- SAUER-DANFOSS HYDROSTATIC TRANSMISSION.

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1 - SAUER-DANFOSS HYDROSTATIC TRANSMISSION. Speed Sensor Checking and adjustment. Speed Sensor Check list. GILL inductive ihing checking and adjustment (CH-130 / 150). FNR solenoids electric signals. Adjustment of the hydrostatic motors.

3 60 CH 130 / CH 150

5 Diagnosis transmision SAUER / SAUER transmission diag. / Diag. Transmission SAUER LED VERDE : Alimentación 12V OK GREEN LED : 12V supply OK LED VERT : Alimentation 12V OK SAUER S1X LED VERDE : Alimentación 5V sensores OK GREEN LED : 5V sensors supply OK LED VERT : Alimentation capteurs 5V OK LED AMARILLO : Parpadeo 1 vez por segundo, OK Parpadeo 10 veces por segundo, falta programación YELLOW LED : Flashing 1time x second, OK Flashing 10times x second, software missed LED JAUNE : Clignot 1 fois x second, OK Clignot 10 fois x second, programation perdue LED ROJO : Si hay un fallo, emite 4 señales luminosas (codigo), se detiene, y reinicia la secueia del error RED LED : If missfire, emits 4 ligth signals (code), stops, and starts again to show mistake sequee LED ROUGE : Si on trouve an erreur, emite 4 signales lumineuses (code), arrete, et re-demarre la secuee de l erreur

6 Diagnosis transmision SAUER / SAUER transmission diag. / Diag. Transmission SAUER Codigo/Code/Code Fallo / Missfire / Erreur Falla sensor velocidad Speed sensor missfire Erreur capteur vitesse Fallo intermitente sensor velocidad Speed sensor missfire (not permanent) Erreur pas permanent capteur vitesse Fallo ihing Ihing missfire Erreur ihing Fallo electrovalvulas (en corto o abiertas) Electrovalves missfire (open or shortcircuit) Erreur electrovalves (circuit oubert o coupe) Fallo interruptor FNR (en corto) Switch FNR missfire ( shortcircuit) Erreur interrupteur FNR (circuit coupé) Nivel de bateria bajo Low battery level Niveaux bas de la batterie Fallo electrónico de la Sauer Electronic Sauer missfire Erreur electronique du Sauer Causas / Due to... / Raison Motor parado, fallo conexión sensor, sensor dañado Engine stopped, connection missfire, sensor damaged Moteur arreté, erreur a la connectique, capteur en panne Fallo conexión sensor, sensor dañado Connection missfire, sensor damaged Erreur a la connectique, capteur en panne Fallo conexión sensor, sensor dañado Connection missfire, sensor damaged Erreur a la connectique, capteur en panne Fallo conexión electrovalvula, bobina dañada Connection missfire, coil damaged Erreur a la connectique, bobine en panne Fallo conexión, interruptor dañado Connection missfire, switch damaged Erreur a la connectique, interrupteur en panne Bateria vieja, descargada Old battery, discharged Vieille pile, déchargé Problema electónico de la centralita Switchboard electronic problem Les standards problème électronique

9 Check list SAUER Transmisión Problem Description : With engine running, there are not speed signal ( Red led error code :.. -. ) POSIBLE PROBLEMS SYMPTOM POSIBLES CAUSES CHECK OPERATIONS SOLUTIONS Check supply between red and black Bad supply from black box. Change it No pulses with engine running. No Herz signal with Frequey Sensor supply not good (+5V DC) wires on sensor conector when ignition on. Bad connection-wire loose. Check loom between sensor and black box Pulses signal are not tester measuring between white Dismount sensor and check on Change if damaged generated in pumpsensor conection (idle rpm, between Adjust acording adjustement and black wire on sensor bottom for damaged area Sensor damaged or bad adjust Re-adjust Hz, max engine speed instructions between Hz) Check deep dimension with caliper Pulse generator wheel damaged acording instructions Change pump Check wire connections between Bad connections Repair-change loom Pulses are generated but sensor and black box Herz signal Ok on sensor still red led error code Check if herz signal arrives to black Black box damaged Bad input signal on black box. Change it box connector

11 Regulation of Ihing with GILL Inductive Sensor part number with minimum ihing screw (from chassis number ) Instructions for the regulation: Needed Materials: - Multimeter or tester for measuring continuous voltage - Flat-tipped screwdriver (not always necessary) - Fixed 10 wreh. - Number 5 Allen key. A) Verification of sensor supply voltage. The sensor is supplied with a voltage of 5Vdc from the SAUER control panel. In order to verify that the supply is correct, it is necessary to measure the value of DC volts (continuous current) between the sensor s blue cable (earth) and red cable (positive) using a tester or multimeter. This measurement may be taken at the sensor ihing installation connector. The value read should be between 4.6Vdc and 5.1Vdc. If the value found is different (or 0 ) we should check the loom, the SAUER control panel power input fuse or the panel itself. B) Checking of the Sensor Signal. The sensor signal is monitored in the same manner as the power input (multimeter in continuous voltage measuring position), albeit taking the readings between the blue cable (earth) and the yellow cable (signal). The values that we should expect to find in correct futioning are: - Without activating ihing (pedal at rest): The measured value should be between 0.5 and 0 8 Vdc. This value should NEVER be lower than 0.5 Vdc. - Maximum ihing (pedal pushed down to the bottom): The measured value should be between 4.3 and 4.6 Vdc. This value should NEVER be higher than 4.7 Vdc. - As we push the ihing pedal down, the signal will change progressively between the minimum value ( Vdc) and the maximum value ( Vdc). If the values read do not change with the position of the pedal, we would have to proceed to change the sensor. If the values read exceed the limit values indicated, it will be necessary to proceed to the adjustment of the ihing pedal as follows.

C) Adjustment of the ihing signal. C.1) Adjustment if the value is less than 0.

If it is necessary to raise the value of the signal (the current signal is less than 0 5 Vdc) loose the Allen screw and stabilise it with the fixing nut in order to allow

8 Vdc), tighten the Allen screw and stabilise it with the fixing nut. 1 Minimum travel screw 2 Check the value with the pedal at rest position C.

7 Vdc when ihing is activated to the maximum (pedal pushed down to the bottom): It is necessary to regulate the stop screw of the sensor s connecting arm.

12 C) Adjustment of the ihing signal. C.1) Adjustment if the value is less than 0.5Vdc or more than 0 8Vdc when ihing is not activated (pedal at rest) : It is necessary to regulate the stop screw of the sensor s connecting arm. If it is necessary to raise the value of the signal (the current signal is less than 0 5 Vdc) loose the Allen screw and stabilise it with the fixing nut in order to allow the sensor more displacement room when the pedal is at rest position. If it is necessary to decrease the value of the signal (the current signal exceeds 0.8 Vdc), tighten the Allen screw and stabilise it with the fixing nut. 1 Minimum travel screw 2 Check the value with the pedal at rest position C.2) Adjustment if the value is less than 4.3 Vdc or more than 4.7 Vdc when ihing is activated to the maximum (pedal pushed down to the bottom): It is necessary to regulate the stop screw of the sensor s connecting arm. If it is necessary to raise the value of the signal (the current signal is less than 4.3 Vdc) tighten the Allen screw and stabilise it with the fixing nut in order to allow the sensor more displacement room when the pedal is stepped on. If it is necessary to decrease the value of the signal (the current signal exceeds 4.7 Vdc), loosen the Allen screw and stabilise it with the fixing nut. 3 Adjustment Screw Maximum Ihing 4 Check voltage value with pedal fully pressed

15 Nr. Hinweise Referees 1 Schaltkontaktleistung min. 6A Contact capability min. 6A 2 Sicherung mittelträge 10A Malting fuse 10A 3 Gezeichnete Stellung: Neutral Position shown: Neutral 4 Zur Benutzung des SUSMIC-DIA 1 Used for SUSMIC-DIA 1 5 Max. Ausgangsstrom 2A max. current output 2A 6 Verstellung: Ohne/2-Punkt/Proportional Displacement: None/2-Position/Proportional Sensor (-) Digital Input AMP Stecker, 42polig AMP connector, 42pin 7 Max. 3,25A = Option * Fahrtrichtungsschalter FNR switch 3 Digital Input 1 Digital Input 2 Digital Input 3 * Betriebsartenschalter Mode switch High Current 0 (+) High Current 1 (+) High Current 0 FB (-) High Current 1 FB (-) * Kriechgangsschalter (Option) Creeper drive switch (option) oder Handbremsschalter (Option) or Hand brake switch (option) NFPE Ventil NFPE valve RS232 Ground Sensor (+) Battery (-) PPU Input 0 PPU Input 1 * RS232 TxD RS232 RxD High Current 4 (+) * High Current 5 (+) * Battery (+) Battery (-) Terminals (+) Sensor Terminals (-) Sensor Impulsaufnehmer Diesel PPU engine Impulsaufnehmer Motor (Option) PPU motor (option) Diagnosestecker Diagnostic connector Motorverstellung Motor displacement Parkbremse (Option) Park brake (option) 6 Terminals (-) Analog Input 0 Analog Input 1 * A B C R V R V Ihpedal Ih pedal R V 1kW Kriechgang (Option) Creeper drive (option) Battery (+) R V Terminals (+) 1 S1 2 F1 + Batt. 12/24V DC DFTR DATE NAME A. Overk. CHKR MATL RAW PART NO. ENGR QC Norm SCALE: NONE SIZE TITLE Anschlußplan Connection Diagram S1X NFPE System ISSUE AUTH DATE BY DWG NO ISSUE

1. AIM INSTRUCTIONS FOR THE ADJUSTMENT OF HYDROSTATIC MOTOR P/N.: 60.13151.00 Provide the instruction for the adjustment of the maximum speed on machines with 2-

17 1. AIM INSTRUCTIONS FOR THE ADJUSTMENT OF HYDROSTATIC MOTOR P/N.: Provide the instruction for the adjustment of the maximum speed on machines with 2- speeds motor p/n OPERATION The adjustment is performed with the stud and the lock nut showed in detail A on picture 1. The stud height must be checked with a slide calipper (measurement A on picture 2). The following chart shows the proper measurement for each machine (model) where this motor is assembled. HYDROSTATIC MOTOR SAUER MMV046C-A-EDCA-NNN AUSA p/n: Machine (Model) Measurement A (mm) Speed (Km/h) 250 AH / AHG 20.2 ± ±1 300 AH / AHG 20 ±1 CH 130x4 17,1 ± ±1 CH 150 / 150x4 20 ±1 To adjust, loose the lock nut with an 18 mm wreh adjusting the stud with a 3/16 Allen key until desired height is reached. Oe adjusted, tight the lock nut holding the stud with the Allen key. Picture 1 Picture 2 CREATED: REVISED: PASSED: DATE: DATE: DATE:

Instruction for the adjustment of hydrostatic motors P/N : 60.71490.00 and 43.71490.00 1. AIM Provide the instruction for the adjustment of the maximum speed on machines with 2-speed motor p/n 60.

Sometimes they can be protected with a metallic cap, which should be removed to proceed. The stud height must be checked with an slide caliper (measurement "A" on picture 1).

18 Instruction for the adjustment of hydrostatic motors P/N : and AIM Provide the instruction for the adjustment of the maximum speed on machines with 2-speed motor p/n and 1-speed motor p/n OPERATION The adjustment is performed with the stud and the lock nut in detail "A" on picture 1. Sometimes they can be protected with a metallic cap, which should be removed to proceed. The stud height must be checked with an slide caliper (measurement "A" on picture 1). If the height doesn't fit with the regulation height for the machine model which will be assembled, it should be regulated with the proper measurement in chart 1. SAUER HYDROSTATIC MOTOR AUSA p/n: and Measurement Speed Machine A Km/h (model) mm 350/400 AHG 28,7 ± Do not adjust it, it's already CH 280/320 adjusted by SAUER 500 AHZ 26 ± Chart 1 To adjust, loose the lock nut with a 17mm wreh (picture 2) adjusting the stud with a 5mm Allen key (picture 3), until desired height is reached. Oe adjusted, tight the lock nut holding the stud with the Allen key. Picture 1 Detail A Picture 2 Picture 3

POWER SYSTEM MODE STATUS

POWER SYSTEM MODE STATUS SX NFPE Control System System Description 4, 60,2 8, 8, 0 9 0 2, 0, AMP Stecker AMP Connector 4 28 29 42 Overview DESCRIPTION The Sauer-Danfoss NFPE (Non-Feedback Proportional Electric) System for Automotive