Bomag BW 180 AD Tandem Vibratory Roller Instructions for Repair Manual 00891253 - PDF DOWNLOAD

Instructions for repair

BW 180 AD 101 870 00 ....

Tandem Vibratory Roller

Catalogue number

008 912 53

06/2002

Table of Contents

General

5 1.1 Foreword

6

1.2 Safety regulations

7

1.3 General repair instructions

9

1.4 Tightening torques

11

1.5 Connection overview

12

Tests and adjustments

15 2.1 Technical data

16

2.2 Special tools

19

2.3 Checking the rotation speeds

21

2.4 Pressure tests in the travel circuit

23

2.5 Checking / adjusting the neutral positions of the travel pump

25

2.6 Check the setting of the high pressure relief valves in the travel circuit

28

2.7 Pressure measurements in the vibration circuit

30

2.8 Check the setting of the high pressure relief valves in the vibration circuit 31 2.9 Checking / adjusting the vibrator shaft speeds

33

2.10 Checking the leakage rate of the vibration motor

34

2.11 Pressure test in steering circuit

35

2.12 Operation of display module for ESX-control

37

2.13 Driving against the closed brake

38

2.14 Adjusting the machine type

39

2.15 Calibration of the angle transducers

41

2.16 Adjusting the angle transducers

43

2.17 Automatic detection of step currents for the steering valves

45

2.18 Adjusting the type of travel range switch

47

2.19 Resetting the step currents in the travel system

49

2.20 Automatic detection of step currents in the travel system

50

2.21 Showing stored faults

53

2.22 Deleting stored faults

54

Flushing

55 3.1 Special tool:

56

3.2 Flushing shematic for front drum drive

58

3.3 Flushing schematic for rear drum drive system

60

3.4 Flashing the travel circuit

62

3.5 Flushing schematic for vibration drive

72

3.6 Flushing the vibration circuit

74

Trouble shooting

81 4.1 General

82

4.2 Trouble shooting diagram

83

Drum

008 912 53

103 5.1 Special tools

104

5.2 Repair overview for drum

106

5.3 Removing and installing the drum

108

5.4 Removing and installing the vibrator unit on the drum drive side

114

5.5 Removing and installing the vibrator unit on the vibration drive side

119

5.6 Repairing the vibrator unit on the drum drive unit

129

BOMAG

3

Table of Contents 5.7 Repairing the vibrator unit on the vibration drive unit 5.8 Dismantling, assembling the change-over weights Pivot steering

140 143

6.1 Removing, repairing and installing the pivot steering

144

6.2 Repairing the oscillation joint

148

Suppliers documentation

4

134

153

7.1 A4VG

155

7.2 A10VG

201

7.3 MS/MSE 02 to 18

255

7.4 Vibration motor A2FM 32

305

BOMAG

008 912 53

1 General

008 912 53

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Introduction 1.1

Foreword

These repair instructions contain all necessary information for training and repair work.

Notes on maintenance, care and trouble shooting can be found in the operating and maintenance instructions.

1

General

2

Tests and adjustments

3

Flushing

4

Trouble shooting

5

Drum

6

Pivot steering

7

Components

This instruction manual contains only assembly groups needed for this type of machine.

The repair instructions describe the removal or dismantling and assembly of components and assembly groups.

The repair of disassembled assembly groups is described as far as this makes sense with respect to available tools and spare parts supply and as far as it can be understood by a skilled mechanic.

Danger Danger of injury

Please observe strictly the safety regulations in these operating instructions and the applicable accident prevention regulations.

Spare parts needed for repairs can be taken from the spare parts catalogue for the machine.

You should only use genuine BOMAG spare parts.

These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional technical service bulletins.

In case of a new release all necessary changes will be included.

In the course of technical development we reserve the right for technical modifications without prior notification.

Information and illustrations in this repair manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved.

BOMAG GmbH & Co. OHG Printed in Germany Copyright by BOMAG

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008 912 53

6DIHW\ UHJXODWLRQV Important notes 1.2

Safety regulations

These safety regulations must be read and applied by every person involved in the repair of this machine. The applicable accident prevention instructions and the safety regulations in the operating and maintenance instructions must be additionally observed.

Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. These repair instructions contain headers like „Note“, „Attention“, „Danger“ and „Environment“, which must be strictly complied with in order to avoid dangers for health and for the environment.

Danger Paragraphs marked like this highlight possible dangers for persons.

Caution Paragraphs marked like this highlight possible dangers for machines or parts of the machine.

●

Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition.

●

Use only safe and approved lifting gear of sifficient load bearing capacity to remove and install parts or components from and to the machine.

●

Be careful with cleansing agents. Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning.

●

Cleaning or repair work on the fuel tank is very dangerous. Do not smoke or allow any ignitable sparks or open fire in the vicinity when cleaning or repairing a tank. .

●

When performing welding work strictly comply with the respective welding instructions.

Special safety regulations ●

Use only genuine BOMAG spare parts for repair purposes. Original parts and accessories have been specially designed for this machine.

●

We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

●

Unauthorized changes to the machine are prohibited for safety reasons.

●

If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine, danger of injury!

●

Do not perform cleaning work while the engine is running.

●

If tests must be performed with the engine running do not touch rotating parts of the engine, danger of injury.

●

Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting the engine in closed rooms.

●

Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel.

●

Keep used filters in a separate waste container and dispose of environmentally.

●

Dispose of oils and fuel environmentally when performing repair or maintenance work.

●

Do not refuel in closed rooms.

●

Do not heat up oil higher than 160 °C because it may ignite.

●

Wipe off spilled oil and fuel.

L Note Paragraphs marked like this contain technical information for the optimal economical use of the machine.

Environment Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts.

Observe the regulations for the protection of the environment.

General ●

Before starting repair work stand the machine on level and solid ground.

●

Always secure the machine against unintended rolling.

●

Secure the engine reliably against unintentional starting.

●

Mark a machine that is defective or being repaired by attaching a clearly visible warning tag to the steering wheel.

●

On machines with articulated joint keep the articulated joint locked during work.

●

Use protective clothes like hard hat, safety boots and gloves.

●

Keep unauthorized persons away from the machine during repair work.

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●

Do not smoke when refuelling or when checking the acid level in the battery.

●

Do not check the acid level of the battery with a naked flame, danger of explosion!

●

Old batteries contain lead and must be properly disposed of.

●

There is a danger of scalding when draining off engine or hydraulic oil at operating temperature.

●

on machines with rubber tires a tire may busr if incorrectly assembled. This can cause severe injury.

●

Do not exceed the specified highest permissible tire pressure.

Hydraulics ●

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines.

●

Before applying pressure to the system make sure that all line connections and ports have been properly tightened and are in perfect condition.

●

Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.

●

Do not step in front of or behind the drums/wheels when performing adjustment work in the hydraulic system while the engine is running. Block drums and/or wheels with wedges.

Reattach all guards and safety installations after all work has been completed.

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008 912 53

*HQHUDO UHSDLU LQVWUXFWLRQV General 1.3

●

●

General repair instructions

Before removing or disassembling and parts, hoses or components mark these parts for easier assembly.

Before assembly oil or grease all parts, as far as this is necessary.

●

Fill new hydraulic units with hydraulic oil before starting operation.

●

After changing a component thoroughly flush and bleed the entire hydraulic system.

●

Perform measurements at operating temperature of the hydraulic oil (approx. 40 °C).

●

After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft.

●

The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. If the soil is too hard place the drums on old rubber tires. Do not activate the vibration on a hard, concreted base, danger of bearing damage.

●

After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized.

Hydraulic system Caution Do not open any hydraulic components if you have not been properly trained and without exact knowledge.

Please note Cleanliness is of utmost importance. Make sure that no dirt or other contaminating substances can enter into the system. ●

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

●

Before disconnecting hoses, pipes or similar relieve the system pressure with the engine shut down.

●

During repair work keep all openings closed with clean plastic plugs and caps.

●

Do not run pumps and motors without oil.

●

When cleaning hydraulic components take care not to damage any fine machine surfaces.

●

Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not use such substances to clean seals and gaskets.

●

●

●

After changing a component clean the hydraulic oil tank thoroughly.

●

Fill the housings of hydraulic pumps and motors with hydraulic oil.

●

Use only hydraulic oils according to the specification in the maintenance instructions.

●

After changing a component clean the hydraulic system as described in the flushing instructions in order to prevent all other components from being damaged by abrasion and metal chips remaining in the system.

Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.

●

Change the hydraulic oil filter.

●

Bleed the hydraulic circuits.

Avoid the formation of rust on fine machined caused by hand sweat.

●

Start up the system without load.

●

Check the hydraulic oil level in the tank, fill up oil if necessary.

●

Grease must not used as a sliding agent for assembly work. Use hydraulic oil.

●

Do not start the engine after the hydraulic oil has been drained off.

●

●

Before commissioning

Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure.

Clean ports and fittings before removal so that no dirt can enter into the hydraulic system.

●

Check the hydraulic oil level before and after the work.

●

Use only clean oil according to specification.

●

Check the hydraulic system for leaks, find and rectify the cause.

008 912 53

Commissioning

After commissioning ●

Check system pressures and speeds.

●

Check fittings and flanges for leaks.

●

After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic system, adjust if necessary.

●

Do not adjust pressure relief valves and control valves to values above their specified values.

Electrical system ●

Always disconnect the battery before starting work in the electrical system.

●

Ensure correct polarity when connecting the battery.

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●

Do not check voltage by tapping against ground.

●

When performing welding work always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location. Strictly disconnect the cables from the generator before starting work.

Seals and gaskets ●

Generally use new seals and gaskets when performing assembly work. The required seal kits are available as spare parts.

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7LJKWHQLQJ WRUTXHV Tightening torques 1.4

Tightening torques

●

Tighten fastening screws and nuts according to the table of tightening torques.

●

Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.

Caution Self-locking nuts must be generally renewed.

Tightening torques for screws with metric unified thread Screw dimension M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

Tightening torque Nm* (ft-lb) 8.8 3 (2) 6 (4) 10 (7) 25 (18) 50 (37) 88 (65) 137 (101) 211 (156) 290 (213) 412 (304) 560 (413) 711 (524) 1050 (774) 1420 (1047)

10.9 5 (4) 9 (7) 15 (11) 35 (26) 75 (55) 123 (91) 196 (145) 300 (221) 412 (303) 578 (426) 785 (559) 1000 (738) 1480 (1092) 2010 (1482)

12.9 5 (4) 10 (7) 18 (13) 45 (33) 83 (61) 147 (108) 235 (173) 358 (264) 490 (361) 696 (513) 942 (695) 1200 (885) 1774 (1308) 2400 (1770)

Tightening torques for screws with metric fine thread Screw dimension M8 x 1 M10 x 1.25 M12 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x2 M30 x 2 *

Tightening torques Nm* (ft-lb) 8.8 26 (19) 52 (38) 98 (72) 93 (69) 152 (112) 225 (166) 324 (239) 461 (340) 618 (456) 780 (575) 1147 (846) 1568 (1156)

10.9 37 (27) 76 (56) 137 (101) 127 (94) 216 (159) 318 (235) 466 (344) 628 (463) 863 (636) 1098 (808) 1578 (1164) 2254 (1662)

12.9 48 (35) 88 (65) 126 (119) 152 (112) 255 (188) 383 (282) 554 (409) 775 (572) 1058 (780) 1294 (1416) 1920 (1416) 2695 (1988)

Strength classes for screws with untreated, non-lubricated surface.

The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.

Compliance with the tightening torques is checked with torque wrenches.

Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.

The values specified in the table apply for screws black, oiled and with surface protection A4C. The quality designation of the screws is stamped on the screw heads.

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Fig. 1

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&RQQHFWLRQ RYHUYLHZ 1

Proportional valve, travel system

21 Adjustment screw, hydraulic neutral position

2

Pressure test port X4, control chamber pressure, travel pump

22 Pressure test port R, travel pump case pressure

3

Pressure test port MB high pressure, reverse travel

24 Pressure override valve 380 bar, vibration pump

4

High pressure port B to rear travel motor, high pressure reverse travel

5

High pressure port B to front travel motor, high pressure reverse travel

26 Pressure test port MA high pressure, forward travel

6

Adjustment screw, high frequency

7

High pressure port A to rear travel motor, high pressure forward travel

8

High pressure port A to front travel motor, high pressure forward travel

9

Port T1, leak oil tank A

23 Pressure test port X2, travel pump 25 Port T, flushing oil, travel motors

27 Pressure override valve 400 bar, travel pump 28 Travel pump 29 Leak oil connection T1 travel pump - T2 vibration pump 30 Port G, charge oil from steering valves 31 Port T2, flushing oil, vibration motors 32 High pressure relief valve, forward travel, 440 bar

10 High pressure port B, to vibration shut-off valve, high pressure low frequency

33 Charge pressure relief valve 25 bar, travel pump

11 High pressure port A, to vibration shut-off valve, high pressure high frequency

35 High pressure relief valve, vibration, 400 bar

34 High pressure relief valve, reverse travel, 440 bar

12 Magnetic coil Y57, low frequency

36 Connecting line, charge pressure supply to vibration pump

13 High pressure test port, low frequency

37 High pressure test port, high frequency

14 High pressure relief valve, vibration, 420 bar

38 Vibration pump

15 Magnetic coil, high frequency

39 Port B, leak oil to cooler

16 Pressure test port X2, vibration pump

40 Port E, leak oil, front travel motor

17 Pressure test port X1, vibration pump

41 Port A, flushing/leak oil, travel/vibration pump

18 Pressure test port R, vibration pump case pressure

42 Port I, leak oil from brake valve

19 Proportional valve, travel system

44 Port F, leak oil from vibration shut-off valve

43 Port D, leak oil, rear travel motor

20 Pressure test port X2, travel pump

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2 Tests and adjustments

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Technical data

Fig. 1

Dimensions in mm

A

B

C

D

H

H1

K

L

O

W

BW 180 AD

3300

1920

815

1400

2400

30500

350

4700

60

1800

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load, front/ rear Dimensions Steering/oscillation angle Track radius, inner/outer Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability without/ with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 IFN Nominal speed low idle speed 16

BW 180 AD

kg

11870

kg kg kg/cm

5935 5935 33/33

± mm

20/8 3900/5700

km/h km/h km/h %

0 ... 4 0 ... 8 0 ... 11 35/30

kW

Cummins 4 BT3.9-C Water 4 76

1 rpm 1 rpm

2500 950 ±50

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high idle speed Electrical equipment Battery Drive system Driven axles Electrical equipment Voltage supply Battery Generator Starter Travel pump Manufacturer Type System Max. displacement High pressure (pressure limitation) High pressure (pressure override) Charge pressure Drum drive motors Manufacturer Type System Displacement max. leak oil rate Vibration pump Manufacturer Type System Max. displacement Start-up pressure (pressure override) Operating pressure (soil dependent) Vibration motors Manufacturer Type System Displacement max. leak oil rate Brakes Service brake Parking brake Brake releasing pressure

1 rpm V V/AH

V V/AH V/AH V/kW

BW 180 AD 2725 ±55 12 12/100 hydrostatic front + rear

12 12/100 12/2,9

cm3/rev. bar

Hydromatik A4VG 71 EP Axial piston/swash plate 71 440 ±10

bar

400 ±10

bar

26 ±1

cm3/rev. l/min

Poclain MS 18 1CX Radial piston 2100 2

cm3/rev. bar

Hydromatik A10VG 45 EZ Axial piston/swash plate 45 380 ±20

bar

approx. 100

cm3/rev. l/min

Hydromatik A2FM 32 Axial piston/bent axle 32 1

hydrostatic Releasing the mech. bar

Steering Type of steering Steering operation Steering angle

±

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2 point pivot hydrostatic 25 17

7HFKQLFDO GDWD

*

mm

BW 180 AD 1220

cm3/rev. bar

Bosch HY/ZFFS11/14+14 Tandem gear pump 2x14 200 ±10

Crabwalk, lateral offsetting of drum Steering/charge pump Manufacturer Type System Displacement max. steering pressure Steering valves Manufacturer Type System

Bucher L.8S Electrically proportional

Vibration system Drive system Frequency 1/2 Amplitude 1/2

Hz mm

hydrostatic 42/55 0,83/0,33

Filling capacities Engine oil Fuel (diesel) Sprinkler system Hydraulic oil Coolant Exciter shaft tube

l l l l l l

approx. 9.5 170 900 approx. 60 approx. 20 approx. 50

*

18

The right for technical modifications remains reserved

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6SHFLDO WRROV 2.2 Special tools 1. Vibration Reed frequency meter BOMAG part-no.: 300 120 80

Fig. 1

2. Engine RPM-meter BOMAG part-no.: 059 711 12

Fig. 2

3. Hydraulic test case BOMAG part-no.: 007 610 03

Fig. 3

4. Electric test case BOMAG part-no.: 057 505 70

Fig. 4

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6SHFLDO WRROV 5. Gear pump testing device BOMAG part-no.: 007 610 05

Fig. 5

6. Vacuum pump for hydraulic oil tank BOMAG part-no.: 007 610 04 (12V)

Fig. 6

20

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&KHFNLQJ WKH URWDWLRQ VSHHGV 2.3 Checking the rotation speeds Special tools

Vibration Reed frequency meter, engien RPMmeter Caution Perform measurements at operating temperature (40 °C).

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

Fig. 1

Checking the engine speed

L Note If necessary, the engine speed may also be checked with the vibration Reed frequency meter.

1. Connect the RPM-meter to the injection line (Fig. 2).

2. Measure the rotation speeds.

Nominal value low idle speed 950 ±50 rpm 3. Run the engine with maximum speed .

4. Measure the rotation speeds.

Nominal value high idle speed 2725 ±55 rpm 5. Switch on vibration of both drums.

Fig. 2

Nominal value nominal speed 2500 rpm Evaluation of test If the nominal value is not reached, perform trouble shooting for the engine.

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&KHFNLQJ WKH URWDWLRQ VSHHGV Checking the vibrator shaft speed 1. Switch the vibration on at max. engine speed.

2. Measure the speed of the vibrator shaft, rest the tester on your thumb (Fig. 3).

Nominal value high amplitude/ low frequency = 42 Hz, 2520 rpm low amplitude/ high frequency = 55 Hz, 3300 rpm Evaluation of test If the nominal value is not reached, perform trouble shooting in the vibration circuit.

Fig. 3

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3UHVVXUH WHVWV LQ WKH WUDYHO FLUFXLW

2.4 Pressure tests in the travel circuit Special tools Hydraulic test case Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Block the wheels with suitable chocks (Fig. 1).

Fig. 1

2. Enter code number 500 on the display module (Fig. 2) to close the brake.

Fig. 2

3. Connect a 600 bar pressure gauge (Fig. 3) to test port MA.

Fig. 3

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3UHVVXUH WHVWV LQ WKH WUDYHO FLUFXLW 4. Connect a 600 bar pressure gauge (Fig. 4) to test port MB.

Fig. 4

5. Connect a 60 bar pressure gauge (Fig. 5) to the charge pressure test port.

6. Start the engine and run it with maximum speed.

7. Read high pressure and charge pressure gauges.

Nominal value Charge pressure 26 ±1bar High pressure 400 bar ±10 bar Evaluation of test If the nominal value is not reached, check the steering/charge pump.

Fig. 5

8. Move the travel lever quickly to forward and backward, read the pressure gauges.

Nominal value Charge pressure min. 25 bar High pressure 400 bar to both travel directions.

Evaluation of test If the specified high pressure is not reached, check the travel pump.

If the charge pressure drops considerably during the high pressure test, check the components individually.

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2.5 Checking / adjusting the neutral positions of the travel pump Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Block the wheels with suitable chocks (Fig. 1).

Fig. 1

2. Enter code number 500 on the display module (Fig. 2) to close the brake.

Fig. 2

3. Connect a 600 bar pressure gauge (Fig. 3) each to test ports MA and MB.

Fig. 3

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&KHFNLQJ DGMXVWLQJ WKH QHXWUDO SRVLWLRQV RI WKH WUDYHO SXPS Mechanical neutral position 1. As a measure to avoid signal residues from the hydraulic neutral position connect both control chambers X1 and X2 with a hose (Fig. 4).

2. Start the engine and run it with maximum speed.

Fig. 4

3. Read the pressure gauges (Fig. 5).

L Note For a more exact adjustment repeat the test with 60 bar pressure gauges Nominal value Both pressure gauges must show identical pressure, if necessary correct the mechanical neutral position.

Fig. 5

4. Adjust the neutral position (Fig. 6) so that both pressure gauges show identical pressure (charge pressure).

L Note Equalize the dead range of the neutral position.

Fig. 6

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Hydraulic neutral position 1. Remove the hose connection between the control chambers and screw the plugs back in (Fig. 7).

2. Start the engine and run it with maximum speed.

Fig. 7

3. Read the pressure gauges (Fig. 8).

L Note For a more exact adjustment repeat the test with 60 bar pressure gauges Do not actuate the travel lever, since this may destroy the pressure gauges.

Nominal value Both pressure gauges must show identical pressure (charge pressure), if necessary correct the hydraulic neutral position.

Fig. 8

4. For this purpose loosen the clamping (Fig. 9).

Caution Do not adjust the eccentric beyond the ± 90° position.

5. Adjust the neutral position on the eccentric (2), so that both pressure gauges show identical pressure (charge pressure).

6. Retighten the clamping.

Fig. 9

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&KHFN WKH VHWWLQJ RI WKH KLJK SUHVVXUH UHOLHI YDOYHV LQ WKH WUDYHO 2.6 Check the setting of the high pressure relief valves in the travel circuit Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Block the wheels with suitable chocks (Fig. 1).

Fig. 1

2. Enter code number 500 on the display module (Fig. 2) to close the brake.

Fig. 2

3. Connect a 600 bar pressure gauge (Fig. 3) each to test ports MA and MB.

Fig. 3

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4. Turn the setscrew (Fig. 4) of the pressure override completely in to block the valve.

5. Start the engine and run it with maximum speed.

Caution Perform the following pressure test for max. 3 seconds, otherwise pump damage caused by overheating.

6. Move the travel lever quickly to both travel directions and read the pressure gauges.

Fig. 4

Nominal value 445 ±5 bar Evaluation of test: If the nominal value is only reached to one direction, clean or replace the valve (Fig. 5) if necessary.

If the nominal value is not reached to both directions check the travel pump, replace if necessary.

Fig. 5

Adjusting the pressure override Caution To assure a reliable function of the pressure override, the pressure override valve must be adjusted 10% lower than the high pressure relief valve.

1. Turn the setscrew (Fig. 6) back out again, until the high pressure is limited to 400 ±10 bar when the drums are blocked.

Fig. 6

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3UHVVXUH PHDVXUHPHQWV LQ WKH YLEUDWLRQ FLUFXLW 2.7 Pressure measurements in the vibration circuit Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

Fig. 1

2. Connect a 600 bar pressure gauge (Fig. 2) each to test ports MA and MB. 3. Connect a 60 bar pressure gauge to the charge pressure test port.

Fig. 2

4. Start the engine and run it with maximum speed.

5. Switch on vibration at high or low frequency and read the pressure gauge.

Nominal value Charge pressure 26 ±1bar Starting pressure 380 bar ±20 bar Operating pressure (soil dependent) approx. 80 ... 100 bar Evaluation of test If the charge pressure drops, check the components individually.

If the starting pressure is not reached, check the vibration pump.

If the starting pressure is only reached for one frequency, check the high pressure relief valves.

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2.8 Check the setting of the high pressure relief valves in the vibration circuit Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

Fig. 1

2. Connect a 600 bar pressure gauge (Fig. 2) each to test ports MA and MB.

Fig. 2

3. Turn the setscrew (Fig. 3) of the pressure override completely in to block the valve.

4. Start the engine and run it with maximum speed.

Caution Perform the following pressure test for max. 3 seconds, otherwise pump damage caused by overheating.

5. Switch on vibration at high or low frequency and read the start-up pressure on the pressure gauge.

Fig. 3

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&KHFN WKH VHWWLQJ RI WKH KLJK SUHVVXUH UHOLHI YDOYHV LQ WKH YLEUD Evaluation of test: If the nominal value is only reached for one frequency, clean or replace the valve (Fig. 4) if necessary.

If the nominal value is not reached for both frequencies check the travel pump, replace if necessary.

Nominal value 400 ±5 bar

Fig. 4

Adjusting the pressure override Caution To assure a reliable function of the pressure override, the pressure override valve must be adjusted 10% lower than the high pressure relief valve.

1. Turn the setscrew (Fig. 5) back out again, so that the start-up pressure for the vibrator shafts is limited to 380 bar.

Fig. 5

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2.9 Checking / adjusting the vibrator shaft speeds Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

2. Start the diesel engine and shift the throttle lever to max. speed position.

3. Select the frequency and switch the vibration on.

Fig. 1

4. Measure the speed of the vibrator shaft (Fig. 2), rest the tester on your thumb.

Nominal value high amplitude/ low frequency = 42 Hz, 2520 rpm low amplitude/ high frequency = 55 Hz, 3300 rpm Evaluation of test In case of deviations exceeding 10% determine the cause, perform trouble shooting for engine / vibration circuit.

Fig. 2

5. Adjust the speed on the corresponding adjustment screw (Fig. 3).

L Note Turning the adjustment screw in reduces the speed, turning the screw out increases the speed.

Fig. 3

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&KHFNLQJ WKH OHDNDJH UDWH RI WKH YLEUDWLRQ PRWRU 2.10 Checking the leakage rate of the vibration motor Special tools Hydraulic test case

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

1. Drive the machine with both drums on an elastic base (rubber buffers) (Fig. 1).

2. Block the wheels with suitable chocks.

Fig. 1

3. Disconnect the leak oil and flushing oil hose (Fig. 2) and close it with plugs.

4. Connect a leak oil hose to the leak oil port of the motor and hold it into a measuring vessel 5. Start the diesel engine and shift the throttle lever to max. speed position.

6. Select the frequency and switch the vibration on.

7. Measure the leak oil over a period of one minute.

Caution This measurement detects only the external leak oil quantity.

Fig. 2

Internal leaks, directly from the high to the low pressure side, are not detected.

Nominal value max. 1.5 litre/min Evaluation of test If the permissible leak oil rate is exceeded, replace the vibration motor.

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2.11 Pressure test in steering circuit Special tools Hydraulic test case

L Note The steering is actuated against an „electronic“ stop by the ESX-control. To actuate the steering against the mechanical stop the ESX-control must be switched to the mode „Calibration of angle transducers“. After the pressure test the calibration process can be aborted.

Danger Danger of squashing!

Do not stand in the range of rotation of the pivot steering.

Caution Perform measurements at operating temperature of the hydraulic oil (40 °C).

Measuring the front steering pressure 1. Enter code number „600“ on display module (Fig. 1).

The steering can now be actuated against the mechanical stop.

2. Enter code number „620“ or switch the ignition off to stop this fuction.

Fig. 1

3. Connect a 600 bar pressure gauge (Fig. 2) to the steering pressure test port.

4. Start the engine and run it at idle speed.

Fig. 2

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3UHVVXUH WHVW LQ VWHHULQJ FLUFXLW 5. Adjust the front steering control (Fig. 3) and turn the steering against an end stop.

6. Read the pressure gauge.

Nominal value approx. 200 ±10 bar Evaluation of test If the nominal value is reached, check the steering cylinder.

If the nominal value is not reached, check the steering/charge pump.

Fig. 3

Measuring the rear steering pressure 1. Enter code number „600“ on display module (Fig. 4).

The steering can now be actuated against the mechanical stop.

2. Enter code number „620“ or switch the ignition off to stop this fuction.

Fig. 4

3. Connect a 600 bar pressure gauge to the rear steering pressure test port (Fig. 5).

4. Start the engine and run it at idle speed.

Fig. 5

5. Adjust the rear steering control (Fig. 6) and turn the steering against an end stop.

6. Read the pressure gauge.

Nominal value approx. 200 ±10 bar Evaluation of test If the nominal value is reached, check the steering cylinder.

If the nominal value is not reached, check the steering/charge pump.

Fig. 6

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2.12 Operation of display module for ESXcontrol Description The display module (Fig. 1) is used for the output of fault codes and display values and for the input of code numbers.

The module consists of a three digit display and two keys, F1 and F2.

Faults are indicated by flashing, if several faults have occurred the displayed fault codes are alternately displayed in 3 second cycles. Display values are permanently displayed.

Values from 000 ... 999 can be displayed. Higher values are displayed in form of „---“. Negative values are indicated by a minus symbol.

Fig. 1

Entering code numbers For calibration of the angle transducers and diagnostics of the control inputs and outputs various code numbers must be entered on the display module.

Code numbers are entered as follows: 1. Press both keys (F1 and F2) together for approx. two seconds.

The display shows „000“, whereby the first digit is flashing.

2. Press key F1 as often as required to adjust the flashing digit.

If key F1 is pressed again when figure „9“ is displayed, the display will jump back to the value „0“.

3. Press key „F2“ to adjust the next digit.

The flashing display moves one digit to the right.

4. Press key F2 to change to the third digit and adjust the desired value with the F1-key.

5. Press the F2-key again to confirm the adjusted values and to execute the corresponding function.

6. To cancel a display function you must either enter the code number „000“ or switch the ignition off.

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'ULYLQJ DJDLQVW WKH FORVHG EUDNH 2.13 Driving against the closed brake

L Note On this machine the electric plug connection to the brake valve must not be pulled off, because the ESX-control would in this case detect a line interruption in the current path to the brake.

1. Enter code number „500“ on display module (Fig. 1).

The brake will not be released when actuating the travel lever.

The warning buzzer sounds to inform the operator about this status.

2. Enter code number „501“ or switch the ignition off to stop this function.

Fig. 1

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$GMXVWLQJ WKH PDFKLQH W\SH 2.14 Adjusting the machine type

L Note Only available from program version 16.

For simple control of the machine type, the adjusted machine type is displayed in the display module for about three seconds after switching the ignition on.

Danger Danger of injury!

Since the same control is used for all pivot steered tandem rollers, it is strictly necessary to specify the correct machine type when replacing the ESX-control.

The machine must not be operated with a wrong type setting.

Caution Adjustments should only be made with the engine shut down.

1. Enter code number „725“ on display module (Fig. 1).

The function „Change machine type“ is activated.

Table „Assignment machine type – machine type code“ Machine type BW 180 AD BW 184 AD BW 184 AD/AM BW 170 AD BW 170 AD BW 170 AD/AM BW 174 AD BW 174 AC BW 174 AD/AM

Fig. 1

Serial-No. 101 870 00 ....

101 870 30 ....

101 870 50 ....

101 870 01 ....

101 870 02 ....

101 870 11 ....

101 870 31 ....

101 870 41 ....

101 870 31 ....

Code 740 740 740 731 733 733 732 732 732

2. Select and enter the correct code from the table above.

The display then permanently shows the entered code number.

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$GMXVWLQJ WKH PDFKLQH W\SH 3. To store the machine type enter code number „726“ on the display module (Fig. 2).

When entering code “726“ the machine type code is permanently stored.

L Note The conversion process takes a few seconds.

During this time the display permanently shows the code number, the minus point flashes in an interval of one second.

Caution During this time the ignition must not be switched off! Otherwise the complete adjustment process must be repeated.

Fig. 2

The new machine type will only become active after the ignition has been switched off and on again!

By changing the machine type all settings are deleted and must be reset as described hereunder.

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2.15 Calibration of the angle transducers In order to assure a correct steering of the machine, both angle transducers for front and rear drums must be calibrated.

L Note Calibration of the angle transducers is only necessary during initial start-up in the factory, after a disassembly or replacement of the angle transducers and after changing the ESX-control.

Caution Calibration must always be performed for both drums.

Calibration is only possible in steering mode selection „Steering front“ and „Steering rear”. With any other steering selection this function is not active. When changing to another, unpermitted steering mode during the adjustment, the complete adjustment procedure must be repeated.

During the calibration process the machine must not drive faster than 3 km/h, as otherwise the complete adjustment procedure must be repeated.

The new values will only become active after the ignition has been switched off and on again.

1. Enter code number „600“ on display module (Fig. 1).

This code number activates the function „Calibration of the angle sensors“. In this case the display permanently shows the value „600“.

Calibrating the front stops

Fig. 1

1. Steer the front drum (Fig. 2) to the left hand stop.

2. When the stop is reached enter code number 601.

In this case the display permanently shows the value „601“.

3. Steer the front drum to the right hand stop.

4. When the stop is reached enter code number 603.

In this case the display permanently shows the value „603“.

Fig. 2

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&DOLEUDWLRQ RI WKH DQJOH WUDQVGXFHUV Calibrating the rear stops 1. Steer the rear drum (Fig. 3) to the left hand stop.

2. When the stop is reached enter code number 611.

In this case the display permanently shows the value „611“.

3. Steer the rear drum to the right hand stop.

4. When the stop is reached enter code number 613.

In this case the display permanently shows the value „613“.

Calibrating the straight ahead position

Fig. 3

1. Steer the front drum (Fig. 4) to straight ahead position.

2. When the stop is reached enter code number 602.

In this case the display permanently shows the value „602“.

3. Steer the rear drum to straight ahead position.

4. When the stop is reached enter code number 612.

In this case the display permanently shows the value „612“.

Fig. 4

L Note The function „Calibration“ is automatically terminated after all codes have been entered.

If the function „Calibration“ is to be aborted prematurely, enter code 620 and switch off the ignition.

5. Switch the ignition off and on again to activate the new values.

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2.16 Adjusting the angle transducers In order to assure an optimal function of the position detection in the steering system, both angle transducers for front and rear drums must be adjusted.

This adjustment determines the position of the angle transducers to the transom bed.

L Note Calibration of the angle transducers is only required during initial start-up in the factory and after disassembly or replacement of the angle transducers.

Caution For the adjustment the angle transducers must have been calibrated, as otherwise the straight ahead position will not be reached (see previous section).

Even if only one angle transducer has been adjusted both transducer must be adjusted anew (see previous section).

1. Align both drums to straight ahead position.

L Note In order to bring both drums to straight ahead position deactivate the crab-walk (green light goes out) and change from „steering front“ to „steering rear“ and back to „steering front“ while driving..

This utilizes the automatic neutral setting of the drums when changing the steering mode.

Steering must be stopped when switching over and it must be assured that the automatic neutral setting of the drum is completed.

Then stop steering, stop the machine and shut down the engine.

Checking the front adjustment Caution For the following steps shut the engine down and switch the ignition off.

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$GMXVWLQJ WKH DQJOH WUDQVGXFHUV 1. Enter code number „250“ on display module (Fig. 1) and read the following display.

Nominal value: 117 to 123, ideal value 120 Evaluation of display If the value is outside this range, the angle transducer must be adjusted.

Fig. 1

Adjusting the angle transducer 1. Loosen fastening screws 3 (Fig. 2) in the slots of angle transducer (2) and turn the transducer, until the value is in the permissible range.

L Note If the adjustment range in the slots is not sufficient, loosen coupling 2 (Fig. 2) between transducer and transom bed and turn also.

2. Retighten all fastening screws and check the display module once again.

Caution Even if only one angle transducer has been adjusted both transducer must be adjusted anew (see previous section).

Fig. 2

Check the rear adjustment Caution For the following steps shut the engine down and switch the ignition off.

1. Enter code number „260“ on display module (Fig. 3) and read the following display.

Nominal value: 117 to 123, ideal value 120 Evaluation of display If the value is outside this range, the angle transducer must be adjusted. (see previous description).

Fig. 3

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2.17 Automatic detection of step currents for the steering valves For a sensitive and exact control of the steering the step currents must be determined for the four control solenoids of both steering valves. The step currents are automatically adjusted after entering the code number, so that no additional meter is required.

After entering the respective code number the current is increased by the control solenoid in 5 mA steps. After each current increase the system waits for two seconds. If the ESX-control has detected a considerable angle change of the drum after the expiration of the waiting time, the step current is reached.

In order to enhance the measuring result the measurement is performed three times. The final step current is the mean value of the three measurements. This step current is automatically stored and is valid from the next time the machine is started.

L Note The determination of the step currents is only required during initial start-up in the factory, after replacing a steering valve, the steering valve control or after changing the ESX-control The measurement is identical for all solenoids.

Caution For the determination of the step current park the machine ón firm and level ground.

The steering system must be thoroughly bled before performing this measurement.

Align the drum to straight ahead position.

The new values will only become active after the ignition has been switched off and on again.

Danger Danger of injury!

During the measuring process the machine cannot be steered, the machine should therefore not be driven during the detection of the step current.

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$XWRPDWLF GHWHFWLRQ RI VWHS FXUUHQWV IRU WKH VWHHULQJ YDOYHV 1. Start the engine and run it with maximum speed (Fig. 1).

Fig. 1

2. Release the brake (Fig. 2).

Fig. 2

3. Enter code number „630“ on display module (Fig. 3).

This code activates the function „Automatic measurement of step currents for the steering valves“. In this case the display shows the value „630“.

Each of the four measurements for the four control solenoids must be started separately by entering a code number.

The code number for the four control solenoids is as follows: Fig. 3

Solenoid Control front left Control front right Control rear left Control rear right

Code No. 631 632 633 634

4. Enter the corresponding code number for step current detection.

During the measurement the present control current is displayed (display x 10 = current [mA]).

Once the measuring process is finished the display value „000“ appears for two seconds, then the code number „630“ is displayed again. The next measurement can be started.

5. After all four step currents have been measured shut down the engine to terminate the function.

The new step currents apply after the next start.

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2.18 Adjusting the type of travel range switch For the selection of the travel speed a 3-stage switch (Fig. 1) is installed as standard.

Fig. 1

A 24 stage switch (Fig. 2) can alternatively be installed.

The switch type must be entered using the respective code, so that the ESX-control is able to evaluate the travel speed switch correctly.

L Note The 3-stage switch is set as standard value, i.e. a standard machine does not require any adjustments.

Caution Adjustments should only be made with the engine shut down.

Fig. 2

The new values will only become active after the ignition has been switched off and on again.

Adjusting the machine for the 24stage switch 1. Enter code number „650“ on display module (Fig. 3).

This code activates the function „Parameter change speed range switch“. In this case the display shows the value „650“.

L Note This code number must be entered before the following step can be performed.

Fig. 3

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$GMXVWLQJ WKH W\SH RI WUDYHO UDQJH VZLWFK 2. Enter code number „652“ on display module (Fig. 4) to select the „24-stage switch“.

The display reading disappears.

3. Switch off the ignition.

With the next start the 24-stage switch is evaluated.

Fig. 4

Adjusting the machine for the 3-stage switch 1. Enter code number „650“ on display module (Fig. 5).

This code activates the function „Parameter change speed range switch“. In this case the display shows the value „650“.

L Note This code number must be entered before the following step can be performed.

Fig. 5

2. Enter code number „651“ on display module (Fig. 6) to select the „3-stage switch“.

The display reading disappears.

3. Switch off the ignition.

With the next start the 3-stage switch is evaluated.

Fig. 6

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2.19 Resetting the step currents in the travel system This function allows the resetting of step currents in the travel system to their minimum value.

This measure avoids that the travel system is controlled with a too high step current.

L Note This measure is only required after replacing the travel pump control or the complete travel pump.

It helps to move the machine before performing the function „Automatic detection of step currents“.

This function does not need to be performed after replacing the ESX-control, because a new ESX control is always set for minimum step current.

Caution During the input the engine must not be running.

The new values will only become active after the ignition has been switched off and on again.

1. Enter code number „665“ on display module (Fig. 1).

This code activates the function „Resetting the step currents in the travel system“. In this case the display shows the value „665“.

Fig. 1

2. Enter code number „666“ on display module (Fig. 2).

Eith this code the step current is reset to the minimum value (350 mA).

3. Switch off the ignition.

The minimum step currents apply after the next start.

Fig. 2

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$XWRPDWLF GHWHFWLRQ RI VWHS FXUUHQWV LQ WKH WUDYHO V\VWHP 2.20 Automatic detection of step currents in the travel system For a sensitive and exact control of the travel system the step currents must be determined for both travel directions. The step currents are automatically adjusted after entering the code number, so that no additional meter is required.

After entering the respective code number the current is increased by the control solenoid in 5 mA steps, starting with 350 mA. After each current increase the system waits for three seconds.

If the ESX-control has detected a considerable movement of the drum after the expiration of the waiting time, the step current is reached.

In order to enhance the measuring result the measurement is performed three times. The final step current is the mean value of the three measurements. This step current is automatically stored and is valid from the next time the machine is started.

L Note The determination of the step currents is only required during initial start-up in the factory, after replacing the travel pump, the travel pump control or after changing the ESX-control The measurement is identical for both travel directions.

Caution For the determination of the step current park the machine ón firm and level ground.

Ensure sufficient space in front of and behind the machine (approx. 10 m), because the machine will move during the measuring process.

Align the drum to straight ahead position.

The new values will only become active after the ignition has been switched off and on again.

Danger Danger of injury!

During the measuring process the machine will start to move when the step current is reached.

Do not leave the machine during the measuring process.

The areas in front of and behind the machine must be free of persons.

Before starting the measurement it must be assured that the speed sensor on the front right hand drum drive motor works correctly.

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The measurement must not be performed if the sensor is defective.

1. Align the seat in forward direction.

2. Switch off the Speed Control.

3. Start the engine and run it with maximum speed (Fig. 1).

Fig. 1

Checking the function of the speed sensor 1. Enter code number „102“ on display module (Fig. 2).

This code shows the number of travel pulses of the sensor.

2. Move the machine to both directions.

The displayed value must change when the machine is moving.

Fig. 2

Detecting the step currents Danger Danger of accident!

After entering the code number the machine can no longer be controlled with the travel lever. The function of the travel lever is only reestablished after the engine is shut down and restarted.

In case of a danger the machine can be stopped by shifting the travel lever to neutral position. In this case the complete measuring process must be repeated.

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$XWRPDWLF GHWHFWLRQ RI VWHS FXUUHQWV LQ WKH WUDYHO V\VWHP 1. Enter code number „660“ on display module (Fig. 3).

This code activates the function „Automatic measurement of step currents in the travel system“. In this case the display shows the value „660“.

Each of the four measurements for the four control solenoids must be started separately by entering a code number.

The code number for both control solenoids is as follows: Travel direction Forward Backward

Fig. 3

Code No. 661 662

Each of the four measurements for the four control solenoids must be started separately by entering a code number.

2. Enter the corresponding code number for step current detection according to the table.

3. Move the travel lever (Fig. 4) forward or backward as required by the entered code number.

During the measurement the present control current is displayed (display x 10 = current [mA]).

Once the measuring process is finished the display value „000“ appears, then the code number „660“ is displayed again. The next measurement can be started.

4. After both step currents have been measured shut down the engine to terminate the function.

The new step currents apply after the next start.

Fig. 4

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6KRZLQJ VWRUHG IDXOWV 2.21 Showing stored faults

L Note Besides stored faults, current faults are also displayed.

Switching the function on 1. Enter code number „700“ on display module (Fig. 1).

The function “Show stored faults“ is switched on.

Fig. 1

Switching the function off 1. Enter code number „701“ on display module (Fig. 2).

The function “Show stored faults“ is switched off.

Fig. 2

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'HOHWLQJ VWRUHG IDXOWV 2.22 Deleting stored faults

L Note Stored faults can only be deleted when the engine is not running.

1. Enter code number „710“ on display module (Fig. 1).

All stored faults are deleted.

Fig. 1

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3 Flushing

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6SHFLDO WRRO 3.1 Special tool: 1. Filling and filtering unit with oil bag BOMAG part-no.: 007 610 01 2. Filter element BOMAG part-no.: 079 930 35

Fig. 1

3. Flushing filter BOMAG part-no.: 007 000 01 4. Filter element 1µ BOMAG part-no.: 079 930 52 5. Flushing hose 25S - 20S (2 pieces) BOMAG part-no.: 055 509 19 6. Screw socket R1“ -- 25S (2 pieces) BOMAG part-no.: 055 400 52 Fig. 2

7. Double-end union 20 S BOMAG part-no.: 055 426 17

Fig. 3

8. Double-end union 16 S BOMAG part-no.: 055 426 16

Fig. 4

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6SHFLDO WRRO 9. Reducing fitting 25S - 20 S BOMAG part-no.: 055 422 98

Fig. 5

10. Elbow 20S BOMAG part-no.: 055 421 37

Fig. 6

11. Elbow 16S BOMAG part-no.: 055 421 36

Fig. 7

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)OXVKLQJ VKHPDWLF IRU IURQW GUXP GULYH

Fig. 1 Schematic for front travel system

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Travel pump

6

Front drum drive motor

2

Elbow 20S

7

Double end union 20S

3

Flushing filter

8

Elbow 20S

4

Screw socket 1“ - 25S

9

Double end union 20S

5

Flushing hose 25S - 20S

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit.

1. Connect the flushing filter outlet "OUT" with the travel pump.

2. Connect the flushing inlet „IN“ with the hose from the front drum drive motor.

Caution Solid particles remaining in the circuit will damage the components again within a short period of time.

Caution The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump.

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

With the connection shown in the illustration the travel pump must therefore be actuated to reverse direction.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the front drum drive motor out of the circuit, for this purpose join the high pressure lines at the drum drive motor together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

L Note

1. Reconnect the drum drive motor.

For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

2. Jack the front drum up for flushing.

Bleeding Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

Change the oil: in case of excessive contamination, oil discoloration, oil change interval almost reached.

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Fig. 1 Schematic of rear travel system

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Travel pump

6

Flushing filter

2

Elbow 20S

7

Screw socket 1“ - 25S

3

Elbow 20S

8

Flushing hose 25S - 20S

4

Double end union 20S

9

Double end union 20S

5

Rear drum drive motor

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit.

1. Connect the flushing filter outlet "OUT" with the travel pump.

2. Connect the flushing inlet „IN“ with the hose from the rear drum drive motor.

Caution Solid particles remaining in the circuit will damage the components again within a short period of time.

Caution The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump.

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

With the connection shown in the illustration the travel pump must therefore be actuated to reverse direction.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the rear drum drive motor out of the circuit, for this purpose join the high pressure lines at the drum drive motor together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

L Note

1. Reconnect the drum drive motor.

For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

2. Jack the rear drum up for flushing.

Bleeding Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

Change the oil: in case of excessive contamination, oil discoloration, oil change interval almost reached.

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)ODVKLQJ WKH WUDYHO FLUFXLW 3.4 Flashing the travel circuit Cleaning the hydraulic oil tank Environment Catch hydraulic oil and dispose of environmentally!

1. Pump the hydraulic oil from the hydraulic oil tank into a clean container or an oil bag using the filling and filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them from the tank cover.

3. Unscrew the fastening screws for the cover and remove the cover.

4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.

Fig. 1

Filter installation for flushing of the front travel circuit Caution Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary.

1. Disconnect the high pressure hose (Fig. 2) from the travel pump.

Fig. 2

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2. Connect the flushing hose (Fig. 3) from filter outlet port „OUT“ to the travel pump using an angle fitting.

Fig. 3

3. Connect the filter inlet port „IN“ (Fig. 4) with the disconnected high pressure hoses from the travel pump using a connecting socket.

Fig. 4

4. Flushing hose (Fig. 5) from filter port „IN“ must be connected with the high pressure hose from the travel pump (port A).

5. Flushing hose from filter port „OUT“ must be connected with the travel pump (port A).

Fig. 5

6. Unscrew the high pressure hoses 3 (Fig. 6) from the front drum drive motor and join them together with angle fittings (2) and socket (1).

7. Fill the hydraulic oil tank again with the filling and filtering unit.

L Note If the hydraulic oil change interval is almost reached use new hydraulic oil.

Fig. 6

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)ODVKLQJ WKH WUDYHO FLUFXLW Bleeding the travel circuit 1. Pull the plug (Fig. 7) off the engine shut-down solenoid, so that the engine cannot start.

2. Secure the drums with chocks .

Environment Catch hydraulic oil and dispose of environmentally.

3. Install pressure test hoses to the charge pressure test port and to the high pressure test ports in the travel system.

Fig. 7

4. Hold the open ends of the pressure test hoses (Fig. 8) into a container.

5. Crank the engine approx. 30 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

6. Disconnect the pressure test hoses from the high pressure test ports.

7. Reconnect the plug to the engine shut-down solenoid.

Fig. 8

8. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 9) and run the engine max. 15 seconds at idle speed.

9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.

Fig. 9

Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

10. For bleeding shift travel lever (Fig. 10) approx. 1/ 3 in travel direction backward while running the engine with idle speed.

11. After running the engine 1 to 2 minutes with idle speed pause for approx. one minute.

Fig. 10

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L Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line.

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

In this case the closed travel circuit is properly bled.

Flushing the lines of the front travel circuit Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

1. Shift the travel lever (Fig. 11) to travel direction backward.

2. Perform the flushing process at various engine speeds for approx. 15 minutes.

3. Shut down the engine.

Environment Catch hydraulic oil and dispose of environmentally!

4. Reconnect the high pressure hoses to the front drum drive motor.

Fig. 11

Flushing the front drum drive motor Danger Danger of squashing!

Do not lay under the jacked up machine.

1. Jack up the front of the machine (Fig. 12), so that the drum can rotate freely.

2. Secure the rear drum with chocks .

Fig. 12

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Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

3. Shift the travel lever (Fig. 13) to travel direction backward.

4. Perform the flushing process at various engine speeds for approx. 15 minutes.

5. Shut down the engine.

Fig. 13

Filter installation for flushing of the rear travel circuit Caution Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary.

1. Disconnect the high pressure hose (Fig. 14) from the travel pump.

Fig. 14

2. Connect flushing hose 1 (Fig. 15) from filter outlet port „OUT“ to the travel pump using an angle fitting.

3. Connect flushing hose (2) from filter inlet port „IN“ with the disconnected high pressure hoses from the travel pump using a connecting socket.

Fig. 15

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4. Flushing hose (Fig. 16) from filter port „IN“ must be connected with the high pressure hose from the travel pump (port A).

5. Flushing hose from filter port „OUT“ must be connected with the travel pump (port A).

Fig. 16

6. Unscrew the high pressure hoses 3 (Fig. 17) from the rear drum drive motor and join them together with angle fittings (2) and socket (1).

7. Fill the hydraulic oil tank again with the filling and filtering unit.

L Note If the hydraulic oil change interval is almost reached use new hydraulic oil.

Fig. 17

Bleeding the travel circuit 1. Pull the plug (Fig. 18) off the engine shut-down solenoid, so that the engine cannot start.

2. Secure the drums with chocks .

Environment Catch hydraulic oil and dispose of environmentally.

3. Install pressure test hoses to the charge pressure test port and to the high pressure test ports in the travel system.

Fig. 18

4. Hold the open ends of the pressure test hoses (Fig. 19) into a container.

5. Crank the engine approx. 30 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

6. Disconnect the pressure test hoses from the high pressure test ports.

7. Reconnect the plug to the engine shut-down solenoid.

Fig. 19

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)ODVKLQJ WKH WUDYHO FLUFXLW 8. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 20) and run the engine max. 15 seconds at idle speed.

9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.

Fig. 20

Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

10. For bleeding shift travel lever (Fig. 21) approx. 1/ 3 in travel direction backward while running the engine with idle speed.

11. After running the engine 1 to 2 minutes with idle speed pause for approx. one minute.

L Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line.

Fig. 21

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

In this case the closed travel circuit is properly bled.

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Flushing the lines of the rear travel circuit

Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

12. Shift the travel lever (Fig. 22) to travel direction backward.

13. Perform the flushing process at various engine speeds for approx. 15 minutes.

14. Shut down the engine.

Environment Catch hydraulic oil and dispose of environmentally!

15. Reconnect the high pressure hoses to the rear drum drive motor.

Fig. 22

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16. Repeat the bleeding process.

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)ODVKLQJ WKH WUDYHO FLUFXLW Flushing the rear drum drive motor Danger Danger of squashing!

Do not lay under the jacked up machine.

1. Jack up the rear of the machine (Fig. 23), so that the drum can rotate freely.

2. Secure the front drum with chocks .

Fig. 23

Caution Move the travel lever only to travel direction backward, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

3. Shift the travel lever (Fig. 24) to travel direction backward.

4. Perform the flushing process at various engine speeds for approx. 15 minutes.

5. Shut down the engine.

Function test

Fig. 24

1. Check the hydraulic oil level (Fig. 25) in the tank, fill up if necessary.

2. Cleaning the machine 3. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.

4. Check all ports and connections for leak tightness (visual inspection).

Fig. 25

Servicing the flushing filter kit 1. Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.

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L Note This is also possible with very cold oil.

2. Clean hoses and connections and store the flushing kit in a clean and protected environment.

3. Change the flushing filter element of the filling and filtering unit when the red control pin of the contamination indicator is pressed out.

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Fig. 1

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Shut-off valve

6

Screw socket 1“ - 25S

2

Elbow 20S

7

Flushing filter

3

Double end union 20S

8

Rear vibration motor

4

Vibration pump

9

Front vibration motor

5

Flushing hose 25S - 20S

After changing a component

Flushing filter installation (Fig. 1)

1. Always flush the closed circuit.

1. Connect the flushing filter outlet "OUT" with the vibration pump.

2. Connect the flushing inlet „IN“ with the hose from the shut-off valve.

Caution Solid particles remaining in the circuit will damage the components again within a short period of time.

Caution The flushing filter must be installed in the low pressure side in the return flow to the pump, so that only cleaned oil will enter the travel pump.

In case of excessive oil contamination (abrasion) 1. Open and clean all other components.

For the connection schematic shown here the vibration must always be filtered with „low frequency / high amplitude“.

2. If necessary replace the hydraulic hoses.

3. Flush also the vibration circuit.

Befor flushing

Flushing of the hoses

1. Change the hydraulic oil filter element.

1. Take the vibration motor out of the circuit, for this purpose join the high pressure lines together.

2. Clean the inside of the hydraulic oil tank.

3. Filter the hydraulic oil with the filtering unit.

Flushing the complete system

L Note For filtering use the filling and filtering unit.

Pump the tank contents through a fine filter into the oil bag or a clean container.

1. Reconnect the vibration motor and pull it out of the coupling for flushing.

Bleeding

Environment Catch hydraulic oil and dispose of environmentally! For filling use also the filtering unit.

1. Always bleed the closed hydraulic circuit if lines had been removed or connected.

Change the oil: in case of excessive contamination, oil discoloration, oil change interval almost reached.

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)OXVKLQJ WKH YLEUDWLRQ FLUFXLW 3.6 Flushing the vibration circuit Cleaning the hydraulic oil tank Environment Catch hydraulic oil and dispose of environmentally!

1. Pump the hydraulic oil from the hydraulic oil tank into a clean container or an oil bag using the filling and filtering unit.

2. Mark all hoses (Fig. 1) and disconnect them from the tank cover.

3. Unscrew the fastening screws for the cover and remove the cover.

4. Clean the hydraulic oil tank thoroughly from inside, reassemble cover and hoses.

Fig. 1

Filter installation for flushing of the vibration drive Caution Before installing the flushing filter check hoses and connections for cleanliness, clean if necessary.

1. Disconnect the high pressure hose (Fig. 2) from the vibration pump.

Fig. 2

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2. Connect flushing hose 3 (Fig. 3) to high pressure hose (5) using connecting socket (4).

3. Connect flushing hose (2) to the vibration pump using elbow fitting (1).

Fig. 3

4. Connect the flushing hose (Fig. 4) from the high pressure hose to flushing filter inlet „IN“.

5. Connect the flushing hose from the vibration pump to the flushing filter outlet „OUT“.

Fig. 4

6. Disconnect hydraulic hoses 2 (Fig. 5) from both vibration motors and join them together with socket (1).

7. Fill the hydraulic oil tank again with the filling and filtering unit.

L Note If the hydraulic oil change interval is almost reached use new hydraulic oil.

Fig. 5

Bleeding the vibration circuit 1. Pull the plug (Fig. 6) off the engine shut-down solenoid, so that the engine cannot start.

2. Secure the drums with chocks .

Environment Catch hydraulic oil and dispose of environmentally.

3. Install pressure test hoses to the charge pressure test port and to the high pressure test ports in the vibration system.

Fig. 6

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)OXVKLQJ WKH YLEUDWLRQ FLUFXLW 4. Hold the open ends of the pressure test hoses (Fig. 7) into a container.

5. Crank the engine approx. 30 seconds with the starter motor. Wait one minute and repeat this procedure, until oil starts to run out from the pressure test hoses.

6. Disconnect the pressure test hoses from the high pressure test ports.

7. Reconnect the plug to the engine shut-down solenoid.

Fig. 7

8. Connect a 60 bar pressure gauge to the charge pressure test hose (Fig. 8) and run the engine max. 15 seconds at idle speed.

9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.

Fig. 8

Caution Use only low frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

10. For bleeding switch on low frequency (Fig. 9) for both drums at idle speed.

11. After running the engine 1 to 2 minutes pause for approx. one minute.

L Note This waiting time is necessary to allow air bubbles to escape through the leak oil return line.

Fig. 9

Repeat this measure, until the charge pressure reading immediately drops to zero when shutting the engine down.

In this case the closed travel circuit is properly bled.

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Flushing the hoses in the vibration circuit

Caution Use only low frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

1. For bleeding switch on low frequency (Fig. 10) for both drums at full engine speed.

2. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.

3. Shut down the engine.

Environment Catch hydraulic oil and dispose of environmentally!

Fig. 10

4. Reconnect both high pressure hoses to both vibration motors.

Flushing the vibration motors 1. Unscrew the fastening screws for both vibration motors and pull the motors out of their couplings (Fig. 11).

Fig. 11

Caution Use only low frequency, as otherwise the flushing filter will be subjected to oil flow from the wrong direction.

2. For bleeding switch on low frequency (Fig. 12) for both drums at full engine speed.

3. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of approx. 30 seconds.

4. Shut down the engine.

Fig. 12

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)OXVKLQJ WKH YLEUDWLRQ FLUFXLW Function test 1. Check the hydraulic oil level (Fig. 13) in the tank, fill up if necessary.

2. Cleaning the machine 3. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting on a gradient.

4. Check all ports and connections for leak tightness (visual inspection).

Fig. 13

Servicing the flushing filter kit 1. Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the filtering process.

L Note This is also possible with very cold oil.

2. Clean hoses and connections and store the flushing kit in a clean and protected environment.

3. Change the flushing filter element of the filling and filtering unit when the red control pin of the contamination indicator is pressed out.

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4 Trouble shooting

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*HQHUDO

General notes on trouble shooting in hydraulic systems

●

Check the hydraulic oil level before and after the work.

The following tests are performed for fault diagnostics and should enable you to encircle a fault in the hydraulic system.

●

Use only clean oil according to specification.

●

Check the hydraulic system for leaks, find and rectify the cause.

●

Ensure strict cleanliness, clean ports and fittings before disconnecting.

●

Fill new hydraulic units with hydraulic oil before starting operation.

●

After changing a component thoroughly flush and bleed the hydraulic system.

●

AS far as possible conduct all measurements at operating temperature 40 ... 50 °C.

●

After changing a component check charge and high pressure, if necessary check the rotational speed.

4.1

General

At this point it is assumed that there is no fault in the electric system, i.e. trouble shooting in the electric system has already been performed.

In some cases these tests may also be conducted to identify faults on hydraulic components of the power transmission system.

On the basis of preliminary tests the individual measurements have the purpose to limit the cause of the fault first of all to a general area and then to determine exactly which oil circuit or hydraulic component is not working correctly.

Important points for trouble shooting and fault rectification

Hydraulic hoses Danger Danger of injury

Danger Danger of injury!

Hydraulic hoses must be visually inspected at regular intervals.

Do not touch rotating parts of the engine.

When working on the travel pump and performing tests in the travel circuit block the drums with suitable wheel chocks.

Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should therefore relieve the pressure in the system before disconnecting any lines. Before repressurizing the system make sure that all line connections and ports are in perfect condition.

Hydraulic hoses must be immediately replaced if: ●

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks, etc.)

●

the outer layer is brittle (formation of cracks in the hose material)

●

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose

●

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

●

the hose is leaking

●

the hydraulic hose has separated from the fitting

●

the fitting shows corrosion that impairs both function and strength

●

the fitting is deformed in a way that both function and strength are affected

●

the storage time and utilization period has expired.

When being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.

Caution It is not recommended to open or repair hydraulic units and components without comprehensive knowledge.

Risk of damage to pressure gauges if incorrectly connected.

When performing trouble shooting it is assumed that the machine is correctly equipped and connected, that connections and hoses are free of faults and that setscrews have not been deadjusted without permission.

Progressive tests drawn up in the trouble shooting diagram lead to the detection of faults and their rectification by trained personnel. ●

Ensure strict cleanliness, clean ports and fittings before disconnecting.

●

Cover all openings and ports or close with plugs.

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4.2

Trouble shooting diagram The machine drives with the travel lever in „NEUTRAL“ Check the mechanical neutral position - Enter code number 500 to close the brake - Connect control chamber ports X1 and X2 with a hose

Neutral position OK?

yes

no

Adjust the hydraulic neutral position - Remove the hose connecting X1 and X2 - Run the engine with maximum speed.

- Adjust the hydraulic neutral position so that identical pressures are indicated at MA and MB (charge pressure)

Adjusting the mechanical neutral position

- Run the engine with maximum speed.

- Connect 600 bar pressure gauges to MA and MB

- Adjust the mechanical 0-position so that identical pressures are indicated at MA and MB (charge pressure) - For a more exact adjustment repeat the test with 60 bar pressure gauges

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Machine does not drive / insufficient travel performance Check high and charge pressure - Connect 600 bar pressure gauges to the high pressure test port - Connect a 60 bar pressure gauge to the charge pressure test port - Start the engine and run it with maximum speed - Drive the machine against the closed brake, for this purpose enter code number 500, actuate the travel lever for a moment and read the pressure gauge Nominal value: High pressure approx. 400 bar ±10 bar, charge pressure approx. 26 bar

High pressure OK?

yes

no

Check the brake releasing pressure - Install a 60 bar pressure gauge to the brake releasing line - Start the engine and check whether the brake valve opens when the brake is released Nominal value: approx. 26 bar (charge pressure)

Brake valve OK?

no

Replace the brake valve

yes

Mechanical fault, blocked drive

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Charge pressure OK?

no

yes

Check the front steering pressure - Connect a 600 bar pressure gauge to the steering pressure test port - Enter code number 600 - Pull the plug off the starter solenoid and crank the engine with the starter - Turn the front steering against one of the end stops and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged) Steering pressure OK?

no

Perform trouble shooting for front steering system

yes Check the rear steering pressure - Connect a 600 bar pressure gauge to the steering pressure test port - Enter code number 600 - Pull the plug off the starter solenoid and crank the engine with the starter - Turn the rear steering against one of the end stops and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

Perform trouble shooting for rear steering system

yes

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Check leakage of brake - Release the brake and perform a charge pressure test

Charge pressure OK?

yes

- Disconnect the brake releasing lines one after the other from the drum drive motors and close them with plugs; repeat the charge pressure test with the brake closed - Repair the unit with which the charge pressure is OK after the brake line has been disconnected

no

Check the charge pressure relief valve

Valve OK?

no

Replace the charge pressure relief valve

yes

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Check the flushing valve

no

yes

Replace the flushing valve

Flushing valve OK? Check the travel pump

- Close the high pressure ports on the pump with plugs - Repeat the pressure test

no High pressure OK? yes

Check the control chamber pressure - Install pressure test ports with 60 bar pressure gauges to X3/X4

yes

- Actuate the travel pump to full displacement and read the pressure gauge Nominal value: approx. 15 bar

Pressure OK?

no Replace/repair the travel pump

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Check the swash time nozzles - Unscrew the nozzles and check for blockage

Nozzles OK?

no

yes Clean the nozzles

Check the case pressure - Install a pressure test port with a 10 bar pressure gauge to G

- Actuate the travel pump to full displacement and read the pressure gauge

Pressure OK?

no

yes Check the leak oil return line to the tank

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Check the servo control - Remove the servo control - Check the nozzles, clean if necessary.

- Check the linkage, repair if necessary

Servo control OK?

no

yes Repair the servo control

Replace/repair the travel pump Test the travel motors individually - Close the high pressure test ports on the drum drive motors one after the other with plugs - Repeat the pressure test - If the high pressure is O.K., replace the travel motor excluded from the hydraulic circuit.

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Hydraulic oil overheating >90 °C

Check the high pressure relief valves in the travel circuit

Check high pressure relief valves in vibration circuit

- Enter code number 500 to close the brake

- Stand the drums on rubber tires

- Fully actuate the travel lever

- Check high pressure relief valves for excessive heat

- Check the high pressure relief valves for excessive heat

- Switch the vibration on

Valves OK?

no

Check the high pressure relief valves/pressure override

yes Check the thermostat valve - Check whether the hose to the cooler heats up when a hydraulic oil temperature of > 60 °C is reached

Thermostat OK?

no

Replace the thermostat

yes

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Check the flushing valve in the travel system

Check the flushing valve in the vibration system

- Check the moveability of the flushing valve

- Check the moveability of the flushing valve

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No vibration at front and rear Travel system O.K. Check the electric power supply for the solenoid valves - Switch the vibration on and measure the current consumption of both solenoids Nominal value: approx. 1.7 A

Current OK?

no

Perform trouble shooting in the electric system

yes Check the control chamber pressure - Install pressure test ports to X1 and X2 - Connect a 60 bar pressure gauge - Run the engine with maximum speed - Switch the vibration on and read the pressure gauge Nominal value: approx. 12 bar

Pressure OK?

no

yes

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Check the vibration pump

Check the control unit

- Connect 600 bar pressure gauges to the vibration pump

- Remove the control unit

- Close high pressure ports A and B with plugs - Run the engine with maximum speed .

- Switch the vibration on for a moment and read the pressure gauge

- Check the nozzle, clean if necessary.

- Check the control piston, if necessary replace the control unit

Nominal value: approx. 380 bar

Pressure OK?

no

Replace/repair the vibration pump

yes Check the vibrator shaft bearings - Remove the vibration motor - Check end float and moveability of the vibrator shafts - Check the coupling

Bearing / coupling OK?

no

Replace / repair the coupling

yes

Replace/repair the vibration motor

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Speed of front and rear vibrator shafts too low Checking the engine speed - Switch vibration on and measure the speed Nominal value: Nominal speed 2600 rpm

Rated speed OK?

no

Perform engine trouble shooting - Adjust high and low frequency

yes

Drop in vibrator shaft speed >10%

no

yes

Check the pressures in the vibration circuit - Connect 600 bar pressure gauges to the high pressure test port - Connect a 60 bar pressure gauge to the charge pressure test port - Run the engine with maximum speed.

- Switch the vibration on and read the pressure gauge Nominal value: Start up pressure: 380 ±20 bar Operating pressure: approx. 100 bar (depending on soil) Charge pressure: approx. 26 bar

Charge pressure OK?

no

yes

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Operating pressure OK?

yes

no, to high

Start-up pressure OK?

yes

no

Check the leak oil rate of both vibration motors - Measure the leak oil rate at a vibration measure of approx.

100 bar Nominal value: max. 1 l/min

Check the vibrator shaft bearings - Check end float and moveability of the vibrator shafts

Leak oil OK?

End float: 1,0 ... 3.3 mm

008 912 53

no

Replace the respective vibration motor

yes

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Check the vibration pump - Close high pressure ports A and B with plugs - Switch the vibration on for a moment and read the pressure gauges Nominal value: 380 ±20 bar

Pressure OK?

no

yes

Test the individual vibration motors

Check the control chamber pressure - Install pressure test ports with 60 bar pressure gauges to X1and X2

- Close the high pressure hoses of the individual vibration motors one after the other with plugs and repeat the pressure test - If the high pressure is O.K., replace the travel motor excluded from the hydraulic circuit.

- Switch the vibration on and read the pressure gauge Nominal value: approx. 15 bar

Pressure OK?

yes

Replace/repair the vibration pump

no

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Check the servo control - Remove the servo control - Check the nozzles, clean if necessary.

Servo control OK?

no

Replace the servo control

yes

Replace/repair the travel pump

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No front steering

steering sticky

Check the front steering pressure - Connect a 600 bar pressure gauge to the steering pressure test port - Enter code number 600 - Pull the plug off the starter solenoid and crank the engine with the starter - Turn the front steering against one of the end stops and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

yes

Check the front steering pump - Close the pump outlet with a 200 bar pressure relief valve - Connect a 600 bar pressure gauge - Crank the engine with the starter - Read the pressure gauges Nominal value: approx. 200 bar (battery fully charged)

no Pressure OK?

yes

Change the steering / charge pump

Check / replace the front steering cylinder

98

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Check the front steering valve - Install a 600 bar pressure gauge to the steering pressure outlet - Enter code number 600 - Turn the front steering against an end stop Nominal value: approx. 200 bar

Steering pressure OK?

no

Replace the steering valve

yes

Check the moveability of steering cylinders and pivot bearing

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No rear steering

steering sticky

Check the rear steering pressure - Connect a 600 bar pressure gauge to the steering pressure test port - Enter code number 600 - Pull the plug off the starter solenoid and crank the engine with the starter - Turn the rear steering against one of the end stops and read the pressure gauge Nominal value: approx. 200 bar (battery fully charged)

Steering pressure OK?

no

yes

Check the rear steering pump - Close the pump outlet with a 200 bar pressure relief valve - Connect a 600 bar pressure gauge - Crank the engine with the starter - Read the pressure gauges Nominal value: approx. 200 bar (battery fully charged)

no Pressure OK?

yes

Change the steering / charge pump

Check / replace the rear steering cylinder

100

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Check the rear steering valve - Install a 600 bar pressure gauge to the steering pressure outlet - Enter code number 600 - Turn the rear steering against an end stop Nominal value: approx. 200 bar

Steering pressure OK?

no

Replace the steering valve

yes

Check the moveability of steering cylinders and pivot bearing

008 912 53

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101

102

7URXEOH VKRRWLQJ GLDJUDP

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5 Drum

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103

6SHFLDO WRROV 5.1 Special tools 1. Lifting device for vibrator unit BOMAG part-no. 007 215 08

Fig. 1

2. Screw bolt for vibrator unit lifting device

Fig. 2

104

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6SHFLDO WRROV

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105

5HSDLU RYHUYLHZ IRU GUXP

Fig. 1 Drum

106

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Vibrator housing

6

Change-over weight

2

Vibrator shaft

7

Vibrator shaft bearing

3

Drum drive motor

8

Travel bearings

4

Rubber buffer

9

Vibration motor

5

Vibrator shaft coupling

008 912 53

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107

5HPRYLQJ DQG LQVWDOOLQJ WKH GUXP 5.3 Removing and installing the drum

L Note Removal and installation of the drum is exemplary described for the front drum. The rear drum must be removed and installed in the same way.

Removal 1. Drain the water from the corresponding water tank for the water sprinkling system.

2. Fasten lifting gear to front and rear frame (Fig. 1).

3. Lift the machine up, until the rubber buffers are unloaded.

Fig. 1

4. Remove the cover plates (Fig. 2) from both sides.

Fig. 2

5. Disconnect water hoses 1 (Fig. 3) from the sprinkling tubes.

6. Remove scraper brackets (2) with the sprinkling tubes .

Fig. 3

108

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7. Mark the hydraulic hoses (Fig. 4) on the vibration motor and disconnect them from the ports.

Caution Close all openings with plugs.

Environment Catch running out oil and dispose of environmentally.

Fig. 4

8. Mark the hydraulic hoses on the travel motor (Fig. 5) and disconnect them from the ports.

Caution Close all openings with plugs.

Environment Catch running out oil and dispose of environmentally.

Fig. 5

9. Open the hose brackets (Fig. 6) on both sides of the support legs and pull the hoses out of the suport legs.

Fig. 6

10. Unscrew fastening screws (Fig. 7) from the support legs.

Fig. 7

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5HPRYLQJ DQG LQVWDOOLQJ WKH GUXP

Danger Danger of squashing!

Do not step under suspended loads.

11. Fasten lifting gear to the support leg and unscrew fastening screws (Fig. 8).

12. Pull the support leg off and lay it down.

13. Remove the support leg also from the opposite side.

Fig. 8

14. Lift the machine up (Fig. 9), so that the drum can be removed from under the frame.

15. Support the frame safely.

Fig. 9

16. Check rubber buffers (Fig. 10), replace if necessary.

Fig. 10

110

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5HPRYLQJ DQG LQVWDOOLQJ WKH GUXP Installation Danger Danger of squashing!

Do not step under suspended loads.

1. Lift up the frame and roll the drum parallel under the frame (Fig. 11).

Fig. 11 872739

2. Assemble the support legs to the drum (Fig. 12).

3. Tighten all fastening screws for both support legs and remove the lifting gear.

Fig. 12 872740

4. Align the bores in the support leg with the bores in the traverse, turn in and tighten the fastening screws (Fig. 13).

Fig. 13 872741

5. Connect the hydraulic hoses for the travel motor (Fig. 14) by following the marking and tighten them.

Fig. 14 872734

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5HPRYLQJ DQG LQVWDOOLQJ WKH GUXP 6. Connect the hydraulic hoses for the travel motor (Fig. 15) by following the marking and tighten them.

Fig. 15 872733

7. Fasten the hose bracket (Fig. 16) to the support legs on both sides.

Fig. 16 872732

8. Fasten the cover plates (Fig. 17) on both sides.

Fig. 17 872730

9. Install scrapers and water sprinkling tubes (Fig. 18).

Fig. 18 732731

112

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10. Check the hydraulic oil level (Fig. 19), top up if necessary.

Caution Bleed the hydraulic system before starting operation.

11. Perform a test drive, check function of travel system and vibration.

12. Check all connections and fittings for leak tightness.

Fig. 19

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113

5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH GUXP GULYH VLGH 5.4 Removing and installing the vibrator unit on the drum drive side 1. Remove the drum.

Environment Catch running out oil and dispose of environmentally.

2. Drain the oil from the drum.

Removing the vibrator unit 1. Unscrew the fastening nuts (Fig. 1) and take off the angle plate.

Fig. 1

2. Examine all rubber buffers 1 (Fig. 2) for wear, replace if necessary.

Fig. 2

3. Unscrew the fastening screws (Fig. 3) and take off the drive disc with rubber buffers.

Fig. 3

114

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4. Unscrew two fastening screws opposite each other (Fig. 4) and turn in guide bolts.

5. Unscrew all other fastening screws.

Fig. 4

6. Turn adapter 1 (Fig. 5) of the lifting device with three washers (2) into the travel motor.

Danger Danger of squashing!

Do not step under suspended loads.

7. Fasten the lifting device to a crane and slide it over the adapter.

8. Pull the travel motor off the flange.

Caution If dirt or chips are found in the travel motor flush the hydraulic system before restarting the machine.

Fig. 5

9. If necessary unscrew the fastening screws (Fig. 6) and take off the flange.

Fig. 6

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115

5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH GUXP GULYH VLGH 10. Unscrew two fastening screws opposite each other (Fig. 7) and turn in guide bolts.

11. Unscrew all other fastening screws and force the housing off with the help of two screws.

Fig. 7

12. Fasten the lifting device to the flange and pull the housing out of the drum (Fig. 8).

13. Take off the O-ring.

Fig. 8

Installing the vibrator unit

Caution Fitting and contact surface of the connection between vibration unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent.

L Note Always assemble the vibration unit on the drum drive side first.

1. Grease and assemble the O-ring (Fig. 9).

Fig. 9

2. Fasten the lifting device to the flange and turn two guide bolts into the drum(Fig. 10).

3. Insert the vibrator unit into the drum.

Fig. 10

116

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4. Remove the guide bolts (Fig. 11).

5. Turn in and tighten the fastening screws.

Fig. 11

6. Attach the flange to the drum drive motor, turn in and tighten the fastening screws (Fig. 12).

Fig. 12

7. Turn adapter 1 (Fig. 13) of the lifting device with three washers (2) into the travel motor.

Danger Danger of squashing!

Do not step under suspended loads.

8. Fasten the lifting device to a crane and slide it over the adapter.

Caution If dirt or chips are found in the travel motor flush the hydraulic system before restarting the machine.

Fig. 13

9. Turn in two guide bolts.

10. Push on the drum drive motor, turn in and tighten the fastening screws (Fig. 14).

Fig. 14

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117

5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH GUXP GULYH VLGH 11. Attach the drive disc with rubber buffers, turn in and tighten the fastening screws (Fig. 15).

Fig. 15

12. Attach the angle plate, turn on and tighten the fastening nuts with washers (Fig. 16).

Fig. 16

118

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5.5 Removing and installing the vibrator unit on the vibration drive side 1. Remove the drum.

Environment Catch running out oil and dispose of environmentally.

2. Drain the oil from the drum.

3. Remove the vibrator unit on the drum drive side.

Removing the vibrator unit 1. Unscrew the fastening nuts (Fig. 1) and take off the angle plate.

Fig. 1

2. Examine all rubber buffers (Fig. 2) for wear, replace if necessary.

Fig. 2

3. Unscrew fastening screws 1 (Fig. 3) and take off the vibration motor (2).

Caution If dirt or chips are found in the travel motor flush the hydraulic system before restarting the machine.

Fig. 3

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119

5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH 4. If necessary unscrew fastening screw 1 (Fig. 4) and pull off coupling hub (2).

Fig. 4

5. Remove coupling element 1 (Fig. 5)and pull off coupling hub (2).

Fig. 5

6. Unscrew the fastening screws (Fig. 6) and remove the cover.

Fig. 6

7. Unscrew the fastening screws (Fig. 7) and take off the intermediate ring.

Fig. 7

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8. Take off the V-ring (Fig. 8).

Fig. 8

9. Remove the circlip (Fig. 9).

Fig. 9

10. Attach the lifting gear side plate (Fig. 10).

Danger Danger of squashing!

Do not step under suspended loads.

Fig. 10

11. Pull the side plate off the flange using a special pulling device (Fig. 11).

Fig. 11

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5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH 12. Press the travel bearing (Fig. 12) out, check its condition and replace if necessary.

Fig. 12

13. Take off the V-ring (Fig. 13).

Fig. 13

14. Unscrew the fastening screws (Fig. 14) and take off the flange.

Fig. 14

15. Turn two guide bolts into the drum and unscrew the fastening screws (Fig. 15).

Fig. 15

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16. Fasten the lifting device to the flange and pull the housing out of the drum (Fig. 16).

17. Take off the O-ring.

Fig. 16

18. Remove circlip 3 (Fig. 17) from coupling sleeve (1).

19. Pull off coupling and disc (2).

Fig. 17

Installing the vibrator unit

Caution Fitting and contact surface of the connection between vibration unit and drum must be absolutely dry and free of grease, oil, paint and conserving agent.

L Note Always assemble the vibration unit on the drum drive side first.

1. Grease and assemble the O-ring (Fig. 18).

Fig. 18

2. Push on coupling sleeve 1 (Fig. 19).

3. Insert disc (2) and assemble circlip (3).

Fig. 19

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5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH 4. Turn two guide bolts into the drum (Fig. 20).

5. Attach the lifting gear to the flange and insert the housing carefully into the drum.

Caution Ensure correct engagement of the coupling!

After installation the vibrator shaft must still have sufficient end float.

Fig. 20

6. Unscrew the guide bolts, turn in and tighten the fastening screws (Fig. 21).

Fig. 21

7. Attach the flange, turn in and tighten the fastening screws (Fig. 22).

Fig. 22

8. Press the travel bearing with spacer disc (Fig. 23) into the drive disc.

Fig. 23

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9. Assemble the V-ring . (Fig. 24)

Fig. 24

10. Attach the lifting gear to the side plate and place it onto the flange (Fig. 25).

Danger Danger of squashing!

Do not step under suspended loads.

Fig. 25

11. Pull the side plate onto the flange using a special pulling device (Fig. 26).

Fig. 26

12. Insert the circlip into the groove (Fig. 27).

Fig. 27

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5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH 13. Assemble the V-ring (Fig. 28).

Fig. 28

14. Assemble the intermediate ring, turn in and tighten the fastening screws (Fig. 29).

Fig. 29

15. Attach the cover, turn in and tighten the fastening screws (Fig. 30).

Fig. 30

16. Pull the vibrator shaft towards you (Fig. 31) (must touch the collar of the bearing on the drive side).

Fig. 31

126

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17. On the vibration drive side of the drum measure the depth to the stop of the coupling hub on the vibrator shaft (Fig. 32).

Nominal value: 122 ... 121.8 mm 18. Compensate the difference to the measured value with shims between coupling hub and vibrator shaft.

Fig. 32

19. Insert shims (Fig. 33) of calculated thickness.

L Note If the fitting key is already assembled the shims must be punched out accordingly.

Fig. 33

20. Press the coupling have 2 (Fig. 34) onto the vibrator shaft and insert coupling element (1).

Caution Mind the fitting key!

Fig. 34

21. Slide coupling hub 2 (Fig. 35) onto the shaft and tighten fastening screw (1).

Fig. 35

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5HPRYLQJ DQG LQVWDOOLQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH 22. Install the vibration motor 2 (Fig. 36), turn in and tighten the fastening screws (1).

Fig. 36

23. Assemble the angle plate, turn on and tighten the fastening nuts (Fig. 37).

Fig. 37

24. Fill in oil as specified in the maintenance instructions.

128

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5.6 Repairing the vibrator unit on the drum drive unit 1. Remove the vibrator unit.

Dismantling the vibrator unit 1. Unscrew fastening screws 1 (Fig. 1) and take the flange off the housing.

2. Unscrew plugs (2).

L Note The bores with the plugs (2) are used to force off the cylinder roller bearings.

Fig. 1

3. Take the flange off the housing (Fig. 2).

4. Take off the O-rings.

Fig. 2

5. Remove the safety lock (Fig. 3).

6. Force bearing (2) out of the flange with the help of screws.

Fig. 3

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129

5HSDLULQJ WKH YLEUDWRU XQLW RQ WKH GUXP GULYH XQLW 7. Take the vibrator unit (Fig. 4) out of the housing.

Fig. 4

8. Check the condition of the inner bearing race (Fig. 5), replace if necessary.

Fig. 5

9. Pull coupling pinion 1 (Fig. 6) off the exciter shaft.

10. Check the condition of the inner bearing race (2), pull off if necessary.

Fig. 6

11. Remove circlip 1 (Fig. 7).

12. Press bearing (2) out of the housing.

Fig. 7

130

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Assembling the vibrator unit 1. Press bearing 2 (Fig. 8) into the housing.

2. Assemble circlip (1).

Fig. 8

Danger Danger of burning!

Wear protective gloves.

3. Heat the inner bearing race up to approx. 80 °C. 4. Push inner bearing race 3 (Fig. 9) with the collar towards the eccentric weight all the way against the end stop.

5. Insert circlip (2) into the groove in the vibrator shaft.

6. Insert the fitting key into the keyway in the vibrator shaft.

Fig. 9

7. Heat coupling pinion (1) up to approx. 80 °C and slide it onto the shaft against the stop.

Danger Danger of burning!

Wear protective gloves.

8. Heat the inner bearing race up to approx. 80 °C. 9. Push inner bearing race 2 (Fig. 10) with the collar towards the eccentric weight all the way against the end stop.

10. Insert circlip (1) into the groove in the vibrator shaft.

Fig. 10

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5HSDLULQJ WKH YLEUDWRU XQLW RQ WKH GUXP GULYH XQLW 11. Move the vibrator unit (Fig. 11) carefully into the housing, until the inner bearing race is seated in the bearing.

Fig. 11

12. Press bearing 2 (Fig. 12) into the housing.

13. Assemble circlip (1).

Fig. 12

14. Grease the O-ring and lay it into the groove (Fig. 13).

Fig. 13

15. Grease the O-ring and lay it around the collar (Fig. 14).

Fig. 14

132

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16. Attach the flange to the housing (Fig. 15).

Fig. 15

17. Insert and tighten fastening screws 1 (Fig. 16).

18. Insert the plugs into the forcing off bores (2) with seal rings.

Fig. 16

19. Check the end float of the vibrator shaft (Fig. 17).

Nominal value: 0.6 ... 1.2 mm

Fig. 17

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133

5HSDLULQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH XQLW 5.7 Repairing the vibrator unit on the vibration drive unit 1. Remove the vibrator unit.

Dismantling the vibrator unit 1. Unscrew the fastening screws (Fig. 1) and take the flange off the housing.

Fig. 1

2. Take the flange off the housing (Fig. 2).

3. Take off the O-rings.

Fig. 2

4. Pull radial seal 1 (Fig. 3) out of the flange.

5. Unscrew plugs (2).

L Note The bores with the plugs (2) are used to force off the cylinder roller bearings.

Fig. 3

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6. Remove circlip 1 (Fig. 4).

7. Force bearing (2) out of the flange with the help of screws.

Fig. 4

8. Take the vibrator unit (Fig. 5) out of the housing.

Fig. 5

9. Check the condition of inner ring 1 (Fig. 6) for radial seal and inner bearing race (2), pull off if necessary.

Fig. 6

10. Pull coupling pinion 1 (Fig. 7) off the exciter shaft.

11. Check the condition of the inner bearing race (2), pull off if necessary.

Fig. 7

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5HSDLULQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH XQLW 12. Remove circlip 1 (Fig. 8).

13. Press bearing (2) out of the housing.

Fig. 8

Assembling the vibrator unit 1. Press bearing 2 (Fig. 9) into the housing.

2. Assemble circlip (1).

Fig. 9

Danger Danger of burning!

Wear protective gloves.

3. Heat the inner bearing race up to approx. 80 °C. 4. Push inner bearing race 6 (Fig. 10) with the collar towards the eccentric weight all the way against the end stop.

5. Insert circlip (5) into the groove in the vibrator shaft.

6. Insert fitting key (4) into the keyway in the vibrator shaft.

Fig. 10

7. Slide locking ring (3) and washer (2) to fasten the coupling onto the shaft.

8. Heat coupling pinion (1) up to approx. 80 °C and slide it onto the shaft against the stop.

136

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Danger Danger of burning!

Wear protective gloves.

9. Heat the inner ring and inner bearing race up to approx. 80 °C. 10. Push inner bearing race 3 (Fig. 11) with the collar towards the eccentric weight all the way against the end stop.

11. Insert circlip (2) into the groove in the vibrator shaft.

Fig. 11

12. Slide inner ring (1) with the chamfered side towards the outside onto the shaft.

13. Move the vibrator unit (Fig. 12) carefully into the housing, until the inner bearing race is seated in the bearing.

Fig. 12

14. Press bearing 2 (Fig. 13) into the housing.

15. Assemble circlip (1).

Fig. 13

16. Grease the O-ring and lay it into the groove (Fig. 14).

Fig. 14

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5HSDLULQJ WKH YLEUDWRU XQLW RQ WKH YLEUDWLRQ GULYH XQLW 17. Grease the O-ring and lay it around the collar (Fig. 15).

Fig. 15

18. Attach the flange to the housing (Fig. 16).

Fig. 16

19. Turn in and tighten the fastening screws (Fig. 17).

Fig. 17

20. Press the new radial seal 1 (Fig. 18) into the housing with the sealing lip pointing down.

21. Insert the plugs into the forcing off bores (2) with seal rings.

Fig. 18

138

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22. Check the end float of the vibrator shaft (Fig. 19).

Nominal value: 0,6 ... 1.2 mm

Fig. 19

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139

'LVPDQWOLQJ DVVHPEOLQJ WKH FKDQJH RYHU ZHLJKWV 5.8 Dismantling, assembling the changeover weights Dismantling 1. Unscrew all other fastening screws (Fig. 1).

Fig. 1

2. Turn the screws (Fig. 2) into the tapped bores of the cover and force the cover off.

Environment Catch running out oil and dispose of environmentally.

3. Tip the oil into a suitable container.

Fig. 2

4. Pull O-rings 1 and 2 (Fig. 3) out of the grooves.

Fig. 3

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5. Take the weight (Fig. 4) out of the housing.

Fig. 4

Assembly 6. Lay the change-over weight into the housing with the chamfered inner edge (Fig. 5) facing up.

L Note Before reassembling check whether the weight correctly changes its position after the cover has been installed (without oil) .

Fig. 5

7. Place O-rings 1 and 2 (Fig. 6) with some grease into the grooves.

Fig. 6

8. Fill the housing up to the edge with approx. 0.39 litres of silicone oil 47V 1000 cSt (Fig. 7).

Fig. 7

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'LVPDQWOLQJ DVVHPEOLQJ WKH FKDQJH RYHU ZHLJKWV 9. Attach the cover (Fig. 8) to the housing.

10. Cover the fastening screws with LOCTITE green (No. 601).

11. Tighten the fastening screws evenly with 35 Nm.

Fig. 8

142

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6 Pivot steering

008 912 53

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143

5HPRYLQJ UHSDLULQJ DQG LQVWDOOLQJ WKH SLYRW VWHHULQJ 6.1 Removing, repairing and installing the pivot steering Removal 1. Remove the respective drum (see respective section).

2. Disconnect the steering cylinders (Fig. 1) on both sides from the cross-member.

Fig. 1

3. Unscrew all fastening screws from the hood (Fig. 2) and take off the hood.

Fig. 2

4. Remove steering angle transducer 1 (Fig. 3) and cover (2).

Fig. 3

144

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5. Pull hydraulic hoses and electric cables (Fig. 4) out of the cross member.

Fig. 4

6. Attach the lifting tackle to the cross-member (Fig. 5).

Danger Danger of squashing!

Do not step under suspended loads.

Fig. 5

7. Unscrew all fastening screws (Fig. 6) from both sides and lower the cross-member to the ground.

Fig. 6

8. Unscrew all fastening screws (Fig. 7) and lower the transom bed to the ground.

Fig. 7

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145

5HPRYLQJ UHSDLULQJ DQG LQVWDOOLQJ WKH SLYRW VWHHULQJ 9. Check four point bearing , replace if necessary.

Danger Danger of squashing!

Support the bearing so that it cannot fall down.

10. Unscrew all fastening screws (Fig. 8) from the four-point bearing and take the bearing off.

Fig. 8

Installation

Danger Danger of squashing!

Do not step under suspended loads.

1. Lift up the cross-member and place it in front of the transom bed (Fig. 9).

Fig. 9

2. Turn in and tighten the fastening screws (Fig. 10).

Fig. 10

3. Route hydraulic hoses (Fig. 11) and electric cables through the cross member.

Fig. 11

146

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4. Assemble the steering angle transducer (Fig. 12) with the angle plate.

Caution Adjust the angle transducers before starting operation of the machine!

Fig. 12

5. Connect the steering cylinders (Fig. 13) with the cross-member.

Fig. 13

6. Reinstall the drum (see corresponding section).

7. Calibrate and adjust the steering angle transducers (see respective section).

8. Reassemble the hood (Fig. 14) and perform a test drive.

Fig. 14

008 912 53

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147

5HSDLULQJ WKH RVFLOODWLRQ MRLQW 6.2 Repairing the oscillation joint Dismantling the oscillation joint 1. Remove drum and pivot steering (see corresponding section).

2. Unscrew the fastening screws (Fig. 1) and remove the cover.

Fig. 1

3. Pull out the rocker bearing (Fig. 2) and take off the supporting disc.

Fig. 2

4. Remove the cover (Fig. 3) also on the other side and pull out the rocker bearing.

Fig. 3

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5. Press the joint bolt out using three screws (Fig. 4).

Fig. 4

6. Lift the beam out of the cross member (Fig. 5).

Fig. 5

Assembling the oscillation joint 1. Insert the beam into the cross member and knock in the joint bolt (Fig. 6).

Fig. 6

2. Insert the support ring and press the joint ring (Fig. 7) onto the joint bolt.

3. Spray the joint ring with sliding agent OKS 571 (BOMAG part-no. 009 700 26).

Caution Insert the rocker bearing without grease, use only sliding agent OKS 571 (BOMAG part-no.

009 700 26).

Fig. 7

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5HSDLULQJ WKH RVFLOODWLRQ MRLQW 4. Spray the bearing race (Fig. 8) with sliding agent and knock it into the cross member.

L Note Allow the bearing to protrude for about 5 mm and pull it completely in later when assembling the cover.

Fig. 8

5. Assemble the cover (Fig. 9) and tighten the fastening screws evenly.

Caution Do not mix up the cover for both sides by mistake!

Fig. 9

6. Insert the supporting disc and knock in the rocker bearing (Fig. 10).

Fig. 10

7. Place a shim 0f 4.2 mm thickness into the cover on the other side (Fig. 11).

Fig. 11

150

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5HSDLULQJ WKH RVFLOODWLRQ MRLQW 8. Insert both Belleville springs (Fig. 12).

Caution Observe the installation direction!

Fig. 12

9. Assemble the cover (Fig. 13) and tighten the fastening screws evenly.

10. Loosen the screws of the cover again.

Fig. 13

11. Insert the M16 threaded rod through the central bores in both covers and preload the covers with 90 Nm (Fig. 14).

Fig. 14

12. Measure the gap (measurement „Y“) between cover and cross member with a feeler gauge (Fig. 15).

Calculate the shim thickness „S“ S = 3.7 - Y 13. Reassemble the covers and correct the thickness of the shims as calculated.

14. Assemble the covers with the calculated shims and tighten the fastening screws.

Fig. 15

15. Reinstall the drum (see corresponding section).

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7 Suppliers documentation

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154

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7.1

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A4VG

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155

156

$ 9*

%20$*

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$ 9*

RDE 92003-01-R/05.99 ersetzt / replaces RDE 92003-01-R/07.96

Reparaturanleitung Repair instructions

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A4VG 40 - 56 Baureihe 32 A4VG 40 - 56

Series 32

157

Hinweis / Inhalt

Reparaturanleitung A4VG

Notice / Contents

Repair Instructions A4VG

RDE 92003-01-R/05.99

$ 9*

HINWEIS Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage. Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.

Methoden und Vorrichtungen sind Empfehlungen, für deren Resultat wir keine Haftung übernehmen können.

BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.

Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem Teststand vorzunehmen.

Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.

Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermitteln wir in unseren Schulungskursen.

NOTICE Specifications, descriptions and illustrative material shown herein were as accurate as known at the time this publication was approved for printing.

BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to change speci-fications, materials, or design without notice and with-out incurring obligation.

Optional equipment and accessories may add cost to the basic unit, and some options are available only in combination with certain models or other options.

For the available combinations refer to the relevant data sheet for the basic unit and the desired option.

Adjustment and tests have to be carried out on the test bench under operating temperatures.

Protection of personnel and property has to be guaranteed by appropriate measures.

Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

CONTENTS

Seite/ Page

A4VG Schnittbild Turcon-Glyd-Ring Dichtung Allgemeine Reparaturhinweise Dichtsätze und Baugruppen Triebwelle abdichten Hilfspumpe abdichten Stellkolbendeckel abdichten Ventile abdichten Druckabschneidung abdichten Regelventil abdichten Steuergerät demontieren Ansteuergeräte Pumpe demontieren Triebwerk ausbauen Stellkolben demontieren Überprüfungshinweise Kontrolle der Triebwerksteile Stellkolben,Triebwerk einbauen Pumpe montieren Anziehdrehmomente Sicherheitsbestimmungen Einstellhinweise

2

A4VG 3-4 5 6 7-8 9 10 11-12 13 14 15 16 17 18-19 20 21 22 23-24 25-33 34-35 36 37-38 39-44

Sectional view Turcon-Glyd-ring seal General repair instructions Seal kits and sub assembly groups Sealing of the drive shaft Sealing of the boost pump Sealing of the control piston cover Sealing of the valves Sealing of the pressure cut-off valve Sealing of the regulator valve Removal of the control module Control modules Pump disassembly Removal of the rotary group Disassembly of the positioning piston Inspection notes Inspection of the rotary group parts Installation of the rotary group Assembly of the pump Tightening torques Safety regulations Adjustment instructions

Brueninghaus Hydromatik

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Schnittbild

Reparaturanleitung A4VG

Sectional view

Repair Instructions A4VG

HWD

DAD

EPD

HDD

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3

Schnittbild

Reparaturanleitung A4VG

Sectional view

Repair Instructions A4VG

RDE 92003-01-R/05.99

$ 9*

HWD / EPD / HDD

DAD

4

Brueninghaus Hydromatik

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Reparaturanleitung A4VG

Turcon-Glyd-ring seal

Repair Instructions A4VG

Deckel

Stelldruck

Führungsbuchse Stellzylinder

Turcon-Glyd-Ring Lecköl Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung der Verstellung auf Turcon-Dichtungen.

Die Stückliste der kompletten Einheit erhält dabei eine neue Ident.- Nummer.

Typenschlüssel, Typnummer und Außenabmeßungen bleiben dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich vom Stellkolben. Stellkolben ändert sich in eine angefaste Ausführung).

Alten Stellkolben nicht bei Turcon-Dichtung verwenden (scharfkantig - Dichtungen werden beschädigt).

Pumpengehäuse / Pump housing mit Lagerbuchse / with bush ALT / OLD

At present the change of the control into Turcon seal is made for A4VG. The parts list of the complete unit will receive a new identification number.

Type reference and outside dimensions remain unchanged (pump housing will change at the area of the positioning piston. Positioning piston will change into chamfering design).

Do not use old positioning piston with Turcon seal (sharp edged - seal will be damaged)

Pumpengehäuse / Pump housing mit Turcon-Dichtung / with Turcon seal *

NEU / NEW *

Die Umstellung der Verstellung auf TurconDichtung ist im allgemeinen mit einer Funktionsverbesserung verbunden (DA-Verhalten, geringerer Temperatureinfluß auf Stellzeiten).

The change of the control into Turcon seal design improves in general the function (DA-behaviour, lower temperature-influence on control times).

Bei gleicher Düsenbestückung können sich die Stellzeiten geringfügig verändern.

The control times will slightly change with the same throttle sections. Therefore our customers have to be informed about this change.

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Allgemeine Reparaturhinweise

Reparaturanleitung A4VG

General repair instructions

Repair Instructions A4VG

Achtung!

Nachfolgend Hinweise bei allen Reparaturarbeiten an Hydraulikaggregaten beachten!

Attention!

Observe the following notices when carrying out repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK-Ersatzteile verwenden.

Replace all seals.

Use only original BRUENINGHAUS HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium before start- up.

6

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Reparaturanleitung A4VG

Seal kits and sub assembly groups

Repair Instructions A4VG

1

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

2

Äußerer Dichtsatz.

External seal kit.

3

Gehäuse Housing

4

Triebwerk komplett.

Complete rotary group.

5

Stellkolben Positioning piston

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7

Baugruppen

Reparaturanleitung A4VG

Sub assemblies

Repair Instructions A4VG

RDE 92003-01-R/05.99

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6

Anschlußplatte Port block

7

Ansteuergeräte HW - EP Control moduls HW - EP

8

Ansteuergeräte HD - DA Control moduls HD - DA

9

Hilfspumpe Boost pump

10

Regelventil Control valve

8

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Triebwelle abdichten

Reparaturanleitung A4VG

Sealing of the drive shaft

Repair Instructions A4VG

11 12

Triebwelle abkleben.

Sicherungsring ausbauen.

Protecting the drive shaft.

Remove retaining ring.

13

Blechschraube in die mit Gummi gefüllten Löcher eindrehen.

Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes fitted with rubber.

Pull out shaft seal with pliers.

14

Wellendichtring mit Buchse auf Anschlag einpressen.

Press-in shaft seal with bush to stop.

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Hilfspumpe abdichten

Reparaturanleitung A4VG

Sealing of the boost pump

Repair Instructions A4VG

Achtung! * Angefaste "Seite" zum Deckel montieren.

Note! * Mount chamfered side facing cover.

15 16

Lage kennzeichnen, Befestigungsschrauben ausbauen.

Mark position, remove fixing screws.

17

Deckel abdrücken.

Pry-off cover.

18

Teile der Hilfspumpe auf Verschleiß untersuchen.

Pumpe kann nur komplett ausgetauscht werden.

Inspect the parts of the boost pump and wear parts.

Boost pump can only be interchanged completely.

10

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Stellkolbendeckel abdichten

Reparaturanleitung A4VG

Sealing of the control piston cover

Repair Instructions A4VG

19 20

Befestigungsschrauben lösen.

Deckel verdrehen und mit leichten Hammerschlägen lösen.

Loosen mounting screws.

Rotate cover and release by tapping gently with hammer.

21

Kontrolle!

O-Ring (1), Nut (2), Gehäuse (3).

Check!

O-ring (1), groove (2), housing (3).

22

Kontermutter ausbauen, Stellschraube gegenhalten.

Deckel kennzeichnen. Maß festhalten, Kontermutter lösen.

Remove locknut whilst holding setting screw.

Mark cover. Must be fixed, loosen counter nut.

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Stellkolbendeckel abdichten

Reparaturanleitung A4VG

Sealing of the control piston cover

Repair Instructions A4VG

23

Über 0-Lagen-Einstellschraube Deckel abdrücken und drehen.

Pull cover off using zero position adjustment screw.

24

Kontrolle!

O-Ring (1), Nut (2), Gehäuse (3).

Check!

O-ring (19, groove (2), housing (3).

25

Gewinde abdecken, kleinen O-Ring aufschieben.

Montage in umgekehrter Reihenfolge.

Cover threads, push on small O-ring.

Assemble in reversed order.

26

Achtung!

Korrekte mechanische Nullageneinstellung muß nach Einbau im Gerät bzw. Prüfstand erfolgen.

Attention!

Adjustment of the correct zero position to be carried out after installation into the machine or on the test bench.

27

Mechanische Nullage neu einstellen, dazu X1 mit X2 verbinden (>NW6).

Reset mechanical zero position. To do this, connect X1 to X2 (size > 6).

12

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Reparaturanleitung A4VG

Sealing of the valves

Repair Instructions A4VG

PHD -Ventil

mit Bypass

PHD -valve

with bypass-function

PSP -Ventil PSP -valve

28 29

Gewinde vor Montage des neuen O-Ringes abkleben.

(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

30 *

Ventilkegel mit Druckfeder ausbauen. * mit Bypassfunktion Remove valve poppet with spring. * with bypass-function

31

Gewinde vor Montage des neuen O-Ringes abkleben.

(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

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Druckabschneidung abdichten

Reparaturanleitung A4VG

Sealing of the pressure cut-off valve

Repair Instructions A4VG

31 33

Wechsel der Dichtmutter.

Einstellmaß festhalten (*).

Change of the sealing nut.

Note setting measure (*).

Achtung!

Nach Einbau "Ventileinstellung" überprüfen.

Attention!

After assembly check "valve setting".

14

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Reparaturanleitung A4VG

Sealing of the control valve

Repair Instructions A4VG

34 35

Regelventil ausbauen.

Remove control valve.

36

Blendendurchmesser nicht beschädigen.

Do not damage throttle diameter.

37

Gewinde vor Montage des neuen O-Ringes abkleben.

Before installing the new O-ring, tape the threads.

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Steuergerät demontieren

Reparaturanleitung A4VG

Removing of the control module

Repair Instructions A4VG

38 39

Befestigungsschrauben demontieren.

Remove fixing screws.

40

Ansteuergerät abdrücken.

Pry-off the control module.

41

Kontrolle Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check Sealing surface (1), gasket (2), o-rings (3).

16

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Ansteuergeräte

Reparaturanleitung A4VG

Control modules

Repair Instructions A4VG

Ansteuergerät HW HW control module

42

HD

Ansteuergerät HD - EP EP HD - EP control module HD

EP

44

43

Hydraulische Nullage (1) neu einstellen. Beide Manometer müssen gleichen Druckwert anzeigen.

Reset hydraulic zero position (1).

Both gauges must indicate the same pressure.

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Pumpe demontieren

Reparaturanleitung A4VG

Pump disassembly

Repair Instructions A4VG

Verschlußschraube / Stift Locking screw / pin

Verdrillschraube Timing adjustment screw 46

45

Lage der Hilfspumpe und Anschlußplatte markieren.

Hilfspumpe abbauen.

Mark position of the boost pump and the port plate.

Remove the boost pump.

47

Lage der Verdrillschraube markieren (1).

Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).

Set the indexing screw to disassembly position (2).

48

Anschlußplattenbefestigung lösen. Anschlußplatte abheben.

Achtung! Dichtfläche.

Release port plate fitting.

Take off port plate. If necessary, use screwdriver.

Attention! Sealing surface.

18

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Pumpe demontieren

Reparaturanleitung A4VG

Pump disassembly

Repair Instructions A4VG

49

Steuerplatte abdrücken.

Lage notieren.

Lift off control plate.

Note position.

50

Kontrolle!

O-Ring mit Nut (1), Gehäuse (2), Quad-Ring und Quad-Ring Nut (3).

Check!

O-ring and groove (1), housing (2), Quad-ring and groove (3).

51

Zylinder nach unten drücken (1).

Verdrillschraube herausdrehen (2).

Triebwerk ausheben (3).

Press the cylinder to the bottom (1).

Remove fiming indexing screw (2).

Lift out rotary group (3).

"Ausbauen" 1. Zylinder 2. Schwenkwiege 3. Gelenkstift "Remove" 1. Cylinder 2. Swash plate 3. Joint pin 52 Brueninghaus Hydromatik

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Triebwerk ausbauen

Reparaturanleitung A4VG

Removal of the rotary group

Repair Instructions A4VG

53

Seegerring, WDR ausbauen.

Remove retaining ring, radial seal ring.

54

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slight hammer strokes.

55

Lagerschalen ausbauen.

Remove bearing cups.

56 20

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Stellkolben demontieren

Reparaturanleitung A4VG

Disassembly of the positioning piston

Repair Instructions A4VG

57 58

Steuergerät abbauen.

Remove control module.

59

Stellkolben (1) ziehen.

Pull out control piston (1).

60

Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.

Mount fixture and tension spring.

Remove receiving ring.

61

Ringe ausbauen.

Sicherungsring ausbauen.

Achtung! Teile stehen unter Federvorspannung.

Take out rings.

Remove retaining ring.

Note! Parts are spring loaded.

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Überprüfungshinweise

Reparaturanleitung A4VG

Inspection notes

Repair Instructions A4VG

RDE 92003-01-R/05.99

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62

Alle Lager erneuern.

Replace all bearings.

63

Kontrolle!

1. Verzahnung, ausgeschlagen, Passungsrost.

2. Lauffläche.

3. Einlaufrillen vom Wellendichtring.

Check!

1. Splines for damage or fretting.

2. Running surfaces.

3. Groove cut by shaft seal.

64

Stellkolbenlaufbüchse (1) riefenfrei, nicht ausgelaufen.

Check that the control piston guide bush (1) is free of grooves and has not worn out.

65

Kontrolle!

Stellkolben (1) riefenfrei.

Check!

Control piston (1) is not scored.

22

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Reparaturanleitung A4VG

Inspection of rotary group parts

Repair Instructions A4VG

66

Kontrolle!

Gleitfläche riefenfrei.

Check!

Sliding surface free of grooves.

67

Kontrolle!

Verbindung Gleitstein/Schwenkzapfen spielfrei.

Check!

Make sure sliding ring/swivel pin are free of play.

68

Kontrolle!

Rückzugeinrichtung riefenfrei (1), keine Einlaufspuren (2) im Gleitschuhbereich.

Check!

Check that return device is free of grooves (1) no wear in slipper pad area.

69

Kontrolle!

Lauffläche (1) keine Kratzer, keine Metalleinlagerungen, kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!

Check that there are no scratches or metal deposits on sliding surface (1), and there is no axial play (2), (otherwise: pistons must be replaced in sets).

70

Kontrolle!

Zylinderbohrungen (1), Verzahnungen (2).

Check!

Cylinder bores (1), splines (2).

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Kontrolle der Triebwerksteile

Reparaturanleitung A4VG

Inspection of rotary group parts

Repair Instructions A4VG

71

Kontrolle!

Zylindergleitfläche (1) riefenfrei, nicht eingelaufen, keine Einlagerungen, Steuerplatte (2) nicht riefig (nur satzweise austauschen).

Check!

Cylinder gilding surface (1) free of scratches, no traces of wear and no embedded foreign particles. No scratches on the valve plate (2). (Replace ONLY in sets).

72

Kontrolle!

DU-Lagerbuchse (1) nicht ausgelaufen.

Check!

DU-bearing bush (1) is not worn out.

73

Hinweis: Bohrung bei DA-Regelung offen. Ohne DA-Regelventil geschlossen.

Information: Boring for DA-control open.

Without DA-control closed.

74

Kontrolle!

Lagerbahnen (1) Check!

Bearing surfaces (1)

24

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Reparaturanleitung A4VG

Positioning piston, rotary group assembly

Repair Instructions A4VG

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Hilfswerkzeuge / Auxiliary tools: Montagezange / Assembly pliers: B+S x M22

Führungsdorn / Guide thorn: A4VG28 I: 277 4 347 A4VG40 I: 277 4 049 A4VG56 I: 277 4 050 A4VG71 I: 277 4 051 A4VG90 I: 277 4 052 A4VG125 I: 277 4 053 A4VG180 I: 277 4 054 A4VG250 I: 277 4 072

Montage / Assembly A4VG

1 2 3 3 2 Pos. / Item 1

1

Pos. / Item 2 / 3

Pos. / Item 2 / 3

Pos. / Item 1

Pos. / Item 1: Stangenführungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

82 Brueninghaus Hydromatik

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Stellkolben, Triebwerk einbauen

Reparaturanleitung A4VG

Positioning piston, rotary group assembly

Repair Instructions A4VG

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Dichtring (Pos. 2) in die Montagezange einlegen.

Fit the seal ring (Item 2) into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig zusammendrücken. Die Verformung von Turcon-Dichtungen ist sorgfältig vorzunehmen, damit die Dichtkanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the assembly tool. The deformation of the Turcon seal has to be done with care so as not to damage the sealing edges.

Dichtring ins Gehäuse einführen und in der Aufnahmenut plazieren. Dann Spannung lösen und Montagezange heraus ziehen. Lage des Dichtringes prüfen - eventuell mit dem Finger egalisieren.

Position the seal ring into the housing and place it into the groove. Release the tension and withdraw the assembly tool.

Check the position of the seal ring if necessary straighten using a finger.

Führungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

Führungsdorn leicht einfetten.

Stellkolben mit Führungsdorn einbauen.

Grease slightly guide thorn.

Install positioning piston with guide thorn.

26

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Triebwerk einbauen

Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

75

Stellkolben ins Gehäuse einsetzen.

Hinweis: Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction: Oil positioning piston before assembly.

76

Lagerschalenpaar einsetzen.

Insert bearing cup set.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett Assemble bearing, wire, gliding stone and articulating pin.

Assistance: Devices e.g. - Clamp / rubber rings / grease

77 78

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse "achten".

Montagehilfe ausbauen.

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in the housing.

Remove auxiliary device.

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

Kontrolle:

Sitz der Schwenklager in der Lagerbahn.

Schwenkwiege mit Stellkolben verschwenken "Leichtgängig".

Mittig stellen mit Meßvorrichtung (Uhr oder Tiefenmaß) Punkt 1 und 2 kontrollieren - gleiches Maß.

Check:

Location of the swivel-bearing in the bearing.

Swivel the swivel bearing by using the control piston "it should move easily".

Centralise by using a measuring device (dial gauge or depth measurement).

Check points 1 and 2 - they should have the same dimension.

79 80

Gelenkstift montieren.

Fit joint pin.

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

82

Neue Montageposition!

Triebwelle mit Lager und Wellendichtring einbauen.

Assemble drive shaft with bearings and radial seal rings.

83

84

Scheibe 1, 2 Disc 1, 2

1

82

2 85

Kolben mit Rückzugeinrichtung montieren.

Hinweis: Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note: Oil piston and piston pad.

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

86

Vorrichtung ausbauen.

Zylinder mit Kolben und Rückzugeinrichtung einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

87

Montagehilfe: Mit O-Ring Kolben festhalten.

Assembly aid: Hold the pistons by using an O-ring.

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Reparaturanleitung A4VG

Installation of the rotary group

Repair Instructions A4VG

89

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung!

Geräuschkerben sind drehrichtungsbezogen eingeschliffen.

Control plate clockwise rotation - indexed in the direction of rotation.

Note!

Noise grooves are machined - in based on direction of rotation.

90

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung!

Geräuschkerben sind drehrichtungsbezogen eingeschliffen.

Control plate counter clockwise rotation - indexed in the direction of rotation.

Note!

Noise grooves are machined - in based on direction of rotation.

91

Zylinderflächen und DU-Lager einölen, neue O-Ringe mit Fett einreiben und einsetzen.

Oil the running surfaces of the cylinder barrel and the DU- bearing. Grease the O-rings and insert in grooves.

92

Grundeinstellung - Verdrillschraube A4VG...40 * = 24 ± 0,75 mm.

A4VG...56 * = 21 ± 0,75 mm.

Basic setting - indexing screw A4VG...40 * = 24 ± 0,75 mm.

A4VG...56 * = 21 ± 0,75 mm.

93

Zylinder nach unten drücken (1).

Verdrillschraube einbauen (2).

Kerbe in Montageposition.

Press the cylinder to the bottom (1).

Screw in the indexing screw (2).

Groove in mounting position.

32

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Pumpe montieren

Reparaturanleitung A4VG

Assembly of the pump

Repair Instructions A4VG

94

Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

95

Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise rotation.

96

Lagerichtig aufsetzen.

Hinweis: HW, HD, EP - Steuerplatte mit Fett auf Anschlußplatte.

Place in correct position.

Note: HW, HD, EP - Put control plate with greas to the port block.

97

Schrauben über Kreuz anziehen.

Verdrillschraube auf Markierung drehen.

Tighten screws (Cross-corner).

Turn the indexing screw to marking.

98

Hilfspumpe montieren.

Assemble boost pump.

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Pumpe montieren

Reparaturanleitung A4VG

Assembly of the pump

Repair Instructions A4VG

99

Ansteuergerät montieren.

Mount control module.

100

34

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Reparaturanleitung A4VG

Tightening torques

Repair Instructions A4VG

Anziehdrehmomente für Schaftschrauben (Metrisches ISO-Regelgewinde)

Tightening torques for shaft bolts (Metric ISO Standard Thread)

Festigkeitsklassen Die nebenstehenden Werte für An-

Strength Classes 8.8

size

Tightening Torque(lb.ft)

M3

1,3

2,0

M4

3,1

4,5

5,3

DIN 931 and DIN 933. These values are

M5

6,1

8,9

10,4

also valid only for light or unoiled,

M6

10,4

15,5

18.0

untreated surface as well as for use only

M8

25

37

43

87

with torque-indicating

M10

51

75

87

130

150

wrenches and force limiting tools.

M12

87

130

150

140

205

240

M14

140

205

240

215

310

370

M16

215

310

370

M18

300

430

510

M18

300

430

510

M 20

430

620

720

M 20

430

620

720

M 22

580

830

970

M 22

580

830

970

M 24

740

1060

1240

M 24

740

1060

1240

M 27

1100

1550

1850

M 27

1100

1550

1850

M 30

1500

2100

2500

M 30

1500

2100

2500

8.8

größe

Anziehdrehmoment(Nm)

M3

1,3

2,0

2,3

M4

3,1

4,5

5,3

M5

6,1

8,9

10,4

leicht oder nicht geölte, unbehandelte

M6

10,4

15,5

18.0

Oberflächen, sowie nur bei Verwen-

M8

25

37

43

dung von Drehmoment- und Kraftbe-

M10

51

75

grenzungsschlüsseln.

M12

87

M14 M16

ziehdrehmomente gelten nur für Schaftschrauben mit metrischem ISORegelgewinde und Kopfauflagemaßen nach DIN 912, DIN 931 und DIN 933.

Außerdem gelten diese Werte nur für

The values for tightening torques

Thread

Gewinde

10.9

12.9

shown in the table are valid only for shaft bolts with metric ISO- standard threads and head support surface dimensions in accordance with DIN 912,

10.9

Gewindegröße

Bezeichnung

Thread size

Designation

M8x1

VSTI 8 x 1

-ED/SA

=5

M8x1

VSTI 8 x 1

-ED/SA

=4

M 10 x 1

VSTI 10 x1

-ED

= 10

M 10 x 1

VSTI 10 x1

-ED

=7

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 20

M 12 x 1,5

VSTI 12 x 1,5

-ED

= 15

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 30

M 14 x 1,5

VSTI 14 x 1,5

-ED

= 22

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 30

M 16 x 1,5

VSTI 16 x 1,5

-ED/SA

= 22

M 18 x 1,5

VSTI 18 x 1,5

-ED/SA

= 40

M 18 x 1,5

VSTI 18 x 1,5

-ED/SA

= 29

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 50

M 20 x 1,5

VSTI 20 x 1,5

-ED/SA

= 37

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 60

M 22 x 1,5

VSTI 22 x 1,5

-ED

= 44

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 70

M 26 x 1,5

VSTI 16 x 1,5

-ED/SA

= 51

M 27 x 2

VSTI 27 x 2

-ED

= 90

M 27 x 2

VSTI 27 x 2

-ED

= 66

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 100

M 30 x 1 ,5

VSTI 30 x 1,5

-ED/SA

= 74

M 33 x 2

VSTI 33 x 2

-ED/SA

= 120

M 33 x 2

VSTI 33 x 2

-ED/SA

= 88

Anziehdrehmoment(Nm)

Tightening torques (lb.ft)

M 42 x 2

VSTI 42 x 2

-ED/SA

= 200

M 42 x 2

VSTI 42 x 2

-ED/SA

= 147

M 48 x 2

VSTI 48 x 2

-ED

= 300

M 48 x 2

VSTI 48 x 2

-ED

= 220

Anziehdrehmomente für Seal-Lock Bundmuttern (Metrisches ISO-Regelgewinde)

Tightening torques for seal-lock nuts (Metric ISO-Standard Thread)

Festigkeitsklassen Gewinde

8.8

ziehdrehmomente gelten nur für Seal-

größe

Lock Bundmuttern der Festigkeitsklasse 8.8 mit metrischem ISO-Regelgewinde.

10.9

Strength classes 12.9

The values for tightening torques shown

Thread

8.8

Anziehdrehmoment (Nm)

in the table are valid only for seal-lock

size

Tightening torque (lb.ft)

M6

10

nuts of the strength class 8.8 and with

M6

7,4

M8

22

metric ISO-standard thread.

M8

16,2

M 10

40

M 10

29,5

M 12

69

M 12

50,9

M 14

110

M 14

81,1

M 16

170

M 16

125,3

Anziehdrehmomente für Linsenschrauben mit Kreuzschlitz DIN 7985 (Metrisches ISO-Regelgewinde)

ziehdrehmomente gelten nur für Linsenschrauben mit Kreuzschlitz DIN 7985 der Festigkeitsklasse 8.8 mit metrischem ISO-Regelgewinde

10.9

10.9

12.9

Tightening torques for cross-slotted lens head screws DIN 7985 (Metric ISO- Standard Thread)

Festigkeitsklassen Die nebenstehenden Werte für An-

2,3

Tightening torques for locking screws VSTI (Metric ISO fine thread)

Anziehdrehmomente für Verschlußschrauben VSTI (Metrisches Feingewinde)

Die nebenstehenden Werte für An-

12.9

Strength classes

Gewinde

8.8

12.9

größe

Anziehdrehmoment(Nm)

M3

1,1

M4

2,9

M5

The values for tightening torques shown

Thread

8.8

size

Tightening torques (lb.ft)

M3

0,8

M4

2,1

6

M5

4,4

M6

10

M6

7,4

M8

25

M8

18,4

M10

49

M10

36,1

in the table are valid only for crossslotted lens head screws DIN 7985 of the strength class 8.8 and with metric ISOstandard thread.

10.9

12.9

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Sicherheitsbestimmungen

Reparaturanleitung A4VG

Safety regulations

Repair Instructions A4VG

Allgemein

General advice

· Machen Sie sich mit der Ausstattung der Maschine vertraut. · Fahren Sie die Maschine nur, wenn Sie sich völlig mit den Bedien- und Steuerelementen sowie der Arbeitsweise der Maschine vertraut gemacht haben. · Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, Sicherheitsschuhe und Gehörschutz. · Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. · Benutzen Sie die Maschine nur für den ihr zugedachten Zweck.

· Make yourself familiar with the equipment of the machine. · Only operate the machine if your are completely familiar with the operating and control elements as well as the functioning of the machine. · Use your safety equipment like helmet, safety shoes and hearing protection. · Make yourself familiar with your working field. · Only operate the machine for its intended purpose.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft und des Maschinenherstellers

Please observe the guidelines of the Professional Association and the machine manufacturer.

Vor dem Start

Before starting

· Beachten Sie die Bedienungshinweise vor dem Starten. · Prüfen Sie die Maschine auf auffällige Fehler. · Fahren Sie die Maschine nicht mit defekten Instrumenten, Kontrolleuchten oder Steuerorganen. · Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. · Nehmen Sie keine losen Gegenstände mit bzw. befestigen Sie diese an der Maschine. · Halten Sie die Maschine von öligem und zündfähigem Material frei. · Prüfen Sie vor dem Besteigen der Maschine, ob sich Personen oder Hindernisse neben oder unter der Maschine befinden. · Vorsicht beim Besteigen der Maschine, benützen Sie Treppen und Griffe. · Stellen Sie vor dem Start Ihren Sitz ein.

· Observe the operating instructions before starting. · Check the machine for obvious faults. · Do not operate the machine with defective instruments, warning lights or control elements. · All safety devices must be in a secure position. · Do not carry with you movable objects or secure them to the machine. · Keep oily and inflammable material away from the machine. · Before entering thc driver’s cabin, check if persons or obstacles are beside or beneath the machine. · Be careful when entering the driver’s cabin, use stairs and handles. · Adjust your seat before starting.

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Reparaturanleitung A4VG

Safety regulations

Repair Instructions A4VG

Starten · Beim Starten müssen alle Bedienhebel in “Neutralstellung” stehen. · Die Maschine nur vom Fahrersitz aus Starten. · Prüfen Sie die Anzeigeinstrumente nach dem Start, um sicher zu gehen, daß alles ordnungsgemäß funktioniert. · Lassen Sie die Maschine nicht unbewacht, während der Motor läuft. · Beim Start mit Batterieverbindungskabeln verbinden Sie Plus mit Plus und Minus mit Minus. Massekabel (Minus) immer zuletzt anschliesen und zuerst abtrennen.

Start · When starting all operating levers must be in “neutral position”. · Only start the machine from the driver’s seat · Check the indicating instruments after start to assure that all functions are in order. · Do not leave the machine unobserved when the motor is running. · When starting with battery connection cables connect plus with plus and minus with minus.

Always connect negative (-) cable last and disconnect negative cable first.

Vorsicht · Auspuffgase sind lebensgefährlich. Bei Start in geschlossenen Räumen für ausreichende Luftzufuhr sorgen!

Attention · Exhaust gas is dangerous. Assure sufficient fresh air when starting in closed rooms!

Hydraulikanlage 1. Hydraulikanlage steht unter hohem Druck!

Hydraulic equipment 1. Hydraulic equipment is standing under high pressure.

Unter hohem Druck austretende Hochdruck-

High pressure fluids (fuel, hydraulic oil) which

Flüssigkeiten (Kraftstoff, Hydrauliköl) können die Haut durchdringen und schwere Verletzungen verursachen. Daher sofort einen Arzt aufsuchen, da anderenfalls schwere Infektionen entstehen können!

2. Bei der Suche nach Leckstellen wegen Ver letzungsgefahr geeignete Hilfsmittel verwenden!

3. Vor Arbeiten an der Hydraulikanlage diese unbedingt drucklos machen und angebaute Geräte absenken!

4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor abstellen und Maschine gegen Wegrollen sichern (Feststellbremse, Unterlegkeil)!

5. Beim Anschließen von Hydraulikzylindern und -motoren ist auf vorgeschriebenen Anschluß der Hydraulikschläuche zu achten!

6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (z.B. Heben/Senken) - Unfallgefahr!

7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei Beschädigung und Alterung austauschen! Die Austauschschlauchleitungen müssen den technischen Anforderungen des Geräteherstellers entsprechen!

escape under high pressure can penetrate the skin and cause heavy injuries.

Therefore immediately consult a doctor as otherwise heavy infections can be caused.

2. When searching leakages use appropriate auxiliary devices because of the danger of accidents.

3. Before working at the hydraulic equipment, lower pressure to zero and lower working arms of the rnachine.

4. When working at the hydraulic equipment, absolutely stop motor and secure machine against rolling away (parking brake, shim)!

5. When connecting hydraulic cylinders and motor pay attention to correct connection of hydraulic flexible hoses.

6. In case of exchanging the ports, the tunctions are vice versa (f. ex. lift-up/lower) - danger of accidents!

7. Check hydraulic flexible hoses regularly and replace them in case of dammage or wear! The new hose pipes must comply with the technical requirements of the machine manufacturer!

Orderly disposal or recycling of oil, fuel and filters!

Öle, Kraftstoffe und Filter ordnungsgemäß entsorgen!

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Einstellhinweise - Mechanische "Nullage"

Reparaturanleitung A4VG

Adjustment instructions - Mechanical "zero position"

Repair Instructions A4VG

HW

HD

EP

DA

101

Achtung!

Sicherheitsbestimmungen beachten!

Mit Schlauch NW6 beide Stellkammern verbinden. Vermeidung von Restsignal aus hydraulischer Nullage.

Manometer an MA und MB anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Totband der Nullage - vermitteln.

Attention!

Observe safety regulations!

Connect both control chambers with hose NW6. Avoidance of rest signal from hydraulic zero position.

Connect manometer to MA and MB. Adjust zero position so that at blocked drive both manometer indicate the same pressure valve.

Note: Adjust death line of zero position.

102

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Einstellhinweise - Hydraulische "Nullage"

Reparaturanleitung A4VG

Adjustment instructions - Hydraulic "zero position"

Repair Instructions A4VG

HW

HD

EP Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

103

Manometer an X1 und X2 anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Excenterjustierung - nicht über ±90° verdrehen.

Connect manometer to X1 and X2.

Adjust zero position so that at blocked drive both manometer indicate the same pressure value.

Note: Eccentric adjusting - Do not turn over ±90°.

104

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Einstellhinweise - ND-Ventil (Speisedruck)

Reparaturanleitung A4VG

Adjustment instructions - Low pressure valve (Boost pressure)

Repair Instructions A4VG

Achtung!

Sicherheitsbestimmungen beachten!

Hinweis: Nachjustierung nur bei Betriebstemperatur.

Manometer an "G" anschließen.

Achtung! * Speisedruckeinstellung!

Nenndruck pH - 18 bar Höchstdruck pH - 40 bar Bei Max.-Drehzahl.

Hinweis: Einstelldaten nach Werksauftrag.

"G" *

* bei DA-Ausführung

Attention!

Observe safety regulations!

*

Note: Readjusting only at operating temperature.

Connect manometer to "G".

Attention! * Boost pressure setting!

Nominal pressure pH - 18 bar Peak pressure pH - 40 bar at max. speed.

Note: Adjusting data according to order.

105

40

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Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Reparaturanleitung A4VG

Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Repair Instructions A4VG

Achtung!

Sicherheitsbestimmungen beachten!

Druckabschneidung Pressure cut-off

HD-Ventil ohne Bypass 1 . HD- Ventile sind immer 10% höher eingestellt als die Druckabschneidung.

Bei Veränderung eines Einsteilwertes immer beide kontrollieren.

2. Nachjustierung nur bei Betriebstemperatur Manometer an MA und MB anschließen.

Druckabschneidung: Maß X Einstellschrauben notieren!

Einstellschraube auf Block drehen.

HD- Ventile: Mit geringer Pumpenmenge über Ventile fahren. Einstellwert kontrollieren.

(Nur kurzzeitig "Temperatur“.)

Drucklos "Einstellwert“ verändern - Kontrolle Druckabschneidung: Einstellschraube auf Maß (*) zurückdrehen.

Druckwert kontrollieren bzw. nachjustieren.

Achtung! Differenz von 10% HD- Ventile und Druckabschneidung beachten!

Hinweis: Einstelldaten nach Werksauftrag.

106

Attention!

Observe safety regulations.

HP valve without bypass-function HD- Ventile HP- valves

1 . HP valves are always adjusted 10% higher than the pressure cut-off.

If one setting value is changed, always check both values.

2. Readjusting only at operating temperature.

Connect manometer MA and MB. Pressure cut-off: Note measure X setting screw! Turn setting screw on block.

HP valves: Operate valves with small pump flow volume.

Check setting value. ("temperature“ only for a short time).

Change "setting value“ - check.

107

Pressure cut-off: Turn back setting screw to measure (*).

Check pressure value and readjust.

Attention! Observe 10% pressure difference HP valves and pressure cut-off!

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Einstellhinweise - Bypassventil

Reparaturanleitung A4VG

Adjustment instructions - Bypass valve

Repair Instructions A4VG

1 1

1

108

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung (Freilauf).

Vehicle with hydrostatic transmission and gear shift without idling setting position (free wheeling).

Hydrostatischer Antrieb / Bypaß-Schaltung

Hydrostatic transmission / Bypass-switching

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. Zu diesem Zweck haben die in der Verstellpumpe integrierten Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion.

D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich ist.

Bypass:Pos.1 einschrauben bis eben mit Mutter.

Mutter wieder anziehen.

In this case the travel transmission is switched on to free wheeling.For this purpose the variable displacement pump has incorporated high pressure relief valves with bypass function.

The screw (item 1) is unscrewed to such an extent, that the valve cartridge is released and free oil circulation is possible.

Bypass: Screw in item1 up to planeness with nut.

Screw up nut again.

Schleppgeschwindigkeit Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht überschreiten.

Towing speed The max. towing speed of 2 km/h should not be exceeded.

-

-

Höhere zulässige Schleppgeschwindigkeiten sind abhängig von der Hydromotordrehzahl bzw. dem eingelegten Gang.

Higher admissible towing speeds depend on the avaiable hydr. motor speed and engaged gear shift.

Abschleppdistanz Die Schleppentfernung sollte 1 km nicht überschreiten.

Towing distance The towing distance should not exceed 1 km.

-

-

Bei fehlender Einspeisung entleert sich der Hydraulik-Kreislauf.

Zu beachten ist die Wärmeentwicklung im Hydromotor-Triebwerk.

Abschleppvorgang beendet Nach beendetem Abschleppvorgang Pos.1 zurückdrehen. Der ursprüngliche Einstellwert der Hochdruckventile liegt somit wieder vor.

Towing operation terminated After termination of the towing operation turn item 1 back. The original pressure value setting of the high pressure relief valves will be avaiable again.

Valve function: Screw back item 1 up to stop.

Screw up the nut.

Ventilfunktion: Pos.1 zurückschrauben bis Anschlag. Mutter anziehen.

42

If there is a lack of oil boosting, the hydraulic circuit will get empty.

Take care of the heat development in the hydr. motor-rotary group.

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RDE 92003-01-R/05.99

$ 9* Einstellhinweise - DA- Regelung

Reparaturanleitung A4VG

Adjustment instructions - DA control

Repair Instructions A4VG

Achtung!

Sicherheitsbestimmungen beachten! Überprüfung der Einstelldaten Betriebstemperatur soll während des Überprüfungsvorgangs weitgehend konstant gehalten werden.

Antriebsmotor starten, Leerlaufdrehzahl Blockzustand Fahrtrichtungsschalter "0“ Motordrehzahl langsam steigern bis zur max.

Motordrehzahl, dabei Meßgeräte beobachten.

Speisedruck: Leerlaufdrehzahl Psp = ca. 15-20 bar max. Motordrehzahl Psp = . . . . . . . . bar* Blockzustand Fahrtrichtungsschalter - vorwärts (Straßengang und Festgebremst)

Verdrillung Regelbeginn

109

Einstelldaten Pumpe A4V/DA überprüfen Regelbeginn HD 40 - 50 bar Motordrehzahl . min.1 * Psp . . . . . bar* HD . . . . . . bar Nachjustierung - Regelbeginnschraube Regelende HD . . . . . bar* Motordrehzahl . . . . . min.1 * Psp . . . . . bar* Nachjustierung - Verdrillschraube Hinweis: Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

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Reparaturanleitung A4VG

Adjustment instructions - DA control

Repair Instructions A4VG

Attention!

Observe safety regulations!

Check setting data.

Operating temperature should be kept largely constant during the check procedure.

Start prime mover, idle speed.

Block position Drive direction switch - "0“.

Slowly increase motor speed up to the max. motor speed and thereby observe measuring instruments.

Boost pressure: Idle speed of prime mover Psp = approx. 15 - 20 bar max. motor speed Psp = . . . . . . . . . bar* Block position Drive direction switch - forward (Road gear and fully applied brake)

Timing adjustment screw

Check setting data pump A4VIDA Begin of control: HD 40 - 50 bar Motor speed . . . . . rpm* Psp . . . . . . . bar* HD . . . . . . . bar* Readjusting - control start screw

Begin of control

111

End of control HD . . . . . . . . bar Motor speed . . . . . . rpm* Psp . . . . . . . bar* Readjusting timing adjustment screw Note: Eccentric adjusting - observe direction of rotation * Setting data according to order!

112

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Telex 712538, Fax (07308) 7274 Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Telex 765321, Fax (07451) 8221

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Reparaturanleitung / Repair instructions A10VG ... 28-63 Baureihe/Series 10

RDE 92750-01-R/10.01 ersetzt/replaces 07.97

Mobile Hydraulics

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Hinweis / Inhalt Notice / Contents

Reparaturanleitung A10VG Repair Instructions A10VG

HINWEIS

NOTICE

Bezeichnungen, Beschreibungen und Darstellungen entsprechen dem Informationsstand zum Zeitpunkt der Drucklegung dieser Unterlage.

Specifications, descriptions and illustrative material shown herein were as accurate as known at the time this publication was approved for printing.

Änderungen können den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.

Methoden und Vorrichtungen sind Empfehlungen, für deren Resultat wir keine Haftung übernehmen können.

BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.

BRUENINGHAUS HYDROMATIK reserves the right to discontinue models or options at any time or to change speci-fications, materials, or design without notice and with-out incurring obligation.

Optional equipment and accessories may add cost to the basic unit, and some options are available only in combination with certain models or other options.

Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem Teststand vorzunehmen.

For the available combinations refer to the relevant data sheet for the basic unit and the desired option.

Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.

Adjustment and tests have to be carried out on the test bench under operating temperatures.

Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermitteln wir in unseren Schulungskursen.

Protection of personnel and property has to be guaranteed by appropriate measures.

Expert knowledge, the precondition of any service work, can be obtained in our training courses.

INHALT

CONTENTS

Seite/ Page

A1 0VG

A1 0VG Schnittbild Allgemeine Reparaturhinweise Dichtsätze und Baugruppen Triebwelle abdichten Hilfspumpe abdichten Stellkolbendeckel abdichten Ventile abdichten Druckabschneidung abdichten Regelventil abdichten Steuergerät demontieren Ansteuergeräte Pumpe demontieren Triebwerk ausbauen Stellkolben demontieren Überprüfungshinweise Turcon-Glyd-Ring montieren Pumpe montieren Triebwerk einbauen Pumpe montieren Montageanweisung für Anziehdrehmomente Sicherheitsbestimmungen Einstellhinweise

2

3-4 5 6-8 9 10-12 13 14 15 16 17 18-22 23-25 26 27-28 29-31 32 33-35 36-38 39 40-43 44-45 46-52

Sectional view General repair instructions Seal kits and sub assembly groups Sealing of the drive shaft Sealing of the boost pump Sealing of the control piston cover Sealing of the valves Sealing of the pressure cut-off valve Sealing of the regulator valve Removal of the control unit Control units Pump disassembly Removal of the rotary group Disassembly of the positioning piston Inspection notes Turcon-Glyd-ring Assembly of the pump Installation of the rotary group Assembly of the pump Assembly guidelines for tightening torques Safety regulations Adjustment instructions

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Schnittbild

Reparaturanleitung A10VG

Sectional view

Repair Instructions A10VG mit Druckabschneidung with pressure cut-off

HW

ohne Druckabschneidung without pressure cut-off

HDD

EPD

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Schnittbild

Reparaturanleitung A10VG

Sectional view

Repair Instructions A10VG

RDE 92750-01-R/10.01

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DA

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Reparaturanleitung A10VG

Seal kits and sub-assemblies

Repair Instructions A10VG

Ansteuergerät HW Control unit HW

Ansteuergerät HW mit Nullagenanzeige Control unit HW with zero indicator

alt / old neu / new

Ansteuergerät HD Control unit HD

alt / old neu / new

Ansteuergerät EP Control unit EP

alt / old neu / new Ansteuergerät DA Control unit DA

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Dichtsätze und Baugruppen

Reparaturanleitung A10VG

Seal kits and sub-assemblies

Repair Instructions A10VG

Hilfspumpe mit Verschleißplatte Boost pump with wear plates

1

2

1. HD - Ventil 2. HD - Ventil mit Bypass 3. ND - Ventil 1. High pressure valve 2. High pressure valve with bypass function 3. Low pressure valve

3

Druckabschneidung Pressure cut-off

3 2 1

1. DA - Regelventil, verstellbar mit Hebel 2. DA - Regelventil, festeingestellt 3. Zuschaltventil 1. DA control valve, adjustable via a lever 2. DA control valve, fixed 3. Switching valve

8

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Druckabschneidung abdichten

Reparaturanleitung A10VG

Sealing of the pressure cut-off valve

Repair Instructions A10VG

*

Wechsel der Dichtmutter.

Einstellmaß festhalten (*).

Exchanging the sealing nut.

Ascertsion the adjustment dimension (*).

Achtung!

Nach Einbau "Ventileinstellung" überprüfen.

Attention!

After assembly check "valve setting".

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Reparaturanleitung A10VG

Control units

Repair Instructions A10VG

RDE 92750-01-R/10.01

$ 9*

NG / Size 28

Ansteuergerät HW HW control unit

NG / Size 45

Ansteuergerät DA DA control unit

18

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Reparaturanleitung A10VG

Control units

Repair Instructions A10VG

Ansteuergerät HD - EP alt HD - EP control unit old HD alt / old

EP alt / old

HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP New HD - EP control unit old

202,0 mm

1 31 ,0 mm 21 4,4 mm

77,4 mm

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Reparaturanleitung A10VG

Control units

Repair Instructions A10VG

RDE 92750-01-R/10.01

$ 9*

Ansteuergerät HD neu HD - control unit new

Ansteuergerät EP neu EP - control unit new

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Reparaturanleitung A10VG

Pump disassembly

Repair Instructions A10VG

HD alt/old

EP alt/old

HD neu/new

EP neu/new

Druckabschneidung Pressure cut-off

DA alt/old DA neu/new

Excenterschraube Eccentric screw

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$ 9* Montageanweisung für Anziehdrehmomente

Reparaturanleitung A10VG

Assembly guidelines for tightening torques

Repair Instructions A10VG

A1 0V - Düsen / orifices

Gewinde / Thread M6 M10

Anziehdremomente Nm / Tightening torques Nm bisher / up to

neu / new

6,5 28

3 1 2

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Einstellhinweise - Mechanische "Nullage"

Reparaturanleitung A10VG

Adjustment instructions - Mechanical "zero position"

Repair Instructions A10VG

HW alt / old

alt / old DA neu / new

HD

neu / new

EP

alt / old

neu / new HW mit Nullagenschalter HW with zero position switch

Achtung!

Sicherheitsbestimmungen beachten!

Mit Schlauch NW6 beide Stellkammern verbinden. Vermeidung von Restsignal aus hydraulischer Nullage.

Manometer an MA und MB anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Totband der Nullage - vermitteln.

Attention!

Observe safety regulations!

Connect both control chambers with a nominal size 6 hose. Avoidance of residual signals from hydraulic zero position.

Connect pressure gauges to MA and MB. Adjust the zero position so that with at blocked drive both pressure gauges indicate the same pressure valve.

Note: Ascertain the zero position dead band.

46

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Einstellhinweise - Hydraulische "Nullage"

Reparaturanleitung A10VG

Adjustment instructions - Hydraulic "zero position"

Repair Instructions A10VG

HD neu/new HW HD alt/old

Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

HW mit Nullagenschalter HW with zero position switch

EP alt/old EP neu/new

Manometer an X1 und X2 anschließen.

Nullage so einstellen, daß bei blockiertem Antrieb beide Manometer auf gleichem Druckwert stehen.

Hinweis: Excenterjustierung - nicht über ±90° verdrehen.

Connect pressure gauges to X1 and X2.

Adjust the zero position so that with a block drive both pressure gauges indicate the same pressure value.

Note: Eccentric adjusting - Do not turn more than ±90°.

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Einstellhinweise - ND-Ventil (Speisedruck)

Reparaturanleitung A10VG

Adjustment instructions - Low pressure valve (Boost pressure)

Repair Instructions A10VG

Achtung!

Sicherheitsbestimmungen beachten!

Attention!

Observe safety regulations!

Hinweis: Nachjustierung nur bei Betriebstemperatur.

Note: Readjusting only at operating temperature.

Manometer an "G" anschließen.

Connect pressure gauge to "G".

Achtung! * Speisedruckeinstellung!

Nenndruck pH - 18 bar Höchstdruck pH - 40 bar Bei Max.-Drehzahl.

Attention! * Boost pressure setting!

Nominal pressure pH - 18 bar Peak pressure pH - 40 bar at max. speed.

Hinweis: Einstelldaten nach Werksauftrag.

Note: Setting data is in accordance to the works order.

* bei DA-Ausführung

* with the DA version

"G" *

*

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256

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Hydraulikmotoren Hydraulic motors

MS Reparaturen Repairs

02 MS MSE

05

08

11

18

Störungsbeseitigung Trouble Shooting

Wartungsarbeiten Maintenance

Reparaturen Repairs 5767

Ersatzteile Spare Parts

0549

5766

5763

0545

5764 0550

Ref : 800378128J REPAR MS2-18 D/GB Rev : A - Avr - 00

008 912 53

POCLAIN HYDRAULICS Industrie B.P. 106 60411 VERBERIE CEDEX - FRANCE Tel.: 33 3 44 40 77 77 Fax: 33 3 44 40 77 99 www.poclain-hydraulics.com

%20$*

5765

0547

POCLAIN HYDRAULICS Certifié ISO 9001

257

06 06( WR

POCLAIN HYDRAULICS Dieses Dokument richtet sich an die Hersteller von Maschinen und Systemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Installationsangaben und den Inbetriebnahmevorgang, damit ihre optimale Funktionsweise gewährleistet wird.

Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer angemessene Ausbildung durchgeführt werden. Sie müssen die Informationen in diesem Dokument gelesen und verstanden haben und vom Hersteller der Maschine bevollmächtigt sein.

Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheit und zur Unfallverhütung beachten.

Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werden auf folgende Weise gekennzeichnet:

!

This document is provided to machine manufacturers integrating POCLAIN-HYDRAULICS products.. It suggests processes that manufacturers may utilize to repair products after the warranty period.

It is recommended that all operations be performed by technicians trained accordingly. The technicians should read and understand the information given in this document and be authorized by the machine manufacturer.

It is essential that the technicians comply with safety instructions to prevent injury.

This document includes major safety warnings announced in this way:

!

Sicherheitshinweis.

Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Betrieb des Produkts sowie allgemeine Informationen. Sie werden auf folgende Weise gekennzeichnet:

Additionally, this document includes instructions essential to product function as well as those providing general information. Both are announced similar to the following examples:

Essential instruction.

Wesentliche Anweisung.

General information.

Allgemeine Information.

POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht werden, die auf die Anwendung der in diesem Dokument empfohlenen Verfahren zurückgehen.

POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion und die Betriebsbedingungen der Maschinen und Systeme, die mit PHProdukten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS weder für die Folgen eines falschen Einbaus der Produkte noch für ein falsches Parametrieren einstellbarer Werte, noch für ungültige oder unvollständige Gebrauchs- und Wartungsanweisungen, die den Endverbrauchern von den Maschinenherstellern zur Verfügung gestellt worden sind, verantwortlich.

Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine Neuzulassung der Maschinen erforderlich machen.

Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HYDRAULICS seinen Kunden, jede Anwendung von POCLAIN HYDRAULICS prüfen und freigeben zu lassen.

Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Systems sowie die Sicherheit beeinträchtigen.

Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung alle Änderungen vorzunehmen, die als nützlich für die in diesem Dokument beschriebenen Produkte bewertet werden.

Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Abschnitte, die Übersetzung in englischer Sprache darstellen.

Im Zweifelsfall ist die französische Version ausschlaggebend.

Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unterrichtung angegeben.

Die Abbildungen haben unverbindlichen Charakter.  POCLAIN HYDRAULICS Industrie 1998.

Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von POCLAIN HYDRAULICS SA. Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Industrie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftliches Einverständnis weder gesamt noch teilweise verwendet, vervielfältigt, kopiert oder an Dritte weitergegeben werden.

FACOM ist ein eingetragenes Warenzeichen der FACOM SA. LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA. AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.

2

Safety warning.

POCLAIN HYDRAULICS designs products that are integrated by its customers in the machines they design.

Subsequently POCLAIN HYDRAULICS disclaims liability for consequences of improper integration of its products and of improper set-up of adjustable devices. In the same way, POCLAIN HYDRAULICS may not be liable for incomplete or improper operating and maintenance instructions provided to the end user by the machine manufacturer nor for failures resulting from operations performed by any person using these suggested procedures.

A re-certification of the machine may be required for every change in set-up of adjustable devices.

In order to offer the best quality service, POCLAIN HYDRAULICS recommends to its customers to have applications approved by POCLAIN HYDRAULICS. Opening of products voids the warranty contract.

Use only POCLAIN HYDRAULICS genuine spare parts. Using parts from different sources could reduce the performance of the product and pose a safety hazard..

In accordance with its policy of continuous improvement, POCLAIN HYDRAULICS reserves the right to modify the specifications of all products described herein without prior notice.

This document contains sections written in German and sections printed in italics composing the English translation of the French sections. The French sections will be the reference in case of dispute.

All measures are expressed in metric units. Converted values to other systems (notably US and UK) are given for reference only.

The illustrations for information only.  POCLAIN HYDRAULICS Industrie 1998.

The trademark POCLAIN HYDRAULICS is the property of POCLAIN HYDRAULICS S.A. This document is the property of POCLAIN HYDRAULICS Industrie.

It is strictly confidential. It must not be used, duplicated, copied or disclosed to a third party in full or in part without our prior written consent.

FACOM is FACOM SA registered trademark.

LOCTITE is LOCTITE SA registered trademark.

AUTO-TOP is AGIP SPA registered trademark.

REPAR MS2-18 D/GB

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POCLAIN HYDRAULICS

Inhaltsverzeichnis

Contents

INHALTSVERZEICHNIS ............................................. 3

CONTENTS................................................................. 3

SICHERHEIT UND QUALITÄT ................................... 4

SAFETY AND QUALITY ............................................. 4

VOR DEN W ARTUNGSARBEITEN ....................................... 4 W ÄHREND DER W ARTUNGSARBEITEN............................... 4 NACH DEN W ARTUNGSARBEITEN ..................................... 4 IDENTIFIZIERUNG DES BAUTEILS ....................................... 5

BEFORE SERVICING ........................................................ 4 DURING SERVICING ......................................................... 4 AFTER SERVICING ........................................................... 4 IDENTIFICATION OF THE COMPONENT................................. 5

STÖRUNGSBESEITIGUNG........................................ 6

TROUBLE SHOOTING ............................................... 7

WARTUNGSARBEITEN.............................................. 8

MAINTENANCE .......................................................... 8

AUSTAUSCHEN DES MOTORS........................................... 8 Ausbau..................................................................... 8 Einbau...................................................................... 8 MECHANISCHE BREMSLÖSUNG ........................................ 9 KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10

REPLACING THE MOTOR .................................................. 8 Removal................................................................... 8 Installation................................................................ 8 MECHANICAL BRAKE RELEASE .......................................... 9 CHECKING THE PARKING BRAKE EFFICIENCY..................... 10

REPARATUREN. ...................................................... 11

REPAIRS. ................................................................. 11

AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11 Demontage ............................................................ 11 Wiedereinbau......................................................... 13 AUSWECHSELN DES LAGERTEILES (070)......................... 16 Demontage ............................................................ 16 Wiedereinbau......................................................... 18 AUSWECHSELN DER BREMSBACKEN ............................... 20 Demontage ............................................................ 20 Wiedereinbau......................................................... 23 AUSWECHSELN DES NOCKENRINGS (026)....................... 27 Demontage ............................................................ 27 Wiedereinbau......................................................... 27 AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28 Demontage ............................................................ 28 Wiedereinbau......................................................... 28 AUSWECHSELN DES VERTEILERS (047). ......................... 29 Demontage ............................................................ 29 Wiedereinbau......................................................... 29 AUSWECHSELN DER DECKELDICHTUNG (045).................. 32 Demontage ............................................................ 32 Wiedereinbau......................................................... 33 AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34 Demontage ............................................................ 34 Wiedereinbau......................................................... 35

REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11 Disassembly........................................................... 11 Reassembly. .......................................................... 13 REPLACEMENT OF THE BEARING SUPPORT (070).............. 16 Disassembly........................................................... 16 Reassembly ........................................................... 18 REPLACING THE BRAKE SHOES....................................... 20 Disassembly........................................................... 20 Reassembly ........................................................... 23 REPLACEMENT OF THE CAM (026) .................................. 27 Disassembly........................................................... 27 Reassembly ........................................................... 27 REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28 Disassembly........................................................... 28 Reassembly ........................................................... 28 REPLACEMENT OF THE VALVING (047). ........................... 29 Disassembly........................................................... 29 Reassembly ........................................................... 29 REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32 Disassembly........................................................... 32 Reassembly ........................................................... 33 REPLACING THE SENSOR (OPTIONAL) .............................. 34 Disassembly........................................................... 34 Reassembly ........................................................... 35

WERKZEUG-LISTE .................................................. 36

TOOLING INVENTORY............................................. 36

Standard Werkzeug................................................ 36 Spezialwerkzeuge .................................................. 37 ANZIEHDREHMOMENTE NM ± 10%........................... 38 ERSATZTEILE.......................................................... 39 MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 0205-08-11-18. .............................................................. 42 MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE 02-05-08-11-18. ......................................................... 44

Standard tools ........................................................ 36 Special tools........................................................... 37 TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38 SPARE PARTS LIST ................................................ 39 SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-1118. ............................................................................. 42 DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

3

259

06 06( WR

POCLAIN HYDRAULICS

Sicherheit und Qualität

Safety and Quality

Vor den Wartungsarbeiten

Before servicing

• Alle notwendigen Sicherheitsvorkehrungen treffen (Menschen und Material) und die geltenden Sicherheitsvorschriften beachten.

• Parkbremse betätigen und Maschine mit Keilen festsetzen.

• Energieerzeugung (Motor) des Hydrauliksystems abstellen und die Stromversorgung ausschalten.

• Gegebenenfalls eine Sicherheitszone einrichten.

• Be extremely careful to prevent personal injury and to avoid damage to material. Comply with all safety regulations.

• Die Außenflächen der Bauteile reinigen, um Schmutz und Fett restlos zu entfernen.

• Warten, bis das Hydrauliksystem vollständig abgekühlt und druckentlastet ist (die Speicher entlasten).

• Wash dirt and grease from exterior of the components.

Das heiße oder unter Druck stehende Öl kann zu schweren Verbrennungen mit Entzündung führen.

Bei einem Unfall einen Arzt hinzuziehen.

Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body.

Consult a physician in case of accident.

!

• Apply the parking brake and prevent the machine from rolling with tire blocks.

• Stop the hydraulic system power source (engine) and disconnect the battery.

• If necessary, block off the safety area.

• Await the complete cooling down and depressurization of the hydraulic system (accumulators must be purged).

!

Während der Wartungsarbeiten

During servicing

• Bestimmte Bauteile sind sehr schwer. Sie müssen bei der Abnahme vom Rahmen mit einer angemessen ausgelegten Hebevorrichtung gehalten werden.

• Die Sauberkeit ist wesentlich beim Betrieb der Hydraulikbauteile. Die meisten Teile können mit einem sauberen Lösungsmittel gereinigt werden.

• Während der Handhabung alle empfindlichen Oberflächen gegen Stöße schützen (Zentrierungen, gleitende Teile, Auflagen, Dichtungs- und Lagerauflagen usw.).

• Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity when removing from the machine frame.

•

•

• Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned with a clean solvent.

• During handling, protect all sensitive surfaces from shocks (piloting and interface surfaces, thrust & bearings surfaces, seal races, etc...)

Diese Flächen vor dem Wiederzusammenbau reinigen.

• Systematisch die demontierten Dichtungen beim Wiederzusammenbau durch neue ersetzen. Wir empfehlen, vor der Montage alle Dichtungen zu fetten.

• Always install new O-rings, seals & gaskets discarding the old ones. We recommend lubricating all seals prior to assembly.

• Alle gleitenden Flächen durch Aufbringen eines Films sauberer Hydraulikflüssigkeit ölen, der eine korrekte Schmierung beim ersten Neustart gewährleistet.

• Lubricate all surfaces which have relative motion between parts by coating them with a film of clean hydraulic fluid to assure lubrication at first start.

• Niemals die Hydraulikflüssigkeit, die sich bei hohen Temperaturen entzünden kann, erwärmen. Einige Lösungsmittel sind ebenfalls entzündlich.

• Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also flammable.

Während der Arbeiten nicht rauchen.

Do not smoke during servicing.

Nach den Wartungsarbeiten

After servicing

Die Bauteile wieder einbauen und das Hydrauliksystem gemäß den Anweisungen in den folgenden Dokumenten wieder in Betrieb nehmen: • INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION CIRCUITS D/GB (ref. 677777853U)

Reinstall the components and restart the hydraulic system according to instructions defined in the following documents: • INSTALLATION MS F/GB (ref. 677777844K)

!

4

Clean up these surfaces before reassembling.

• INSTALLATION CIRCUITS F/GB (ref. 677777831V)

Die Einstellung der Sicherheitsventile nicht erhöhen.

!

REPAR MS2-18 D/GB

260

%20$*

Do not overset relief valves.

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Identification of the component

Identifizierung des Bauteils

A

MS18-2-D11-F19-2A10-K000 B

D 000143896J C

40712

001

0349

A : Handelsbezeichnung: Ex : MSE18-2-D11-F19-2A10-K000

A: Commercial description: E.g : MSE18-2-D11-F19-2A10-K000

B : Code : Artikelnr.: Ex : 000143896J

B: Code: Part number.

E.g : 000143896J

C : Serie : Herstellungsnummer Ex : 001

C: Series: Manufacturing batch number.

E.g : 001

D : Num : Chronologische Ordnungsnummer Ex : 40712

D: Num: Chronological serial number.

E.g : 40712

Bei sämtlichen Ersatzteilbestellungen müssen die Artikelnummer und die chronologische Ordnungsnummer angegeben werden.

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

The part number and the chronological serial number must be specified to order spare parts.

5

261

06 06( WR

POCLAIN HYDRAULICS

Störungsbeseitigung BECHÄDIGUNG → ABRIEB → ERKENNUNG DURCH FILTER → VORBEUGUNG……

Störung

Ursachen Ohne Last

LAUTE GERÄUSCHE DES MOTORS Unter Last

MOTOR DREHT SICH NICHT

DER MOTOR DREHT SICH NICHT MIT NORMALER LASTDREHZAHL

DER MOTOR DREHT SICH UNREGELMÄSSIG

ÄUSSERE ÖLUNDICHTIGKEITEN

6

Regelmäßiges Brummen

Lagerteil verschlissen

Lagerteil ersetzen

Vibrationen

Lockere Befestigungen und / oder Anschlüsse

Mit entsprechendem Drehmoment anziehen

Klappern

Speisedruck zu niedrig

Speise- und Austauschdruckventil kontrollieren.

Kavitation

Interne Lecks zu groß

Zylinderblock und Ölverteiler ersetzen

Der Motor wird nicht versorgt

Den Antrieb der Pumpe und ihre Versorgung überprüfen

Kein Druckanstieg im Kreis

Hochdruck-Begrenzungsventile kontrollieren (Regler)

Interne Lecks zu groß

Zylinderblock und Ölverteiler ersetzen

Die Bremse bleibt angezogen

Den Steuerkreis der Bremse kontrollieren

Der Fördermenge der Pumpe ist unzureichend

Die Antriebsdrehzahl und den Zustand der Pumpe kontrollieren

Interne Lecks zu groß

Den Zustand des Zylinderblocks und des Ölverteilers überprüfen

Der Betriebsdruck ist zu niedrig

Den Zustand des Sicherheitsventils kontrollieren (Regler)

Die Fördermenge der Pumpe schwankt

Steuerdruck und Fördermenge der Pumpe kontrollieren

Interne Lecks zu groß

Den Zustand des Zylinderblocks und des Ölverteilers überprüfen.

Gehäusedruck zu groß

Den Leckagekreis und den Zustand des Filters überprüfen

Dichtungen beschädigt

Die Dichtungen ersetzen

Fehlerhafte Montage

Das Anziehmoment der Montageschrauben, der Entlüftungsschrauben und der Anschlüsse kontrollieren

REPAR MS2-18 D/GB

262

Abhilfe

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Trouble shooting DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……

Troubles

Causes Without load

Regular rumbling

Worm bearing support

Replace the bearing support

Vibrations

Mountings and/or hydraulic piping becoming loose

Tighten to torque

Clattering

Boost pressure too low

Check the setting and condition of counter-pressure valve

Cavitation

Excessive internal leaks

Replace the cylinders- block and distribution valve assembly

No supply to the motor

Check pump drive and pump inlet

The circuit does not reach working pressure

Check condition of safety valve (regulator)

Excessive internal leaks

Replace the cylinders block and distribution valve assembly

The brake stays engaged

Check the brake pilot circuit

Pump flow is too low

Check drive speed and condition of the pump

Excessive internal leaks

Check condition of cylindersblock and distribution valve assembly

Working pressure is too low

Check safety valve setting pressure (regulator)

Irregular flow

Check the pump flow

Excessive leaks

Check condition of cylindersblock and distribution valve assembly

Too high casing pressure

Check the leakage circuit and filter condition

Seals damaged

Replace seals

Incorrect assembling

Check tightening of mounting screws, bleed screws and unions

NOISY MOTOR Under load

THE MOTOR DOES NOT REVOLVE

THE MOTOR DOES NOT REVOLVE AT ITS NORMAL SPEED UNDER LOAD

THE MOTOR REVOLVES IRREGULARLY

EXTERNAL OIL LEAKS

Remedies

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

7

263

06 06( WR

POCLAIN HYDRAULICS

Wartungsarbeiten

Maintenance

Austauschen des Motors

Replacing the motor

Ausbau

Removal

• •

• •

• • • •

Druck im Arbeitskreis abbauen.

Leckageleitung am Tank abschrauben, um ein Leerlaufen zu verhindern.

Die Rohre oder Schläuche, die am Motor angeschlossen sind, abklemmen.

Drehzahlsensor abklemmen.

Die Befestigungsschrauben demontieren und den Motor ausbauen.

Das Motorgehäuse entleeren.

Einbau Die zum Ausbau angegebenen Arbeitsgänge in umgekehrter Reihenfolge ausführen.

Für weitere Informationen beziehen Sie sich bitte auf folgende Dokumente: • INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION CIRCUITS D/GB (ref: 677777853U)

8

• • • •

Release the pressure in the supply circuit.

Disconnect the drain line at the tank level to avoid its siphoning.

Disconnect and plug the pipes or hoses which are connected to the motor.

Disconnect the speed sensor.

Disconnect the mounting screws, and remove the motor.

Drain the casing.

Installation Execute the removal operations in the reverse order.

Please refer to the following documentation brochures: • •

INSTALLATION MS F/GB (ref: 677777844K) INSTALLATION CIRCUITS F/GB (ref: . 677777831V)

REPAR MS2-18 D/GB

264

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Mechanische Bremslösung

Mechanical brake release

Bei bestimmten Reparaturfällen oder zum Abschleppen der Maschine muß die integrierte Parkbremse gelöst werden.

In certain service situations, it may be necessary to release the motor brake.

• Stopfen (142) aus der Schutzkappe (141) herausziehen.

• Extract and release the plug (142) from the brake cover (141).

142

6499

•

Schraube im Kolben festziehen

•

Tighten the screw in the piston

6556

• Mutter so weit anziehen, bis die Welle frei dreht.

• And tighten the nut until the motor shaft turns freely.

6555

Force [lbf]

F02-F04

18000

[4.000]

42

[30.9]

M12

F05-F07

20000

[4.500]

47

[34.6]

M12

F08

34000

[7.600]

110

[81.1]

M16

F11

45000

[10.000]

140

[103]

M16

F12

45000

[10.000]

140

[103]

M16

F19

45000

[10.000]

140

[103]

M16

!

Brakes

Entsprechendes Drehmoment Nm

Kraft N

Bremsen

Nach Bremslösung, einen neuen Stopfen (142) einbauen.

!

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

Equivalent torque [lbf.ft]

Mutter Nut

After brake release, mount a new plug (142).

9

265

06 06( WR

POCLAIN HYDRAULICS

Checking the parking brake efficiency.

Kontrolle der statische Haltebremse.

!

Bei fahrbaren Maschinen den Test auf ebenem Grund durchführen.

Bremssteuerdruck:

!

For a rolling machine, make the test on a horizontal ground.

Pilot brake pressure : minimum 12 bar [174 PSI] Maximum 30 bar [435 PSI]

mini 12 bar Maxi 30 bar.

• Sich vergewissern, daß der Bremsversorgungsdruck gleich Null ist, • Die Bremse über die höchstgelegene Schraube (112) entlüften, • Den Motor mit Maximaldruck beaufschlagen,

• Purge the brake using the screw (112) located at the highest level, • Supply the motor up to the setting pressure.

• Die Motorwelle darf sich nicht drehen, da andernfalls die Bremse ausgetauscht werden muß :

• The motor shaft must not turn, otherwise it is necessary to replace the brake :

!

10

Make sure that the brake supply pressure is zero,

Mehrscheibenbremsen nicht einfahren.

!

REPAR MS2-18 D/GB

266

%20$*

Do not run multidisc brakes in.

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Repairs.

Reparaturen.

Auswechseln der kolbendichtung

Brems-

Replacement of the O-ring of the brake piston.

Demontage

Disassembly

• •

• Remove the motor.

• Place the motor on the bearing support.

Den Motor ausbauen.

Motor auf das Lagerteil stellen.

Muttern zum Schutz der Gewindebolzen wieder aufsetzen

!

• Schutzkappe (141) abnehmen und beseitigen.

!

Protect the studs by reinstalling the nuts

• Remove and discard the brake cover.(141)

141

6500

• O-Ring (143) herausziehen und beseitigen.

• Extract and discard the O-ring (143).

143

6501

• Tellerfeder (108) zusammendrücken:

•

Compress the washer (108).

• Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite 36) (fig 6502) • Mit Hilfe des Dorns und einer Schraube Klasse 12.9 (siehe Werkzeug Seite 36) • Mit Hilfe des Dorns und einer Presse (fig 6503). Die Kraft F beibehalten (siehe Schaubild Seite 9)

• Using a mandrel and an extractor (see tools page 36) (fig 6502) • Using a mandrel and a screw class 12.9 (see tools page 36) • Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

Einsatzrichtung des Sicherungsrings markieren.

Mark the mounting direction of the snap ring.

6502

6503

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

11

267

06 06( WR

POCLAIN HYDRAULICS • Sicherungsring (109) mit Hilfe einer Zange für Innenringe herausnehmen (siehe Werkzeuge Seite 36)

• Remove the snap ring (109) using internal snap ring pliers. (see tools page 36) • Extractor and pliers (fig 6504 and 6505) • Press and pliers (fig 6506 and 6507)

• Abzieher und Zange (fig 6504 und 6505) • Presse und Zange (fig 6506 und 6507)

!

•

Bei Verwendung der Presse das Lagerteil nicht auf den Gewindebolzen abstützen.

Tellerfeder (108) herausziehen.

!

•

6504

6505

6506

6507

If you use the press do not place the bearing support on the studs.

Extract the washer (108).

108

6508

• Bremskolben (107) herausziehen.

•

Extract the brake piston (107)

6513

•

O-Ring (106) beseitigen.

•

Discard the O-ring (106).

106

6511

12

REPAR MS2-18 D/GB

268

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS Wiedereinbau.

Vor dem Wiedereinbau ist unbedingt sicherzustellen, daß alle Teile, Nuten und Dichtungs-Auflageflächen sauber sind.

!

Reassembly.

Before reassembling, it is necessary to ensure that all parts, the surface condition of the piston seal contact surface and the grooves are clean.

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein

Mit Korrosionsschutzfett (siehe Werkzeug Seite 36) einschmieren: die Nut, die obere Fläche des Bremskolbens, die Tellerfeder, den Sicherungsring und die Auflagefläche der Kolbendichtung im Bremsgehäuse.

!

All traces of rust, mud, water must be removed.

• Neuen O-Ring (106) auf den Kolben (107) montieren.

Coat with anti-oxidizing grease (see tools page 36), the grooves, the top of the brake piston, the spring washer, the snap ring and the piston seal contact surface in the brake body.

• Install a new O-ring (106) on the piston (107).

Der Ring muß fest an den Kolben gepreßt und nicht verdreht werden.

The ring should be tight on the piston and not twisted.

!

!

106

6512

•

Bremskolben (107) einsetzen.

!

Achtung, wenn die Dichtung über die Nut des Sicherungsrings geführt wird.

•

Install the brake piston (107).

!

Take care when passing the seal over the snap ring groove.

107

6509

•

Tellerfeder

(108)

einlegen.

Install the spring washer (108).

108

6513

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

13

269

06 06( WR

POCLAIN HYDRAULICS • Tellerfeder (108) zusammendrücken:

• Compress (108).

the spring washer

• Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite 36) (fig 6502) • Mit Hilfe des Dorns und einer Presse (fig 6503). Die Kraft F einbehalten (siehe Schaubild Seite 9)

• Using a mandrel and an extractor (see tools page 36) (fig 6502) • Using a mandrel and a press (fig 6503). Respect the force F (see table page 9)

Bei Verwendung der Presse das Lagerteil nicht auf den Gewindebolzen abstützen.

If you use the press do not place the bearing support on the studs.

!

!

6502

6503

• Sicherungsring (109) mit Hilfe einer Zange für Innenringe gemäß der bei der Demontage angebrachten Kennzeichnung montieren: (siehe Werkzeuge Seite 36) • Abzieher und Zange (fig 6504 und 6505) • Presse und Zange (fig 6506 und 6507)

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (143) in die Nut einsetzen (siehe Werkzeuge Seite 36).

• Install the snap ring (109) using internal snap ring pliers in line with the mark made during disassembly . (see tools page 36) • Extractor and pliers (fig 6504 and 6505) • Press and pliers (fig 6506 and 6507)

• Install a new O-ring (143) coated with anti-oxidizing grease in its groove. (see tools page 36)

6504

6505

6506

6507

143

6515

• Neue Schutzkappe (141) auf den Anschnitt legen.

• Place the new cover (141) on the entry chamfer .

141

6516

14

REPAR MS2-18 D/GB

270

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS • Schutzkappe mit Hilfe des Dorns einrasten lassen (siehe Werkzeug Seite 36).

• Click the cover into place using the right mandrel. (see tools page 36).

Sich vergewissern, daß der Außenrand des Schutzkappe in die Nut eingreift ist.

Make sure that the outer edge of the cover is engaged in the groove.

!

!

6517

•

Neuen Stopfen (142) einsetzen.

!

•

Sich vergewissern, daß zwischen Schutzkappe und Stopfenrille einwandfreier Kontakt besteht.

Install a new plug (142).

!

Make sure about the contact between the cover and the plug groove.

142

6518

•

Motor wieder einsetzen.

•

Install the motor.

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

15

271

06 06( WR

POCLAIN HYDRAULICS

Auswechseln teiles (070)

des

Lager-

Replacement of the bearing support (070)

Demontage

Disassembly

Motor herausnehmen.

Motor auf der Bremse oder Verschlussplatte abstützen (Motor ohne Bremse).

Remove the motor.

Place the motor on the brake or on the end cover (motor without brake).

• Position des Lagerteiles (070) in Bezug auf Nockenring (026) und Verteilerdeckel (040) kennzeichnen.

• Mark the position of the bearing support (070) in relation to the cam (026) and to the valving cover (040).

070 025

040

• Schrauben nehmen.

(042)

heraus-

•

6519

Remove the screws (042).

042 6520

• Lagerteil (070) herausnehmen.

• Remove the bearing support (070).

070

6521

• Nockenring nehmen.

(026)

heraus-

•

Remove the cam (026).

026

6524

16

REPAR MS2-18 D/GB

272

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS • O-Ring (027) vom Verteilerdeckel (041) entfernen.

• Discard the O-ring (027) from the valving cover (041).

027

041

6525

• O-Ring (027) vom Lagerteil (071) entfernen.

• Discard the O-ring (027) from the bearing support (071)

027

071

6522

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

17

273

06 06( WR

POCLAIN HYDRAULICS Wiedereinbau

Reassembly

Vor dem Wiedereinbau ist unbedingt sicherzustellen, daß die Nut sauber ist

Before reassembling it is necessary to ensure that the groove is clean

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein.

All traces of rust, mud, water must be removed

!

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (027) in die Nut des Lagerteiles (071) einsetzen (siehe Werkzeuge Seite 36) .

!

• Install a new O-ring (027) coated with anti-oxidizing grease (see tools page 36) in the groove of the bearing support (071).

027

071 6523

• Neuen, mit Korrosionsschutzfett eingeschmierten O-Ring (027) in die Nut des Verteilerdekkels (041) einsetzen (siehe Werkzeuge Seite 36) .

• Install a new O-ring (027) coated with anti-oxidizing grease (see tools page 36) in the groove of the valving cover (041)

041

6525

• Nockenring (026) gemäß der bei der Demontage markierten Kennzeichnung montieren.

!

Große Ansenkungen in Richtung Lagerteil

Den Nockenring anhand von zwei einander gegenüberliegenden Schrauben (042) zentrieren.

18

• Install the cam (026) in line with the marks made during disassembling.

!

The big chamfers oriented towards bearing support

Center the cam using two screws (042) diametrically opposite.

REPAR MS2-18 D/GB

274

026

%20$*

6526

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS •

•

Lagerteil montieren

!

Bei Wellenmotoren müssen die Anschlüsse quer zur Einbauachse des Motors liegen.

(Abb. 6521)

!

Install the bearing support For shaft motors the ports must be perpendicular to the mounting axis of the motor. (Fig 6521) 6521 A

A

6527

• Befestigungsschrauben (042) einsetzen und mit dem angegebenen Drehmoment anziehen. (siehe Schaubild Seite 38).

• Install and tighten the mounting screws (042) to the right torque. (see table page 38).

042

6520

•

Motor wieder einsetzen.

•

Install the motor.

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

19

275

06 06( WR

POCLAIN HYDRAULICS

Brems-

Replacing the brake shoes.

Vor der Demontage kann man die Abnutzung der Bremsbeläge durch die Inspektionsöffnungen kontrollieren.

Before disassembling it is possible to make a visual checking of the brake pads wear via the inspection ports.

Auswechseln der backen

2055

Demontage

!

Disassembly

Das Auswechseln des Bremsbacken und das Schleifen der Trommeln muß auf allen Motoren der gleichen Achse vorgenommen werden.

!

The same repairs should be made on each motor of the same axle when replacing shoes and brake drums.

• Befestigungsmuttern der Felge lösen.

• Maschine auf der Höhe der auszubauenden Felge hochheben.

• Rad abnehmen (Reifen).

• Mechanische Bremse lösen.

• Loosen the wheel rim retaining nuts.

• Raise the machine on the side of the wheel rim to be removed.

• Remove the wheel rim (tyre).

• Release the mechanical brake.

•

•

Trommel (096) abziehen.

!

20

Reibfläche der Trommel überprüfen, die weder tiefe Rillen (tiefer als 0,2 mm) noch abnormale Abnutzungserscheinungen aufweisen darf, sonst muß sie geschliffen werden.

(Ra 1,6 bis 3,2)

Extract the drum (096).

!

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0,2 mm [0.0078 in]) nor abnormal wear. Otherwise, the brake drum should be replaced. (Ra 1.6 to 3.2)

REPAR MS2-18 D/GB

276

%20$*

096 6528

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS •

Rückholfeder (154.a) abbauen.

• Remove (154.a).

the

return

spring

154.a

6529

6530

• Halterungsfedern (154.b) abbauen.

• Remove the retention springs (154.b).

1

154.b

2 6531

• Bremsbacken aus der Betätigungsvorrichtung lösen.

• Release the brake shoes from the regulating mechanism.

6532

• Rückholfedern (154.c) abbauen.

• Remove (154.c).

the

return

springs

154.c

6533

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

21

277

POCLAIN HYDRAULICS • Bremsbacke (154.1) abbauen.

06 06( WR •

Remove the brake shoe (154.1)

154.1 6534

• Den mechanischen Bremshebel vom Bremsseil lösen und Bremsbacke (154.2) entfernen

• Releasing the mechanical brake control lever from its cable, remove the brake shoe (154.2) 154.2

6535

6536

22

REPAR MS2-18 D/GB

278

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS Wiedereinbau

!

Vorrichtung entstauben, sich vergewissern, daß der Radzylinder dicht ist.

Reassembly

!

Remove all dust from the whole assembly. Make sure there are no leaks at the wheel cylinder.

Reibfläche der Trommel überprüfen, die weder tiefe Rillen (tiefer als 0,2 mm) noch abnormale Abnutzungserscheinungen aufweisen darf, sonst muß sie geschliffen werden.

Check the friction surface condition of the drum which should show no deep scratches (deeper than 0.2 mm) [0.0078in] nor abnormal wear.

Otherwise, the brake drum should be replaced.

• Den Bremshebel am Bremsseil (098) befestigen und Bremsbacke (154.2) einbauen

• Attaching the control lever on the brake cable (098), install the brake shoe (154.2)

6549

098

154.2

6536

6535

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

23

279

POCLAIN HYDRAULICS • Rückholplatte an die Bremsbacke (154.2) montieren.

06 06( WR • Mount the return plate on the brake shoe (154.2)

6537

6538

•

Bremsbacke (154.1) einsetzen.

•

Install the brake shoe (154.1)

6539

• Bremsbacken auf der Betätigungseinrichtung positionieren.

• Position the brake shoes on the regulating mechanism.

6532

• Rückholfedern (154.c) einsetzen.

Install the return springs (154.c)

154.c

6533

24

REPAR MS2-18 D/GB

280

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS • Bremsbacken in die Betätigungseinrichtung einbauen.

• Install the brake shoes in the regulating mechanism

6532

• Halterungsfedern (154.b) einsetzen.

• Install (154.b).

the

retention

springs 1

154.b

2 • Rückholfedern (154.a) einsetzen.

•

6531

Install the return spring (154.a).

154.a 6530

• Reibungsdurchmesser D der Trommel und der eingesetzten Backen messen.

• Measure the brake drum friction diameter D and that of the brake shoes, which have been installed.

Durchmesser D diameter 6529

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

25

281

06 06( WR

POCLAIN HYDRAULICS • Backendurchmesser anpassen, um bei Bremsen mit mechanischer Einstellvorrichtung mit Hilfe des einen Zahnrads (156.1), oder bei Bremsen mit automatischer Bremsennachstellung mit Hilfe der zwei Zahnräder (156.2 und 156.3), das nötige Spiel zwischen Belag und Trommel zu erzielen. In diesem Fall muß die Wirkung auf die Zahnräder symmetrisch (a) sein. Den Hebel (156.4) muss zu diesem Zweck freigängig sein.

Bremsen Brake 250 x 60 270 x 60 325 x 80 350 x 60

• Adjust the brake shoes diameter to obtain correct clearance between the brake padding and the drum using the adjusting wheel (156.1) for brakes equipped with mechanical adjustment system or two adjusting wheels (156.2 and 156.3) for brakes equipped with automatic clearance adjustment. In this case, the adjusting wheels should be adjusted symmetrically (a). Release the lever slightly (156.4) to enable this operation to take place.

Trommeldurchmesser (mm) Drum diameter [in] nominal maximum 250 [9.84] 252 [9.92] 270 [10.63] 272 [10.70] 325 [12.79] 350 [13.78]

327 [12.87] 352 [13.85]

• Trommel aufsetzen und überprüfen, ob sie frei dreht.

1 5 6 .4 1 5 6 .2

1 5 6 .3

a

a

6540

Total Spiel (mm) Total clearance [in] 0.55 [0.02] 0.80 [0.03] 0.80 [0.03] 0.80 [0.03]

• Install the drum, check that it can turn freely.

6528

• Wenn nötig, den Radzylinder entlüften.

• Felge montieren.

Siehe Dokument INSTALLATION MS D/GB (ref: 800078173V)

26

• Bleed the wheel cylinder, if necessary.

• Install the wheel rim.

See documentation INSTALLATION MS F/GB (ref 677777844K )

REPAR MS2-18 D/GB

282

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Auswechseln des Nockenrings (026)

Replacement of the cam (026)

Demontage Dazu die im Kapitel « Auswechseln des Lagerteils » unter « Demontage » beschriebenen Arbeiten ausführen, Seite 16 Wiedereinbau Dazu die im Kapitel « Auswechseln des Lagerteils » unter " Wiedereinbau " beschriebenen Arbeiten ausführen, Seite 18.

Allerdings muß bei Motoren mit 2 Schluckvolumen mit einem Schluckvolumenverhältnis über oder unter 2 die Winkelposition berücksichtigt werden.

Beispiel: Motor MS18, Schluckvolumen 1747-1049-698 3 Kleines Schluckvolumen: 698 cm Buchstabe P 3 Mittleres Schluckvolumen: 1 049 cm Buchstabe M Die Buchstaben P oder M müssen sich in der Achse befinden und in Richtung des Schiebers für das Wechseln des Schluckvolumens zeigen, auf der der Nockenring auf dem Lagerteil befestigt ist.

Disassembly Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16 Reassembly Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18.

The angular position of the cam must be respected on dual displacement motors with a displacement ratio different from 2.

Example : Motor MS18 with displacement 1747-1049-698.

3 Small displacement : 698 cm [42.59 cu.in] letter P 3 Medium displacement : 1049 cm [64.01 cu.in] letter M. The letter P or M must be located in the axis and towards the displacement change spool, with the blind hole towards the fixing of the cam on the bearing support.

P

M M

P

MS08 MSE08 R A

R

P

M

M

P

A MS18 MSE18

MS11 MSE11

R A

A

P

M

2035

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

27

283

06 06( WR

POCLAIN HYDRAULICS

Auswechseln des kompletten Zylinderblocks (010)

Replacement of the cylinders block assembly (010)

Demontage

Disassembly

Dazu die im Kapitel « Auswechseln des Lagerteils » unter « Demontage » beschriebenen Arbeiten ausführen, Seite 16

Do operations described in chapter "replacement of the bearing support" section "disassembly" page 16

• Nach Demontage des Nockenrings den Zylinderblock ausbauen.

• After removing the cam, remove the cylinders block.

6541

Wiedereinbau

Reassembly

•

•

Neuen O-Ring (027) einsetzen.

Install a new O-ring (027).

6542

• Kompletten Zylinderblock (010) einsetzen.

• Install the cylinders block assembly (010).

6541

• Dazu die im Kapitel « Auswechseln des Lagerteils » unter "Wiedereinbau" beschriebenen Arbeiten ausführen, Seite 18

28

• Do operations described in chapter "replacement of the bearing support" section "reassembly" page 18

REPAR MS2-18 D/GB

284

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Auswechseln des Verteilers (047).

Replacement of the valving (047).

Demontage

Disassembly

• Dazu die im Kapitel « Auswechseln des kompletten Zylinderblocks (010)» unter « Demontage » beschriebenen Arbeiten ausführen, Seite 28.

• Do operations described in chapter "replacement of the cylinders bloc assembly (010)" section "disassembly" page 28.

Position des Verteilers (047) in Bezug auf Verteilerdeckel (041) kennzeichnen. (Motor mit 2 Hubvolumen).

Mark location to the valving (047) in relation to the valving cover (041) (Dual displacement motor).

!

• Den Verteiler (047) durch Anheben an den Ausrichtungszapfen oder am Flansch vom Verteilerdekkel (041) abmontieren.

!

• Separate the valving (047) from the cover (041) by levering at the indexing pins or at the flange.

2031

!

Den Verteiler vor Staub schützen.

!

Protect the valving from dusts.

• Federn (052) ausbauen.

• Dichtungen und Gegendichtungen (048) vom Verteilerdeckel (041) herausziehen und beseitigen.

• Remove the springs (052).

• Remove and discard the seals and back-up rings (048) from the cover (041).

Wiedereinbau

Reassembly

!

Es dürfen keine Rost-, Schmutz- oder Wasserspuren vorhanden sein.

• Neue Dichtungen und Gegendichtungen (048) ölen und einsetzen; dabei die Gegendichtungen so wenig wie möglich verformen.

!

All traces of rust, mud, water must be removed.

• Lubricate and install new seals and back-up rings (048), ensuring the back up rings are twisted as little as possible.

1135

• Die Federn (052) in ihr zuvor mit Fett gefülltes Gehäuse einsetzen.

• Die Dichtungsauflageflächen des Verteilers (047) fetten.

• Den Verteiler(047) in den Verteilerdeckel (041) drücken

• Place the springs (052) in their housings, previously filled with grease.

• Lubricate the faces of the seals of the valving (047).

• Press the valving (047) into the cover (041).

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

29

285

06 06( WR

POCLAIN HYDRAULICS

!

Die Einbaurichtung des Verteilers (047) in bezug auf den Verteilerdeckel (041) beachten).

!

Den Einsatz des Verteilers (047) in den Verteilerdeckel (041) nicht forcieren.

!

Respect the assembly sense of the valving (047) in relation to the cover (041).

!

Do not force when installing the valving (047) into the cover (041).

Montage der Verteilerausführung 1C (konstanter Hubvolumen).

Valving assembly type single displacement motor.

• Keine besondere Montagerichtung.

•

No particular assembly sense.

041 047

Montage der Verteilerausführung 2C (umschaltbarer Hubvolumen).

Valving assembly type Dual displacement motor.

• Den gewählten Buchstaben, der die Drehrichtung anzeigt, gegenüber dem Steuerkolben (053) anordnen.

• Write the chosen letter indicate the rotation sense in front of the displacement change spool (053).

POSITIONIERUNG DES VERTEILERS G/L Links

VALVING POSITIONING

2031

G/L Left

041 R

047 L

053 6758 R

053

A

3 2 2 7

30

REPAR MS2-18 D/GB

286

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS D/R Right

D/R Rechts

047 R

R

041 L

6757 A

053

3 2 2 8

• Falls kein Buchstabe vorhanden ist, die Ausrichtung anhand der beim Ausbau festgelegten Markierungen vornehmen.

• If there is no letter, do the indexing according to the marks made during disassembly.

• Dazu die im Kapitel « Auswechseln des kompletten Zylinderblocks (010)» unter « Wiedereinbau » beschriebenen Arbeiten ausführen, Seite 28.

• Do operations described in chapter "replacement of the cylinders block" section "reassembly" page 28.

Motoren SE02 und S05

Situation of SE02 and S05 motors

SE02 Motor : SE02 motor :

D/R Rechts D/R Right

G/L Links G/L Left

6959 6 9 5 9

S05 Motor : S05 motor G/L Links G/L Left

D/R Rechts D/R Right 053

6 9 4 8

6948 800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

31

287

06 06( WR

POCLAIN HYDRAULICS

Auswechseln der Deckeldichtung (045)

Replacement of the O-ring (045) of the end cover

Demontage

Disassembly

• Motor auf Lagerteil stellen (Muttern sind zum Schutz der Gewindebolzen aufgesetzt) • Schrauben (066) herausnehmen.

• • Place the motor on the bearing support (fitted with nuts for studs protection) • Remove the screws (066)

066

6543

•

Verschlussplatte abnehmen.

•

Remove the end cover

6544

•

O-Ring (045) entfernen.

•

Discard the O-ring (045) 045 057

6545

• Wenn Motor mit 2 Hubvolumen, O-Ring (057) entfernen

• Discard the O-ring (057) if the motor has 2-displacement

6546

32

REPAR MS2-18 D/GB

288

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS Wiedereinbau

Reassembly

•

Install

Neuen O-Ring (045) einsetzen.

a

new

O-ring

(045).

6547

• Wenn Motor mit 2 Hubvolumen, neuen O-Ring (057) einsetzen, andernfalls zum nächsten Schritt übergehen

• Install a new O-ring (057) if the motor has 2-displacement. If not go to the next section

6548

•

Verschlussplatte montieren.

•

Install the end cover

6544

• Schrauben (066) einsetzen und mit entsprechendem Drehmoment anziehen (siehe Schaubild Seite 38)

• Install and tighten the screws (066) to the right torque (see table page 38)

6543

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

33

289

06 06( WR

POCLAIN HYDRAULICS

Auswechseln des Drehzahlsensors (Option)

Replacing the sensor (optional)

Demontage

Disassembly

•

• Disconnect (161.3)

Stecker (161.3) abziehen

the

connector

6550

• Schraube (165) aufschrauben und ausbauen

• Unscrew and remove the screw (165)

165

6551

• Sensor (161) mit dem Träger (166) abziehen

• Extract the sensor (161) with its support (166)

166

161

6552

34

REPAR MS2-18 D/GB

290

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS Reassembly

Wiedereinbau

!

Der Dichtung (164) auf Sauberkeit der Auflagefläche dem Verteilerdeckel (041) prüfen.

!

Make sure that the seal mounting surface (164) on the valving cover (041) is clean.

• Neuen Haltering (163) und neue Dichtung (164) auf den Sensor (161) mit seiner Distanzscheibe (167) schieben.

• Install the new brake washer (163) and the new seal (164) on the sensor (161) fitted with its adjusting sticker (167).

• Den Sensor in die Halterung (166) stecken, so daß die Dichtung (164) korrekt in ihrer Aufnahme sitzt.

• Push the sensor assembly into the support (166) until the seal (164) is in its housing.

6552

• Sensor (041) in die Bohrung des Verteilerdeckels bis zum Kontakt mit dem Zylinderblock (011) schieben.

• Push the sensor into the valving cover (041) until it comes in contact with the cylinders block (011),

2064

Die Kerbe im Steckeranschluss des Sensors muss radial zur Mitte des Motors (Richtung Welle) zeigen.

the notch of the sensor should be oriented towards the center of the motor.

1 5 ° m a x i 1 5 ° m a x i 6558

• Schrauben (165) einsetzen und mit entsprechendem Drehmoment anziehen (siehe Schaubild Seite 38)

• Install and tighten the screw (165) to the right torque (see table page 38)

6551

• Stecker schließen.

(161.3)

wieder

an-

• Reconnect (161.3).

the

connector

6550

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

35

291

06 06( WR

POCLAIN HYDRAULICS

Tooling inventory

Werkzeug-Liste

Standard tools

Standard Werkzeug • Innensechskant-Schlüssel

Hollow head wrench

5 6 8 10 12 14

• Ring-/Maulschlüssel für Sechskantschraube

Hex head wrench

13 17 19 22 24

• Drehmoment-Schlüssel

FACOM J 250 A

Torque wrench

6 bis 30 N.m [4.4 to 22.1 lbf.ft]

• Drehmoment-Schlüssel

FACOM S 250 A Torque wrench

50 bis 240 N.m [35 to 175 lbf.ft]

• Drehmoment-Schlüssel

FACOM K 250 A Torque wrench

160 bis 800 N.m [120 à 600 lbf.ft]

• Korrosionsschutzfett

Auto-top 2000 Anti-oxidizing grease origine AGIP

Leuchtend grüne Farbe / fluorescent green color

•

Zange für Innenringe

FACOM 499.32

Internal snap ring pliers

•

Abzieher

FACOM U 20 B

Extractor

• Sechskantschlüssel für Innensechskantschraube

6553

Hex head wrench

13 17 19 22 24

•

Drehmoment-Schlüssel

FACOM J 250 A

Torque wrench

6 à 30 N.m [4.4 to 22.1 lbf.ft]

•

Drehmoment-Schlüssel

FACOM S 250 A Torque wrench

50 à 240 N.m [35 to 175 lbf.ft]

•

Drehmoment-Schlüssel

FACOM K 250 A Torque wrench

160 à 800 N.m [120 à 600 lbf.ft]

36

REPAR MS2-18 D/GB

292

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Special tools

Spezialwerkzeuge

Ø

A

G

• Mandrel for reassembling the brake cover or to compress the spring washer.

E

• Montagewerkzeug zum Anheben der Schutzkappe oder zum Komprimieren der Tellerfeder.

B

F

Ø

Ø

C Ø

D 0759

ØA

F02 F03 F04

ØB

ØC

ØD

mm

[inch]

mm

[inch]

mm [inch]

mm

[inch]

110

[4.3]

100

[4.0]

125

[4.9]

135

[5.3]

M12

F05

125

[4.92]

115

[4.52] 151 [5.94]

159

[6.25]

125

[4.92]

115

[4.52] 151 [5.94]

159

[6.25]

E

F

G

mm

[inch]

mm

[inch]

mm

[inch]

50

[1.96]

10

[0.39]

20

[0.78]

50

[1.96]

10

[0.39]

20

[0.78]

50

[1.96]

20

[0.78]

30

[1.18]

F07 F08 F09 F11 F12

M16

F18

190

[7.48]

180

[7.08] 205 [8.07]

215

[8.46]

F19

[0.39]

10

[2.75]

70

• Rohr zum Festsetzen des Motors

Tube to immobilize the motor

Ø

Ø 2 5 [0 .9 8 " d ia ]

F21

1 6

[0 .6 2 " d ia ] 5 5 [2 .1 6 " ] 7 0 0 [2 7 .5 5 " ]

M 1 2 H

x 1 2 0

M 1 6 x 1 2 0 c l. 1 0 .9

M 1 2

H M 1 6

Z 1 2 N

• Werkzeuge zur mechanischen Bremslösung.

Tools for mechanical brake release

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

A = 2 0 0

A = 2 8 0

F 0 2 F 0 3 F 0 4 F 0 5 F 0 7 F 0 8 F 0 9

F 1 1 F 1 2 F 1 8 F 1 9 F 2 1

A

Ø

6 0 x 3 0

1 6 .5 [0 .6 4 ] 5 0 x 5

37

293

06 06( WR

POCLAIN HYDRAULICS

Anziehdrehmomente Nm ± 10%

Tightening torques in [lbf.ft] ± 10%

(Gemäß Norm DIN 912)

(According to the standard DIN 912)

Größe Size

8.8

10.9

12.9

8.8

10.9

12.9

M6 M8 M10 M12 M14 M16 M18 M20

10 25 49 86 135 210 290 410

14 35 69 120 190 295 405 580

17 41 83 145 230 355 485 690

7.5 18.4 36 63.4 100 155 214 302

10 26 51 88.4 140 218 299 428

12.5 30 61 107 170 262 358 509

38

REPAR MS2-18 D/GB

294

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Ersatzteile

Spare parts list

Nummer

} 010

} 026

} 026

} 010

} 040

} 065 } 070

Bezeichnung Kompletter Zylinderblock 012 Kompletter Kolben Cl. 0 013 Kompletter Kolben Cl. 1 015 Reparatursatz Kompletter Nockenring 027 O-Ring Komplettes Verteilerdeckel 041 Verteilerdeckel 042 Schraube 043 Dichtungsring 044 Schraube 045 O-Ring 047 Verteiler 048 Dichtungssatz 050 Stopfen 051 O-Ring 052 Feder 053 Umschaltkolben 054 Scheibe 055 Sicherungsring 056 Feder 057 O-Ring 059 Stift Kompletter Verschlussplatte 066 Schraube 067 Dichtring Komplettes Lagerteil 071 Lagerteil 072 Innerer Lippendichtring 073 Rollenlager 074 Rollenlager 075 Scheibensatz 076 Stützring 077 Sicherungsring 078 Äußerer Dichtring 079 Abweiser 081 Dichtungsträger 087 Passfeder 090 Welle 091 Radbolzensatz 096 Bremstrommel 097 Schraube 098 Bremsseil 099 Sicherungsring 154 Komplette Bremsbacke 155 Kompletter Radzylinder 156 Gegenhalter

Item

} 040

} 065 } 070

Description Cylinders-block assembly 012 Piston Cl 0 assembly 013 Piston Cl 1 assembly 015 Repair kit Cam assembly 027 O-ring

Valving cover assembly 041 Valving cover part 042 Screw 043 Seal washer 044 Screw 045 O-ring 047 Valving 048 Seal kit 050 Plug 051 O-ring 052 Spring 053 Valve spool 054 Washer 055 Snap ring 056 Spring 057 O-ring 059 Pin End cover assembly 066 Screw 067 Sealing ring Bearing support assembly 071 Bearing support part 072 Radial lip seal 073 Roller bearing 074 Roller bearing 075 Set of shims 076 Thrust ring 077 Snap ring 078 Lip seal 079 Deflector 081 Seal support 087 Key 090 Shaft 091 Set of studs 096 Drum brake 097 Screw 098 Brake cable 099 Snap ring 154 Brake shoe sub-assembly 155 Brake cylinder sub-assembly 156 Brake adjustment

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

39

295

06 06( WR

POCLAIN HYDRAULICS Nummer Bezeichnung 100 Komplette Bremse 101 Bremsgehäuse 102 Schraube 106 O-Ring 107 Kolben 108 Tellerfeder 109 Sicherungsring 110 Welle 111 Dichtsatz Bremswelle 112 Schraube 113 Dichtungsring 135 Satz Bremslamellen 141 Schutzkappe 142 Stopfen 143 O-Ring

}

} 150 } 160

Drehzahlsensor-Vorbereitung 152 Scheibe 153 Scheibe Kompletter Sensor 161 Sensor 162 Mutter 163 Scheibe 164 Dichtung

} Als Satz lieferbare Baugruppe

40

Item

} 100

} 150 } 160

Speed sensor predisposition 152 Washer 153 Washer Speed sensor assembly 161 Speed sensor part 162 Nut 163 Washer 164 Seal

} Sub-assembly sold assembled

REPAR MS2-18 D/GB

296

Description Brake assembly 101 Brake body 102 Screw 106 O-ring 107 Brake piston 108 Spring washer 109 Snap ring 110 Brake shaft 111 Seal 112 Screw 113 Seal washer 135 Brake kit 141 Cover 142 Plug 143 O-ring

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

41

297

06 06( WR

POCLAIN HYDRAULICS

Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.

0987

42

REPAR MS2-18 D/GB

298

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Dichtungssatz Seal kit

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

0988

43

299

06 06( WR

POCLAIN HYDRAULICS

Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.

0990

44

REPAR MS2-18 D/GB

300

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

Dichtungssatz Seal kit

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

0989

45

301

06 06( WR

POCLAIN HYDRAULICS

46

REPAR MS2-18 D/GB

302

%20$*

800378128J

008 912 53

06 06( WR

POCLAIN HYDRAULICS

800378128J

REPAR MS2-18 D/GB

008 912 53

%20$*

47

303

06 06( WR

China

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POCLAIN HYDRAULICS BEIJING rep. office Unit A0808, Hui Bin Officies No.8 Beichendong St. BEIJING 100101 CHINA Tel.: 86 10 6499 3988 Fax: 86 10 6499 3979 e-mail: info-china@poclain-hydraulics.com

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S.A.S. au capital de 85 124 000 Francs Siège social: Route de Saint Sauveur VERBERIE (OISE) R.C.S. Senlis B 414 781 823 Siret 414 781 823 00011

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Instructions for repair A2FM32 058 010 53

Vibration motor

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008 196 03 008 912 53

6.00

6.01

Repair survey vibration motor

6.02

Special tools

6.03

General notes for repairs

6.04

Sealing the vibration motor

6.05

Repairing the vibration motor drive

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6.01

Fig. 1

4 Drive 5 Locking ring 6 Drive shaft

1 Housing 2 Connecting plate 3 Valve plate

6.01 Repair survey vibration motor Installation weight: approx. 11 kg

Opening the motor will result in the loss of all warranty and policy adjustment claims!

The description of the repair procedures is in accordance with economical and technical aspects. We do not recommend any further repairs.

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6.02 6.02 Special tools 1. Puller 079 944 02

Fig. 1

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6.03

6.03 General notes for repairs

Please observe the following notes when carrying out repairs on hydraulic components!

1. Close all openings on hydraulic components.

Fig. 1 2. Replace all seals and gaskets.

Fig. 2 3. Check all sealing and sliding surfaces for signs of wear.

Fig. 3 4. Fill the hydraulic components with hydraulic oil before taking them into operation.

Fig. 4 4 312

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6.04 6.04 Sealing the vibration motor 1. Mark the position of the connecting plate to the housing and unscrew the socket head cap screws (Fig. 1).

Fig. 1 2. Swivel the connecting plate 1 (Fig. 2) around the timing pin and lift it off.

Fig. 2 3. Cover the drive shaft with adhesive tape to prevent the new radial seal from being damaged (Fig. 3).

Fig. 3 4. Remove the circlip (Fig. 4).

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6.04

5. Force the locking ring out (Fig. 5).

Fig. 5 6. Remove the radial seal 1 (Fig. 6) and the O-ring (2).

Fig. 6 7. Check the drive shaft for running grooves (Fig. 7).

Fig. 7 8. If the running groove is very deep place an appropriate shim 1 (Fig. 8) in front of the radial seal.

Fig. 8 6 314

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6.04 9. Press the new radial seal in dry by using a suitable sleeve (Fig. 9).

Fig. 9 10. Insert the new O-ring 1 (Fig. 10) with some grease and fill the new radial seal (2) with grease.

Fig. 10 11. Knock the locking ring in by tapping it lightly with a hammer (Fig. 11).

Fig. 11 12. Install the circlip (Fig. 12).

Fig. 12 008 196 03 008 912 53

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6.04

13. Make sure that the circlip is sitting correctly in the groove (Fig. 13).

Fig. 13 14. Insert new O-ring 1 (Fig. 14) with some grease.

Fig. 14 15. Make sure that the timing pin 1 (Fig. 15) is in assembling position and attach the connecting plate.

Fig. 15 16. Observe the marks and fasten the socket head cap screws crosswise with 25 Nm (Fig. 16).

Fig. 16 8 316

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6.04 17. Unscrew the plug 1 (Fig. 17) and insert a new O-ring (2) with some grease.

Fig. 17

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6.05

6.05 Repairing the vibration motor drive Dismantling the drive 1. Mark the position of the connecting plate to the housing and unscrew the socket head cap screws (Fig. 1).

Fig. 1 2. Swivel the connecting plate 1 (Fig.2) around the timing pin and lift it off.

Fig. 2 3. Remove the O-ring 1 (Fig.3) 4. Remove the valve plate (2).

Fig. 3 5. Remove the circlip (Fig. 4).

Fig. 4 10 318

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6.05 6. Force the locking ring out (Fig. 5).

Fig. 5 7. Remove the radial seal 1 (Fig. 6) and the O-ring (2).

Fig. 6 8. Remove the shims 1 (Fig. 7).

Fig. 7 9. Dismantle the drive by using the puller as shown in Fig. 8.

Guide the cylinder in by hand.

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6.05

10. Check the housing for signs of scoring (Fig. 9).

Fig. 9

Assembling the drive

The drive 1 (Fig. 10) can only be renewed completely as the hydraulical and the mechanical parts are adjusted to each other.

Fig. 10 1. Insert the spring cup 1 (Fig. 11) and the Belleville springs (2) into the cylinder (3) by using a piece of wire.

Fig. 11 2. Slide all pistons into the cylinder by moving them slightly from side to side (Fig. 12).

Fig. 12 12 320

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6.05 3. Stand the new drive into a suitable bore and swash it to maximum displacement (Fig. 13).

Fig. 13 4. Heat the housing up to a temperatur of approx.

80 ˚C (Fig. 14).

Fig. 14 5. Slide the warm housing onto the drive as far as it will go (Fig. 15).

Danger of injury!

Fig. 15

Let the housing cool down, before further assembly to avoid damages to the O-ring.

6. Insert the shims 1 (Fig. 16).

Fig. 16 008 196 03 008 912 53

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6.05

7. Press the new radial seal in dry by using a suitable sleeve (Fig. 17).

Fig. 17 8. Insert the new O-ring 1 (Fig. 18) with some grease and fill the new radial seal (2) with grease.

9. Cover the drive shaft with adhesive tape to prevent the new radial seal from being damaged.

Fig. 18 10. Knock the locking ring in by tapping it lightly with a hammer (Fig. 19).

Fig. 19 11. Install the circlip (Fig. 20).

Fig. 20 14 322

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6.05 12. Make sure that the circlip is sitting correctly in the groove (Fig. 21).

Fig. 21 13. Pull the drive against the locking ring by using the puller (Fig. 22).

When the drive is touching, the locking ring is free of clearance.

Fig. 22 14. Insert the O-ring (Fig. 23) with some grease into the the groove.

15. Stick the valve plate (2) onto the drive by using oil.

Fig. 23 16. Make sure that the timing pin 1 (Fig. 24) is in assembling position and put on the connecting plate.

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17. Observe the marks and tighten the socket head cap screws crosswise with 25 Nm (Fig. 25).

Fig. 25 18. Screw the socket head cap screw into the drive shaft and check if the drive shaft can be turned by using an Allen key (Fig. 26).

The vibration motor has to be bled and filled with hydraulic oil before taking it into service.

Fig. 26

16 324

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