws

90000305

Series 90 Minor Repair

Filtration Options

Suction Filtration Installation

1. Install the hydraulic fitting to connect the external suction filter to the charge pump inlet port.

2. The reducer fitting (placed on the charge pressure gauge port) is installed as follows.

eziSemarFeziShcnerWeuqroT

240-030hcni4/1-1)tf•fbl25(mN07 031-550hcni2/1-1)tf•fbl09(mN221

052-081hcni2/1-1)tf•fbl511(mN651

Charge Pump Inlet Reducer Fitting and

Gauge Port Plug

9000024390000310

The gauge port plug takes a 1/4 inch internal hex wrench and is torqued to 27 Nm (20 lbf•ft).

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 pressure gauge port, from pump end cap (this part will not be used).

E192200T

90000311 90000314

Manifold

Install Remote Pressure

Filter Manifold

Integral Pressure Filter Headremote Pressure Filter

Install Integral Pressure

Filter Head

2. Install the filter manifold or filter head into the port. The hydraulic tube should enter its mating bore in the pump end cap with a low force.

3. After rotating the filter manifold or filter head clockwise so that the threads engage with the threads in the end cap, continue to rotate it clockwise between 6 and 7 revolutions. Face manifold or head to the desired position.

Caution Failure to install the filter manifold or filter head to a sufficient depth in the end cap will result in insufficient engagement of the tube in the end cap bore. This may allow unfiltered oil to bypass the filter and enter the

9000031590000312

charge system.

S000 021E

4. While holding the filter manifold or filter head in the desired position, tighten the swivel lock nut.

eziSemarFeziShcnerWeuqroT

240-030hcni8/3-1)tf•fbl25(mN07 031-550hcni8/5-1)tf•fbl09(mN221

052-081hcni8/5-1)tf•fbl511(mN651

E292200T

Tighten Remote Pressure

Filter Manifold Lock Nut

90000313 90000316

Tighten Integral Pressure

Filter Head Lock Nut

5. After installing the integral pressure filter head assembly, install the filter canister per the instructions on the filter canister.

Series 90 Minor Repair

Pump controls

Cover Plate

1. Thoroughly clean external surfaces prior to removal of cover plate.

2. Using a 5 mm internal hex wrench, remove the eight cover plate mounting screws. Remove the cover plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

3. In preparation for installing the cover plate, place a new gasket on the housing. Place the cover plate into position and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing.

S000 023E

Pump with Cover Plate

90000361

Series 90 Minor Repair

Manual Displacement Control (MDC)

1. Thoroughly clean external surfaces prior to removal of control.

2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

Remove Mounting Screws Remove Control

Inner Face of Control Assemble Control to Linkage

9000032090000319

9000032290000321

3. In preparation for installing the control, place a new gasket on the housing. Inspect to assure that the control orifice check valve and spring are in their proper position in the control.

4. While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5. With the control in position, move control lever both directions to check proper engagement of control linkage pin. Proper engagement will be indicated by centering torque as the lever is moved from center. Non-engagement of control linkage pin is indicated by lack of centering torque as the lever is moved. In case of non-engagement remove the control and repeat the above procedure.

6. Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into "thru" holes in the housing.

S000 023E

Assemble Control to

Pump

Torque Mounting Screws

9000032490000323

7. If the control is equipped with a neutral start switch, refer to the "MDC Neutral Start Switch Adjustment" instructions.

WARNING The neutral start switch "neutral" must be readjusted after reassembling the MDC module.

S000 024E

Series 90 Minor Repair

Solenoid Override Valve for MDC

1. Thoroughly clean external surfaces prior to removal of valve.

2. Using a 5 mm internal hex wrench, remove the two screws and remove solenoid manifold from housing. Remove the old gasket.

3. The solenoid may be removed from the valve by removing the nut with a 3/4 inch hex wrench. The solenoid valve may be removed from the manifold with a 7/8 inch hex wrench.

4. When installing the solenoid valve into the manifold, the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 lbf•ft). When installing the solenoid onto the valve, torque the nut to 6 Nm (53 ± 12 lbf•in).

5. In preparation for installing the solenoid manifold, place a new gasket on the control housing. Install the manifold onto the control housing, align the gasket, and install the screws. Torque the screws to

13.5 Nm (10 lbf•ft).

Components of Solenoid Override for MDC

90000363

Solenoid Override Valve for MDC with Pressure Released Brake

1. Thoroughly clean external surfaces prior to removal of valve.

2. Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings) from the adapter plate.

3. Using a 4 mm internal hex wrench, remove the four adapter plate mounting screws. Remove the adapter plate and O-rings from the control housing.

4. Remove the check valve seat and O-ring from the control side of the adapter plate. Remove the check ball and spring.

5. Install a new O-ring on the check valve seat and reassemble the check valve spring, ball, and seat into the adapter plate.

6. Install new O-rings on the adapter plate. Place the adapter plate into position and install the screws. Torque the screws to 5.4 Nm (48 lbf•in).

7. Install new O-rings onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to 5.4 Nm (48 lbf•in).

Components of Solenoid Override with Brake Pressure

90000364

Defeat for MDC

Series 90 Minor Repair

Hydraulic and Electric Displacement Controls

1. Thoroughly clean external surfaces prior to removal of control.

2. Using a 5 mm internal hex wrench, remove the eight control mounting screws. Remove the control (with orifice check valve and spring) and control gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

Remove Mounting Screws Remove Control

Inner Face of Control Assemble Control to Linkage

Install Mounting Screws Torque Mounting Screws

9000032690000325

9000032890000327

9000033090000329

3. In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control.

4. While setting the control into position, engage the pin on the control linkage into the mating hole in the link attached to the swashplate.

5. With the control in position, move control assembly left and right to check engagement of pin in the link. Proper engagement will be indicated by an increasing resistance as the control is moved away from center position. Non-engagement of pin will be indicated by lack of spring force. In case of non-engagement, remove control and repeat the above procedure.

6. Align the control gasket and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

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 Displacement Control

1. Thoroughly clean external surfaces of control.

PCP Components Torque PCP Valve Screws

2. Using a 4 mm internal hex wrench, remove the four screws and remove the PCP.

3. Check surfaces for nicks or damage. Clean internal screens.

4. Install new O-rings in PCP Housing. Place PCP against EDC housing and install the screws. Torque to 5.4 Nm (48 lbf•in).

9000033490000332

Note: Do not remove black plastic cover from the

aluminum plate. This is not a serviceable item and will void the product warranty.

Series 90 Minor Repair

3-Position (FNR) Electric Control

1. Thoroughly clean external surfaces prior to removal of control.

2. Using a 4 mm internal hex wrench, remove the four solenoid valve mounting screws. Remove the solenoid valve (with O-rings and orifice) from the adapter plate.

3. Using a 5 mm internal hex wrench, remove the eight adapter plate mounting screws. Remove the adapter plate and gasket from housing.

Caution Protect exposed surfaces and cavities from damage and foreign material.

S000 022E

4. Inspect the orifice installed between the valve and adapter plate. This orifice MUST be installed in the case drain passage for proper pressure limiter operation.

5. In preparation for installing the adapter plate, place a new gasket on the housing. Place the adapter plate into position and install the screws. Torque the screws to 16 Nm (12 lbf•ft).

NOTE A sealing washer must be installed under the head of any mounting screws that are installed into „thru“ holes in the housing.

S000 023E

6. Install new O-rings and the orifice onto the solenoid valve assembly and install the solenoid valve onto the adapter plate. Install the screws and torque to

5.4 Nm (48 lbf•in).

Displacement Control Components

3-Position Electric Control Components

90000362

Displacement Control Orifices

1. Remove the control assembly as described in the instructions for the specific displacement control.

2. Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove the orifice plugs with a 4 mm internal hex wrench. Note the location of each plug, do not interchange plugs. Torque the orifice plugs to 3 Nm (26 lbf•in).

3. Assemble the control onto the pump. Refer to the instructions for the specific control.

Orifice Plugs

Orifice Check Valve

Underside of an HDC/EDC Module Showing Orifice

Locations

90000849E

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

Orifice Plugs

Orifice check Valve

Underside of an MDC Module Showing Orifice Locations

90000848E

assembly, at the surface of the pump housing face. Remove the spring retainer and spring from the orifice check valve cavity and then remove the orifice check valve.

3. Install the desired orifice check valve in the cavity and then install the spring and spring retainer to hold the orifice check valve in position.

4. Assemble the control onto the pump. Refer to the instructions for the specific control.

Displacement Control Adapter Plate (Early production 130 Pumps only)

Displacement Control Adapter Plate (Early production

90000847

130cc Pumps only)

The screws fastening the control adapter plate to the housing have retaining compound on the threads. They are removed with a 6 mm internal hex wrench.

When installing the adapter plate, ensure the O-rings are in the proper position and torque the screws to 32 Nm (24 lbf•ft).

Displacement Control Filter Screens

If the pump is equipped with control filter screens in the pump housing (late production), they should be pressed into position (with the rounded edge of the filter screens facing the control until they are flush to 2.0 mm (0.08 inch) below the surface of the housing.

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

shuttle valve spool. Late production motors use a larger diameter spool.

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 lbf•ft) on 030 through 100 motors or 68 Nm (50 lbf•ft) on 130 motors.

Motor Charge Relief Valve

1. Remove the shim adjustable charge relief valve plug with a 7/8 inch hex wrench.

Before removing the screw adjustable relief valve plug, mark the plug, lock nut, and housing so as to be able to maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the lock nut with a 1-1/16 inch hex wrench for 030 through 100 units, or a 1-5/8 inch hex wrench for 130 units, and unscrewing the plug with a large screwdriver or 1/2 inch hex wrench.

2. Remove the spring and valve poppet.

Remove Plugs Springs

Install Flushing Shuttle

Spool

Remove Flushing Shuttle

Spool

Torque Plugs

9000033990000338

9000034190000340

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.

Remove Shim Charge Relief

Valve

Remove Screw Charge Relief

Valve

9000034390000342

Series 90 Minor Repair

5. Check and adjust the charge pressure.

Shim Adjustable Charge

Relief Valve

Lock Nut

Plug

O-ring

Spring

Poppet

Plug with O-ring

(defeat)

Plug

O-ring

Spring

Shoulder Washer

Screw Adjustable Charge

9000034590000344

Relief Valve

Plug

O-ring

Shims

Spring

Poppet

Plug with O-ring (defeat)

Spool (defeat)

Plug with O-ring (defeat)

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 lbf•ft).

4. Remove charge relief valve components (these parts are not necessary).

5. Replace with the hex plug provided and torque to 41 Nm (30 lbf•ft).

Note orientation of washers!

Shoulder OUT (toward spring).

Spool

Shoulder Washer

Spring

O-ring

Plug

90000850E

Motor charge Relief Valve and Loop Flushing Valve Parts

Series 90 Minor Repair

Minimum Displacement Limiter Screw

Seal Lock Nut

Tamper-Resistant Cap

Seal Lock Nut

Maximum Displacement Limiter Screw

Tamper-Resistant Cap

SAE Flange Version shown

(cartridge Version similar)

Variable Motor Displacement Limiters

1. Remove the tamper-resistant cap from the displacement limiter. Measure and note the length of the adjustment screw up to the seal lock nut. Using a 19 mm hex wrench, loosen the seal lock nut and remove the nut. Remove the limiter screw from the motor housing with a 6 mm internal hex wrench.

2. Install the limiter screw with the noted length between adjustment screw and the seal lock nut. Do not install a new tamper-resistant cap until the limiter has been adjusted.

3. Final adjustment of the displacement limiters should be performed on a test stand.

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.

S000 026E

4. Following the final adjustment, install new tamper

One full turn of the displacement limiter adjustment screw will change the displacement as follows:

eziSemarF

550mc6.5 570mc1.7

ni43.0(veR/

ni34.0(veR/

wercSgnitsujdA

foveRreppsiDniegnahCxorppA

)veR/ )veR/

E592200T

resistant caps.

MV Displacement Limiters

90000851E

Series 90 Minor Repair

Variable Motor Controls

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.

Remove BEFORE removing control.

Note:

Hydraulic 2-Position

Control Valve

Install AFTER installing control. Refer to "Control Orifices" Section

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.

Electric 2-Position

Control Valve

MV Control components

1/8 in. int. hex wrench Torque: 5.4 Nm (48 lbf•in)

9/16 in. hex wrench Torque: 34 Nm (25 lbf•ft)

7/8 in. hex wrench Torque: 68 Nm (50 lbf•ft)

90000852E

7. Install new O-rings on the control valve.

8. Install the valve into the motor housing and torque to 47 Nm (35 lbf•ft). Do not overtorque the control valve. Over-torquing may result in the valve spool sticking.

9. Install the solenoid onto the valve and torque the hex nut to 5 Nm (44 lbf•in). Do not overtorque the nut.

10. If previously removed, reinstall the orifice check valve. Reconnect the external signal connection.

Hydraulic 2-Position Control (Type PT)

Follow the steps above, except that in step 2 a hydraulic signal line will be disconnected, and steps 3 and 9 are not applicable.

Control Plugs

Remove the control plugs from the housings of earlier production motors, if necessary. Install new O-rings, reinstall, and torque.

MV Control Plugs

90000853E

Series 90 Minor Repair

Variable Motor Control Orifices

Control Supply Orifice

1. Remove the control supply orifice from the motor housing with an 1-1/16 inch hex wrench.

2. Remove the O-rings and the backup washers. Check that the filter screen is secure in the orifice body and that the screen and the orifice are not plugged.

Backup Washer

Control Suply Orifice

Screen (pressed in)

O-ring

Backup Washer

O-ring

3. Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf•ft).

Caution Do not interchange the control supply orifice with the minimum displacement orifice (next section).

S000 027E

Minimum Displacement Cylinder Orifice or Orifice Check Valve

1. Remove the minimum displacement cylinder drain orifice or the orifice check valve from the motor housing with an 1-1/16 inch hex wrench.

2. Remove the O-rings and the backup washers. Check that the orifice is not plugged. Check that the check valve seat is secure in the body and that the check ball is free.

Backup Washer

Screen

(pressed in)

Orifice

O-ring

Backup Washer

Orifice Body

Cross-section View of

Control Supply Orifice Assembly

MV Control Supply Orifice

Orifice / Check Valve Assembly

O-ring

Backup Washer

O-ring

Backup Washer

O-ring

90000854E

3. Install new backup washers and O-rings onto the orifice body. Install the orifice into the motor housing and torque to 37 Nm (27 lbf•ft).

Caution Do not interchange the control supply orifice (previous section) with the minimum displacement orifice.

S000 028E

O-ring

Orifice Body

Backup Washer

O-ring

Backup Washer

Cross-Section View of

Orifice Assembly

Spring Pin

Kugel

MV Minimum Displacement Orifice

O-ring

Orifice Body

Backup Washer

O-ring

Backup Washer

Orifice Seat (Spot welded)

Cross-Section View of

Orifice / Check Valve

Assembly

90000855E

Series 90 Minor Repair

Maximum Displacement Cylinder Orifice Check Valve

1. Remove the seal lock nut with a 3/4 inch hex wrench.

Housing Plug

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

Seal Lock Nut (seal toward housing)

O-ring

Remove the maximum displacement cylinder orifice check valve from the motor housing with a 1/4 inch end wrench. Remove the O-ring. The check ball in the valve must be free.

2. Reinstall the check valve and torque to 15 Nm (11 lbf•ft). Install a new O-ring. Install the seal lock nut with the seal toward the motor housing.

Hold the check valve from turning while torquing the seal lock nut to 34 Nm (25 lbf•ft).

3. If no orifice check valve is installed, the housing plug may be removed with a 9/16 inch hex wrench. Always install a new O-ring. Reinstall the plug and torque to 20 Nm (15 lbf•ft).

MV Maximum Displacement Orifice

90000856E

Series 90 Minor Repair

Speed Sensor

1. Remove the speed sensor by disconnecting the electrical connector, loosening the lock nut, and unscrewing the speed sensor from the pump or motor housing.

2. Always install a new O-ring before installing the sensor.

3. Reinstall the speed sensor (with lock nut and O-ring) into the housing. Adjust the gap between the sensor and the magnetic speed ring as instructed in Section "Speed Sensor Adjustment" and torque the sensor lock nut.

4. If a speed sensor is not installed, the housing plug should be torqued as indicated in the accompanying figure.

Speed Sensor

1-1/16 in. hex wrench Torque: 13 Nm (10 lbf•ft) After adjustment!

Typical Location of Speed Sensor - PV

1-1/16 in. hex wrench

Torque: 13 Nm (10 lbf•ft)

Housing Plug 1/4 in. int. hex wrench Torque: 23 Nm (17 lbf•ft)

After adjustment!

90000857E

Housing Plug

1/4 in. int. hex wrench

Torque: 23 Nm (17 lbf•ft)

Typical Location of Speed Sensor - MF

1-1/16 in. hex wrench

Torque: 13 Nm (10 lbf•ft)

After adjustment!

Speed Sensor

Typical Location of Speed Sensor - MV

Speed Sensor

Housing Plug 1-1/16 in. hex wrench Torque: 37 Nm (27 lbf•ft)

90000858E

90000859E

Series 90 Exploded View Parts Drawings / Parts Lists

Exploded View Parts Drawings / Parts Lists

Variable Pumps

Minor Repair Parts

B83

P30

P2A_

P2B_

P06

B83

P13

B82

P06

G542 G546

P13

G522 G526

(G63)

(G64)

G532 G536

B70

B80

BOTH SIDES

K90 K10

K50 K70

K80

(B90)

G63 (CODE 61 OPTION)

G64 (CODE 61 OPTION)

K018 bis K042

(G502 G506)

G541 G548

(B70)

L35 (Early Production 075 Frame Size)

(B80)

B90

(G502 G506)

G531 G538

G512 G516

G502 G506

(L40)

B71

G172 G176

L50

L30

(K018 THRU K042)

(L70)

L60

L40

G501 G508

G511 G518

G63 (CODE 61 OPTION)

L70

G521 G528

(G501 G508)

(G63)

(G64)

G64 (CODE 61 OPTION)

90000860E

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List

Item Description Qty Item Description Qty

B70 ............... Plug ......................................................... 2

B71 ............... Plug ......................................................... 1

B80 ............... Plug ......................................................... 1

B82 ............... Plug ......................................................... 1

B90 ............... Filter screen ............................................ 3

G63 .............. Split flange clamp .................................... 4

G64 .............. Plug ......................................................... 4

G172 ............ Plug ......................................................... 1

G176 ............ O-ring ...................................................... 1

G501 ............ Plug ......................................................... 3

G502 ............ Plug ......................................................... 3

G506 ............ O-ring ...................................................... 3

G508 ............ O-ring ...................................................... 3

G511 ............ Plug ......................................................... 1

G512 ............ Plug ......................................................... 1

G516 ............ O-ring ...................................................... 1

G518 ............ O-ring ...................................................... 1

G521 ............ Plug ......................................................... 1

G522 ............ Plug ......................................................... 1

G526 ............ O-ring ...................................................... 1

G528 ............ O-ring ...................................................... 1

G531 ............ Plug ......................................................... 1

G532 ............ Plug ......................................................... 1

G536 ............ O-ring ...................................................... 1

G538 ............ O-ring ...................................................... 1

G541 ............ Plug ......................................................... 1

G542 ............ Plug ......................................................... 1

G546 ............ O-ring ...................................................... 1

G548 ............ O-ring ...................................................... 1

K10 ............... Plug assembly ......................................... 1

K50 ............... O-ring ...................................................... 1

K70 ............... Spring ...................................................... 1

K80 ............... Poppet .....................................................1

K90 ............... Nut ........................................................... 1

L30 ............... Seal carrier .............................................. 1

L35 ............... Seal carrier .............................................. 1

L40 ............... Lip seal .................................................... 1

L50 ............... O-ring ...................................................... 1

L60 ............... Retainer ................................................... 1

L70 ............... Screw ...................................................... 3

L8 ................. Key .......................................................... 1

L9 ................. Slotted nut ............................................... 1

Series 90 Exploded View Parts Drawings / Parts Lists

Variable Pump Controls

M95M

M96M

T001 THRU T009, T022 T050

M97M

M9ME

T201 THRU T209, T222 T250

T301 THRU T309, T322 T350

M98M

T401 THRU T409, T422 T450

M76M

M92M

M77M

M1MA M1MB M1MC M1MD M1ME M1MF M1MG

M850

M0MA M0ME M0MB M0MF M0MC M0MG M0MD M0M9

M90M M880

M870

M840

M840 REF

M830

M74M

M860

M840 REF

M78M

M75M

M87M

S40

M72M

M71M

M11M

M90D

M7MA M7MB M7MC M7MD M7ME M7MF M7MG

M810

M820

M11D

M1DC M1DD

M0DC M0DD

M0EA M0EF M0EP

M1EA M1EF M1EP

M11C

M90E

M880

M11E

M1CA

M91E

M9EA M9EP

M87E

M87C

M97E

M0CA

M90C

M98E

M95E

M96E

(Early Production 130 cc Frame Size)

M1HA, M1HC M1HF, M1HG M1HH, M1HJ M1HK, M1HL M1HM, M1HN

M11H

M90H M880

M87H

M0HA, M0HC M0HF, M0HG M0HH, M0HJ M0HK, M0HL M0HM, M0HN

90000861E

Series 90 Exploded View Parts Drawings / Parts Lists

Control Parts List

Item Description Qty Item Description Qty

M0CA ........... Cover plate kit ......................................... 1

M1CA ........... Cover plate .............................................. 1

M11C ........... Control gasket ......................................... 1

M11D ........... Control gasket ......................................... 1

M87C ........... Washer, seal (042) ................................. 1

M90C ........... Screw ...................................................... 6

M0DC ........... Control kit, 3-position FNR 12V .............. 1

M0DD ........... Control kit, 3-position FNR 24V .............. 1

M1DC ........... Control, 3-position FNR 12V ................... 1

M1DD ........... Control, 3-position FNR 24V ................... 1

M80 .............. Control gasket ......................................... 1

M87D ........... Washer, seal (042) ................................. 1

M90D ........... Screw ...................................................... 6

M0EA ........... Control kit, EDC with

MS connector .......................................... 1

M0EP ........... Control kit, EDC with

Packard connector .................................. 1

M1EA ........... Control, EDC with

MS-connector .......................................... 1

M1EP ........... Control, EDC with

Packard-connector .................................. 1

M9EA ........... PCP type 3 oil filled (MS) ........................ 1

M9EA ........... PCP type 3 oil filled (Packard) ................ 1

M80 .............. Control gasket ......................................... 1

M87E ............ Washer, seal (042) ................................. 1

M90E ............ Screw ...................................................... 6

M91E ............ Plastic cap (MS) ......................................1

M95E ............ O-ring ...................................................... 2

M96E ............ O-ring ...................................................... 1

M97E ............ O-ring ...................................................... 1

M98E ............ Screw ...................................................... 4

M1MA........... Servovalve kit .......................................... 1

M0HA ........... Control kit, hydraulic, HDC ..................... 1

M0HC ........... Control kit, hydraulic, HDC ..................... 1

M1HA ........... Control, hydraulic, HDC .......................... 1

M1HC ........... Control, hydraulic, HDC .......................... 1

M11H ........... Control gasket ......................................... 1

M80 .............. Control gasket ......................................... 1

M87H ........... Washer, seal (042) ................................. 1

M90H ........... Screw ...................................................... 6

M0MA........... Control MDC

w/o neutral start switch ........................... 1

M7M ............. Control handle ......................................... 1

M71M ........... Washer .................................................... 1

M72M ........... Nut ........................................................... 1

M80 .............. Control gasket ......................................... 1

M87M ........... Washer, seal (042) ................................. 1

M90M ........... Screw ...................................................... 6

M71M ........... Washer .................................................... 1

M72M ........... Nut ........................................................... 1

M80 .............. Control gasket ......................................... 1

M87M ........... Washer, seal (042) ................................. 1

M90M ........... Screw ...................................................... 6

S40 ............... Neutral start switch kit ............................. 1

M0MC .......... Control MDC w/ sol. valve ...................... 1

M7M .............Control handle ......................................... 1

M71M ........... Washer .................................................... 1

M72M ........... Nut ........................................................... 1

M74M ........... Solenoid valve ......................................... 1

M75M ........... Control manifold ...................................... 1

M77M ........... Manifold gasket ....................................... 1

M78M ........... Screw ...................................................... 2

M80 .............. Control gasket ......................................... 1

M87M ........... Washer, seal (042) ................................. 1

M90M ........... Screw ...................................................... 6

M0MD .......... Control MDC w/ sol. valve and

neutral start switch .................................. 1

M7M .............Control handle ......................................... 1

M71M ........... Washer .................................................... 1

M72M ........... Nut ........................................................... 1

M75M ........... Control manifold ...................................... 1

M76M ........... Solenoid valve ......................................... 1

M77M ........... Manifold gasket ....................................... 1

M78M ........... Screw ...................................................... 2

M80 .............. Control gasket ......................................... 1

M87M ........... Washer, seal (042) ................................. 1

M90M ........... Screw ...................................................... 6

S40 ............... Neutral start switch ................................. 1

M810 ............ Adapter plate - Control (130 cc) ............. 1

M820 ............ O-ring (130 cc) ........................................ 1

M830 ............ O-ring (130 cc) ........................................ 1

M840 ............ O-ring (130 cc) ........................................ 2

M850 ............ Plug (130 cc) ........................................... 1

M860 ............ Screw (130 cc) ........................................ 6

M870 ............ Plug (130 cc) ........................................... 1

M9ME........... 4/2 Way valve ......................................... 1

M92M ........... Screw ...................................................... 4

M95M ........... O-ring ...................................................... 1

M96M ........... O-ring ...................................................... 1

M97M ........... O-ring ...................................................... 1

M98M ........... Screw ...................................................... 4

T001-9 .......... Control orifice kit ..................................... 1

T201-9 .......... Orificed check valve ................................ 1

T301-9 .......... Spring ...................................................... 1

T401-9 .......... Spring retainer ......................................... 1

M0MB........... Control MDC

w/ neutral start switch ............................. 1

M7M ............. Control handle ......................................... 1

Series 90 Exploded View Parts Drawings / Parts Lists

Filter and Options

N00R

H50

N10R

H50L

N35R

H50

N00M

N30R

H60

N35M REF

N20R

H30

N15R

H05

H50

N40P

N31R

N25R

H60

N35M

N20M

H40

N10M

N15M

H05

N25M

(H30)

N40L

H30

N35S

H40

N10S

H50

H60

N00S

H05

H40

90000862E

J80N

H90L

H80

H70

J15N

J40N

J30

J95_

J80_

J92_

J70_

J90_

J00_

J60_

J15_

J50_

J10_

J30

H70

H80

90000863E

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List Filter and Options

Item Description Qty Item Description Qty

H05B-H ........ Kit - Charge pump ................................... 1

H50L ............ Spacer (No charge pump) ...................... 1

H30 .............. Port plate ................................................. 2

H40 .............. Pin ........................................................... 1

H50 .............. Charge pump shaft ................................. 1

H60 .............. Key .......................................................... 1

H70 .............. Retaining plate ........................................ 1

H80 .............. Screw ...................................................... 6

H90L ............ Plug ......................................................... 1

J00A ............. Aux. mtg. SAE A flange .......................... 1

J00B ............. Aux. mtg. SAE B flange .......................... 1

J00C ............. Aux. mtg. SAE C flange .......................... 1

J00D ............. Aux. mtg. SAE D flange .......................... 1

J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1

J00V ............. Aux. mtg. SAE B-B flange ....................... 1

J00N ............. Aux. mtg. flange - none .......................... 1

J10A-V ......... Coupling .................................................. 1

J15 ............... Charge pump cover assembly ................ 1

J15N ............. Charge pump cover assembly ................ 1

J30 ............... Bushing ................................................... 1

J50A-V ......... O-ring ...................................................... 1

J60A/T .......... Flange adaptor SAE A ............................ 1

J60B/V ......... Flange adaptor SAE B ............................ 1

J60C ............. Flange adaptor SAE C ............................ 1

J60D ............. Flange adaptor SAE D ............................ 1

J70A-V ......... Washer .................................................... 4

J80A-V ......... Screw ...................................................... 4

J80N ............. Screw ...................................................... 4

J90A-V ......... O-ring ...................................................... 1

J92A-V ......... Cover plate .............................................. 1

J95A-V ......... Screw ................................................... 2/4

N00M ........... Filtration manifold kit (Int) ....................... 1

N10M ........... Manifold ................................................... 1

N15M ........... O-ring ...................................................... 2

N20M ........... Nut ........................................................... 1

N25M ........... Tube ........................................................ 1

N35M ........... Plug ......................................................... 2

N40L ............ Filter ........................................................ 1

N40P ............ Filter ........................................................ 1

N00R ............ Filtration manifold kit (Rmt) ..................... 1

N10R ............Manifold ................................................... 1

N15R ............O-ring ...................................................... 1

N20R ............ Nut ........................................................... 1

N25R ............ Tube ........................................................ 1

N30R ............ Plastic plug .............................................. 2

N35R ............ Plug ......................................................... 1

N00S ............ Filtration kit (Suction Flt) ......................... 1

N10S ............Reducer fitting (Suction Flt) .................... 1

N35S ............ Plug ......................................................... 1

Name Plates

Model Number

Serial Number

saue

Ames, Iowa, U.S.A. Neumünster, Germany

Model Code Typ

90L055 EA 1 N

6 S 3 C6 C 03

Model No. Ident Nr

94 – 2029

Serial No. Fabr Nr

MADE IN U.S.A.

Place of Manufacture

Name Plate (U.S.A. Production)

Model Code

Model Number

Serial Number

saue

Ames, Iowa, U.S.A. Neumünster, Germany

Model Code Typ

90L055 EA 1 N

6 S 3 C6 C 03

Model No. Ident Nr

687459

Serial No. Fabr Nr

MADE IN GERMANY

Place of Manufacture

Name Plate (German Production)

Model Code

Series 90 Exploded View Parts Drawings / Parts Lists

Fixed Motor

Minor Repair Parts

H68W

H60N

(B80)

L35 (Early Production 075 Frame Size)

(L40)

L50

L40

L30

(L70)

L60

L70

(H50W)

(H40W)

H60W

H62W

H64W

H66W

(H50N)

(G50)

(H30W)

(H20W)

(G63)

(G64)

G70

G63 (CODE 61 OPTION)

G64 (CODE 61 OPTION)

B80

B83

H10W

B83

H30W

G50

H10N

H50N

H20W

H40W

H50W

G63 (CODE 61 OPTION)

G64 (CODE 61 OPTION)

(G63)

(G64)

(B80)

B80

(B83)

90000864E

Series 90 Exploded View Parts Drawings / Parts Lists

Parts List

Item Description Qty

B80 ............... Plug ......................................................... 2

B83 ............... Plug ......................................................... 1

B83 ............... Speed sensor .......................................... 1

G50 .............. Plug ......................................................... 2

G70 .............. Plug ......................................................... 1

G63 .............. Split flange screw ....................................4

G64 .............. Screw - Shipping Cover .......................... 4

H10N ............ Loop flushing spool - defeat .................... 1

H50N ............ Plug ......................................................... 2

H10W ........... Shuttle valve spool .................................. 1

H20W ........... Spring guide ............................................ 2

H30W ........... Spring ...................................................... 2

H40W ........... O-ring ...................................................... 2

Name Plates

Item Description Qty

H50W ........... Plug ......................................................... 2

H60W ........... Charge relief valve plug .......................... 1

H62W ........... O-ring ...................................................... 1

H64W ........... Spring ...................................................... 1

H66W ........... Charge relief poppet ............................... 1

H68W ........... Lock nut ................................................... 1