Page 1 Service Manual Version 1.00 US - 02.2017 HARDI® reserves the right to make changes in design, material, or specification without notice thereof. HARDI® and other product names are registered trademarks of HARDI® Inc. in the U.S. and in other countries.
Page 3: Table Of Contents
Table of contents Table of contents Welcome Welcome Letter ............................8 ................................................8 OPERATOR SAFETY Operator safety ...........................10 Symbols ............................................. 10 Recommendations to users of treatment products ........................10 Filling and application ..................................... 11 Usage ............................................11 Operator's skill ........................................11 TECHNICAL SPECIFICATIONS OVERALL DIMENSIONS ....................................
Page 4 Table of contents Set the hydraulic pressure ..................................... 48 Mechanical stop bar ......................................48 SUSPENSION ............................50 General info ..........................................50 Air circuit diagram ......................................50 Air pressure limiting valve setting ................................51 Air regulator for Ace pump ................................... 51 Air suspension adjustment ................................... 52 Wheels - Tires - Rims ......................................
Page 5 Table of contents Operating parameters .........................93 Overview ..........................................93 Input Speed ..........................................93 System Pressure ........................................93 Charge Pressure ........................................93 Charge Inlet Pressure ......................................93 Case Pressure ......................................... 94 Temperature and viscosity .................................... 94 Technical specifications ........................95 Overview ..........................................95 General Specifications ......................................
Page 6 Table of contents Charge pump ........................................120 Charge pump (continued) ..................................121 High Pressure Relief Valve (HPRV) ................................123 Charge Pressure Relief Valve ..................................124 Pressure Limiter Pressure Valve Replacement ..........................125 Fastener Size and Torques ...................................126 Plug Size and Torques ....................................126 Fasteners and plugs ......................................127 Fasteners and plugs (continued) ................................128 Integrated Speed Limitation ......................
Page 7 Table of contents Check the Log via the Service Tool ................................181 MC050 and PLUS+1 Calibration ................................182 Check Log via PLUS+1 screen ...................................183 Harness overview ..........................184 Main Harness ........................................184 Headlights ..........................................185 Harness Headlight diagram (USA version) ............................187 Rear left lights harness ....................................188 Rear right lights harness ....................................188 Hydraulic oil level switch (Old version) ...............................189 Hydraulic oil level switch (New version) .............................189...
Page 8 Table of contents Storing the combined air filter ..................................226 Maintenance of the combined air filter ..............................226 FUNCTIONALITY TEST - TESTING THE SPECIFIED STATUS OF THE FUNCTIONS ............228 Air conditioning maintenance ..................................228 PC -K MANAGEMENT SOFTWARE ...................... 229 Software installation ......................................229 Operating the K-protect Management ...............................230 Main menu description ....................................230 Calibration of the ventilation and temperature buttons ..............
Page 9: Welcome
HARDI® is your specialist in spraying and we spend all of our time and keep all of our focus on spraying. We do not share our resources between other types of products or compromise on anything in providing the best quality sprayers to the market today.
Page 10 Welcome...
Page 11: Operator Safety
Recommendations to users of treatment products This sprayer has been designed and manufactured by HARDI to operate with treatment products that you select. For the proper functioning of the sprayer, we invite you to comply strictly to our recommendations, such as occasions in the Instructions of Use which is delivered to you at the time of the sale of the sprayer.
Page 12: Filling And Application
• For further information, see the Spray Technique book. Usage This HARDI self-propelled sprayer is exclusively intended for use in farming work, (i.e. the application of plant protection chemicals and liquid fertilizers). Any other use is considered contrary to normal usage and is therefore forbidden.
Page 13 • Failure to respect these rules may make your machine dangerous. In the event of damage or injury, HARDI shall not be held liable in any way.
Page 14 • In case of poisoning, immediately seek medical advice. Remember to identify chemicals used. • Keep children away from the equipment. • If any portion of this instruction book remains unclear after reading it, contact your HARDI dealer for further explanation before using the equipment.
Page 15 Illustrations, technical information and data in this book are to the best of our belief correct at the time of printing. As it is, HARDI always strives to improve our products. HARDI reserves the right to make changes in design, features, accessories, specifications and maintenance instructions at any time and without notice.
Page 16 OPERATOR SAFETY Explanation of symbols on safety decals Mandatory Read manual • Consult Safety Manual, located inside the black manual canister or in manual slot in the cab. Remove key • Used in conjunction with ‘Read Manual’ symbol to warn that manual must be read before operating the sprayer.
Page 17 OPERATOR SAFETY Do not drink • Hand wash tank water is only for personal hygiene use. Do not overfill tank • Risk of contamination • Risk of tank damage Overhead wires • Take care operating near wires to prevent entanglement or electrocution. Fluids under pressure •...
Page 18 OPERATOR SAFETY...
Page 19: Technical Specifications
TECHNICAL SPECIFICATIONS OVERALL DIMENSIONS 150" 48" (1,2) 54" 374" 120" to 160" 156" 168" (1) Wheels set 380/90 R50 (2) Wheels set 480/80 R50 (3) Wheels set 520/85 R46 (4) Transport 138 in. The unit of measure Conversion Units US Units Legal Units Conversion legal units Units Conversion US...
Page 20: Lubrication
TECHNICAL SPECIFICATIONS Lubrication General information Always store lubricants in a clean, dry and cool place - preferably at a constant temperature. Keep oil filling jugs, hoppers and grease guns clean, and clean the lubricating points thoroughly before lubricating. Avoid skin contact with oil products for longer periods.
Page 21: Service Intervals
TECHNICAL SPECIFICATIONS Service intervals Interval +500 hours Hydraulic Hydraulic oil level Hydraulic oil Check hydraulic filters clogged Hydraulic filters Drain the hydraulic tank Wheel Drive (gearbox) Oil level (Every 150 hours) Oil replacement (Every 500 hours) Tightening screws Cabin Combined filter (category 4) (Every 250 hours) Air conditioning gas (Every 5 years)
Page 22: Engine Lubrication Oil
TECHNICAL SPECIFICATIONS Engine Lubrication Oil RUBIA WORKS 1000 15W-40 Very high performance specific multigrade lubricant dedicated to aspirated and turbocharged engines of Earth Moving or Construction machinery from worldwide origins. USES « Public works » Particularily dedicated to the lubrication, throughout the year of engines used in Earth Moving activities like quarries, constructions, minings, etc...
Page 23: Transmission Hydraulic Oil
TECHNICAL SPECIFICATIONS Transmission Hydraulic Oil EQUIVIS ZS Lubrication High viscosity index anti-wear hydraulic oils. APPLICATIONS Hydraulic systems EQUIVIS ZS range is recommended for all kind of hydraulic systems operating under high pressure (limit as indicated by the pump manufacturer) and high temperature. Lubricants especially suitable for hydraulic systems working under extreme temperature variations and equipment operating outside : easy start up at low temperature and regular operating in all seasons : civil engineering, agriculture, marine, transport and...
Page 24: Engine Coolant
TECHNICAL SPECIFICATIONS Engine Coolant COOLELF AUTO SUPRA -37°C Ready-to-use coolant • O.A.T. DESCRIPTION COOLELF AUTO SUPRA -37°C is the premium product of our cooling liquid range. COOLELF AUTO SUPRA -37°C is a «very long life» coolant based on monoethylene glycol and organic inhibitors of corrosion.
Page 25: Antifreeze Oil For Pneumatic System
TECHNICAL SPECIFICATIONS Antifreeze Oil for Pneumatic System PNEUMA SY Pneumatic tools Anti-freeze oil for pneumatic tools. APPLICATIONS Pneumatic tools Percussion air tools, all sound proof pneumatic tools. Non miscible with conventionnal mineral oils. ADVANTAGES Long lasting equipment High impact strenght due to the extreme pressure additivation preventing the equipment wear.
Page 26: Wheel Drive Gearbox Lubrication
TECHNICAL SPECIFICATIONS Wheel Drive Gearbox lubrication The motor and the gearbox have separate lubrication. The gearbox is lubricated by oil splashing. The recommended oil type has to be EP characteristics according to MIL-L-2105 C & API GL5 For heavy duty working conditions the recommended oil is SAE 85W/140 or SAE 75W/140 ÷...
Page 27 TECHNICAL SPECIFICATIONS Table of the other common brands of lubricant and the types recommended are shown Air conditioning Gas: R134a Pressure: 21.75 psi - (1.5 bar).
Page 28 TECHNICAL SPECIFICATIONS...
Page 29: Transmission - Gearbox
ID plate. Installation Diagram Gear box P/N Dynamic brake 1-2 - Front 28011101 Gear box P/N Dynamic brake SARITOR S/N 28008001 Until 55944 3-4 - Rear 28011101 From 55951 Service Intervals Oil level...
Page 30: Lifting And Handling
TRANSMISSION - GEARBOX Lifting and handling If the handling occurs when the product is still packaged, simply follow the instructions given on the packaging and/or use normal hoisting means. ÷ Considering that the size and form of the product does not allow manual shifting, in particular handling, (e.g. installation) it is necessary to use accessories that guarantee human safety and which also avoid damages to the product.
Page 31: Product Description
TRANSMISSION - GEARBOX Product description Spindle and brake unit Reduction unit The BONFIGLIOLI TRASMITAL gearboxes, of the series described in this manual, are designed and built for applications such as track drive for crawled machines equipped with an open loop hydraulic circuit. The unit includes a planetary gearbox, 2 stages, rotating housing type.
Page 32: Wheel Drive Installation
TRANSMISSION - GEARBOX Wheel drive installation HM 20/50 -8.8 Grade 415 Nm (x2) (3673 lbf.in) 667 Nm (5903 lbf.in) (x16) Grade 12.9 CHC M 20/40 -12.9 μ ATTENTION! The person authorized to do the work must, if necessary, set out a safety plan to protect the health and safety of all persons directly involved and apply all applicable legislation During installation of hydraulic motor, the following precaution must be observed: •...
Page 33: First Start Up And Running In
TRANSMISSION - GEARBOX First start up and running in In this first stage it is advised to follow the measures given below. • Check for correct lubrication of the unit. • Bleed air from every part of the hydraulic circuit and add oil in the tank if necessary. ÷...
Page 34: Maintenance Informations
TRANSMISSION - GEARBOX Maintenance Informations Periodic Maintenance The gear-motor only requires the scheduled maintenance procedures set out by the manufacturer (see table below). Good maintenance will ensure an on going functionality as well as maximum reliability. Should irregularities in function arise, it will be necessary to consult the troubleshooting checklist to find the most adequate solution.
Page 35: Trouble Shooting
TRANSMISSION - GEARBOX Trouble shooting The following table was created to help localize troubles in the gearbox. External oil leakage Anomalies Causes Remedies From the lifetime seal Lifetime damaged Replace lifetime seal From the end cover O-ring seal damaged Replace O-ring seals Plug seal damaged Replace plug seal From the plugs...
Page 36 TRANSMISSION - GEARBOX Oil filling The gearbox is supplied without oil when replaced or rebuilt. It has filling, draining and oil level plugs. Before putting the gearbox into operation, it is necessary to fill it with oil. This procedure is undertaken following the instructions given below: •...
Page 37: Chassis And Suspension
---------- 39000201 BUSH 63097301 UPPER SLIDING PLATE GUIDE 460806 LOCKNUT M20 A2 DIN985 14029701 SLIDING PLATE L205 SARITOR 16670901 MOUNTING TOOL FOR SIDE SLIDING PLATE 438036 SCREW HM 16-60/38 8.8 DAC DIN931 16671001 MOUNTING TOOL FOR UP/DW SLIDING PLATE 430286...
Page 38: Disassembling The Half-Axle
CHASSIS AND SUSPENSION Disassembling the half-axle μ ATTENTION! You need to remove the motor support, the steering cylinder or steering lock bar, also disconnect the track cylinder and mechanical axle stop before pulling out the half-axle (i). 1. Extend the track width to the maximum position 2.
Page 39: Mounting The Heading Spacer
CHASSIS AND SUSPENSION 6. Remove the bolt (f) to allow the mechanical axle stop (g) disassembly 7. Dismantle 16 screws (h) located on each side of the axle (o) 8. Remove the sliding plates (j) and (k) of axle to allow removal the half-axle. Mounting the heading spacer (19) 9.
Page 40: Hold The Track Cylinder
CHASSIS AND SUSPENSION Hold the track cylinder (22) μ ATTENTION! To allow sliding of the half-axle (i) into the axle, it is necessary to raise the track cylinder (m) slightly and hold it horizontally, For this use thee guide for holding cylinder tool (22). 12.
Page 41: Where To Place The Shims
CHASSIS AND SUSPENSION Where to place the shims?
Page 42: General Info
CHASSIS AND SUSPENSION General info Shimming in horizontal plane Shims are placed primarily in position 1 & 2 on the ha f-axle, and 4 on the axle, so that the half-axles point slightly forward. ÷ If the clearance is out of range, put shims in position 3 Shimming in vertical plane Shims are placed only in position 6 on the half-axle, and 7 on the axle, so that the half-axles point slightly to downward.
Page 43: Assemble Sliding Plates On The Axle
CHASSIS AND SUSPENSION Sliding plates on top and bottom of the half-axle (position 5-6) ÷ Respect a minimum clearance at the top of 1.0 mm to 3.0 mm to assist the sliding of the half-axle. 15. Put the appropriate shims (15-17) on the bottom, between the half-axle (i) and the sliding plate (18). Do not put shims on top of the half-axle ÷...
Page 44: Upper Sliding Plate Replacement
CHASSIS AND SUSPENSION 18. Place the half-axle at a distance of 25 5/8” (650mm) 19. Place the sliding plates (18) on each side by using the mounting tools (6) designed for this purpose. 20. Assemble sliding plates with washers (21) and appropriate screws (9) or (10) or (11). ÷...
Page 45 CHASSIS AND SUSPENSION 25. Grease the sliding plate before positioning the assembly as shown on the illustration (a) Ø 17mm 26. Attach the guide bracket (a) to the axle by using screws (4) and washer (5). ÷ Before drilling make sure that the flat surface of the guide plate is against the axle face. 27.
Page 46: Reassemble The Track Cylinder On The Half-Axle
CHASSIS AND SUSPENSION Reassemble the track cylinder on the half-axle 29. Push in the half-axle (i) until it is in the correct position. Use a clamp or other means to push the half-axle. eassemble the axis (e) and the internal circlip (1). ÷...
Page 47: Reassemble The Motor Support On The Half-Axle
CHASSIS AND SUSPENSION Reassemble the motor support on the half-axle (24) 32. Reassemble the motor support (b) by using a new washer (24) Reassemble the steering cylinder (20) 33. Reassemble the steering cylinder (c) (front axle) or the coupling rod (d) (rear axle). Insert a new split pin (20) and bend it outward in opposite directions.
Page 48: Reassemble The Mechanical Axle Stop
CHASSIS AND SUSPENSION Reassemble the mechanical axle stop (p) (r) 35. Dismantle the adjustable rod (p) from the mechanical axle stop (n). 36. Place the new M18 lock-nut (q) into the bar 37. Reassemble the new style mechanical axle stop (d) on the axle (o) 38.
Page 49: Set The Hydraulic Pressure
CHASSIS AND SUSPENSION Set the hydraulic pressure 200 bar 2900 psi 42. Set the pressure to control the variable track width (The oil must be hot and engine rpm at the maximum). Mechanical stop bar 2 versions are available according the track width required Mechanical stop bar for Australia Designed for metric dimensions b c d e f g h i...
Page 50 CHASSIS AND SUSPENSION Mechanical stop bar settings Track width minimum intermediate maximum...
Page 51: Suspension
CHASSIS AND SUSPENSION SUSPENSION General info The compressed air is used to control the following: 1. The suspension of the machine 2. Ace pump Air circuit diagram 2 bar (30psi) Air pressure limiting valve Front airbag suspension Air tank Rear airbag suspension Air regulator Air height control leveling valve Air filter and lubricator...
Page 52: Air Pressure Limiting Valve Setting
CHASSIS AND SUSPENSION Air pressure limiting valve setting For proper functioning of the suspension, the air pressure should be set to 8 bar (116 psi). The air pressure limiting valve is located on the left side of the engine. For setting the air pressure: •...
Page 53: Air Suspension Adjustment
CHASSIS AND SUSPENSION Air suspension adjustment μ Check beforehand that the compressed air pressure is adjusted correctly. (see “Air pressure limiting valve setting” page 51). • Turn the adjustable linkage (1) to change the height of the front and/or rear airbag according the table below ÷...
Page 54: Wheels - Tires - Rims
CHASSIS AND SUSPENSION Wheels - Tires - Rims Rims description Description Offset Thicknes Bolts Bolts/ Circle Hub diam. (mm) Diam.(mm) Diam. (mm) (mm) (mm) 28011901 W12Ax50 28042501 W12-46 350,1 +/- 0,1 28028901 W15Ax50 28013101 W16A-46 28038501 W16A-46 Tire characteristics General info Overloading and under-inflating a tire both have the effect of over-deflecting it.
Page 55: Wheel Nuts
CHASSIS AND SUSPENSION Wheel nuts 405-480 Ft/lb • Tighten the nuts and apply a torque of 405-480lbf-ft (550 - 650Nm). ± WARNING! Never oil or grease the wheel nut threads. Observe the tightening torque.
Page 56: Air Treatment Filtration And Lubrication Of The Compressed Air
CHASSIS AND SUSPENSION Air treatment Filtration and lubrication of the compressed air Excludes Sprayers prior serial# 55864 Sprayers fitted with a compressed air system have filter and lubricator mechanisms for the compressed air which is necessary for correct operation of the pneumatic components. Air lubricator system location Metal bowl protector with transparent polycarbonate bowl Semi-automatic drain...
Page 57 CHASSIS AND SUSPENSION • Press the clip (2) to unlock the protective bowl. • Rotate 1/8 turn to remove the protective bowl. • Rotate the tank (4) 1/4 turn to dismantle it. μ ATTENTION! Use only an alkaline solution (soapy water) and not a solvent for cleaning the polycarbonate bowls and sight glasses.
Page 58: Pneumatic System - Technical Data
CHASSIS AND SUSPENSION Pneumatic system - Technical data CR Control Leveling Valve The Controlled Response (CR) Height Control Valve (HCV) automatically adds air to, or exhausts air from air suspension to maintain a constant static design height. The CR Height Control Valve does not respond to short duration dynamic changes in axle position.
Page 59: Airbag Suspension
4 goujons M x1.5 - 41 mm classe 4.8 (équidistants) Coupe A-A Marquage 29,5 Ø statique 410 Ø maxi 440 N° Axle Manufacturer Hardi P/N Serial number Note FRONT FIRESTONE 28028101 From 54173 to 55951 REAR FIRESTONE 280282001 From 54173 to 55925...
Page 60: Characteristics Of Antifreeze Oil For Pneumatic Circuit
CHASSIS AND SUSPENSION Characteristics of antifreeze oil for pneumatic circuit PNEUMA SY Pneumatic tools Anti-freeze oil for pneumatic tools. APPLICATIONS Pneumatic tools Percussion air tools, all sound proof pneumatic tools. Non miscible with conventionnal mineral oils. ADVANTAGES Long lasting equipment High impact strenght due to the extreme pressure additivation preventing the equipment wear.
Page 61: Engine
Engine General Information Display of the frequency of maintenance The following alert symbols appear in the display after 150 hours and 500 hours to indicate that maintenance work needs to be performed on the sprayer: 1. Maintenance after 150 hours of use. 2.
Page 62 Engine Check engine The main elements must be verified before the first starting of the engine: • Coolant Level and Engine Oil Level • Correct tightness of the oil and fuel filters • Tension on the belts Daily • Check sprayer filters. •...
Page 63: Service And Maintenance Intervals
Engine Service and Maintenance intervals Interval +500 hours Hydraulic Hydraulic oil level Hydraulic oil Check hydraulic filters clogged Hydraulic filters Drain the hydraulic tank Wheel Drive (gearbox) Oil level (Every 150 hours) Oil replacement (Every 500 hours) Tightening screws Cabin Combined filter (category 4) (Every 250 hours) Air conditioning gas...
Page 64: Maintenance Of The Engine
Engine Maintenance of the Engine Change engine oil and filter every 250 or 6 months Drain Plug location Fuel water separator filter location.
Page 65: F - Hydraulic-General Info
F - HYDRAULIC-General info Maintenance Auxiliary hydraulic filters ÷ Use only original parts - P/N 782856 1. Steering valve, track width, sprayer hydraulics filter 3. Regulating valve filter for hydraulic motor to ACE Pump. 2. Brake circuit filter To replace the filter cartridge: •...
Page 66: Tank Hydraulic Filters
F - HYDRAULIC-General info Tank hydraulic filters ± WARNING! When replacing the filters, wear protective gloves to avoid the oil making any contact with the skin. € DANGER! Hot oil can cause serious burns. ± WARNING! It is critical to use original filters. μ...
Page 67 F - HYDRAULIC-General info 500 hours service - Hydraulic filters in the tank Prior to Serial 55864 ± WARNING! Wear protective gloves while replacing filters to prevent the oil from making any contact with the skin. € DANGER! Hot oil can cause serious burns. ±...
Page 68: Hydraulic Oil Level
F - HYDRAULIC-General info Hydraulic oil level • Fill up to the maximum level • Start the engine on idle then stop it after a few seconds. This evacuates the air contained in the hydraulic system. • Start the engine again on idle and then gradually increase the engine speed. •...
Page 69: Towing The Machine
F - HYDRAULIC-General info Towing the machine General information Before any towing of the machine, following a failure in the engine or the hydraulic transmission, it is essential to check the hydraulic motors and the transmission pump. μ ATTENTION! To avoid any risk of damage to the transmission components (pump, motors etc.), the machine should be towed over a short distance and at low speed.
Page 70: Release The High Pressure Valves Of The Transmission Pump
F - HYDRAULIC-General info Release the high pressure valves of the transmission pump This operation consists of releasing the 2 high pressure valves located on the transmission pump to allow free circulation of oil in the system when towing the machine. •...
Page 71: Power Transmission Circuit
F - HYDRAULIC-General info Power transmission circuit Front Right Front Left Rear Right Rear Left...
Page 72 F - HYDRAULIC-General info Power transmission Location: Front Right motor P1: Port A - 6961 psi [480 bar] max. P2: Port B - 6961 psi [480 bar] max. Power transmission Location: Front Left motor ± 10 bar] max. P3: Port B - 6961 psi [480 ±...
Page 73: Parking And Dynamic Brake
F - HYDRAULIC-General info Parking and Dynamic brake...
Page 74: New Style Brakes
F - HYDRAULIC-General info New Style Brakes Dynamic and static brakes Location: Under the machine and behind the hydraulic tank P6: Static brake (parking brake) - 435 psi[30 ± 2 bar] max. Minimum pressure to release the brake - 218 psi [15 bar] P7: Dynamic brake - 580 psi [40 ±...
Page 75: Old Style Brakes
F - HYDRAULIC-General info Old Style Brakes Dynamic and static brakes Location: Under the machine and behind the hydraulic tank ± 2 bar] max. P6: Static brake (parking brake) - 435 psi[30 Minimum pressure to release the brake - 218 psi [15 bar] Static brake brakes Location: Under the cab center of hydraulic tank ±...
Page 76: Steering Hydraulic Diagram
F - HYDRAULIC-General info Steering hydraulic diagram...
Page 77 F - HYDRAULIC-General info Steering - Boom Control - Track Width Adjustment Location: At the left hand side of he engine P8: 2900 psi [200bar] max. • Adjust the relief valve (31) to achieve the required pressure (P8) Priority Valve for Steering Location: At the left hand side of he engine ÷...
Page 78: Track Width Adjustment, Banjo Pump, Boom Controls
F - HYDRAULIC-General info Track width adjustment, Banjo pump, Boom controls Not Conn Bypass...
Page 79 F - HYDRAULIC-General info Boom Control Location: at the rear of the machine P9: 2755 psi [190 bar]. • Adjust the relief valve (31) if necessary, located at the left hand side of the engine, to achieve the pressure (P9). Track Adjustment control Location: at the left hand side of the machine 12.
Page 80: Ace Pump Control
F - HYDRAULIC-General info ACE Pump control 0 - 17 gal/min 2538 psi 101.5 psi 29 gal/min max. Return manifold 0.26 gal 0.58 gal...
Page 81 F - HYDRAULIC-General info Ace pump control Location: at the left hand side of the machine Oil flow regulator with integrated filter (33) ÷ The pressure is preset. It is not necessary to change the pressure of the circuit. Hydraulic motor for spraying pump (Ace pump) Location: Flanged to the spraying pump ÷...
Page 82: Steering Cylinder Characteristics
F - HYDRAULIC-General info Steering cylinder characteristics Applying glue to the mounting Description Dimension Double acting cylinder / self-bleeding cylinder Total length 490 mm 19,29 inch Stroke 245 mm 9,645 inch Cylinder bore 80 mm 3,149 inch Diameter of rod 40 mm 1,574 inch Diameter of left-hand-thread (metric)
Page 83: Hydraulic - Sauer H1 Pump
HYDRAULIC - SAUER H1 PUMP AXIAL PISTON PUMP H1-P-115-R-A-A4-C2-N-E2-G-G2-H4-L-45-L-45-L-L-30-PN-NNN-G21...
Page 84: Introduction
HYDRAULIC - SAUER H1 PUMP Introduction Overview This manual includes information on the installation, maintenance, and minor repair of H1 pumps. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures. Warranty Performing adjustments and minor repairs according to the procedures in this manual will not affect your warranty. Major repairs requiring the removal of a unit’s center section, servo sleeves, or front flange voids the warranty unless a Sauer-Danfoss Authorized Service Center performs them.
Page 85: Symbols Used In Sauer-Danfoss Literature
HYDRAULIC - SAUER H1 PUMP ± WARNING! hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state, and federal environmental regulations. Symbols Used in Sauer-Danfoss Literature The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader.
Page 86: Identification
HYDRAULIC - SAUER H1 PUMP Identification H1 Axial Piston Pumps Technical Information Frame 115/130 cm Single Pump Engine SAUER HARDI SAUER DANFOSS Machines Pos. DANFOSS Comment see details “Description Code Details” page 87 Concerned Code (Current version) From S/N 55809...
Page 87 HYDRAULIC - SAUER H1 PUMP...
Page 88: Description Code Details
HYDRAULIC - SAUER H1 PUMP Description Code Details Auxiliary Mounting Pad (align with option G: Endcap Selection) Displacement None 115.2 cm³ [7.03 in³] 130.0 cm³ [7.93 in³] SAE A pad, 9 teeth coupling, shipping cover SAE A pad, 11 teeth coupling, shipping cover Rotation SAE B pad,...
Page 89: Design
HYDRAULIC - SAUER H1 PUMP Design Sauer-Danfoss H1 closed circuit piston pumps convert input torque into hydraulic power. The input shaft transmits rotational force to the cylinder block. Bearings at the front and rear of the pump support the shaft. Splines connect the shaft to the cylinder block.
Page 90 HYDRAULIC - SAUER H1 PUMP Above schematic shows the function of a hydrostatic transmission using an H1 axial piston variable displacement pump with electric displacement control (EDC) and a series 51-1 bent axis variable displacement motor with two-position control (T1).
Page 91: Pressure Limiter Valve
HYDRAULIC - SAUER H1 PUMP Pressure Limiter Valve Pressure limiter valves provide system pressure protection by compensating the pump swash-plate position when the set pressure of the valve is reached. A pressure limiter is a non-dissipative (non heat generating) pressure regulating system. Each side of the transmission loop (and each section of the tandem pump) has a dedicated pressure limiter valve that is set independently.
Page 92: By Pass Function
HYDRAULIC - SAUER H1 PUMP By Pass function The HPRV valve also provides a loop bypass function when each of the two HPRV hex plugs are mechanically backed out 3 full turns. Engaging the bypass function hydraulically connects both A & B sides of the working loop to the common charge gallery.
Page 93: Manual Override (Mor)
HYDRAULIC - SAUER H1 PUMP Manual Override (MOR) All controls are available with a Manual Override (MOR) for temporary actuation of the control to aid in diagnosis. FNR controls always include MOR functionality. € DANGER! Depressing the plunger causes the pump to go into stroke which will move the machine or mechanism. Ensure the vehicle or machine is in a safe condition (wheels off the ground or mechanism disconnected) before attempting to use the MOR feature.
Page 94: Operating Parameters
HYDRAULIC - SAUER H1 PUMP Operating parameters Overview This section defines the operating parameters and limitations for H1 pumps with regard to input speeds and pressures. For actual parameters, refer to the operating parameters for each displacement. Input Speed Minimum speed is the lowest input speed recommended during engine idle condition. Operating below minimum speed limits the pumps ability to maintain adequate flow for lubrication and power transmission.
Page 95: Case Pressure
HYDRAULIC - SAUER H1 PUMP Case Pressure Do not exceed rated case pressure under normal operating conditions. During cold start, keep case pressure below maximum intermittent case pressure. Size drain plumbing accordingly ± WARNING! Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings, causing external leakage.
Page 96: Technical Specifications
HYDRAULIC - SAUER H1 PUMP Technical specifications Overview Specifications and operating parameters for pumps are given here for reference. General Specifications Physical Properties...
Page 97: Operating Parameters
HYDRAULIC - SAUER H1 PUMP Operating Parameters Fluid Specifications Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing oxidation, rust, and foam inhibitors. Fluid and Filter Recommendations To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure.
Page 98 HYDRAULIC - SAUER H1 PUMP Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc.) or if the fluid is subjected to temperature levels greater than the recommended maximum. Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.
Page 99: Pressure Measurements
HYDRAULIC - SAUER H1 PUMP Pressure measurements Port Location and Gauge Installation The following table and drawings show the port locations and gauge sizes needed. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use a snubber to protect gauges. Port information Port locations...
Page 100: Specialized Tools
HYDRAULIC - SAUER H1 PUMP Specialized tools Overview You can perform the service procedures described in this manual using common mechanic’s hand tools. This section details any specialized tools helpful to service H1 pumps. Shaft seal Installation Tool Shaft Seal Installation Tool Drawing...
Page 101: Initial Startup Procedure
HYDRAULIC - SAUER H1 PUMP Initial Startup Procedure General Follow this procedure when starting-up a new pump installation or when restarting an installation in which the pump has been removed and re-installed on a machine. Ensure pump has been thoroughly tested on a test stand before installing on a machine ±...
Page 102: Troubleshooting
HYDRAULIC - SAUER H1 PUMP Troubleshooting Overview This section provides general steps to follow if you observe undesirable system conditions. Follow the steps listed until you solve the problem. Some of the items are system specific. We reference the section in this manual if more information is available.
Page 103: System Operating Hot
HYDRAULIC - SAUER H1 PUMP System operating hot Integral Filter Bypass Neutral Difficult or Impossible to Find...
Page 104: System Will Not Operate In Either Direction
HYDRAULIC - SAUER H1 PUMP System Will Not Operate in Either Direction System Noise or Vibration...
Page 105: Sluggish System Response
HYDRAULIC - SAUER H1 PUMP Sluggish System Response Transmission Operates Normally in One Direction Only...
Page 106: Adjustments
HYDRAULIC - SAUER H1 PUMP Adjustments Pump Adjustment This section offers instruction on inspection and adjustment of pump components. Read through the entire topic before beginning a service activity. Standard procedures ± WARNING! Contamination can damage internal components and void your warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines 1.
Page 107: Pressure Limiter Adjustment
HYDRAULIC - SAUER H1 PUMP Listed pressures assume a pump speed of 1800 min¯¹ (rpm). At higher pump speeds (with higher charge flows) the charge pressure will rise over the rated setting. 3. Loosen the locknut and turn the adjusting screw clockwise to increase the setting; counterclockwise to decrease it. The table gives approximate adjustment per turn.
Page 108: Pressure Limiter Settings
HYDRAULIC - SAUER H1 PUMP Pressure Limiter Valve Adjustment ÷ End caps are different for clockwise and counterclockwise rotation. The model code on the serial plate gives the factory setting of the PL (Pressure Limiter). The PL setting is referenced to charge pressure.
Page 109: Engaging The Bypass Function
HYDRAULIC - SAUER H1 PUMP Engaging the Bypass Function Use this procedure to bypass the pump to allow moving the vehicle/machine short distances when you cannot start the prime mover. ± WARNING! It is possible to damage the drive motor(s) by operating in bypass mode without charge pressure. Move the vehicle/machine at a speed not more than 20% of maximum for a duration not exceeding 3 minutes.
Page 110: Displacement Limiter Adjustment (Continued)
HYDRAULIC - SAUER H1 PUMP Displacement Limiter Adjustment (continued) Displacement Limiter Adjustment Data Control Neutral Adjustment All functions of the Electric Displacement Control (EDC), are preset at the factory. If necessary, adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. If adjustment fails to give satisfactory results, you may need to replace the control or coils.
Page 111: Control Neutral Adjustment (Continued)
HYDRAULIC - SAUER H1 PUMP Control Neutral Adjustment (continued) Neutral adjustment (EDC) (bottom view) Rotate the neutral adjusting screw (D015) clockwise until the pressure increases on the gauge. Note the angular position of the wrench. Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge.
Page 112: Mechanical Neutral Adjustment
HYDRAULIC - SAUER H1 PUMP Mechanical Neutral Adjustment Mechanical neutral is set with the pump running at 1800 min¯¹ (rpm). To set neutral, you must stroke the pump in each direction. You can do this with a small movement of the eccentric screw on EDC controls, however non-feedback controls (NFPE/FNR) lack this mechanism.
Page 113: Mechanical Neutral Adjustment (Continued)
HYDRAULIC - SAUER H1 PUMP Mechanical Neutral Adjustment (continued) Servo Adjustment 1. Run the prime mover at 1800 min¯¹ (rpm). 2. If using a PWM signal, ensure the signal is off. Check the servo pressure gauges. Ensure the differential between M4 and M5 is less than 22 psi [1.5 bar].
Page 114: Minor Repair
HYDRAULIC - SAUER H1 PUMP Minor Repair Standard Procedures, Removing the Pump Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached, remove both pumps as a single unit. Tag and cap all hydraulic lines as they are disconnected, and plug all open ports to ensure that dirt and contamination do not get into the system.
Page 115: Edc Control
HYDRAULIC - SAUER H1 PUMP EDC Control Removal Refer to exploded diagram, next page. 1. Using a 5 mm internal hex wrench, remove the six cap screws (D250). 2. Remove the control module and gasket (D150). Discard the gasket. 3. If necessary, remove orifices (F100) using a 3 mm internal hex wrench. Tag and number them for re installation. If screen (D084) is clogged, use a hook to remove retaining ring (D098) and screen.
Page 116: Edc Control (Continued)
HYDRAULIC - SAUER H1 PUMP EDC Control (continued) Control Module and Solenoid Removal/Installation...
Page 117: Control Solenoids
HYDRAULIC - SAUER H1 PUMP Control Solenoids Removal 1. Disconnect electrical connection and remove the three cap screws (D050) using a 4 mm internal hex wrench. 2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring. 3. If necessary, remove the coil using a 12 point 26 mm socket. 4.
Page 118: Automotive Control (Continued)
HYDRAULIC - SAUER H1 PUMP Automotive Control (continued) Inspection Inspect machined surfaces on control and pump housing. Inspect plastic PC board housing and its sealing areas. If any damage is found, replace damaged components. Controls are available as a complete unit. Do not disassemble the control Assembly 1.
Page 119: Automotive Control (Continued)
HYDRAULIC - SAUER H1 PUMP Automotive Control (continued) ÷ If pump has been rebuilt or a new control is being installed, control software must be re-calibrated. Refer to H1- ”Automotive Control User Manual” 70012797 for recalibration instructions. 2. If previously removed, use a 3 mm internal hex to install orifices (F00A, F00B) in original orientation.
Page 120 HYDRAULIC - SAUER H1 PUMP Bearing and shaft Replacement (continued) Inspection 6. Inspect the shaft and bearing for wear, scratching, and pits. Rotate the bearing and feel for roughness. Replace damaged components Reassembly 7. Press bearing (J150) on shaft. Install snap-ring (J300). 8.
Page 121: Charge Pump
HYDRAULIC - SAUER H1 PUMP Charge pump If the pump has an auxiliary pump attached, remove the auxiliary pump and coupling before removing the auxiliary pad. Charge Pump removal (removable auxiliary pad/cover) 1. Using a 10 mm internal hex wrench, remove cap screws (K400). 2.
Page 122: Charge Pump (Continued)
HYDRAULIC - SAUER H1 PUMP Charge pump (continued) Charge Pump Removal (integrated auxiliary pad) 1. Remove auxiliary pump and O-ring (K250). Discard O-ring. 2. Remove charge pump cover screws (K450) and charge pump cover (K550). 3. Remove thrust washer (K500). Note its orientation. Coated side is towards charge pump coupling (K200). 4.
Page 123 HYDRAULIC - SAUER H1 PUMP Charge Pump Removal (integrated auxiliary pad) (continued) 1. Install new seals (S300) in the valve (S250) and pressure-balance plates(S200). 2. Install valve plate (S250) in the same orientation as it was removed. 3. Lubricate and install the charge pump gear set (S100) and outer ring (S150). 4.
Page 124: High Pressure Relief Valve (Hprv)
HYDRAULIC - SAUER H1 PUMP High Pressure Relief Valve (HPRV) Removal 1. Using a hex wrench shown in the table below, remove the HPRVs (L150). Remove and discard the O-rings (L060) and backup rings (L068) Inspection 2. Inspect the sealing surfaces in the pump for nicks or scratches. Check the valves for damage. Replace any damaged components Reassembly 3.
Page 125: Charge Pressure Relief Valve
HYDRAULIC - SAUER H1 PUMP Charge Pressure Relief Valve Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to repair the internal components of the valve. Torque to 38lbf-ft [52 Nm]. See “Charge Pressure Relief Valve Adjustment” page 105, for adjustment instructions. Removal 1.
Page 126: Pressure Limiter Pressure Valve Replacement
HYDRAULIC - SAUER H1 PUMP Pressure Limiter Pressure Valve Replacement Replace the pressure limiter valve as a complete unit. Do not attempt to repair individual components. See“Pressure Limiter Adjustment” page 106, for adjustment instructions. Removal 1. Using a 22 mm wrench, remove the pressure limiter valve (L100). Discard O-ring. Inspection 2.
Page 127: Fastener Size And Torques
HYDRAULIC - SAUER H1 PUMP Fastener Size and Torques Plug Size and Torques...
Page 128: Fasteners And Plugs
HYDRAULIC - SAUER H1 PUMP Fasteners and plugs...
Page 129: Fasteners And Plugs (Continued)
HYDRAULIC - SAUER H1 PUMP Fasteners and plugs (continued)
Page 130: Integrated Speed Limitation
HYDRAULIC - SAUER H1 PUMP Integrated Speed Limitation General Description The H1 axial piston variable displacement pumps are of cradle swash-plate design and are intended for closed circuit applications. The flow rate is proportional to the pump input speed and displacement. The latter is infinitely adjustable between zero and maximum displacement.
Page 131: System Schematic
HYDRAULIC - SAUER H1 PUMP System Schematic Above schematic shows the function of a hydrostatic transmission using a H1 axial piston variable displacement pump with electric displacement control (EDC) and a bent axis variable displacement motor with two-position control. Operation For machines which are equipped with hydrostatic propel drive systems.
Page 132: Function Of The Integrated Speed Limitation
HYDRAULIC - SAUER H1 PUMP Function of the Integrated Speed Limitation Example of the dynamic braking: the machine is driving on flat ground at a high speed and should be stopped hydro- statically. This is usually done by pulling back the control handle. As a result, the displacement of the pump will be decreased by the servo control and consequently, the machine will slow down.
Page 133: Technical Specifications
HYDRAULIC - SAUER H1 PUMP Technical Specifications Definitions of the following specifications, see below Operating parameters.
Page 134: Isl - Model Code
HYDRAULIC - SAUER H1 PUMP ISL - Model Code 1 1 5 R A A4 C 2 G2 H4 L 4 5 L 4 5 PN NNN H1 P 1 1 5 R A A4 C 2 G3 H3 L 4 5 L 4 5 PN NNN H1 P G21 = ISL Pressure setting 210 bar [3046 psi]...
Page 135: Hydraulic - Sauer Bent-Axis Motor
HYDRAULIC - SAUER BENT-AXIS MOTOR BENT AXIS MOTOR H1 B 110 A L1 BA N A PB CS JS S A 15 NN 000 N NNN...
Page 136: Introduction
HYDRAULIC - SAUER BENT-AXIS MOTOR Introduction Overview This section includes information for the installation, maintenance, and minor repair of the H1 bent-axis motor. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures. Performing minor repairs may require removal from the vehicle/machine.
Page 137 HYDRAULIC - SAUER BENT-AXIS MOTOR Safety precautions Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system. € DANGER! Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
Page 138: Model Code Description
HYDRAULIC - SAUER BENT-AXIS MOTOR Model Code Description 2010 - juin - 15 Customer Application Model Code H1-B-110-A-L1-BA-N-A-PB-CS-JS-S-A-15-NN-000-N-00-NNN Material Number 83008678 List Price unknown Series Product Family H1 Product Type Motor, Variable, Bi-directional Frame Size Displacement 110 cc/rev at maximum angle Product Version Product Version Control...
Page 139: Design
HYDRAULIC - SAUER BENT-AXIS MOTOR Design Cross section of an H1 Electric proportional control Series H1 variable displacement motors are of a bent axis design, incorporating spherical pistons. These motors are designed primarily to be combined with other products in closed circuit systems to transfer and control hydraulic power. Series H1 motors have a large maximum/minimum displacement ratio of 5:1 and high output speed capabilities.
Page 140 HYDRAULIC - SAUER BENT-AXIS MOTOR System diagram System schematic...
Page 141: Technical Specifications
HYDRAULIC - SAUER BENT-AXIS MOTOR The schematic above shows the function of a hydrostatic transmission using an H1 Axial variable displacement pump with electric proportional displacement control (EDC) and an H1 Bent axis variable displacement motor with electric proportional control (L*) and integrated loop flushing device. Technical Specifications General Specifications Operating Specifications...
Page 142 HYDRAULIC - SAUER BENT-AXIS MOTOR Loop Flushing Relief Valve The loop flushing relief valve is incorporated into all H1 motors. Use the loop flushing option, in installations that require fluid to be removed from the low pressure side of the system circuit due to cooling requirements, and also used to facilitate the removal of contaminants from the loop.
Page 143: Control Circuit Diagram - Nomenclature- Description
HYDRAULIC - SAUER BENT-AXIS MOTOR Minimum Displacement Limiter All Series H1 Motors incorporate mechanical displacement limiters. The minimum displacement of the motor is preset at the factory with a set screw in the motor housing. A tamper-proof cap is provided. Control Circuit Diagram - Nomenclature- Description L1 (Electric Proportional 12 V/de-energized = max.
Page 144: Initial Startup Procedures
HYDRAULIC - SAUER BENT-AXIS MOTOR Initial Startup Procedures € DANGER! This service procedure may require disabling the vehicle/machine (raising the wheels off the ground, disconnecting work function) while performing; to prevent injury to the technician and bystanders. Take the necessary safety precautions. ÷...
Page 145: Troubleshooting
HYDRAULIC - SAUER BENT-AXIS MOTOR Troubleshooting Overview This section provides general steps to follow if you observe undesirable system conditions. Follow the steps until you solve the problem. Some of the items are system specific. Always observe the safety precautions in the section “Introduction” page 135.
Page 146 HYDRAULIC - SAUER BENT-AXIS MOTOR Excessive noise and vibrations Motor operates normally in one direction only Improper Output Speed...
Page 147 HYDRAULIC - SAUER BENT-AXIS MOTOR Low Output Torque...
Page 148: Required Tools And Standard Procedure
HYDRAULIC - SAUER BENT-AXIS MOTOR Required tools and standard procedure Required tools The service procedures described in this manual can be performed using common mechanic’s hand tools. Special tools, if required, are shown. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use a snubber to protect gauges.
Page 149: Adjustments
HYDRAULIC - SAUER BENT-AXIS MOTOR Adjustments Minimum displacement limiter Adjusting the minimum displacement limiter 1. Remove cap (N0120). ÷ Removing the cap destroys the caps locking mechanism. Replace with a new cap 2. Using a 6 mm internal hex wrench, hold adjusting screw (N0010) in place. 3.
Page 150 HYDRAULIC - SAUER BENT-AXIS MOTOR Optional threshold adjustment - electric proportional controls 1. Connect flow meter to A or B system port. 2. Connect solenoid to PWM signal generator at 100 Hz. ÷ Threshold is the electric signal when the motor starts to change from maximum to minimum displacement. 3.
Page 151 HYDRAULIC - SAUER BENT-AXIS MOTOR Optional threshold adjustment - hydraulic proportional controls Adjusting threshold on test stand 1. Connect flow meter to A or B system port. 2. Connect a variable pressure supply to X1 port (0-725)(0-50 bar). Threshold is the pressure at which the motor starts to change from maximum to minimum displacement. 3.
Page 152: Minor Repair
HYDRAULIC - SAUER BENT-AXIS MOTOR Minor Repair Shaft seal Removal 1. Using snap ring pliers, remove retaining ring (G0030). 2. Use a slide-hammer style puller to remove seal (G0020). Be careful not to damage the shaft or seal bore when removing.
Page 153 HYDRAULIC - SAUER BENT-AXIS MOTOR Electric proportional solenoid replacement Removal 1. Disconnect the electrical connection and remove the three cap screws (B0050) using a 4 mm internal hex wrench. 2. Remove the solenoid (B0010) and O-ring (B0035A). Discard the O-ring. 3.
Page 154 HYDRAULIC - SAUER BENT-AXIS MOTOR Control module replacement Removal 1. Remove the four cap screws (C0110 and/or C0120). Refer to table for wrench sizes. 2. Remove control (C0010) from motor. Remove and discard gasket (C0130). 3. Proportional control only - using a magnet, remove spring seat (F0030) and spring (F0040). Inspection 1.
Page 155 HYDRAULIC - SAUER BENT-AXIS MOTOR Electric proportional control module ÷ Coil O-rings are not included in the overhaul seal kit. They may be purchased as a separate kit. Disassembly 1. Remove plastic cap (B0040) and O-ring (B0029). Discard the O-ring. 2.
Page 156 HYDRAULIC - SAUER BENT-AXIS MOTOR Servo piston cover – proportional control Removal 1. Using a 10 mm internal hex wrench, remove the four screws (P0020). 2. Remove servo piston cover (P0010). 3. Remove and discard O-ring (P0030). 4. Remove screw (P0050). See table for wrench size. 5.
Page 157 HYDRAULIC - SAUER BENT-AXIS MOTOR Inspection 1. Clean and inspect bushings and machined surfaces for wear or damage. If wear or damage are found, replace the component in question. Assembly 1. Lubricate and install a new O-ring (P0043) and seal ring (P0044) on piston (P0041). ÷...
Page 158 HYDRAULIC - SAUER BENT-AXIS MOTOR Loop flushing spool Removal 1. Remove plugs (K0030) using a 24 mm hex wrench. 2. Remove and discard O-rings (K0030A). 3. Use a magnet to remove springs (K0020) and spool (K0010). Inspection 1. Clean and inspect spool (K0010). If the spool is damaged or worn replace it. Replace the springs if they are cracked or bent.
Page 159 HYDRAULIC - SAUER BENT-AXIS MOTOR Loop flushing charge relief valve Removal 1. Using a 24 mm hex wrench remove valve (L00**) 2. Remove and discard O-ring (L0050). ÷ Do not disassemble the valve. If you suspect a malfunction, replace the valve. Assembly 1.
Page 160 HYDRAULIC - SAUER BENT-AXIS MOTOR Assembly 1. Using a 6 mm internal hex wrench, install adjustment screw (N0010) to the original position. 2. 2. Using a 6 mm internal hex wrench to hold the position of the adjustment screw, install a new locknut seal (N0020) using a 19mm hex wrench.
Page 161: Torque Charts
HYDRAULIC - SAUER BENT-AXIS MOTOR Torque charts Fasteners and plugs Fastener size and torque chart...
Page 162: Speed And Temperature Sensor
HYDRAULIC - SAUER BENT-AXIS MOTOR Speed and Temperature Sensor Theory of operation The speed sensor is externally powered, and in response to the speed of the target ring, outputs a digital pulse signal. A magnet inside the sensor provides the magnetic field that changes with the position of the target teeth. The target ring is attached to the cylinder block or the shaft.
Page 163: Speed And Temperature Sensor Technical Data
HYDRAULIC - SAUER BENT-AXIS MOTOR Speed and temperature sensor technical data...
Page 164: Speed And Temperature Sensor Technical Data (Continued)
HYDRAULIC - SAUER BENT-AXIS MOTOR Speed and temperature sensor technical data (continued) Temperature sensor...
Page 165: Plus +1 Operating
ELECTRONICS PLUS +1 OPERATING Multifunction screen description The multifunction screen displays the information relating to the operation of the engine (tachometer, temperature, etc.) and the various modes of lines (hare, tortoise, etc.). The display also shows the errors that may occur during the use of the machine (temperature and pressure of the engine oil, transmission errors, etc...).
Page 166: Messages In Normal Operating Mode
ELECTRONICS Messages in normal operating mode Engine temperature Battery charge voltage 0-100%. Limitation of the motor speed mode [field] Engine oil pressure 1800 Restriction of the speed in movement mode [road] Turbocharger pressure 35.0 km/h Hydraulic pressure of the transmission Restriction of the speed in movement mode [Field] Instant fuel consumption...
Page 167: Electronic Diagram Of The Transmission
ELECTRONICS Electronic diagram of the transmission Front Right Rear Right Speed & Temp. sensor Speed sensor Speed sensor Speed sensor Front Left Rear Left Pump A Pump B 600 b Speed selector Engine RPM Joystick DP250 54.5 rpm x100 160 b CAN1...
Page 168: Transmission Error Codes
ELECTRONICS Transmission Error Codes 54.5 rpm x100 • Press button (1) to scroll to the SD function display. • Press button (2) to display the error menu. A red bar means a malfunction of the hydraulic system. Messages Description CAN 0 ECU MC050 and engine communication CAN 1 MC050 ECU and DP250 display communication...
Page 169: Engine Code Error
ELECTRONICS Engine Code Error Transmission error codes 54.5 rpm x100 Error Description Error Description codes codes Low battery voltage Loop error Low battery voltage PWM2 current loop error 12V sensor low supply voltage Loop error pump 1 12V sensor high supply voltage Brake pressure sensor signal out of range 5V sensor low supply voltage CAN bus communication error: signal not received...
Page 170: Cummins Engine Error Codes
ELECTRONICS CUMMINS engine error codes 54.5 rpm x100 Component / Location Description (Error location) Hand throttle Cable break or short circuit, signal implausible compared to signal or idle sensor 2,3, 4, 11 Vehicle speed signal Speed above target range, signal missing or implausible 0, 8, 12, 14 Accelerator pedal Cable break or short circuit, signal implausible compared to signal of idle sensor...
Page 171 ELECTRONICS Oil temperature sensor Cable break or short circuit 2, 3, 4 Oil temperature Below target range with system reaction 0, 11 Engine speed sensor Engine running with cam-shaft speed signal only 11, 12 Engine speed sensor Speed signal from cam-shaft bad or missing 8, 11, 12 Engine speed sensor Speed signals from crank-shaft bad or missing...
Page 172 ELECTRONICS 1231 CAN bus off-state Cable break or short circuit, off-state (CAN bus B) 11, 14 1235 CAN bus off-state Cable break or short circuit, off-state (CAN bus C) 11, 14 1237 Override switch Switch hangs 2, 11 Component / Location Description (Error location) 523451 Multi state switch...
Page 173 ELECTRONICS 523568 Begin of injection period Outside target range or missing (cylinder 8) 523600 ECU internal error Serial communication interface defective 11, 12 523601 ECU internal error Wrong voltage of internal 5V reference source 3 3, 4, 11 523602 Fan speed Above target range with system reaction 2, 11 523604...
Page 174: Plus +1 Service Tool
ELECTRONICS PLUS +1 SERVICE TOOL General Info This chapter describes how to install the software on the computer and use the service tool. Service Tool Installation on the computer 1. Download the service tools software from the address: http://powersolutions.danfoss.com/products/plus-1-software/plus-1-service-tool-software-and-license/ 2. Click on PLUS 1 Service Tool 8.0.5 setup.exe to install the PLUS+1 Service Tool on the computer. 3.
Page 175 ELECTRONICS 5. Connect the DP250 display to the computer, by using the Mini USB/USB cable. 6. Launch the Plus+1 Service Tool.exe. 7. Power ON the DP250 and MC050 Electronic Controller Unit. 8. Click on the menu Communication>Online Mode to start the communication.
Page 176: Download The Firmware
ELECTRONICS 9. Click on Display to select the channel, then DP250 + CAN0+1. 10. Click on Change to accept. The list of ECUs is displayed on the screen. Download the firmware Click on File>File Download.
Page 177 ELECTRONICS 11. Click on the current version to download the firmware to PLUS+1 ECU. The DP250 ECU is ready to download the software. 12. Click on Start Download to transfer the firmware to the ECU.
Page 178 ELECTRONICS 13. Click on the current version to download the firmware to MC050 ECU. The MC050 ECU is ready to download the firmware. 14. Click on Start Download to transfer the firmware to the ECU.
Page 179: Download The Parameters To Ecu
Download the parameters to ECU 15. Click on System Navigator and All Saritor. 16. Click on the tab (1) to set all values to the default value, then click on the tab (2) to download the parameters to the ECU.
Page 180: Calibrating The Pedal And Joystick
ELECTRONICS Calibrating the pedal and joystick Before operating the system, it is necessary to calibrate the throttle pedal and the joystick (grip). This calibration can be performed with either the service tool or by the PLUS+1 ECU. 1. Pedal Calibration 2.
Page 181: Throttle Pedal Calibration Via Plus+1 Screen
ELECTRONICS Throttle pedal Calibration via PLUS+1 Screen Refer to the chapter “MC050 and PLUS+1 Calibration” page 182. Joystick calibration via the service tool 1. Click on tab “Joystick Calibration” to display the Joystick Calibration Page. 2. Press Start Calibration to start the procedure. 3.
Page 182: Check The Log Via The Service Tool
ELECTRONICS Check the Log via the Service Tool This section below describes the main functions of the transmission system. Check the speed sensor input 1. Click on the tabs Diagnosis Navigator>Input>Speed Sensor. Check the hydraulic pressure 1. Click on the tabs Diagnosis Navigator>Input>Pressure to check the at 2320 and 8702 PSI (160 and 600 bar).
Page 183: Mc050 And Plus+1 Calibration
ELECTRONICS MC050 and PLUS+1 Calibration To access to the calibration menu: 1. Press buttons (1) and (2) simultaneously for 3 sec. 2. Enter the password by pressing buttons (1) and/or (4): Password: 0 0 10 ENTER PASSWORD 0 0 1 0 This page allows the calibration of the throttle pedal and /or joystick.
Page 184: Check Log Via Plus+1 Screen
ELECTRONICS Check Log via PLUS+1 screen To access to the diagnosis pages: 1. Press buttons (1) and (2) simultaneously for 3 sec. 2. Enter the password by pressing buttons (1) and/or (4): Password: 1 0 0 0 ENTER PASSWORD 1 0 0 0 Press button (2) or (3) to display the next or previous page Front Angle Sensor : 10 °...
Page 185: Harness Overview
ELECTRONICS Harness overview Main Harness external light switch horn FL lights FR lights Oil level tank See section ‘Headlights’ Rear lights Rear lights License plata G078A Backward alarm...
Page 186: Headlights
3. Working headlamp High Beam for US Type: SAE - for USA high beam Hella Part Number: 1K0 008.191-051 Hardi Part Number: 26045001 Bulb Type: Halogen - H9 Dipped/low Beam for US Type: SAE - for USA low beam Hella Part Number: 1BL 008.193-021...
Page 187 ELECTRONICS Mounting...
Page 188: Harness Headlight Diagram (Usa Version)
ELECTRONICS Harness Headlight diagram (USA version) Harness Part Number: 26056301...
Page 189: Rear Left Lights Harness
ELECTRONICS Rear left lights harness Rear right lights harness...
Page 190: Hydraulic Oil Level Switch (Old Version)
S82/124C S82/124C Manufacturer Part Number: CLS3285A - S82/124C Hardi Part Number: 26050301 Power Voltage: 7.35 VDC Output 1: Transistor switched to GND (Sink) Signal: Normally Open (Close in fluid) ÷...
Page 191 ELECTRONICS Electrical connection 1 (+) signal Yellow / green GND (-)
Page 192: Overview Of Main Power Transmission Harness
ELECTRONICS Overview of Main Power Transmission Harness Rear Left Wheel Rear Right Wheel Sensor Solenoid Solenoid Sensor Front Right Wheel Solenoid Transmision Control Unit Sensor Sensor Front Left Wheel Solenoid Presssure sensor (160 bar) Presssure sensor (600 bar) Primary hydostatic pump Secondary hydrostatic pump...
Page 193: Pressure Transmitter (600 Bar - 8702Psi)
ELECTRONICS Pressure Transmitter (600 bar - 8702psi) Cabling Pe 0.. 160Bar 22 N.m Pe 0.. 600 Bar 22 N.m...
Page 194 ELECTRONICS Pressure transmitters Location (New Cab) 2320 PSI (160 Bar) Pressure transmitter The Pressure transmitter (27) is fitted on the brake pedal pin 1. GND sensor pin 2. 5VDC power pin 3 No connected pin 4 Output 0.5.-4.5 V Deutsch DT04 8702 PSI (600 Bar) Pressure transmitter The Pressure transmitter (28) is fitted on the top of the hydrostatic pump.
Page 195: Speed Sensor/Temperature Probe
ELECTRONICS Speed Sensor/Temperature Probe Cabling Rear Left Wheel Rear Right Wheel Front Right Wheel Front Left Wheel Speed sensor/temperature probe location Speed sensor and temperature probe Speed sensor (30) is fitted on hydraulic motor casing pin 1. Speed signal pin 2. Not used pin 3 Not used...
Page 196: Angular Sensor
ELECTRONICS Angular Sensor Cabling Angular Sensor Angular sensor, 2 output (redundant) with Deutsch connector The sensor is fitted on the front right steering pivot pin 1. GND sensor pin 2. 5VDC power pin 3 Output 1 (A1) pin 4. GND sensor 424RD166P070 pin 5 5VDC power...
Page 197: Track, Park, And Bypass Harness
ELECTRONICS Track, Park, and Bypass Harness...
Page 198: Trimble Auto Steering
ELECTRONICS TRIMBLE Auto Steering Main Harness 26051001_4...
Page 199: Sasa Sensor - General Description
ELECTRONICS SASA Sensor - General Description The SASA sensor detects the absolute position and speed of the steering wheel. The sensor can be used in electro-hydraulic steering systems using Sauer-Danfoss EH or EHPS steering valves with programmable controller. The SASA sensor is used for variable steering ratio and closed loop set-ups where steering wheel position and steering have to match.
Page 200: Ospe Steering Valve
ELECTRONICS OSPE Steering Valve General On self-propelled sprayers, there is often a need for electrically actuated steering to make automatic GPS controlled steering possible. Also, manual steering with a variable ratio is an often wanted feature to improve productivity and driver comfort. For this purpose Sauer-Danfoss has developed a combined steering unit and electro hydraulic steering valve named OSPE: OSP for normal manual steering wheel activated steering and E for electro hydraulic steering activated by electrical input signal, either for GPS or vehicle controller, or from steering wheel sensor (Sauer-Danfoss type SASA), or variable steering ratio.
Page 201: Geosteer System
ELECTRONICS GeoSteer System 26050401 Steer Command cable 201-0605-02 unswiched Power Power Activation Vehicle CAN B Extension CAN A Serial Ethernet to display...
Page 202: Armrest Harness (Pre S/N 56307)
ELECTRONICS Armrest harness (Pre s/n 56307) 26023801 ÷ Post s/n 56307 is 26051601.
Page 203: Mode Selector Change From 5V To 12V
ELECTRONICS Mode Selector Change from 5v to 12v...
Page 204 ELECTRONICS Harness updates due to Mode Selector change Pre s/n 56307 Post s/n 56307 Hydraulic Harness 26018401 Spray-center Harness 26023401 26068701 Armrest Harness 26023801 26051601 DP250 Harness 26023901 26072301 Firmware Change MC050-110: Saritor_MC050_110V_V1_0.ihx DP250: Saritor_DP250_V1_5.lhx...
Page 205: Connections Of The Steer Command Cable
ELECTRONICS Connections of the Steer Command cable To antenna Ag6500 Ethernet to display Power Activation 201-0605-02 unswiched Power Extension CAN A Serial Vehicle CAN B...
Page 206: External Control Diagram
ELECTRONICS External Control diagram HC6400 ISO HW 2.1 P/N 26035100 S/N 1528 0011 Function Outsidebox Fluidbox Armrest Setbox black CON03 brown black CON02 brown brown CON01 blue CON04 CON32 CON34 CON31 CON33...
Page 207: External Controls Panel
ELECTRONICS External Controls panel Connection Seal fitting Check the polarity Test click! Sticker replacement 1. Remove all switches and lights from the front panel 2. Place the new sticker on the panel Light replacement 1. Before connecting, check the polarity of the light (LED), then clip the pins into the connector ÷...
Page 208 ELECTRONICS...
Page 209: Cabin- General
CABIN- General Air filtration and conditioning system A. Class 4 filter D. Air inlet to filter B. Pressurization unit E. Sealing liner C. Air conditioning unit F. Cab aeration ducting External air is sucked in through the Class 4 filter and a second anti-dust filter positioned upstream from the former (see (A) in “Air filtration and conditioning system”...
Page 210: Opening Th Roof
CABIN- General Opening th Roof The cab’s roof contains the aeration, air filtration, and air conditioning system, and the motor for the front windshield wiper. In order to access the storage compartment beneath the roof, the roof can be opened by rotating it around the two hinges positioned at the front (B in “Opening th roof”...
Page 211 CABIN- General Opening the roof A. Opening knob C. Roof locking clip B. Roof...
Page 212: Maintenance
CABIN- General MAINTENANCE General safety checks • Make sure that the maintenance operations assigned to the operator have effectively been performed. • Keep the driver’s seat clean. • Make sure that the doors always close correctly. • Make sure that the sealing liners on the doors and roof are always integral, in good condition, and free from leaks. •...
Page 213: Electric Circuits Of The Cabin
CABIN- General ELECTRIC CIRCUITS OF THE CABIN Top view of the cabin...
Page 214: Cabin Harness - List Of Connectors
CABIN- General Cabin harness - list of connectors...
Page 215: Cabin Harness (1/3)
CABIN- General Cabin harness (1/3)
Page 216: Cabin Harness (2/3)
CABIN- General Cabin harness (2/3)
Page 217: Cabin Harness (3/3)
CABIN- General Cabin Harness (3/3)
Page 218: Fuses Box Location
CABIN- General Fuses box location Remove the knobs (A) to access to the compartment for inspection Main PCB power cab X212 Cabin cable X280 Chassis cable X226 After ignition extra power supply X294 Option 4 X216 Cabin cable X295 Option 5 X221 Engine cable X255...
Page 219: Main Circuit Fuses And Relays (U100163B)
CABIN- General Main circuit fuses and relays (U100163B) Code Description Code Amp. Description Code Amp. Description Outdoor cab light timer 15 A hazard lights 10 A 12 V after ignition - 10 A side lights/back-lighting 15 A cigarette lighter - 12V sockets 10 A road- parking 12 V BAT - ceiling...
Page 220: Hvac - Air Conditioning Unit Fuses
CABIN- General Relays Description Relays Description not used not used not used back-lighting - side lights air conditioning power engine starter control air conditioning compressor forward handle neutral position Not used circuit control after contact Not used circuit control after contact HC9500 only (boom lights 3 and 4) BRAKE lights HC9500 only (boom lights 1 and 2)
Page 221: Position Lights Fuses
CABIN- General Position lights fuses 2 fuses are placed at the rear of the main printed circuit to protect the lighting circuit (position lights). • Remove the screw (1) and rock the main printed circuit to access the fuses. • Check and replace the defective fuse (7.5 A). ÷...
Page 222: Cabin Lighting
CABIN- General Cabin lighting Interior cab lighting To replace a bulb: • Use a screwdriver and remove the cover. • Replace the bulb. bulb 12 V - 10Watt bulb 12 V - 21Watt Working lights μ ATTENTION! Before changing the bulb, ensure that the component is disconnected and wait for the bulb to fully cool down in order not to burn yourself.
Page 223: Cabin - Air Conditioning
CABIN - Air Conditioning Cabin ceiling controls Control Module of the ATC air conditioning Automatic Temperature Control (ATC) A. Temperature control in the cab • Turn the temperature control dial (1) clockwise to increase the temperature, or counter-clockwise to lower the temperature in the cab.
Page 224 CABIN - Air Conditioning Cabin error codes ERROR # Description Fault operation High pressure switch - Wiring or cycling 2 in 1 minute Heat mode - compressor clutch disabled Low pressure switch - Wiring or open for 1 minute Heat mode - compressor clutch disabled only while low pressure switch is open Blower speed select pot open/shorted to power Auto blower speed Temperature select pot open/shorted to power...
Page 225: Air Conditioning Controls
CABIN - Air Conditioning Selecting ATC mode Once you have activated the ATC mode, you can press switch (5) to switch between the AUTO mode and the defog mode. In defog mode, the air conditioning compressor operates full-time, and the air is warmed up to promote the defogging of the windows. In this mode, the display indicates symbol (2).
Page 226: Automatic Mode
CABIN - Air Conditioning AUTOMATIC Mode • Turn the control knob (1) to AUTO. The air conditioning light (6) will come on • Turn the control knob (4) to the desired temperature The fan speed will adjust depending on the selected temperature. DEFROST Mode •...
Page 227: K Protect Pressurization
CABIN - Air Conditioning K PROTECT Pressurization The control panel comes with firmware that controls the cabin pressure. The firmware verifies and maintains. • a minimum pressure air flow of 39 yard /hour (30 m /hour) • a cabin pressure higher than 23 Pa ÷...
Page 228 CABIN - Air Conditioning • Once the combined air filter has been changed, press and hold the button for 3 seconds to reset the indicator light.
Page 229: Functionality Test - Testing The Specified Status Of The Functions
CABIN - Air Conditioning FUNCTIONALITY TEST - TESTING THE SPECIFIED STATUS OF THE FUNCTIONS Pressurizer maintenance instructions The control panel features a warning light (5) that indicates a problem with cabin pressure. Follow the instructions below to troubleshoot. If a problem persists, contact your dealer. Symptom Cause Solution...
Page 230: Pc -K Management Software
CABIN - Air Conditioning PC -K MANAGEMENT SOFTWARE Software installation The PC-K can be connected to a computer using the USB port located behind the front cover. The PCK Management software allows you to diagnose problems and configure settings • Click on Setup.exe and follow the instructions to install K Protect Management software on the computer.
Page 231: Operating The K-Protect Management
CABIN - Air Conditioning Operating the K-protect Management Use the K-Protect software To use the K-protect management you need: • The USB key Manager p/n 340.30.249 (provided from the manufacturer). • Enter the administrator password: COMPACT Main menu description 1. Software version 4.
Page 232: Calibration Of The Ventilation And Temperature Buttons
CABIN - Air Conditioning Calibration of the ventilation and temperature buttons Calibrate the ventilation button • Click on tab (1) Front Panel • Click on tab (2) Calibrate ventilation button • Turn knob (3) to AUTO • Press any button (e.g. button (2)) to continue...
Page 233 CABIN - Air Conditioning • Turn knob (3) to OFF • Press any button (e.g. button (2)) to continue • Turn knob (3) to V1 • Press any button (e.g. button (2)) to continue • Turn knob (3) to V2 •...
Page 234: Calibrate The Temperature Button
CABIN - Air Conditioning • Turn knob (3) to V3 • Press any button (e.g. button (2)) to escape Calibrate the temperature button • Click on tab (1) Front Panel • Click on tab (2) Calibrate temperature button • Turn knob (3) to LOW (59°f) (15°c) •...
Page 235 CABIN - Air Conditioning • Turn knob (3) on position 71°f (22°c) • Press any button (e.g. button (2)) to continue • Turn knob (3) on position 79°f (26°c) Press any button (e.g. button (2)) to continue • Turn knob (3) on position 84°f (29°c) •...
Page 236: A/C Electric Circuits
CABIN - Air Conditioning A/C ELECTRIC CIRCUITS Air conditioning - Fuses table Fuse description Relay description 30 A 12V BAT - A/C A/c Power supply A/C compressor A/C compressor 12V BAT - ignition HVAC - Air conditioning unit fuses The Heating, Ventilation Air conditioning (HVAC) fuses are located at the rear of main box fuses Protected device Fuse value Inlet connection...
Page 237: Air Conditioning - Electrical Diagram
CABIN - Air Conditioning Air conditioning - Electrical diagram...
Page 238: Electrical Diagram - Harness
CABIN - Air Conditioning Electrical diagram - harness Fuse box Compressor relay HVAC Fuse box To the compressor To the pressure switch output To the pressure switch input Panel control PCK HVAC Falkon double...
Page 239: K-Protect Electrical Diagram
CABIN - Air Conditioning K-Protect Electrical diagram...
Page 240: Components And Probes Specifications
CABIN - Air Conditioning COMPONENTS AND PROBES SPECIFICATIONS This section describes the main components of the HVAC system Differential pressure switch This sensor is connected to the K-Protect system and measures the differential pressure between the exterior and the interior of the cab To external pressure To cab pressure 1 Common (COM)
Page 241: Air Mixing Probe
CABIN - Air Conditioning Air mixing probe Resistance (77°f ) (25°Celsius): 10k ohm +/- 1% Heating solenoid valve When the heating solenoid valve is replaced, respect the flow direction Flow direction Heating Ventilation Air Conditioning - HVAC Cooling power Heating power 840m Air flow Ø16...
Page 242: Dehydrator Filter
CABIN - Air Conditioning Dehydrator filter (New Cab) Raccord Oring Male 5/8 - 18UNF Pressure binary switch (thread=1/4 SAE) (Old Cab)
Page 243: Technicals Specifications
CABIN - Air Conditioning TECHNICALS SPECIFICATIONS Refrigerant R134a Oil for compressor PAG (polyalkylene glycol) Vacuum delay 90 min Vacuum delay 90 min Gas pressure 30.45 PSI (2.1 bar)
Page 244 CABIN - Air Conditioning...
Page 245 Definition of the working place, 12 Driving in fields, 13 Driving on public roads, 12 Hydraulic filters on tank, 66 Lights, working at night, 12 Operator's skill, 11 Releasing the hydraulic motor brakes, 68 Responsibilities of the manufacturer and the user, 12 Safety symbols, 13...
Page 247: Warranty Policy And Conditions
HARDI® dealer that such equipment is at the time of delivery to such purchaser, free from defects in material and workmanship and that such equipment will be warranted for a period of one year from the time of delivery to the end user, providing the machine is used and serviced in accordance with the recommendations in the Operator’s Manual and is...
Page 248 11. No employee or representative is authorized to change this warranty in any way or grant any other warranty unless such change is made in writing and signed by the CEO of HARDI® NORTH AMERICA INC. Approval of warranty is the responsibility of the HARDI®...

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