Case Vibratory Rollers SV212 & SV216 Service Manual 7-29530 - PDF DOWNLOAD

Vibratory Rollers SV212 and SV216 Service Manual

Cre 7-29530

NOTE: CASE Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

Cre 7-29530

Copyright  2001 Case France Printed in France April 2001

CONTENTS

SECTION 00 - MAINTENANCE CHAPTER 1 - General Instructions Description

Page

Introduction ........................................................................................................................................................ 1 Safety instructions.............................................................................................................................................. 3 Environmental measures and health precautions.............................................................................................. 6 Product identification.......................................................................................................................................... 8 Torque specifications ......................................................................................................................................... 9

CHAPTER 2 - General Specifications Description

Page

Description of the machine ................................................................................................................................ 1 Fluids and lubricants .......................................................................................................................................... 2 Specifications..................................................................................................................................................... 5 Overall machine dimensions.............................................................................................................................. 9

CHAPTER 3 - Troubleshooting Description

Page

Troubleshooting - Engine................................................................................................................................... 2 Troubleshooting - Hydraulic system oil overheating - emulsifying ..................................................................... 3 Troubleshooting - Vibration................................................................................................................................ 3 Troubleshooting - Travel .................................................................................................................................... 5 Troubleshooting - Brakes................................................................................................................................... 6 Troubleshooting - Steering................................................................................................................................. 6

SECTION 10 - ENGINE CHAPTER 1 - Removal and installation Description

Page

Specifications..................................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Torque specifications ......................................................................................................................................... 4 Special tools....................................................................................................................................................... 4 Removal............................................................................................................................................................. 6 Installation........................................................................................................................................................ 13 Accelerator cable assembly removal and installation ...................................................................................... 13

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CONTENTS

SECTION 21 - TRANSMISSION CHAPTER 1 - Hydraulic motor Description

Page

Description ......................................................................................................................................................... 2 Specifications..................................................................................................................................................... 3 Torque specifications ......................................................................................................................................... 3 Disassembly....................................................................................................................................................... 3 Reconditioning and replacement ....................................................................................................................... 5 Assembly ........................................................................................................................................................... 8

CHAPTER 2 - Travel reduction gear Description

Page

Specification....................................................................................................................................................... 1 Torque specifications ......................................................................................................................................... 2 Special tools....................................................................................................................................................... 2 Exploded view of travel brake ............................................................................................................................ 6 Disassembly and assembly ............................................................................................................................... 7 Brake test........................................................................................................................................................... 9 Exploded view.................................................................................................................................................. 10 Disassembly and assembly ............................................................................................................................. 11

SECTION 29 - HYDROSTATIC DRIVE CHAPTER 1 - Pumps - Cento drive coupling Description

Page

Specifications..................................................................................................................................................... 1 Tightening torque ............................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Special tools....................................................................................................................................................... 3 Removal of pumps, Cento clutch ....................................................................................................................... 3 Cento drive coupling .......................................................................................................................................... 7

SECTION 35 - HYDRAULIC SYSTEM CHAPTER 1 - Hydraulic cylinders Description

Page

Torque Specifications ........................................................................................................................................ 1 Description ......................................................................................................................................................... 2 Special tools....................................................................................................................................................... 3 Hood hydraulic cylinders.................................................................................................................................... 5 Cab hydraulic cylinder........................................................................................................................................ 7 Hydraulic cylinders............................................................................................................................................. 7

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CONTENTS

CHAPTER 2 - Vibration Motor Description

Page

Description ......................................................................................................................................................... 2 Specifications..................................................................................................................................................... 3 Torque specifications ......................................................................................................................................... 3 Disassembly....................................................................................................................................................... 3 Assembly ........................................................................................................................................................... 9 Supply pressure relief valve adjustment .......................................................................................................... 13

CHAPTER 3 - Hydraulic circuit Description

Page

Hydraulic installation .......................................................................................................................................... 2 Functional description ........................................................................................................................................ 2 Travel without activation .................................................................................................................................... 3 Travel activated, moving forward ....................................................................................................................... 4 The multi-function valve ..................................................................................................................................... 5 The idler-wheel lock-block on the flow divider ................................................................................................... 6 ASC valve .......................................................................................................................................................... 7 Vibration hydraulics............................................................................................................................................ 8 Vibration without activation ................................................................................................................................ 8 Vibration activated ............................................................................................................................................. 9 Steering hydraulics .......................................................................................................................................... 10 Steering without activation ............................................................................................................................... 11 Steering to the right.......................................................................................................................................... 12 Lifting hydraulics .............................................................................................................................................. 13 Lifting of the cab or hood ................................................................................................................................. 14 Lowering the cab and hood.............................................................................................................................. 15 Reservoir hydraulics ........................................................................................................................................ 16 Hydraulic reservoir ........................................................................................................................................... 16 Discharging of closed circuits .......................................................................................................................... 17 Brake release - emergency towing .................................................................................................................. 18 Test points ....................................................................................................................................................... 19 Releasing transmission and wheel hydraulic motor brakes ............................................................................. 20 Hydraulic diagram ............................................................................................................................................ 22

CHAPTER 4 - Hydraulic pump Description

Page

Specifications..................................................................................................................................................... 1 Torque specifications ......................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Disassembly....................................................................................................................................................... 3 Reconditioning and replacement of parts .......................................................................................................... 8 Assembly ......................................................................................................................................................... 14 Inspection and adjustments ............................................................................................................................. 26

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CONTENTS

SECTION 39 - FRAMES CHAPTER 1 - Drum Description

Page

Description ......................................................................................................................................................... 2 Specifications..................................................................................................................................................... 4 Torque specifications ......................................................................................................................................... 4 Special tools....................................................................................................................................................... 4 Drum removal .................................................................................................................................................... 7 Vibrator plate assembly ................................................................................................................................... 14 Removal of the right side of the drum .............................................................................................................. 16 Inspection and adjustment of vibration frequency............................................................................................ 19

CHAPTER 2 - Articulation Description

Page

Specifications..................................................................................................................................................... 1 Torque specifications ......................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Special tools....................................................................................................................................................... 3 Disassembly....................................................................................................................................................... 4

CHAPTER 3 - Drum Segments and Scrapers Description

Page

Specifications..................................................................................................................................................... 1 Hardware torque ................................................................................................................................................ 1 Special tools....................................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Segment installation........................................................................................................................................... 3

SECTION 41 - STEERING CHAPTER 1 - Control Description

Page

Specifications..................................................................................................................................................... 1 Special tools....................................................................................................................................................... 1 Description ......................................................................................................................................................... 2 Fault finding - steering ....................................................................................................................................... 3 Disassembly and assembly of steering wheel ................................................................................................... 3

CHAPTER 2 - Steering cylinders Description

Page

Specifications..................................................................................................................................................... 1 Special torques .................................................................................................................................................. 1 Special tools....................................................................................................................................................... 2 Removal of steering cylinders............................................................................................................................ 3 Replacing the seals............................................................................................................................................ 4

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CONTENTS

CHAPTER 3 - Steering control valve Description

Page

Specifications..................................................................................................................................................... 1 Tightening torques ............................................................................................................................................. 1 Description ......................................................................................................................................................... 2 Special tools....................................................................................................................................................... 3 Disassembly....................................................................................................................................................... 4 Reassembly ....................................................................................................................................................... 7 Functional check .............................................................................................................................................. 12

SECTION 50 - HEATER - AIRCONDITIONING CHAPTER 1 - Removal and installation Description

Page

Specifications..................................................................................................................................................... 1 Removal............................................................................................................................................................. 2 Defects in the airconditioning system ................................................................................................................ 4 Replacing (tightening) the belt ........................................................................................................................... 5

SECTION 55 - ELECTRICAL CIRCUIT CHAPTER 1 - Wiring diagram Description

Page

Electrical installation .......................................................................................................................................... 1

SECTION 90 - PLATFORM, CAB CHAPTER 1 - Operator’s compartment Description

Page

Torque specifications ......................................................................................................................................... 1 Operator’s compartment .................................................................................................................................... 2 Travel brake control adjustment......................................................................................................................... 8

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CONTENTS

NOTES

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

1

SECTION 00 - MAINTENANCE Chapter 1 - General Instructions CONTENTS Section

10000

Description

Page

Introduction .................................................................................................... 1 Safety instructions ......................................................................................... 2 Environmental measures and health precautions ...................................... 5 Product identification .................................................................................... 7 Torque specifications ..................................................................................... 8

INTRODUCTION This series of Vibratory Rollers is suitable for compaction of all kinds of ground and for large and averagescale groundwork in highway construction (construction of motorways, railways, aiports), in hydro-engineering (construction of dams), in building construction (industrial areas, ports), and the like.

The main purpose of this manual is to give the information necessary for carrying out assembly and disassembly of the machine as well as service repairs of main assemblies of the equipment. It contains technical and installation data, instructions on how to adjust the machine and how to use special tools, fixtures and aids.

These machines are manufactured in conformity with the latest developments and standards, which ensure their safe function.

The manufacturer continuously seeks to make product improvements on the basis of experience and latest developments in the field.

If the machine is used incorrectly, by untrained operators or for other purposes than those stipulated above, there is a danger of an accident or damage to the equipment.

For this reason, the manufacturer may make some changes in drawings, descriptions and designs in this manual.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE As used in this manual, the terms “right”, “left”, “front” and “rear” indicate the sides of the machine as seen from the operator’s seat.

A

A. FRONT B. REAR C. RIGHT-HAND SIDE D. LEFT-HAND SIDE

D

C

B CS00M511

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

3

SAFETY INSTRUCTIONS GENERAL SAFETY INSTRUCTIONS

7.

Attach a "Do not operate" warning note to the steering wheel and leave it there for the duration of the service work.

8.

Wash the equipment thoroughly. If you use steam, do not expose electrical components and insulation directly to the steam, or otherwise cover them beforehand.

9.

Keep all parts absolutely clean when dismantling, mounting, and servicing each assembly. Protect removed parts from getting soiled.

The following safety instructions must be observed by ALL repairing the machine.

1.

Repairs may be carried out by skilled, trained and experienced personnel only.

2.

When performing repairs, always use our shop manual. Special instructions for the assembly work are given in individual chapters of the manual.

3.

Before putting the machine into operation acquaint yourselves with the machine controls as explained in the “Operator’s Manual” and make sure that you are perfectly familiar with the machine.

4.

Do not use the machine if you do not fully understand all controls and until you know how the machine works.

5.

Familiarize yourself with the area where you will work.

6.

Do not carry out any redesign work or modifications on the machine because you could compromise the safety of the equipment.

7.

Original parts and accessories have designed especially for this machine.

been

8.

Installation and use of spare parts not supplied by the manufacturer of the machine or not authorized by him can have negative effects on operational characteristics and safe operation of the machine.

10. Clean the surface of dismantled parts and do the necessary to ensure adequately dust-free working conditions and a suitable storage area.

11. Be careful when handling cleaning agents. Do not use petrol or other easy inflammable materials for cleaning.

12. Dry the cleaned parts and immediately cover with anticorrosive protective oil- never install corroded parts.

13. Tools, hoists, safety equipment on chains, and other additional items must be serviceable and in good condition.

14. Use hoists and fasteners (ropes, chains) that have sufficient lifting capacity and are in good condition.

15. Make sure that there is enough fresh air supply when starting up the equipment in an enclosed area.

REPAIRING AND INSPECTING THE MACHINE 1.

Wear working clothes and boots.

2.

Use gloves when handling oils, fuel or coolant.

3.

Protect your eyes with goggles or a shield when handling the battery.

4.

Place the equipment on a flat and firm surface before starting repair. Secure the machine to prevent spontaneous movement.

5.

Secure the frame of the machine and the drum to prevent rotation using a locking pin and a draw bar.

6.

Before starting work remove the ignition key, disconnect the batteries and let hot parts cool down.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

16. Before operating the equipment make sure there is nobody on the machine or close by. Starting up of the machine must always be announced with an audible alarm, also after any pause in operation before the equipment is restarted. Those present on the machine and dangerously close by must leave the machine after the alarm has been sounded.

17. Do not adjust moving equipment.

18. When working (adjusting) on a running engine, avoid touching hot and rotating parts. During work on a running engine, another person must be present that can easily access the emergency switch and must be in contact at all times with the person performing the adjustment, to be able to switch off the engine immediately when necessary.

19. Use only approved makes of motor, gear and hydraulic oil and coolant.

WORKING ON HYDRAULIC CIRCUITS 1.

Make sure that no hydraulic circuit is under pressure before opening it. Hydraulic oil leaks under pressure may penetrate your skin and cause serious injury.

2.

Mark all parts, hoses and pipes before removing them.

3.

Do not operate hydraulic pumps and hydraulic motors without oil.

4.

There is danger of being scalded when handling hot oil.

5.

Do not warm oil to temperatures above 160°C (320°F)- oil or its fumes may ignite.

6.

For cleaning and wiping hydraulic parts use such textiles that do not leave traces of lint.

7.

When reassembling parts use hydraulic oil - not grease - as a lubricant.

8.

Clean screws and bolts carefully before installation, wash hoses and pipes and blow them through using compressed air.

9.

Always use new packing in sealing areas.

SV212 - SV216

10. Fill new components with hydraulic oil before installation.

11. Rinse the hydraulic circuit after replacing a hydraulic component; clean the hydraulic reservoir as well.

12. Replace the oil filter cartridge.

13. Fill the hydraulic circuit with pure oil of the recommended viscosity, but only when the engine has been stopped.

14. Wipe off excess oil.

15. Check connections for tightness and any oil leaks, before applying pressure to the system.

16. Do not adjust safety valves.

17. After all work has been finished, recheck all connections and replace all safety items.

18. After finishing the work put all protective devices back in place.

19. After putting the machine into operation.

• Check the level in the hydraulic reservoir.

• Check the output pressure of hydraulic pumps if they have been replaced as well as safety valve pressure. Carry out the measurements at a temperature of 40°C (104°F).

WORKING ON THE FUEL SYSTEM Mixtures of gasoline and diesel (winter fuel) are as inflammable as gasoline.

1. Do not refuel in closed areas.

2. Wipe off excess fuel.

3. Do not smoke when working on the fuel system and do not use naked lights. There is a danger of fire.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

5

WORKING ON ELECTRICAL WIRING

15. Never add sulfuric acid (H2SO4).

1.

Disconnect the battery when carrying out any repairs on the charging circuit to avoid accidental short-circuits.

16. Do not overturn the batteries because electrolyte could run out of the air vents in the battery.

2.

When dismantling, first disconnect the cable from the negative pole (-), then the cable from the positive one (+).

3.

Do not disconnect batteries when the engine is running.

4.

Connect the “minus” pole of the battery to the chassis and the “plus” pole to terminal “B+” from the alternator. In case of opposite connection the whole semi-conductor device can be destroyed.

5.

6.

17. If acid (electrolyte) is spilled, rinse the area with water and neutralize it with lime.

18. When the batteries are being charged, hydrogen is released and, mixed with air, makes an explosive, easily combustible mixture. Do not use naked lights and do not smoke.

WELDING ON THE MACHINE Before starting arc welding, disconnect all parts with semi-conductors from electrical wiring, i.e.:

• engine alternator,

When starting with an auxiliary external supply, do not disconnect the supply sooner than the battery of the machine is connected. Make sure of the starting voltage of the auxiliary external supply (for 24 V).

• hourmeter, • control unit under the instrument panel, • earth both the supply and the machine that is being repaired,

Do not put the alternator into no-load operation, i. e. with the wire disconnected from the “+” terminal and connected to the “D+” terminal.

7.

Do not check the presence of voltage in the wire by sparking it on the chassis of the equipment.

8.

Do not do anything that produces sparks.

9.

When handling batteries, use protective rubber gloves and goggles.

10. Protect your skin and clothes from stains caused by electrolyte or lead particles.

11. If electrolyte gets into your eye, rinse it with running water for a few minutes. Then see a doctor as soon as possible.

12. When electrolyte stains your skin or clothes, take off your clothes, wash the stained area with soapy water or with a solution of baking soda and water and see a doctor.

13. In the event of accidentally swallowing electrolyte, drink as much milk or water as possible or a solution of milk of magnesia and immediately see a doctor.

14. Never pour distilled water into the cells unless the operation of the machine or charging outside the machine follows. In this case the battery would discharge rapidly.

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• protect the supply point against moisture, • place the ground terminal close to the welded joint, • when parts are welded or when the machine is in the suspended position, insulate the point of current transfer to avoid current entering the hoist, or use a non-conducting rope.

SEALS 1.

Always use new packing.

2.

You can obtain packing kits in spare part form.

HARDWARE TORQUE 1.

Use a torque wrench to obtain the right hardware torque.

2.

Fastening screws and nuts of the given grade are tightened according to the table.

3.

Screw grade is shown visibly on the screw head.

4.

Hardware torque is given in the tables.

5.

Threaded connections of hydraulic circuits are tightened as specified in the tables.

6.

The given hardware torque specifications are valid for dry screw threads.

7.

Use new self-locking nuts only.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS

When repairing the machine, observe the general principles of health protection and environment protection, along with all laws, regulations, and guidelines related to these problems, as applicable to the territory where the machine is used.

4.

Oil products, coolants, batteries, and paint including organic thinners as well as cleaners and preservatives should be always stored in their original packaging and properly labeled. Do not store such products in unlabeled bottles and other containers because there is a danger of confusion. Confusion with food or drinks is especially dangerous.

5.

If your skin or eyes are by accidentally splashed or fumes inhaled, apply first aid immediately. In case of accidental consumption of such products see your doctor immediately.

HYGIENE 1.

Oil products, coolants, battery acids, and paints including thinners can be harmful to your health and they can cause serious injury.

2.

It is necessary to observe consistently safety and health instructions enclosed with the products and to use personal protective aids when handling them.

ECOLOGICAL PRECAUTIONS 1.

Personnel in contact with these products during servicing must observe the general principles relating to conservation and keep in mind safety and health guidelines as given by manufacturers of such products, especially the following:

Contents of machine systems and some parts of the machine, when no longer in use, represent great risks to the environment.

2.

The following products especially belong to this category:

3.

• both organic and synthetic lubricating materials, oils and fuel,

• protection of eyes and skin when working with batteries,

• coolants,

• protection of the skin when handling oil products, paint, and coolants,

• battery acids and batteries themselves, • cleaning agents and preservatives,

• workers should wash their hands properly after finishing their work and apply proper healing hand lotions, • when working with the cooling system it necessary to observe the instructions in the manuals supplied with the machine.

SV212 - SV216

• all removed filters and filter elements, • all used and discarded hydraulic and fuel hoses, rubber - metals and the other elements exposed to the above products.

3.

The above parts and materials must be handled, after they had been discarded, in accordance with prevailing national regulations on environmental protection and in conformance with directives relating to health conservation.

4.

When hydraulic liquids, fuel, cooling systems and their components are being removed it is necessary to prevent their infiltration into the ground by using retaining vessels and by plugging all orifices.

5.

In the event of leakage, the contaminated areamust be immediately dried with sawdust, Vapex, or similar.

6.

Contaminated earth must be removed to prevent further infiltration. Then the soil and absorbing material must be disposed of safely.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

7

FIRE PRECAUTIONS 1.

From a fire risk point of view, the inflammable liquids used are divided into the following risk classes II. Risk class - oil IV. Risk class - mineral oils - lubricants - antifreeze

2.

The place where oil is being changed must not situated in an area where there is danger of explosions or fire.

3.

Notices showing that smoking and naked lights are not allowed must be installed there.

4.

The receptacles used to catch drained inflammable liquids must be of adequate capacity.

5.

Portable fire-extinguishers must be available.

6.

Oil and oil products should be handled in special containers, e.g. metal barrels, drums or cans.

7.

Liquid containers must be properly closed when stored.

8.

The containers should have an air vent. They should be always stored with the air vent up and there must be measures taken to prevent leakage.

9.

The vessels must be labeled with indelible inscriptions showing their contents and inflammability class.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 PRODUCT IDENTIFICATION

Serial and type numbers are important for machine identification and/or in case of warranty claims. A name plate with basic machine data is attached to the left side of the frame below the cab.

CD00M008

2

CD00M009

3

A plate with the serial number of the Cummins engine is attached to the fuel injection pump drive housing.

Serial numbers and data relating to major components may be found on the components concerned.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

9

TORQUE SPECIFICATIONS FASTENING HARDWARE Inspection and re-tightening 1.

Regularly check that hardware is not loose.

2.

Use torque limiting wrenches to tighten screws and nuts.

Screws with metric threads Torque Screw For screws size 5.8 (5 S)

For screws

For screws

8.8 (8 G)

10.9 (10 K)

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

M4

2

1

3

2

4

3

M5

4

3

6

4

8

6

M6

7

5

10

7

14

10

M8

16

12

22.5

17

32.5

24

M10

31.5

23

44

32

62

46

M12

53

39

75

55

105

77

M14

79

58

118

87

165

122

M16

113

83

165

122

226

167

M18

172

127

245

181

343

253

M20

226

167

314

232

441

325

M22

284

209

392

289

559

412

M24

392

289

549

405

755

557

NOTE: Lock nuts may be used a maximum of 3 times when approved.

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

SCREW TYPE HOSE CONNECTIONS Screw type connections with “O” Rings Nm

lb-ft

Wrench size

Thread

Hose

Nominal

Min

Max

Nominal

Min

Max

14

M12x1.5

6

20

15

25

15

11

18

17

M14x1.5

8

38

30

45

28

22

33

19

M16x1.5

45

38

52

33

28

38

22

M18x1.5

51

43

58

38

32

43

24

M20x1.5

58

50

65

43

37

48

27

M22x1.5

74

60

88

55

44

65

30

M24x1.5

16

74

60

88

55

44

65

32

M26x1.5

18

105

85

128

77

63

92

36

M30x2

135

115

155

100

85

114

166

140

192

122

103

142

41 46 50 50

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36x2

8 10 10 12 12 14 15

20 22 25 28

M42x2

30

240

210

270

177

155

199

M45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

M52x2

38 42

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

11

PLUGS AND NECKS Table of tightening torques for necks and plugs with tightening edge, or with flat packing:

Ø

Ø

Ø 4

CS01C502

5

CS01C503

Plugs torque

Neck torque Ø

Nm

lb-ft

Ø

Nm

lb-ft

G 1/8“

25

18

G 1/8“

15

11

G 1/4“

40

30

G 1/4“

33

24

G 3/8“

95

70

G 3/8“

70

52

G 1/2“

130

96

G 1/2“

90

66

G 3/4“

250

184

G 3/4“

150

111

G 1“

400

295

G 1“

220

162

G 11/4“

600

443

G 11/4“

600

443

G 11/2“

800

590

G 11/2“

800

590

M 10x1

25

18

M 10x1

13

10

M 12x1.5

30

22

M 12x1.5

30

22

M 14x1.5

50

37

M 14x1.5

40

30

M 16x1.5

60

44

M 16x1.5

60

44

M 18x1.5

60

44

M 18x1.5

70

52

M 20x1.5

140

103

M 20x1.5

90

66

M 22x1.5

140

103

M 22x1.5

100

74

M 26x1.5

220

162

M 26x1.5

120

89

M 27x1.5

250

184

M 27x1.5

150

111

M 33x1.5

400

295

M 33x1.5

250

184

M 42x1.5

600

443

M 42x1.5

400

295

M 48x1.5

800

590

M 48x1.5

500

369

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SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

NOTES

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

1

SECTION 00 - MAINTENANCE Chapter 2 - General Specifications CONTENTS Section

10000

Description

Page

Description of the machine ........................................................................... 1 Fluids and lubricants ..................................................................................... 2 Specifications ................................................................................................. 5 Overall machine dimensions ........................................................................ 9

DESCRIPTION OF THE MACHINE This vibratory roller is a self-propelled compaction machine consisting of two articulated sections, i.e. the drum and the towing unit.

Drum unit This consists of the frame in which the drum with the travel drive and vibration drive is placed. Two levels of amplitude, which can be selected together with the corresponding frequency, make it possible to compact materials with different characteristics. Two scrapers placed on the front side of the beam and on the rear side on the cross member of the drum frame are provided for removing any soil adhering to the drum.

Towing unit This consists of a welded frame with the articulation support and hydraulic travel motors in front and the fuel tank, batteries and tool box to the rear. The hydraulic reservoir, operator’s compartment and ROPS frame are mounted on top.

The static linear load and dynamic parameters for this machine place it in the heavy vibratory roller category.

Articulation Connects both units of the roller and enables independent horizontal and vertical movement of both sections.

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

ATTACHMENTS

The ROPS protection frame

Tamping segments These segments make it possible to convert a smooth drum for tamping compaction duties.

This protects the driver in case of the machine ovesturning. Data concerning the frame is to be found on the plate.

Dozer blade

Asc lock

This attachment is useful for spreading bulk soil and for leveling the area being compacted. The arms of the blade are pendular and fixed to the frame of the drum.

The blade is lifted and lowered using two bracketmounted linear hydraulic motors on the right and left side drum frame members.

This makes it possible to negotiate rough terrain (gradients) with better adhesion and helps when loading on a trailer or trying to free the machine in mud, etc.

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

!

WARNING

!

The conditions of use for individual fluids and lubricants must be respected.

ENGINE OIL IMPORTANT: Use high quality oil and respect the oil changing intervals so as to ensure maximum engine life.

Categories of oil to be used: API CE - CCMC D5 NOTE: In certain countries, if CE grade oils are not to be found, it is possible to use CC/CD grade oils, but in this case the oil must be changed more frequently.

The type of oil to use depends on ambient temperature: - SAE 15W40: All seasons - SAE 10W30: Winter - SAE 5W30: Arctic The following table gives the temperature ranges for different oils, depending on their viscosity.

NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on lubricants.

CS00N532

SV212 - SV216

1

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

3

HYDRAULIC FLUID

ANTI-FREEZE/ANTI-CORROSION

Use high quality hydraulic fluid which is suitable for use at high pressures.

Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

The type of fluid use depends on ambient temperature:

For areas where ambient temperature is over -36°C (33°F), use a blend of 50% ethylene-glycol based antifreeze.

ISO VG46: Temperate climates (-8°C to +40°C) (17°F to 104°F) ISO VG68: Hot climates (0°C to +80°C) (32°F to 176°F) TRANSMISSION OIL

For areas where the temperature is below -36°C (33°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

Use extreme pressure type oil, of the API GL5 SAE 80W90 category.

GREASE Use extreme pressure grease of the NLGI grade 2 category.

FUEL Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade N°2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel consumption.

When the temperature is very cold, the use of a mixture of N°1 and N°2 fuel is permitted. See your fuel vendor for winter fuel requirements in your area.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

IMPORTANT: In cold weather, fill the fuel tank at the end of the day’s work, in order to prevent the formation of condensation.

Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.

Drain off water and impurities regularly.

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SV212 - SV216

4

SECTION 00 - SPECIFICATIONS - CHAPTER 2

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS Components

Fluids and lubricants

Capacity

Engine

SAE 15W40 - API CE/SGE, ACEA E1-E2, 16.3 litres (4.3 gal CCMC D2-D3 - 10W30 - 5W30 oil US)

Hydraulic system

ISO VG46 - VG48 oil

90 litres (23.8 gal US)

Transmission

API GL5 - SAE 80W90 oil

4.2 litres (1.1 gal US)

Axle

API GL5 - SAE 80W90 oil

xx litres

Fuel system

Grade N°2 fuel

410 litres (108.3 gal US)

Machine articulation

NLGI grade 2 grease

as needed

Cooling system

Coolant - Water - Anti-freeze

25 litres (6.6 gal US)

Drum vibration

SAE 15W40 - 10W30 - 5W30 oil

8 litres (2.1 gal US)

Batteries

Distilled water

as needed

Windshield washers

Water - Anti-freeze

2.75 litres (0.72 gal US)

ENVIRONMENT Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Contact your local ecological recycling center or your Dealer to obtain information on the correct method of disposing of these materials.

SV212 - SV216

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

5

SPECIFICATIONS SV212

SV216

ENGINE Make ................................................................................................................................. Cummins Type ................................................................................................................................ B5.9 - C148 Power rating...............................................................................................................110.0 kW (148 HP) Standard .................................................................................................................ISO 3046/1 (DIN 6271) Rated speed..................................................................................................................... 2200 RPM STEERING Oscillation angle.................................................................................................................... ±10° Steering angle....................................................................................................................... ±36° Turning radius: Inner (edge) ......................................................................................................... 3050 mm (120.08 in) Outer (overall)........................................................................... 5370 mm (211.4 in) ........... 5395 mm (212.4 in) CAPACITIES Fuel tank ................................................................................................................410 litres (108.3 gal US) Engine oil ................................................................................................................ 16.3 litres (4.3 gal US) Cooling system .........................................................................................................25 litres (6.6 gal US) Hydraulic system......................................................................................................90 litres (23.8 gal US) Drum gearbox ............................................................................. 2 litres (0.53 gal US) ........ 4.2 litres (1.1 gal US) Vibrating drum............................................................................................................8 litres (2.1 gal US) ELECTRICAL SYSTEM Voltage ................................................................................................................................24 Volts Batteries........................................................................................................................... 2 x 100 Ah WHEELS Size of tires ....................................................................................................................... 23.1 x 26" Tread................................................................................................................................ UK5 10 PR Average ground contact pressure.............................................................................. 304 kPa (44.1 psi) Tire inflation ............................................................................................................... 160 kPa (23.2 psi)

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6

SECTION 00 - SPECIFICATIONS - CHAPTER 2 SV212

SV216

TRAVEL Drive axles ............................................................................................................................... 2 No. of travel speeds ................................................................................................................. 4 Travelling speed - continuously controlled in both directions 1st speed range Position of the shifter for working speed 1st position of the pre-selector ........................................... 0-2.9 km/h (0-1.8 MPH) ...0-2.4 km/h (0-1.49 MPH) 2nd position of the pre-selector ........................................... 0-4 km/h (0-2.48 MPH) ...0-3.1 km/h (0-1.92 MPH) 3rd position of the pre-selector.............................................. 0-7 km/h (0-4.3 MPH) ....0-5.7 km/h (0-3.54MPH) 2nd speed range Position of the shifter for transport speed (hare) Pre-selective gear control disengaged .......................... 0-16.0 km/h (0-9.91 MPH) ....0-13 km/h (0-8.07 MPH) Transversal stability - straight .................................................................................36° .....................................37° Brakes: Service......................................................................................................................... Hydrostatic Parking and emergency................................................................................................ Multi-disc Practical gradeability: Without vibration...............................................................................................50% ................................... 56% With vibration.................................................................................................................... 40% Vibration: Frequency..................................................................................................30/34 Hz ............................28/34 Hz Amplitude...................................................................1.8/1.05 mm (0.071/0.041 in) 2.1/1.1 mm (0.079/0.41 in) WEIGHTS Operating weight (CECE) * with cab and ROPS frame .............. 11 250 kg (24802 Ib) ......... 14 480 kg (31922 Ib) Operating weight (CECE) - maximum.........................................12 590 kg (27756 Ib) ......... 15 300 kg (33730 Ib) Drum load (CECE) .........................................................................7020 kg (15476 Ib) ......... 10 160 kg (22399 Ib) Static linear weight..................................................................................... 31.9 kg/cm .........................46.2 kg/cm Ballast ......................................................................................................................... 1200 kg (2645 Ib) Cab ...............................................................................................................................220 kg (485 Ib) ROPS frame..................................................................................................................230 kg (507 Ib) Three tamping compaction segments......................................................................... 1680 kg (3704 Ib) Tires with liquid ballast ............................................................................................. 2x600 kg (2x1323 Ib) * When using tamping compaction segments or liquid tire ballast the basic machine weight figures shown must be increased accordingly.

SV212 - SV216

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

7

PERFORMANCE LEVELS SV212 (soil compaction) Square output Number m2/h of passes (yd2/h) 3960 (4736) 1980 (2368) 1320 (1579) 990 (1184)

2 4 6 8

SV216 (soil compaction) Square output Number m2/h of passes (yd2/h) 3960 (4736) 1980 (2368) 1320 (1579) 990 (1184)

2 4 6 8

Working speed (km/h): 4.5 (2.8 mph)

Volumetric Output m3/h (yd3/h)

0.2 (8)

0.3 (12)

792 (1036) 396 (518) 264 (345) 198 (259)

594 (777) 396 (518) 297 (388)

Correction factor: 0.8 Compacted lift thickness m (in) 0.4 (16) 0.5 (20) 0.6 (24) 0.7 (28) 0.8 (31)

528 (691) 396 (518)

660 (863) 495 (647)

0.4

792 (1036) 396 (518) 264 (345) 198 (259)

792 (1036) 528 (691) 398 (518)

693 (906)

792 (1036)

Working speed (km/h): 4.5 (2.8 mph)

Volumetric Output m3/h (yd3/h)

0.2

792 (1036) 594 (777)

Correction factor: 0.8 Compacted lift thickness m (in) 0.6 0.8 1 1.2

1188 (1554) 792 (1036) 594 (777)

1056 (1381) 792 (1036)

990 (1295)

1188 (1554)

1.4

1386 (1813)

Less economical compaction modes MAXIMUM COMPACTED LIFT THICKNESS AT OPTIMAL WORKING CONDITIONS

SV212 SV216

Rockfill 0.8 m (31 in) 1.4 m (55)

Sand/gravel 0.6 m (24 in) 0.9 m (35 in)

Mixed soils 0.5 m (20 in) 0.75 m (30 in)

Silt 0.4 m (16 in) 0.55 m (22 in)

Clay 0.25 m (10 in) 0.3 m (12 in)

EQUIPMENT Standard

Options

Lockable vandal guard Single lever control Both drum and wheels are hydrostatically driven Double mode vibration Interaxle differential lock Articulated chassis Halogen working lamps Tires 23.1 x 26” tread UK 5 (10 PR) Tire ballast water filling device

ROPS protection Segment kits, 150 feet Airconditioning Engine air pre-cleaner Tires 23.1 x 26” TR1 (10PR) Tire ballast liquid filling to 0 centigrade C Tire ballast liquid filling to minus 25 centigrade C Compaction indicator Fan safety screen Alternator safety screen Turn indicators Rotating beacon

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8

SECTION 00 - SPECIFICATIONS - CHAPTER 2

NOISE AND VIBRATION LEVELS Internal noise The acoustic pressure level affecting the driver during travel (measured according to EN 11 202 on sand): 1) With door closed Using vibration ......................................................................................................................................... 81 dB (A) Without vibration ...................................................................................................................................... 78 dB (A) 2) With door open Using vibration ......................................................................................................................................... 91 dB (A) Without vibration ...................................................................................................................................... 90 dB (A) External noise Measured according ISO 6393 on concrete, machine stationary .......................................................... 108 dB (A) Vibration The mean effective value of vibration acceleration: - Transferred to the hands (measured according to ISO 5349 on sand, using vibration): aw < 2.5 m/s2 (vectorial sum).

- Transferred to the body (measured according to EN 1032 on sand, using vibration): aw < 0.5 m/s2 (vectorial sum)

SV212 - SV216

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SECTION 00 - SPECIFICATIONS - CHAPTER 2

9

OVERALL MACHINE DIMENSIONS

L

E F

B C

D

A

K

G

H J

2 SV212 SV216 A................................................................................................................................... 2.820 m (111 in) B....................................................................................................................................1.500 m (59 in) C ................................................................................................................................. 0.420 m (16.5 in) D ................................................................................................................................. 0.430 m (16.9 in) E................................................................................................................................. 3.030 m (119.3 in) F.................................................................................................................................. 2.500 m (98.4 in) G ................................................................................................................................ 5.686 m (223.8 in) H ................................................................................................................................. 2.200 m (86.6 in) J ........................................................................................................2.450 m (96.4 in) ............... 2.500 m (98.4 in) K.......................................................................................................... 0.118 m (4.6 in) ................. 0.142 m (5.6 in) L ........................................................................................................0.025 m (0.98 in) ............... 0.040 m (1.57 in) CS01A508

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10

SECTION 00 - SPECIFICATIONS - CHAPTER 2

NOTES

SV212 - SV216

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SECTION 00 - MAINTENANCE - CHAPTER 3

1

SECTION 00 - MAINTENANCE Chapter 3 - Troubleshooting CONTENTS Section

10000

Description

Page

Troubleshooting - Engine .............................................................................. 2 Troubleshooting - Hydraulic system oil overheating - emulsifying .......... 3 Troubleshooting - Vibration .......................................................................... 3 Troubleshooting - Travel ............................................................................... 5 Troubleshooting - Brakes .............................................................................. 6 Troubleshooting - Steering ........................................................................... 6

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SV212 - SV216

2

SECTION 00 - MAINTENANCE - CHAPTER 3 TROUBLESHOOTING - ENGINE Problem

Engine stops suddenly while traveling

Starter motor runs but engine does not fire

Starter motor does not run and engine does not fire

SV212 - SV216

Possible cause

Remedy

Fuel tank empty

Fill the fuel tank

Fuel filter restriction

Change the filter

Contaminants or water in fuel circuit

Empty the tank and decontaminate the circuit

Air in fuel circuit

Check the fuel liner and connections (leaks).

Bleed the circuit

Hydraulic oil gauge defective

Replace gauge S14

Hydraulic oil reservoir level too low

Look for signs of leakage from the hydraulic circuit. Repair if necessary and fill the reservoir

Emergency shut-down button pressed down

Release the emergency stop button

RH safety arm contactor position

Lower the safety arm and check the contactor position

Fuel tank empty

Fill the tank

Fuel filter restriction

Replace the filter

Defective charge pump

Check the pump and replace it if necessary

Contaminants or water in fuel circuit

Empty the fuel tank and decontaminate the system

Air in fuel circuit

Check the fuel liner and connections (leaks).

Bleed the circuit

Incorrect injection pump timing

Check the injection pump timing

Hydraulic oil reservoir level too low or hydraulic oil gauge defective

Look for signs of leakage from the hydraulic circuit. Repair if necessary and fill the reservoir.

Replace the gauge if necessary

Engine shut-down electrovalve activated

Check the electrical circuit between fuse F3, relay K3 and engine shut-down electrovalve Y5

Starting up procedure not being followed

Make sure that: - The battery master switch is on and the travel control in neutral - The emergency cut-out button is not pressed down - The R14 safety arm is lowered

Batteries flat

Check and charge the batteries. Replace them if necessary

Corroded or loose battery terminals

Clean, inspect and tighten the terminal nuts.

Replace the terminals if necessary

Electrical circuit defective

Check continuity between switch S3, fuse F3, switches S10, S11 and S13, relay K4 and the starter motor. If continuity is good, check out each component

Defective starter motor

Repair or replace the starter motor

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SECTION 00 - MAINTENANCE - CHAPTER 3

3

TROUBLESHOOTING - HYDRAULIC SYSTEM OIL OVERHEATING - EMULSIFYING Problem

Hydraulic oil overbearing

Hydraulic oil emulsifying

Possible cause

Remedy

Clogged radiator fins

Clean radiator fins

Incorrect valve pressure setting

Check travel, vibration and steering circuit valve pressure settings. Adjust if necessary

Seized drum bearings (too much pressure on vibrating circuit)

Check drum bearings and replace if necessary

Steering articulation seized (too much pressure on steering circuit)

Check steering articulation pin and bushings.

Repair if necessary

Hydraulic oil contaminated or of wrong viscosity

Drain the circuit and fill with the correct oil

Air getting into steering pump suction circuit

Check hoses and hose tightness on the suction circuit. Tighten the clamps and replace the hoses and clamps if necessary

Hydraulic oil contaminated or of wrong viscosity

Drain the circuit and fill with the correct oil

TROUBLESHOOTING - VIBRATION Problem

Oil leaking from roller

Vibratory system not working

7-29530 - 04-2001

Possible cause

Remedy

Breather loose or defective

Tighten the breather or replace it if necessary

Cover (7 & 8) screws loose

Tighten screws to the correct torque; see Section 39, chapter 1

O-rings (57) on covers defective

Remove the covers and replace the seals; see Section 39, chapter 1

Vibration hydraulic motor shaft defective

Remove the hydraulic motor shaft and replace the seal

Plate/hub seal (22) defective

Remove the plate and hub and replace the seal; see Section 39, chapter 1

Travel control in wrong position

Put the control in a suitable position

Engine speed below 2000 rpm

Adjust engine speed to over 2000 rpm

Electrical circuit defective

Check the S18, S19 and S20 switches, the Y9 and Y10 electrovalves, the K5 and K7 relays, plug the corresponding electrical connections

Pilot pressure below 22 bar (319 psi)

Adjust the pilot pressure relief valve on the travel pump. Repair or replace if necessary

Steering pump defective, steering not working

Repair or replace the steering pump

Vibration safety valves out of adjustment

Adjust the vibration circuit safety valves. Repair or replace if necessary

Internal leakage or worn vibration pumpSeal off hydraulic motor supply lines at the pump outlets and check maximum pressure (400 bar) (5801 psi)

If this pressure is not obtained, repair or replace the pump. If the pressure is obtained, check vibration hydraulic motor leak off.

Vibration motor leakage exceeding 15L/min (3.29 gal/mn)

Repair or replace the vibration hydraulic motor

SV212 - SV216

4

SECTION 00 - MAINTENANCE - CHAPTER 3

TROUBLESHOOTING - VIBRATION (continued) (

Problem

Vibratory system only works in one selected position

Vibratory system not working (hydraulics OK)

Vibratory system works at low engine speed

Vibratory system not reaching frequency level required

SV212 - SV216

Possible cause

Remedy

Electrical circuit defective

Check the S18 switch, the Y9 and Y10 electrovalves. repair or replace if necessary

One of the safety valves is out of adjustment

Adjust the vibration circuit safety valve. Repair or replace if necessary

Return circuit pressure too high

Check the vibration motor relief valve and spool.

Repair or replace if necessary

Bearings (28) seized or damaged.

Filings detected in drained drum oil

Replace the bearings and check the vibration system operates freely; see Section 39, chapter 1

Coupling between hydraulic motor and vibration system defective

Replace the coupling shaft and pinion

Mechanical adjustment between throttle stop and S20 switch

Adjust to ensure contact at 2000 rpm

S20 switch defective

Replace the switch

Poor adjustment

Adjust the mini or maxi frequency; see Section 39, chapter 1

Vibration safety valves out of adjustment

Adjust the safety valves on the vibration circuit; repair or replace if necessary

Internal leakage or worn vibration pump. Seal off hydraulic motor supply lines at the pump outlets and check maximum pressure (400 bar) (5801 psi)

If this pressure can not be obtained, repair or replace the pump. If the pressure is obtained, check the vibration hydraulic motor leak off

Vibration motor leakage exceeding 15L/min (3.29 gal/mn)

Repair or replace the vibration hydraulic motor

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SECTION 00 - MAINTENANCE - CHAPTER 3

5

TROUBLESHOOTING - TRAVEL Problem

Machine will not travel

Travel lacks power

Machine only travels in fast speed

Machine will not travel in Forward or Reverse and lacks power on one side

7-29530 - 04-2001

Possible cause

Remedy

Brake pressure switch defective

If the machine travels when the pressure switch is disconnected, replace the pressure switch

Electrical circuit defective

Check continuity between fuse F3, relay K6 and controls S16 and S17, as well as between control box A3 and electrovalve Y13. If there is continuity, check each component

Travel safety valves out of adjustment

Set the travel circuit safety valve pressure to 420 bar (6091 psi). Repair or replace if necessary

Internal leakage or worn travel pump.

Seal off hydraulic motor supply lines at the pump outlets and check maximum pressure (420 bar) (6091 psi)

If this pressure can not be obtained, repair or replace the pump. If the pressure is obtained, check the travel hydraulic motor leak off

Travel hydraulic motor internal leakage higher than 5 L/min (1.1 gal/mn)

Replace a hydraulic motor with leak off above 5 L/min (1.1 gal/mn)

Travel safety valves out of adjustment

Set the travel circuit safety valves to 420 bar (6091 psi). Repair or replace if necessary

Internal leakage or worn travel pump.

Seal off hydraulic motor supply lines at the pump outlets and check maximum pressure (420 bar) (6091 psi)

If this pressure can not be obtained, repair or replace the pump. If the pressure is obtained, check the travel hydraulic motor leak off

Travel hydraulic motor internal leakage higher than 5 L/min (1.1 gal/mn)

Replace a hydraulic motor with leak off above 5 L/min (1.1 gal/mn)

High speed travel electric control defective

Check continuity between relay K6, control S16 and electrovalves Y7, Y8 and Y14. If there is continuity, check each component

Travel motor cylinder displacement controls defective

Check the cylinder displacement control pistons.

Repair or replace if necessary

Travel safety valves out of adjustment

Set the travel circuit safety valves to 420 bar (6091 psi). Repair or replace if necessary

Drum hydraulic motor return circuit pressure too high

Check the relief valve and control spool on the drum travel motor. Repair or replace if necessary

SV212 - SV216

6

SECTION 00 - MAINTENANCE - CHAPTER 3 TROUBLESHOOTING - BRAKES Problem

Possible cause

Remedy

Brake application procedure not being followed correctly

Make sure travel control is in neutral and that the emergency brake is not on

Electrical circuit defective

Check continuity between fuse F3, relay K5, diode V1, the A2 timer and electrovalve Y6. If there is continuity, check each component

Brakes remain off

Brakes remain on when steering wheel it turned With the engine running, the brakes remain on (they come off when the steering wheel is turned

Steering pressure switch S15 defective Replace pressure switch S15 Electrical circuit defective

Check continuity between fuse F3, steering pressure switch S15 and the A2 timer

Steering pressure switch S15 defective Replace pressure switch S15 A2 timer defective

Check the A2 timer voltage and replace it if necessary

Brake electrovalve seized

Repair or replace the electrovalve

TROUBLESHOOTING - STEERING Problem

Possible cause Main relief valve defective

Steering ineffective on rough ground

Machine will only steer in one direction

SV212 - SV216

Remedy Check pressure at M5, adjust the main relief valve and replace if necessary

Steering control valve defective

Repair or replace the control valve

Steering pump defective

Repair or replace the pump

Leaking steering cylinder

Repair or replace the cylinder

Steering column broken or damaged

Repair or replace the steering column

Secondary relief valve defective

Overset the main relief valve, check pressure at M5 and adjust the secondary relief valve or replace it if necessary

7-29530 - 04-2001

SECTION 10 - ENGINE - CHAPTER 1

1

SECTION 10 - ENGINE Chapter 1 - Removal and installation CONTENTS Section

21603

Description

Page

Specifications ................................................................................................. 1 Description ..................................................................................................... 2 Torque specifications .................................................................................... 4 Special tools ................................................................................................... 4 Removal .......................................................................................................... 6 Installation .................................................................................................... 13 Accelerator cable assembly removal and installation .............................. 13

SPECIFICATIONS Manufacturer............................................................................................................................................ Cummins Type of the engine ................................................................................................................................. B5.9-C148 Number of cylinders .............................................................................................................................................. 6 Cylinder bore................................................................................................................................ 102 mm (4.02 in) Stroke........................................................................................................................................... 120 mm (4.72 in) Total displacement .................................................................................................................... 5880 cm3 (359 in3) Power rating ISO 3046/1 (DIN 6271) ...........................................................................................110 kW (148 HP) Rated speed............................................................................................................................................. 2200 rpm Maximum torque ........................................................................................................................ 479 Nm (353 Ib.ft) Fuel consumption during normal operation....................................................... (SV212) 11.8 l/h; (SV216) 12.5 l/h Fuel filters .............................................................................................................................................. Fleetguard Oil filter................................................................................................................................................... Fleetguard Air filter................................................................................................................................................... Donaldson Air filter element ..................................................................................................................................... Donaldson Safety air filter element .......................................................................................................................... Donaldson Cooling system .................................................................................................. water cooled engine with radiator Drive coupling ...............................................................................................................CENTA CF-H-030-1 Sa 03

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SV212 - SV216

2

SECTION 10 - ENGINE - CHAPTER 1 DESCRIPTION

31 28

3 23 23

48

29 64

51 56

86 64 5

2

6 47 12

51

CS01D543

1.

2.

3.

12.

23.

28.

29.

31.

47.

48.

51.

56.

64.

64

1 64

1

Bracket Bracket Clip Flange Clamp Screw Throttle lever Pipe holder Screw M10x35 Screw M10x80 Screw M12x35 Screw M16x20 Nut M12

SV212 - SV216

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SECTION 10 - ENGINE - CHAPTER 1

3

27 8

35 53

30 8

35 CS01D544

8.

27.

30.

35.

53.

2

Bracket Hose Hose Elbow Screw

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SV212 - SV216

4

SECTION 10 - ENGINE - CHAPTER 1 TORQUE SPECIFICATIONS

Fastening hardware Screws, nuts Thread Torque Flange (12), engine............................................................... 47.......................M10 .................. 44 Nm (32.5 Ib.ft) Hydraulic pump, flange (12)............................................... 112*.......................M14 ..................118 Nm (118 Ib.ft) Rear bracket (5, 6) ................................................................ 51.......................M12 .................. 75 Nm (55.3 Ib.ft) Bracket (1, 2), engine............................................................ 51.......................M12 .................. 75 Nm (55.3 Ib.ft) Engine bracket (1, 2, 5, 6) with rubberized metal pieces)..... 64.......................M12 .................. 75 Nm (55.3 Ib.ft) Cooling fan............................................................................ 48.......................M10 .................. 44 Nm (32.5 Ib.ft) * Secure with Loctite No. 577

SPECIAL TOOLS No1. Installation ND080080 (Cab support)

ND080080

3

ND080220

4

ND101778

5

No2. Installation ND080220 (For securing hydraulic hood lifting cylinders)

No3. Handling ND101778 (Hooks for installing the hood)

SV212 - SV216

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SECTION 10 - ENGINE - CHAPTER 1

5

No4. Installation ND080183 (Engine support)

ND080183

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6

SV212 - SV216

6

SECTION 10 - ENGINE - CHAPTER 1 REMOVAL

1.

Lift the hood and support it with the No.1 tools, in lifted position.

2.

Disconnect the electrical wiring.

3.

Remove the pins from ends of the hydraulic cylinders and secure with the No.2 tools.

No.2

No.1

No.1

7

CD01C013

4.

Install the No.3 tool support.

No.3

5.

CD01C014

8

CD01C015

9

Remove the hinges.

SV212 - SV216

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SECTION 10 - ENGINE - CHAPTER 1 6.

7

Attach the No.3 tool hooks.

No.3

10

CD01C016

7.

Set the hood to one side, using the No.3 tools.

No.3

8.

Loosen the filler cap and drain the coolant.

9.

Remove the hoses (27, 30) and rubber elbow (35).

Remove the hoses to the hydraulic cooler and plug the orifices.

CD01C017

11

CD01C018

12

35

30

CD01C019

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27

13 SV212 - SV216

8

SECTION 10 - ENGINE - CHAPTER 1

10. Remove the supports (8).

8

CD01C020

14

CD01C021

15

CD01C022

16

CD01C023

17

11. Loosen the screws (53).

12. Use hooks to lift the radiator and set it on one side.

13. Remove the hydraulic reservoir cover.

SV212 - SV216

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SECTION 10 - ENGINE - CHAPTER 1

9

14. Remove the suction hose (51) running from the hydraulic reservoir to the steering pump.

51

CD01C024

18

CD01C025

19

15. Disconnect the hoses to the steering pump, and plug the orifices.

16. Loosen the turbo clamp screw (23).

23

23

20

CD01C026

17. Remove the four screws (28) on the air filter holder.

18. Disconnect the wiring to the filter detector and set the filter to one side.

28

CD01C027

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21 SV212 - SV216

10

SECTION 10 - ENGINE - CHAPTER 1

19. Loosen the clamp on the exhaust pipe (3).

20. Remove the exhaust pipe support screws (31). Set the muffler on one side.

31

21. Plug the orifices.

3

CD01C028

22

CD01C029

23

22. Disconnect all wires - ground strap, starter wires, alternator wires, water temperature and oil pressure detectors, tachymeter, and injection pump solenoid.

23. Disconnect the throttle cable (29).

29

CD01C030

24

CD01C031

25

24. Disconnect the fuel intake and overflow.

SV212 - SV216

7-29530 - 04-2001

SECTION 10 - ENGINE - CHAPTER 1

11

25. Lift the cab using the hydraulic lift, then use a suitable lifting device to relieve the piston of the lifting hydraulic cylinder using tool No.1.

26

CD01C032

26. Remove the screws (53). Set the rubber partition to one side.

53

27

CD01C033

27. Remove the screws (47, 56) from the flange (12).

56

47

12

CD01C034

28

CD01C035

29

28. Suspend the pump, using a suitable lifting device.

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SV212 - SV216

12

SECTION 10 - ENGINE - CHAPTER 1

29. Slide out the drive coupling (86) support.

86

30

CD01C036

30. Remove the nuts from the front engine silencer blocks (64).

64

CD01C037

31

31. Remove the nuts from the rear silencer blocks (64).

64

CD01C038

32

CD01C039

33

32. Suspend the engine from a suitable lifting device with hooks.

33. Remove and set to one side on support No.4.

SV212 - SV216

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SECTION 10 - ENGINE - CHAPTER 1

13

INSTALLATION Procede in the reverse order from that of removal, respecting the hardware torques specified in the “Torque specifications”.

ACCELERATOR CABLE ASSEMBLY REMOVAL AND INSTALLATION Disconnect the accelerator cable.

34

CD01D155

Dismantle and raise the instrument panel, loosen the nuts (22) and remove the accelerator (8), bracket (3) and cover (13). When the cable is to be replaced, release the clamp on the fuel injection pump lever.

Grease the new cable. Adjust the clearance between the cover (13) and the switch when installing the cable assembly. Set the position of the cover (13) for the vibrator switch to engage at engine speeds of 2300 + 50 rpm.

1 mm

22

13

8 3 CD01D156

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35

SV212 - SV216

14

SECTION 10 - ENGINE - CHAPTER 1

NOTES

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SECTION 21 - TRANSMISSION - CHAPTER 1

1

SECTION 21 - TRANSMISSION Chapter 1 - Hydraulic motor CONTENTS Section

62731

Description

Page

Description ..................................................................................................... 2 Specifications ................................................................................................. 3 Torque specifications ..................................................................................... 3 Disassembly ................................................................................................... 3 Reconditioning and replacement of shaft assembly .................................. 5 Assembly ........................................................................................................ 8

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2

SECTION 21 - TRANSMISSION - CHAPTER 1 DESCRIPTION

27

27

24

26

13

22

14 23

24

20

25 18 16

22 23

23 17

2

4

5 10

22

1

29

3

35

8 34

11 15 10

33

12

9

32 28

7 6

30

31

36 37 1

CS01D550

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

20.

21.

23.

Screw Screw End cover Gasket Pin Valve segment Distribution plate Pin Cylinder block Support pin Synchronizing shaft Rollers Screw Bearing housing Main housing O-ring O-ring Spacer ring Shaft assembly Screw Screw

SV212 - SV216

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

Feedback fork Setting lug Servo piston Glide ring Sensor ring Shaft Spring seat Spring Pin Bearing Bearing Retaining nut Piston Piston ring

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SECTION 21 - TRANSMISSION - CHAPTER 1

3

SPECIFICATIONS 51C060 (SV212) 51C080 (SV216) Maximum displacement .......................................................... 60 cm3 (3.66 in3)...................... 80.7 cm3 (4.92 in3) Minimum displacement ........................................................... 12 cm3 (0.73 in3)...................... 16.1 cm3 (0.98 in3) Continuous speed at max. disp......................................................... 3600 tr/mn................................... 3100 tr/mn Continuous speed at mini disp.......................................................... 5600 tr/mn................................... 5000 tr/mn Max. speed at max. disp. .................................................................. 4400 tr/mn................................... 4000 tr/mn Max. speed at mini disp. ................................................................... 7000 tr/mn................................... 6250 tr/mn Theoretical torque at max. disp.......................... 0.95 Nm/bar (583 Ibf/1000psi)...... 1.28Nm/bar (784Ibf/1000psi) Theoretical torque at mini disp............................0.19 Nm/bar (117 Ibf/1000psi)..... 0.26 Nm/bar (156Ibf/1000psi) Max. continuous flow ....................................................... 216 L/mn (57 gal/mn).................. 250 L/mn (66 gal/mn) Max. continuous power .............................................................336 kW (450hp)..........................403 kW (540 hp) Mass moment of inertia.......................................... 0.0046 kg.m2 (0.1092 Ib.ft2).........0.0071 kg.m2(0.1685 Ib.ft2) Weight............................................................................................ 28 kg (62 Ib)................................ 32 kg (71 Ib)

TORQUE SPECIFICATIONS 51C060 (SV212) 51C080 (SV216) End cap to motor....................................................................... 66 Nm (49 Ib.ft)........................... 78 Nm (58 Ib.ft) Bearing housing to main housing................................................................................. 32 Nm (24 Ib.ft) End cover plug (21)................................................................... 54 Nm (40 Ib.ft)........................... 95 Nm (70 Ib.ft) Cone point set screw (23) ............................................................................................. 5 Nm (44 Ib.in) Lock screw (22)....................................................................... 8.5 Nm (75 Ib.in)........................... 19 Nm (14 Ib.ft)

DISASSEMBLY 1.

Remove the screws (1), (2) retaining the end cover (3) assembly to the motor housing.

2.

Remove the end cover (3) assembly gasket (4) and alignment pins (5).

3.

Remove the internal motor parts as shown.

4.

Remove the valve segment (6).

7 8

10

5.

12

NOTE: Orientation of the pins (8).

11

6.

Remove the cylinder block (9).

10

7.

Remove the support pin (10).

8.

Remove the synchronizing shaft (11) and rollers (12).

9.

Remove the shaft seal.

2 3 5

CS01D553

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1

9

NOTE: The orientation of the segment in relation to the end cover (3) and housing.

Remove the distribution plate (7) and the pins (8).

6

4

2

SV212 - SV216

4

SECTION 21 - TRANSMISSION - CHAPTER 1

10. Remove the screws (13) attaching the bearing housing (14) to the main housing (15). Separate the bearing housing from the main housing (15).

19

13

11. Remove the O-ring (16), (17).

14

12. Remove the spacer ring (18). Note the orientation.

17

13. Press the shaft assembly (20) out of the bearing housing, taking care to not damage the shaft, piston sockets, and speed sensor ring (if installed).

16 20

14. The inner retaining ring (19) for the shaft seal carrier may be removed from the bearing housing at this time.

18 15

3

CS01D554

15. Remove the end cover plug (21).

22

16. Remove the lock screws (22) and cone point set screws (23).

23

Model 060

24

For 060 frame size 17. Remove the feedback fork (24) through the hole in the end cover (3). Remove the setting lug (25) from inside the end cover (3).

21 27

For 080 frame size 18. Remove the feedback fork (24)/setting lug from inside the end cover (3).

26 25

23 22

19. Remove the servo piston (26) from the end cover (3).

20. Inspect the glide ring (27) for damage or wear.

21. Remove the glide ring (27) from the servo piston (26) if replacement is required.

22. Inspect the servo piston (26) bore in the end cover (3) for damage or wear.

24 27 26 Model 080 CS01D555

SV212 - SV216

23

3 22 4

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SECTION 21 - TRANSMISSION - CHAPTER 1

5

RECONDITIONING AND REPLACEMENT SHAFT ASSEMBLY 1.

The optional magnetic speed sensor ring (28) is pressed on to a machined surface of the output shaft flange.

!

WARNING

!

Do not damage the magnetic speed sensor ring (28).

2.

Check the seal area of the shaft (29) and the output splines for damage or wear.

3.

Inspect the synchronizing shaft insert (10) and the spring seat (30) for wear. The internal spring (31) must not be damaged. These parts are retained by three hardened steel pins (32) pressed into blind holes in the synchronizing shaft insert (10), and are not serviced separately.

4.

36 10

28

Inspect shaft bearings (33) and (34) for wear and roughness. Check that the bearing retaining nut (35) is firmly staked to the output shaft, and that no noticeable looseness is detected in the bearings.

32 30 31

NOTE: If the bearing adjustment for used bearings is incorrect or if used bearings must be replaced, a complete shaft assembly including pistons and new bearings must be installed.

5.

33

Check the piston assemblies (36) for damage or wear. It is normal for the piston sockets to be retained in the output shaft by an interference press fit.

NOTE: If a piston (or pistons) must be replaced, a complete shaft assembly including piston and new bearings must be installed.

6.

29

34

CS01D556

35

5

The replacement output shaft assembly includes pistons and bearings.

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SECTION 21 - TRANSMISSION - CHAPTER 1

PISTON RINGS 1.

A small pair of retaining ring pliers may facilitate the removal of the piston rings (37) from the pistons.

2.

Install new piston rings onto the pistons.

37

NOTE: When installing new spherical piston rings, make sure the spherical surface conforms to the shape of the piston.

3.

A radial identification mark is provided on the “outer” side of the piston rings.

4.

The ends of each piston ring must not overlap each other.

37

6

CS01D557

DISTRIBUTION PLATE, VALVE SEGMENT AND CYLINDER BLOCK 1.

Inspect the running (bronze) surface of the distribution plate (7) for damage and excessive wear. The sealing surfaces must be free of scratches and nicks. The locating pin holes must not be worn.

Replace the distribution plate if damaged or worn.

7

7

CS01D558

2.

Inspect the valve segment (6) for damage or wear on the sealing surfaces. Inspect the spindle for wear.

6

CS01D559

SV212 - SV216

8

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SECTION 21 - TRANSMISSION - CHAPTER 1 3.

4.

5.

7

Check that the spindle is located correctly in the valve segment by measuring distance “A”. If this dimension is not within the range shown in the accompanying chart, it indicates that the spindle has moved in the valve segment and the assembly must be replaced.

Frame size

Distance “A” mm (in)

060

27.5 to 27.7 (1.08 to 1.09)

080

32.6 to 32.8 (1.28 to 1.29)

Inspect the cylinder block assembly for wear or damage. The piston bores must be smooth. The bearing plate surface must be free from scratches or nicks, and the holes for the distribution plate locating pins must not be worn.

“A”

CS01D560

9

CS01D561

10

Inspect the cylinder block bearing. If it requires replacement, remove the bearing using a suitable extractor.

NOTE: Do not damage the distribution plate surface of the cylinder block.

6.

Press the new bearing into the cylinder block using a suitable press pin. Press the bearing into the cylinder block until it is located the proper distance below the distribution plate surface, as indicated by distance “A” in the following table: Frame size 060 080

Distance “A” mm (in)

Distance “B” mm (in)

3.0 to 3.5 (0.12 to 0.14)

25.97 (1.022)

11.5 to 12 (0.45 to 0.47)

“B”

27.97 (1.101) CS01D562

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“A”

11

SV212 - SV216

8

SECTION 21 - TRANSMISSION - CHAPTER 1 ASSEMBLY

1.

Install a new glide ring (27) on the servo piston (26).

2.

Lubricate with hydraulic oil, the glide ring (27) and install the servo piston (26) into the end cover (3).

The end of the servo piston (26) with the glide ring (27) is located opposite the multi-function block/ control mounting surface of the end cover (3).

24

Model 060

26

22

23

21

23 27 25

22

For 060 frame size: 3.

Install the setting lug (25) into the servo piston (26) from inside of end cover (3).

4.

Install the cone point set screw (23) so that its point enters the groove in the setting lug and torque (Torque: 5 Nm).

5.

Install and torque the lock screw (22) (Torque: 8.5 Nm).

6.

Install the feedback fork (24) into the servo piston (26) through the hole in the end cover (3). The contact pads on the fork must face forward the multifunction block/control end cover (3). Install the cone point so that it enters the groove in the feed back fork (24). Do not tighten the set screw at this time.

7.

Install and torque the end cover plug (21) (Torque: 54 Nm (40 Ib.ft)).

22 26

23

Model 080

3 12

CS01D555

For 080 frame size: 8.

Install the feedback fork/setting lug (25) into the servo piston (26) through the hole in the end cover (3). The offset of the fork must be located away from the multi-function block/control end of the end cap (3).

9.

Install the cone point set screw (23) so that its point enters the groove in the feedback fork/setting lug.

Do not tighten the set screw at this time.

10. Install and torque the end cover plug (21). (Torque: 95 Nm (70 Ib.in)).

For all frame sizes 11. The feedback fork (060) or feedback fork/setting lug (080) must be positioned perpendicularly to the setting piston for proper control spring operation.

22

23 CS01D563

SV212 - SV216

060 frame size 13 7-29530 - 04-2001

SECTION 21 - TRANSMISSION - CHAPTER 1

9

12. A 26.9 mm diameter rod with the end machined perpendicularly to its axis may be inserted through the valve sleeve bore in the end cover (3) to align the fork while tightening the cone point set screw (23). Torque the cone point set screw (23) to 5 Nm (3.68 Ib.ft).

13. After torquing the cone point set screw, install and torque the lock screw (22) (Torque: 8.5 Nm (75 Ib.in) for 060 frame; 19 Nm (14 Ib.ft) for 080 frame).

22 23 080 frame size 14

CS01D564

14. The inner retaining ring (19) for the shaft seal carrier may be installed in the bearing housing at this time.

15. Press shaft assembly (20) into bearing housing (14).

15 17

NOTE: Do not damage the piston sockets or shaft seal surface.

16

16. Install spacer ring (18). The end of the spacer with the larger inside diameter is installed next to the inner shaft bearing cup.

18

17. Install O-rings (16) and (17) and install main housing (15).

20

18. Install and torque screws (13). Torque: 32 Nm (24 Ib.ft).

14 13 19 CS01D565

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15

SV212 - SV216

10

SECTION 21 - TRANSMISSION - CHAPTER 1

19. Install the first synchronizing shaft support pin (10) into the recess in the cylinder block (9).

20. Install the synchronizing shaft roller (12) on the journals of the synchronizing shaft (11) and retain with grease.

9 10

21. The recess on each roller (12) must be positioned to face the center line of the synchronizing shaft (11).

12

22. Position each roller (12) with its outside edge flush with the end of the synchronizing shaft (11) journal.

11

23. Install the second synchronizing shaft support pin (10) into the motor shaft assembly and retain with grease.

10

24. Install the synchronizing shaft (11) and rollers (12) into the motor shaft. The cylinder block (9) end of the shaft is larger than the motor shaft end on all frame sizes.

25. The rollers (12) must enter the races in the motor shaft insert, and the recess in the end of the synchronizing shaft (11) must engage the support pin.

26. Tip and rotate the synchronizing shaft (11) in all directions to check for binding. The synchronizing shaft rollers (12) must move freely in the races in the motor shaft insert.

16

CS01D566

27. Position the motor shaft in the housing as shown in the accompanying illustration. Tip the three pistons closest to the minimum angle stop out toward the housing.

Position the motor shaft as shown prior to installing the cylinder block

28. With the synchronizing shaft (11) supported in the motor shaft, install the cylinder block (9) and its synchronizing shaft (11) support pin (10) onto the pistons and synchronizing shaft (11). The cylinder block (9) must be positioned so the synchronizing shaft rollers (12) will enter their races in the block, while each piston enters its corresponding bore in the block.

Cylinder block not installed 17

CS01D568

29. A brass rod may be inserted through the cylinder block (9) kidney-shaped apertures to guide the piston into position. Start with the six pistons closest to “Lowest” part of the end cap mounting surface.

9 10

30. After the six pistons enter their bores, tilt the cylinder block (9) so the synchronizing shaft rollers (12) enter their races in the cylinder block (9) and the support pin enters its recess in the synchronizing shaft (11).

12 11

31. Lift the cylinder block (9) slightly and guide the remaining three pistons into their bores.

CS01D569

SV212 - SV216

18

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SECTION 21 - TRANSMISSION - CHAPTER 1

11

32. Once the last piston is in position, check the position of the rollers closest to the minimum angle stop. Maintain an inward force on the cylinder block (9) and carefully push it toward the “highest” part of the end cover mounting surface and check that all of the synchronizing shaft rollers (12) are in position.

33. If the cylinder block (9) is properly installed, there will be very little rotational free play between the block and the motor shaft.

34. Install the bearing plate locating pins (8) into the cylinder block (9). The longer end of each shouldered pin is installed into the block.

1 3

35. Install the distribution plate (7) on the cylinder block (9), with its steel side facing toward the block.

Lubricate the bronze side of the plate with hydraulic oil.

5

36. Install the end cover alignment pins (5) and gasket (4). Carefully locate the cylinder block (9) in the approximate center of the housing opening.

NOTE: Do not allow the pistons or synchronizing shaft rollers to fall out of position.

8 9

37. Install the valve segment (6) into the end cover (3) so the setting lug in the servo piston engages and retain with heavy grease. The hole in the end of the segment should be installed opposite the minimum displacement adjustment screw. Locate the valve segment and servo piston in the approximate center of their travel.

38. Install the end cover (3) assembly and valve segment (6). The segment spindle must engage the bearing in the cylinder block (9).

2

7

6 4

CS01D572

19

NOTE: Do not allow the pistons or synchronizing shaft rollers (12) to fall out of position.

39. Install the screws (1) and (2) fastening the end cover assembly to the motor. The screws must be installed in their proper locations to ensure adequate thread engagement. The internal spring (in the motor shaft) should hold the end cover (3) a short distance away from the housing.

40. Tighten the screws by hand in a “double X” pattern while rotating the motor shaft to ensure proper positioning of the synchronizing shaft rollers.

NOTE: Do not force the end cover (3) into position on the housing.

41. Place the end cover (3) is in position on the housing.

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12

SECTION 21 - TRANSMISSION - CHAPTER 1

42. When the end cover (3) is in position, torque the screws in a “double X”.

Frame size

Torque Nm (Ib.ft)

060

66 (49)

080

78 (58)

43. Rotate the motor shaft and check for “play” between the shaft and cylinder block (9). Any play indicates thut the synchronizing shaft rollers (12) are not installed correctly. Recheck the end cover (3) screw torque.

44. Reinstall the minimum angle servo cover, control spring (if used). 4 way valve spool and sleeve (if used) and control and multi-function block (if used).

SV212 - SV216

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SECTION 21 - TRANSMISSION - CHAPTER 2

1

SECTION 21 - TRANSMISSION Chapter 2 - Travel reduction gear CONTENTS Section

62737

Description

Page

Specification ................................................................................................... 1 Torque specifications .................................................................................... 2 Special tools ................................................................................................... 2 Exploded view of travel brake ...................................................................... 6 Disassembly and assembly .......................................................................... 7 Brake test ........................................................................................................ 9 Exploded view .............................................................................................. 10 Disassembly and assembly ........................................................................ 11

SPECIFICATION SV212 - SV216 SV212 SV216 Rear Front Front Type Trasmital) ...............................7072B24C33H1HQ ...... 709C3B31C75H1GQU26........................710C3BH2 Total ratio ................................................................1:33 ....................................... 1-75.................................T.B.A Nominal torque............................................................... ..... 3000 daNm (221268 lb.ft).....T.B.A. daNm (T.B.A. lb.ft) Max. output torque .................... 695 daNm (51260 lb.ft) ..... 3500 daNm (258146 lb.ft).....T.B.A. daNm (T.B.A. lb.ft) Oil quantity .............................. 2 l ±10% (0.528 gal US) ..... 3.4 l ±10% (0.898 gal US)..... T.B.A. l (T.B.A. gal US) Oil type....................................................... SAE 80W90 ...........................SAE 80W90.................................T.B.A Technical braking data Braking torque .......................... 40 daNm (2950 lb.ft) ..... 40 daNm ±5% (2950 lb.ft).....T.B.A. daNm (T.B.A. lb.ft) Min. opening pressure ......................14 bar (203 psi) ..................... 12 bar (174 psi).........T.B.A bar (T.B.A psi) Max. operating pressure...................50 bar (725 psi) ..................... 50 bar (725 psi).........T.B.A bar (T.B.A psi)

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2

SECTION 21 - TRANSMISSION - CHAPTER 2 TORQUE SPECIFICATIONS

Cover (20)/flanged hub (18) retaining screws............................................................................. 50 Nm (36.9 lb.ft) Reduction gear cover (2) retaining screws ................................................................................. 75 Nm (55.3 lb.ft) Third stage satellite carrier (13) retaining screws ...................................................................... 585 Nm (431 lb.ft) Hydraulic motor retaining screws............................................................................................ 215 Nm (158.6 lb.ft)

SPECIAL TOOLS TOOLS REQUIRED Loctite 243 Torque wrench (40 to 200 Nm) (29.5 to 147.5 lb.ft) - (120 to 600 Nm) (88.5 to 442.5 lb.ft) TOOLS TO BE MADE No1. Brake spring compression tools 350 mm =

=

=

20 mm

=

40 mm

=

M14x1.5

=

Ø 22

285 mm 3X45°

3

Ø15

30 mm

20 mm Ø 75 Ø 90

CM95K023

SV212 - SV216

M14x1.5 L = 130 mm

1

7-29530 - 04-2001

SECTION 21 - TRANSMISSION - CHAPTER 2

3

24

12

No2. Tool for assembling bearing surface seals

0 3 - 0.1

Ø 318 0 Ø 347.5 + 0.1 0 Ø 351.5 - 0.1

Ø 358

2

PDH0016

No3. Tools for assembling reduction gear housing complete with bearings

B

A

Ø 260 Ø 238

16

-0.1 Ø 220 -0.2

200

b

Ø 100

-0.1 Ø 120 -0.2

PDH0018

3

PDH0017

4

NOTE: Tools A and B are necessary when replacing the reduction gear bearings.

7-29530 - 04-2001

SV212 - SV216

4

SECTION 21 - TRANSMISSION - CHAPTER 2

No4. Tool for extracting third stage satellite shaft

70

Ø 10

95

10

25

M12

A-A 295

Ø 70

Ø 70

Ø 50 Ø 30.5

Ø12 Ø 70

M10 x 55

M10

Ø 14

M12

4

A

20

Ø10.5 A

M8

35

15

15

M10

M8 x 40

PDH0014

SV212 - SV216

5

7-29530 - 04-2001

SECTION 21 - TRANSMISSION - CHAPTER 2

5

No5. Tool for removing and installing third stage satellites, complete with bearings

10

52.5

8

Ø 55

Ø 22 Ø 40

CS01E514

7-29530 - 04-2001

6

SV212 - SV216

6

SECTION 21 - TRANSMISSION - CHAPTER 2 EXPLODED VIEW OF TRAVEL BRAKE

22 23 24 25

27 29 30 31

26 28

7

CS01E512

22.

23.

24.

25.

26.

Coupling sleeve Friction disc Steel disc Spacer O-ring

SV212 - SV216

27.

28.

29.

30.

31.

O-ring Brake piston Spring Spring retainer Snap ring

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SECTION 21 - TRANSMISSION - CHAPTER 2

7

Before performing any service work on the machine, the following steps must be carried out in the order shown: - Park the machine on hard flat ground.

- Stop the engine.

DISASSEMBLY AND ASSEMBLY 1.

Place a receptacle with a minimum capacity of 5 litres under the reduction gear cover. Remove the drain plug and after draining all the oil, install and tighten the plug.

NOTE: When assembling, fill the reduction gear housing with the recommended oil (see "Specifications").

See the Operator’s Manual for the procedure.

2.

Remove the travel motor.

3.

Remove the brake line union and discard the seal.

4.

Install the brake spring compression tool (see "Tools to be made"). Tighten up to the snap ring (31). Remove the snap ring (31) from its housing using snap ring pliers.

31 8

CS01E506

5.

Remove the spring retainer (30).

30

CD01E021

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9

SV212 - SV216

8 6.

SECTION 21 - TRANSMISSION - CHAPTER 2 Remove the springs (29) from their seats in the brake piston (28).

NOTE: When assembling, place the springs (29) as shown in the photograph.

29

29 10

CD01E022

7.

Extract the brake piston (28).

NOTE: When assembling the brake piston (28) and the spacer (25), proceed as follows: assemble the spacer (25) with the new seals (27) on the brake piston (28), making sure it is pointing the right way.

28

25

27

11

PDH0011

8.

Extract the spacer (25) and discard the O-ring (26).

NOTE: When assembling the spacer, see note in Step 7.

25

CD01E023

9.

12

Remove the travel motor/reduction gear coupling sleeve (22).

22

CD01E024

SV212 - SV216

13 7-29530 - 04-2001

SECTION 21 - TRANSMISSION - CHAPTER 2

9

10. Remove the brake disc pack (23, 24).

24 23

14

CD01E025

NOTE: When assembling, the friction discs (23) and the steel discs (24) must be installed alternately as shown in the drawing. Before mounting the hydraulic motor, use a depth gauge to measure the axial distance from the input side of the flanged hub (18) to the coupling sleeve (22).

23

Axial dimension (d) = 93.2 - 94 mm (3.66 - 3.7 in).

NOTE: When assembling, proceed in the reverse order from that of disassembly. Replace all seals with new seals which have been lubricated prior to installation.

d

CS01E507

24 15

BRAKE TEST If the brake has been disassembled then a brake function test is needed before putting it into operation.

Proceed as follows: - Connect the pressure pilot line with the pressure gauge to the brake release port with the flow valve closed.

- Open the flow valve and release the brake with the pilot pressure of 50 bar.

- Close the flow valve and keep the brake released for 3 minutes.

NOTE: If the pressure drops, the gearbox reassembly is not correct, or the seals are damaged: in this case the seals have to be replaced.

CS01E508

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16

SV212 - SV216

10

SECTION 21 - TRANSMISSION - CHAPTER 2 EXPLODED VIEW

11.

1

12.

13.

5 2

14.

10 13

9

8

12

14

4

15 16 7

17 19

18

6

3

11

20 21

17

CS01E513

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Screw Cover Washer Drain plug O-ring Friction disc Central shaft First stage satellite carrier Sun gear Second stage satellite carrier Sun gear

SV212 - SV216

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Screw Third stage satellite carrier Stud Housing with bearing assembly Half seal Brake stop Hub O-ring Cover Screw

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SECTION 21 - TRANSMISSION - CHAPTER 2

11

DISASSEMBLY AND ASSEMBLY 1.

Unscrew and remove the 3 flat headed screws (21), which fix the cover (20) to the flanged hub (18). Remove the cover (20) and the O-ring (19) from its seat in the flanged hub (18).

NOTE: When assembling, tighten the screws to a torque of 50 Nm (36.9 lb.ft).

!

WARNING

21

20

!

In case of oil leakage, it may be necessary to check and eventually replace the half-seal (16), which means both the steel rings and the O-rings.

2.

Use a screwdriver to remove the 1st half-seal (16) from the cover (20).

3.

Use a screwdriver to remove the 2nd half-seal (16) from the flanged hub (18).

4.

Place the reduction gear in the position shown.

Mark the position of the cover (2) in relation to the reduction gear housing. Remove the cover (2) retaining screws (1) and remove the cover (2).

CD01E026

18

CD01E027

19

NOTE: When assembling, tighten the screws to a torque of 75 Nm. Check the position of the coupling sleeve.

2 C08120

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1 20

SV212 - SV216

12 5.

SECTION 21 - TRANSMISSION - CHAPTER 2 Remove and discard the cover (2) and O-ring (5).

5

2 6.

Remove the central shaft (7).

7.

Remove the first stage satellite carrier (8).

8.

Remove the sun gear (9).

SV212 - SV216

C08114

21

C08112

22

C08110

23

CD01E028

24 7-29530 - 04-2001

SECTION 21 - TRANSMISSION - CHAPTER 2 9.

13

Remove the second stage satellite carries (10).

CD01E029

25

C08104

26

10. Remove the sun gear (11).

11. Disassemble the four third stage satellite carrier retaining screws (12).

NOTE: When assembling, tighten the screws to a torque of 585 Nm (431 lb.ft) and apply Loctite 243.

12

C08410

27

PDH0355

28

12. Extract the third stage satellite carrier (13) from the reduction gear housing, using an extractor.

NOTE: When assembling, carefully install the third stage satellite carrier using a press.

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SV212 - SV216

14

SECTION 21 - TRANSMISSION - CHAPTER 2

13. Extract the four third stage satellite shaft and studs (14) using a slide hammer extractor. See "Tools to be made".

NOTE: When assembling, install the four satellite shaft and the four studs (14) using a press.

29

PDH0359

14. Remove the brake stop (17).

17 C08016

30

PDH0379

31

PDH0361

32

15. Extract the reduction gear body from the reduction gear housing (15) using press. Take precautions to prevent the ball bearings escaping from their housing. Remove the upper bearing inner race.

16. Extract the reduction gear body lower bearing inner race, using an extractor.

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SECTION 21 - TRANSMISSION - CHAPTER 2

NOTE: For assembly: - Fit the lower bearings (d), into the gearbox housing (15) holding the inner race (c) with spacers (b) and (tool 3B).

- Remove the spacer (b).

- Install the upper bearings (e).

- Install the inner race (f).

- Place the flanged hub (18) inside the gearbox housing (15). Using a press and a metal plate, push the flanged hub (18) inside.

15

d

c 3B b 33

CS01E509

f

e

3B b

34

CS01E510

- Screw the safety bushing (Tool No.5) in one of the four holes in the flanged hub (18) using the socket head screw (12) and turn the gearbox housing flange hub group (15, 18) upside down.

- At the end of the above Step, remove the safety bushing.

NOTE: When assembling the reduction gear proceed in the reverse order from that of disassembly. Replace all seals by new seals which have been lubricated prior to use.

Tool No.5

12 CS01E511

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35

SV212 - SV216

16

SECTION 21 - TRANSMISSION - CHAPTER 2

NOTES

SV212 - SV216

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SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

1

SECTION 29 - HYDROSTATIC DRIVE Chapter 1 - Pumps - Cento drive coupling CONTENTS Section

62721

Description

Page

Specifications ................................................................................................. 1 Torque specifications ..................................................................................... 1 Description ..................................................................................................... 2 Special tools ................................................................................................... 3 Removal of pumps, Cento drive coupling .................................................... 3 Cento drive coupling ...................................................................................... 7

SPECIFICATIONS

TIGHTENING TORQUE Fastening hardware Screws Nuts Thread Torque Flange (12), engine............................................................... 47.......................M10 ................. 44Nm (32.45 Ib.ft) Flange (12), engine............................................................... 56.......................M16 ............ T.B.A Nm(T.B.A Ib.ft) Flange (12), hydraulic pump ................................................. 55............................... ............ T.B.A Nm(T.B.A Ib.ft) Hydraulic pump ......................................................................11............................... ............ T.B.A Nm(T.B.A Ib.ft) “A” segments......................................................................... T1............................... ... 155/165 Nm (114/122 Ib.ft) Coupling segments (86)/hydraulic pump .............................. T2............................... ................ 120 Nm (88.5 Ib.ft)

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2

SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 DESCRIPTION

86 56 47 55

11

12

CS01D545

11.

12.

47.

55.

56.

86.

1

Screw Flange Screw M10x35 Screw Screw M16x20 Hydraulic drive coupling

SV212 - SV216

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SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

3

SPECIAL TOOLS No1. Handling ND080078 (Cab support)

ND080078

2

ND080155

3

No2. Assembly ND080155 (For Cento drive coupling)

REMOVAL OF PUMPS, CENTO CLUTCH 1.

Lift the cab using the hydraulic lift, then use a suitable lifting device and tool No.1 to relieve the piston of the hydraulic lifting cylinder.

2.

Remove the screws (53). Set the rubber partition to one slide.

4

CD01C032

53

CD01C033

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5

SV212 - SV216

4

SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

3.

Remove the hose clamps.

4.

Disconnect all hydraulic hoses from the hydraulic pumps.

5.

Plug the hydraulic pump orifices and the hose ends.

6.

Disconnect the wires to the hydraulic pumps.

7.

Suspend the vibration hydraulic pump using a suitable lifting device and remove the screws (11) holding both hydraulic pumps.

8.

Slide out the pump and set it on one side.

SV212 - SV216

CD01C097

6

CD01C137

7

CD01C098

8

CD01C099

9 7-29530 - 04-2001

SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 9.

5

Suspend the hydraulic travel pump, using a suitable lifting device.

10

CD01C106

10. Remove the screws (47), (56) from the flange (12).

47

56

12

11

CD01C034

11. Separate the drive coupling (86).

12. Set the hydraulic pump with the flange to one side.

86

12

CD01C036

13. Remove the T1 screws from the “A” segments.

A

T1

CD01C109

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13 SV212 - SV216

6

SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

14. Remove the screws (T2), and remove the coupling segment (86) from the hydraulic drive shaft.

T2

86 14

CD01C110

15. Remove the screws (55) and the flange (12).

55

12 CD01C111

SV212 - SV216

15

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SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

7

CENTO DRIVE COUPLING ASSEMBLING THE CENTO DRIVE COUPLING 1.

Install the “A” segments on the flywheel. Center the segments using tool No.2 Lubricate the screws (T1) under the head with grease and tighten them to the torque specified in the table. Check their position after tightening.

No.2

T1 A A

A

16

CD01C112

2.

Fix flange (12) on the flange of the hydraulic travel drive shaft and coupling (86) with the “B” segments. Tighten the (T2) bolts of coupling (86) to the torque indicated in the table.

12

T2 86

3.

B

CD01C110

17

CD01C113

18

When installing the coupling (86), determine the axial clearance between the flywheel face and the elastic element of the CENTA drive coupling.

Measure the distance “a” from the face of the flywheel housing.

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SV212 - SV216

8 4.

SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 Measure distance “b” from the elastic element face to the seating area of flange (12).

12 B T1

19

CD01C114

5.

Difference in the distances a - b = 1 to 3 mm (0.039 to 0.118 in)

NOTE: Colored (e.g. blue color) material is deposited on the thread of the supplied countersunk hexagonal screws. It includes of film of adhesive and prevents them from coming loose. The time of hardening of such adhesive material after tightening the screws is 4 to 5 hours at an ambient temperature of 20°C (68°F). The machine must not be used this period of time has elapsed. Full hardening is obtained after 24 hours. At higher temperatures the hardening can be faster, e.g.

15 minutes at 70°C (158°F) (heating with a hot air fan).

Temperature stability of the bolts is between -80 and 90°C (-112 and 194°F) and they can be used three times maximum. The adhesive material is sometimes eliminated and it is deposited between the head of the screw and the segment. This is not a defect, rather an advantage - both areas will adhere to each other better.

If original supplied screws are not available, both the bored thread and screw must be carefully degreased and a layer of Loctite or Omnifit should be applied to them.

12 47.71

b a

CS01C506

20

Spring washers must not be used The tandem hydraulic pumps including the connection of hydraulic hoses and electrical wiring should be installed using a suitable lifting device, following the procedure in reverse order.

Hardware torque T1 bolt: 155 to 165 Nm (114 to 122 Ib.ft) T2 bolt: 120 Nm (88.5 Ib.ft)

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

1

SECTION 35 - HYDRAULIC SYSTEM Chapter 1 - Hydraulic cylinders CONTENTS Section

82060

Description

Page

Torque specifications ..................................................................................... 1 Description ..................................................................................................... 2 Special tools ................................................................................................... 3 Hood hydraulic cylinders .............................................................................. 5 Cab hydraulic cylinder .................................................................................. 7 Hydraulic cylinders ........................................................................................ 7

TORQUE SPECIFICATIONS Gland (10) M45x1.5 ....................................................................................................................... 80 Nm (59 Ib.ft) Piston rod (4), nut (8) M14x1 ......................................................................................................... 50 Nm (37 Ib.ft)

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2

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 DESCRIPTION

11

3

11 17

4 4

1

CS01D585

1.

3.

4.

11.

17.

1

Bracket Hydraulic locking device Pin Hydraulic cylinder Hydraulic locking device

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

3

SPECIAL TOOLS No.1 Installation ND080080 (Cab support)

ND080080

2

ND080220

3

ND101778

4

ND080078

5

No.2 Installation ND080220 (For securing hood lifting hydraulic cylinders)

No.3 Handling ND101778 (Hooks for Installing the hood)

No.4 Handling ND080078 (Cab support)

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SV212 - SV216

4

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

No.5 Assembly ND101784 (Wrench for disassembly of gland 10) Assembly ND101785 (Wrench for disassembly of gland 10)

ND101784 - ND101785

6

ND101783

7

No.6 Assembly ND101783 (For assembly of piston in hydraulic cylinder)

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

5

HOOD HYDRAULIC CYLINDERS REMOVAL 1.

Lift the hood and support it with the No.1 tools in lifted position.

2.

Disconnect electrical wiring.

3.

Remove the pins from ends of hydraulic cylinders and secure with tools No.2.

No.2

No.1

No.1

8

CD01C013

4.

Install the No.3 hood lowering support tool.

No.3

5.

CD01C014

9

CD01C015

10

Remove the hinges.

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SV212 - SV216

6 6.

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 Attach the No.3 tool hooks.

No.3

11

CD01C016

7.

Set the hood to one side using the No.3 tools.

No.3

12

CD01C017

8.

Place a receptacle underneath the cylinder to be removed (11). Disconnect the hoses and plug then.

Remove the shims and press out the pins (4) from the piston ends. Use lifting equipment to remove and remove the hydraulic locking device (17).

11

11

17 4 CD01C153

SV212 - SV216

4 17 13

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

7

CAB HYDRAULIC CYLINDER Lift the cab, support it using tool No.4, place a receptacle under the hydraulic cylinder, press piston rod in the cylinder, remove the hydraulic cylinder with the bracket (1) from the machine, press out the pin (4) and remove the hydraulic locking device (3).

3

4

1

14

CD01C154

HYDRAULIC CYLINDERS REPLACEMENT OF SEALS Place a receptacle under the hydraulic cylinder and plug the orifices. Drill out the safety pin from the face of the front gland (10) or bend back the gland (10) safety lug, depending on the type of the linear hydraulic cylinder. Using wrench No.5 (depending on the type of hydraulic cylinder) to remove the gland (10), slide out the piston rod (4) with the piston (5) and remove the nut (8) and the piston. Slide off the gland (10).

8

5

4

10

15

CS01C509

Soak new seals in oil before replacing them.

1. Seal 2. Packing 3. Wiper ring 4. Carrier ring 5. Ring 6. Ring

1

6

5 CS01C509

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6

2

3

4 16

SV212 - SV216

8

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

ASSEMBLY Sliding surfaces should be lubricated - check that the surface of the piston rod is not damaged. New seals should be straightened out. Wait at least 15 minutes before complete assembly of the hydraulic cylinder after new seals have been installed. For assembling piston rod in the piston in the cylinder use tool No.6. Threads to be tightened to the torque indicated in the table.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

1

SECTION 35 - HYDRAULIC SYSTEM Chapter 2 - Vibration Motor CONTENTS Section

82071

Description

Page

Description ..................................................................................................... 2 Specifications ................................................................................................. 3 Torque specifications ..................................................................................... 3 Disassembly ................................................................................................... 3 Assembly ........................................................................................................ 9 Supply pressure relief valve adjustment ................................................... 13

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2

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 DESCRIPTION

2 5 23

1

4

6 3

7

24

26

14

11

16

13

12 23 10

19 27

15

28

21

9

26 8 25 18

20 17

21

1

CS01D551

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Screw Retainer plate Packing ring Retaining ring Bearing Shaft Housing End cover Gasket Retaining tube Slipper guide Cylinder block Piston Pate

SV212 - SV216

22

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Distribution plate Pin Screw Screw Guide sleeve Spool Spring Plug Plug Piston retainer Plug Plug Plug Relief valve

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

3

SPECIFICATIONS SV212 (Motor 042MF) SV216 (Motor 055MF) Maximum displacement ....................................................... 42 cm3 (2.56 in3) ............................ 55 cm3 (3.35 in3) Minimum displacement ................................................................ T.B.A. - cm3 .................................... T.B.A. - cm3 * Rated speed at max. disp............................................................4200 tr/mn ...................................... 3900 tr/mn Rated speed at min. disp. .......................................................... T.B.A. - tr/mn .................................. T.B.A. - tr/mn * Maximum speed at max. disp......................................................4600 tr/mn ...................................... 4250 tr/mn Maximum speed at min. disp ..................................................... T.B.A. - tr/mn .................................. T.B.A. - tr/mn * Maximum attainable speed at max. disp. ....................................5000 tr/mn ...................................... 4700 tr/mn Theoretical torque at max. disp.................... 0,67 Nm/bar (380 Ib.in/1000psi) .....0,88 Nm/bar (530 Ib.in/1000psi) Maximum flow at max. disp............................................ 193 l/mn (51 gal/mn) ...................... 234 l/mn (62 gal/mn) Maximum continuous power ................................................ 155 kW (208 hp) .............................187 kW (251 hp) Weight (SAE Flange) ..................................................................15 kg (34 Ib) ................................... 20 kg (45 Ib) Weight (cartridge motor) .............................................................17 kg (37 Ib) ................................... 26 kg (57 Ib)

TORQUE SPECIFICATIONS Fastening hardware Motor 042MF Motor 055MF Housing, end cover gasket ..................... Large screws.......T.B.A. Nm (T.B.A. lb.ft) ................... 122 Nm (90 Ib.ft) Small screws.......T.B.A. Nm (T.B.A. lb.ft) ..................... 41 Nm (30 Ib.ft) Retainer plate...................................................................................................... 16 Nm (12 Ib.ft)

DISASSEMBLY 1.

Position the motor with the shaft facing up.

2.

Remove the three or four screws holding the retainer plate and seal carrier to the housing using a 10 mm (0.39 in) hex wrench (042 units) or a 5 mm (0.197 in) (internal hex wrench (055 units).

Remove the retainer plate.

NOTE: Certain early production units use a single retainer plate and seal carrier assembly.

3.

After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (0.197 in). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet.

4.

Remove the O-ring from the seal carrier.

5.

Place the seal carrier and seal under a press and press out the old seal.

6.

Using an 17 mm (0.67 in) wrench, remove the hex plugs and O-rings from both sides of the valve.

7.

Remove the springs, shoulder washers and relief valve shuttle spool. Note the orientation of the washers. Remove the relief valve spool.

7-29530 - 04-2001

CD01D129

2

CD01D130

3

SV212 - SV216

4 8.

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 Inspect the parts for damage or contamination.

NOTE: Early production motors used a small diameter shuttle valve spool. Late production motors use a larger diameter spool.

9.

Remove the shim type adjustable supply pressure relief valve plug with a 22 mm (0.86 in) hex wrench.

Before removing the screw type adjustable relief valve plug, mark the plug, lock nut and housing so as to be able to maintain the original adjustment when assembling.

CD01D133

4

CD01D100

5

CD01D101

6

10. Remove the shaft and bearing assembly from the housing. The bearing outside diameter is a slip fit in the housing bore.

11. Remove the retaining ring and press the shaft out of the bearing.

12. Place the motor on the work surface with the end cover up. Using a 19 mm (0.75 in) and a 13 mm (0.51 in) hex wrench for 055 motors, a 19 mm (0.75 in) and a 17 mm (0.67 in) hex wrench for 075 motors, loosen the screws which fasten the end cover to the housing. Remove the five longer screws.

13. Place the motor on its end cover. Remove the two shorter screws holding the end cover to housing.

14. Lift the housing off the end cover.

NOTE: The dowel pins and gasket should remain with the end cover. The thrust plate should remain in the housing. The piston assemblies should remain with the other internal parts on the end cover, but may stick to the thrust plate.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

5

15. Place the housing on the end cover face with soft material between end of the housing and the work surface, so the thrust plate will not be damaged when it is freed from the housing.

16. Entering through the shaft end of the housing, using a brass rod, carefully apply a force to the I.D. of the thrust plate and disengage it from the housing.

CD01D102

7

CD01D103

8

CD01D105

9

17. Remove the end cover gasket from the end cover.

18. Remove the retaining tube with the slipper guide and piston assemblies from the end cover and cylinder block.

19. Remove the slipper guide and piston assemblies from the retaining tube.

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SV212 - SV216

6

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

20. Remove the slipper guide bearing.

21. Remove the slipper guide bearing shim (if used).

CD01D106

10

CD01D107

11

CD01D108

12

22. Remove the cylinder block from the end cover.

23. Remove the distribution plate and alignment pins from the end cover.

24. Remove the piston assemblies from the slipper guide.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

7

RECONDITIONING AND REPLACEMENT OF PARTS 1.

After disassembly all parts should be thoroughly cleaned in a suitable solvent. Replace the shaft seal and all gaskets.

2.

Inspect all parts for damage, nicks, or abnormal wear patterns. Replace all parts showing signs of unusual or excessive wear or discoloration.

3.

If the end cover journal bearing needs replacement (as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material), remove the bearing with a suitable puller. Do not damage the distribution plate surface of the end cover.

4.

CD01D070

13

CD01D071

14

Lightly lubricate the steel backing of a new journal bearing. Press the journal bearing into the end cover using a suitable drives. The split line in the bearing must be located as shown in the accompanying illustrations, but NOT in line with the drain groove in the end cover bearing bore.

Split line in bearing MUST be located within arcs shown, but NOT in line with drain groove in bearing bore

Drain Groove Early production CS01D531

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15

SV212 - SV216

8

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

Split line in bearing MUST be located within arcs shown, opposite drain groove in bearing bore

Drain Groove Later production 5.

When installed correctly, the bearing will be flush to 0.50 mm (0.02 in) below the distribution plate surface of the end cover.

6.

If a new journal bearing was installed, the bearing must be sized with the appropriate arbor to assure the minimum bore diameter is met. Carefully press the sizing arbor into the bearing to size it.

!

WARNING

CS01D532

16

CD01D072

17

CD01D073

18

!

The arbors are precision finished to size the journal bearings without damaging them. Damaged arbors must be replaced. Do not attempt to use the drive shaft in place of an arbor. Bearing damage and shortened life will result from inadequate clearance.

SV212 - SV216

7-29530 - 04-2001

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 7.

9

Compress the cylinder block spring and remove the spiral retaining ring, retainer, spring and spring seat. Reassemble in the reverse order.

CS01D539

19

ASSEMBLY 1.

Clean and lightly oil parts prior to assembly of the motor. Be sure to torque all threaded parts to the recommended torque specification.

!

WARNING

!

Most parts have critical, high tolerance surfaces.

Caution must be exercised to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings, and ports from damage and foreign material.

2.

Place the end cover on the work surface with the distribution plate surface up. Install the alignment pins in the end cover.

NOTE: The size of the alignment pins has changed on certain frame size motors. Refer to the appropriate Service Parts Manual for more information.

CD01D109

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20

SV212 - SV216

10 3.

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 Install the distribution plate on the end cover with the locating notches positioned over the alignment pins.

NOTE: This is a bi-directional distribution plate, with no directional arrow cut-outs. It can be assembled with either side adjacent to the end cover.

4.

Lubricate the end cover journal bearing and the cylinder block and distribution plate running surfaces. Position the cylinder block assembly on the distribution plate.

5.

Place the retaining tube over the cylinder block with the fluted end adjacent to the end cover.

CD01D108

21

CD01D110

22

CD01D112

23

CD01D113

24

NOTE: If a new housing is to be installed, a new tube must also be used.

6.

Position the straight fingers on the retaining tube over the distribution plate locating tabs and in the clearance holes in the end cover. The long side of the tube must be positioned on the same side as the end cover gauge ports.

SV212 - SV216

7-29530 - 04-2001

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 7.

Place the slipper guide retainer shim on the retaining tube. The tab with the “V” notch must be positioned in the tube cutout which is located 45° counter-clockwise from the longest side of the tube assembly.

8.

Assemble the bronze slipper guide bearing on top of the slipper guide retainer shim, positioning the tab with the “V” notch in the same position as noted above.

NOTE: Certain frame sizes use a one-piece slipper guide retainer shim and bearing. The one-piece shim and bearing is installed with the tab with the “V” notch positioned as noted above, and with its bronze side facing “up” (toward the slipper guide).

9.

11

CD01D114

25

CD01D115

26

CD01D103

27

Assemble the piston assemblies into the slipper guide.

10. Lubricate the pistons and cylinder block bores.

Install the assembled slipper guide and pistons into the cylinder block by inserting the pistons into the cylinder block bores.The pistons and bores are not selectively matched, therefore no specific piston and bore matching is required.

11. Place a new gasket on the end cover. The beaded side of the gasket must be positioned away from the end cover.

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SV212 - SV216

12

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

12. Lubricate the slipper running surfaces, then place the thrust plate on the slipper faces. The side of the thrust plate with the chamfered edge must be positioned away from the slipper faces. The slots in the thrust plate must be positioned over the tabs on the retaining tube.

CD01D116

28

CD01D117

29

CD01D120

30

13. Place the housing over the assembled internal parts, with the deep end of the cavity in the housing mated to the long side of the retaining tube. The housing will engage the alignment pins in the end cap. When the housing is properly installed, the retaining tube will hold the housing away from the end cover (approximately 0.75 mm (0.03 in)).

14. Install and hand tighten the two short end cover screws holding the end cover to the housing. Place the motor on the work surface with the end cover up, and install the remaining end cover screws.

Tighten the end cover screws evenly to the torque indicated in the accompanying table.

Torque Frame size

042 055

Large screws Nm (Ib.ft)

Small screws Nm (Ib.ft)

T.B.A. Nm (T.B.A. lb.ft)

T.B.A. Nm (T.B.A. lb.ft)

122 (90)

41 (30)

15. Position the motor on its end cover. Using caution to prevent damage to the sealing surface, press the roller bearing onto the drive shaft. (For units with a 3-piece bearing, press the inner race onto the shaft, then install the outer race/cage assembly and the special washer). Mount the bearing retaining ring on the shaft.

16. Install the shaft and bearing assembly through front of housing, aligning the shaft spline with the cylinder block spline. Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cap journal bearing. Then lower the shaft and bearing assembly into position.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

13

17. Rotate the shaft by hand. The rotating assembly should turn freely. If it does not rotate freely, the motor must be disassembled and the problem corrected.

18. Rotate the motor shaft with a torque wrench to assure correct assembly. When properly assembled, the torque required to turn the shaft (after “break-away”) should be within the ranges shown in the accompanying table.

Torque required to turn shaft (Fixed Motor at 17°) Nm (Ib.ft) Frame Size

Minimum

Maximum

042

T.B.A. Nm (T.B.A. lb.ft)

T.B.A. Nm (T.B.A. lb.ft)

6.8 (5)

13.6 (10)

055

19. Assemble the seal carrier and seal over the shaft and into the housing bore. Install the retainer plate.

20. Install the screws and torque to 16 Nm (11.8 Ib.ft).

21. Install the valve spool in the end cover, then install the shoulder washers (with shoulders facing “out”) and springs on each end of the spool. Install the hex plugs with O-rings, and torque to 41 Nm (30.24 Ib.ft).

22. For shim adjustable valves, install the plug and torque to 68 Nm (50.1 Ib.ft).

SUPPLY PRESSURE RELIEF VALVE ADJUSTMENT 1.

To measure motor supply pressure, install a 50 bar (725 psi) pressure gauge in the motor supply pressure gauge port (M3). Also install a gauge to measure the case pressure. Operate the system with the pump in stroke (forward or reverse) when measuring motor supply pressure.

M3

CD01D121

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31

SV212 - SV216

14 2.

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 The following table shows acceptable motor supply pressures for some nominal supply pressure relief valve settings (see model code). These pressures are based on a reservoir temperature of 49°C (120°F). They relate to case pressure and are valid for a single motor system.

Model code setting

Motor charge pressure (Acceptable range) (±1.4 bar)

3.

10 bar (145 psi)

8.1 bar (117 psi)

18 bar (261 psi)

16.1 bar (233 psi)

20 bar (290 psi)

18.1 bar (262 psi)

24 bar (348 psi)

22.1 bar (320 psi)

28 bar (406 psi)

26.1 bar (378 psi)

30 bar (435 psi)

30.0 bar (435 psi)

90M055 NC 0 N 8 N 0 C6 W 00 NNN

00

00

Nominal charge pressure setting

24

c.g. “24” = 24 bar 32

Early production Series 90 motors are equipped with a shim adjustable supply pressure relief valve.

Shim kits are available as service items. Adjustment of the supply pressure is accomplished by removing the plug (7/8 inch hex) and changing the shim thickness behind the spring. The plug for this type of supply pressure relief port should be torqued to 68 Nm (50 Ib.ft).

CD01D122

33

CD01D123

34

Later production Series 90 motors are equipped with an external screw adjustable supply pressure relief valve. Adjustment of charge pressure is accomplished by loosening the lock nut (with a 1-1/ 16 inch hex, and turning the adjustment plug with a large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and counterclockwise rotation decreases the setting (at a rate of approximately 3.4 bar per turn). The lock nut for this type charge relief supply pressure should be torqued to 52 Nm (40 Ib.ft).

4.

Once the desired supply pressure setting is obtained, remove the gauges.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

1

SECTION 35 - HYDRAULIC SYSTEM Chapter 3 - Hydraulic circuit CONTENTS Section

80000

Description

Page

Hydraulic installation ..................................................................................... 2 Functional description ................................................................................... 2 Travel without activation ............................................................................... 3 Travel activated, moving forward ................................................................. 4 the multi-function valve ................................................................................. 5 the idler-wheel lock-block on the flow divider ............................................ 6 ASC valve ....................................................................................................... 7 vibration hydraulics ....................................................................................... 8 Vibration without activation .......................................................................... 8 Vibration activated ......................................................................................... 9 Steering hydraulics ...................................................................................... 10 Steering without activation ......................................................................... 11 steering to the right ..................................................................................... 12 lifting hydraulics .......................................................................................... 13 Lifting of the cab or hood ............................................................................ 14 Lowering the cab and hood ........................................................................ 15 Reservoir hydraulics ................................................................................... 16 Hydraulic reservoir ...................................................................................... 16 discharging of closed circuits .................................................................... 17 Brake release - emergency towing ............................................................. 18 Test points .................................................................................................... 19 Releasing transmission and wheel hydraulic motor brakes .................... 20 Hydraulic diagram ........................................................................................ 22

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2

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 HYDRAULIC INSTALLATION

The hydraulic system controls all main functions of the machine. The power unit drives hydraulic pumps and supplyies hydraulic pressure to the hydraulic motors which convert this form of energy into kinetic energy.

Distribution through the machine is assured by pipes and pressure hoses. Other controlling, regulating and safety componants are installed in the circuit.

DIAGRAM OF THE HYDRAULIC CIRCUITS

• Electrovalves, safety and control valves, hydrostatic locks.

• The SV216 machine uses a 90r055 pump and 90m055 hydraulic motor for vibration.

The hydraulic system consists of the following circuits:

• Further differences are in the adjustment of a control pressure by-pass valve in the body of the vibration pump, where on the SV212 its pressure is set to 42 bar (609 psi), and on the SV216, 28 bar (406 psi).

Control pressure setting in the bodies of travel pumps is identical in both cases - 22 bar (319 psi). Operation of the individual closed circuits or their parts is described in detail in the following part.

• Hydraulics for travel + hydraulic regulators • Hydraulics for vibration • Hydraulics for control • Hydraulics for lifting • Hydraulic reservoir

• Hydraulic circuit connection is identical in both circuits.

Differences are only in the types of the pumps and hydraulic motors used.

• The SV212 machine uses a 90r042 pump and 90m042 hydraulic motor for vibration.

FUNCTIONAL DESCRIPTION TRAVEL HYDRAULICS In the main closed circuit, the hydraulic oil flows through the pressure hoses between the axial piston variable hydraulic pump and two high-speed hydraulic motors with wheel drive speed reduction gears and one hydraulic motor with the roller drive unit attached. Value of the pump flow is given by the drive speed and displacement of the pump. The displacement is determined by the angle of the pump inclined plate, controlled hydraulically by the servo-valve which is controlled electrically; direction of the pressurized oil flow (travel direction) changes according to the degree of inclination of the oscillation plate from its zero position.

Part of the roller drive hydraulic motor is an electrically controlled control valve for selecting a second speed range (travel). If the ASC inter-axle differential lock in ON, the control valve is controlled by the SAUER S1X control unit with pulses. In this case, it results in continuous inclination of the block with little change in piston displacement and torque, depending on adhesion.

On the left side of the travel pump, a valve (flow divider) is mounted, operating as a wheel hydraulic regulator.

On the right side of the travel pump there is a two-way proportional valve (SAUER), electronically controlled by the SAUER S1X unit, which is the part of the ASC interaxle lock.

Furthermore, the hydraulic circuit is fitted with a filtration block with a 10 micro-millimetre pressure filter, a 2speed control valve for the wheels, and control valve of a parking brake for the roller and the wheels.

In addition, on the steering block there is the oil pressure filter restriction sensor.

THE ASC LOCK Supplied as optional equipment, it is acts as an electronically controlled and hydraulically driven inter-axle lock system, responding to immediate state of adhesion conditions and loading of the machine.

It consists of the SAUER S1X ASC control unit (microprocessor), the SAUER proportional valve and the SAUER machine inclination sensor. The system parts are the speed sensors built in the hydraulic motors for the wheels and roller. The roller hydraulic motor includes an electrovalve which controls volume of the oil flowing through. The control unit evaluates the speed of the roller and wheels by means of the sensors located in the hydraulic motors for the wheels and roller. In the event of different wheel speeds or a difference between the wheels and the roller speed caused by insufficient adhesion, it will the necessary torque adjustment.

Control of torque make on the roller hydraulic motor is performed electronically from the S1X control unit by means of the electromagnetic pulse valve which continuously controls the inclination of the hydraulic motor block.

Control of torque on the wheel (axle) hydraulic motors is obtained by pressure reduction in the SAUER two-way proportional valve, which is controlled by the S1X unit.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

3

TRAVEL WITHOUT ACTIVATION 16bar

T 17bar P 60 10

6

4,5

P1

B

60 L

1,8

450

450

A 420 P 75 60

22

420

40°C 55°C5bar °C

°C

CI01E502 1 Oil reaches the filtration block from the steering pump, and then proceeds to the travel pump. The fluid passes into the pump casing via the 22 bar (319 psi) safety valve.

From there, pressure reaches the multi-function valves, and then the closed circuit of the proportioning devices, ASC, hydraulic motors, and eventually power steering.

The travel casing drains into the vibration casing.

Brakes have been applied to the machine; brakes in the reduction gears are not under pressure.

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4

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 TRAVEL ACTIVATED, MOVING FORWARD 16bar

T 17bar P 60 10

6

4,5

P1

B

60 L

1,8

450

450

A 420 P 75 60

22

420

40°C 55°C5bar °C

°C

CI01E503 2 Oil flows through the steering filtration block to the travel pump. Part of the fluid goes via the 22 bar safety valve (319 psi) into the pump casing, the other part flows through the safety valve spool in the closed circuit of the drum hydraulic motor into the drum hydraulic motor casing. From there the fluid goes into the casing on the hydraulic motors of the wheels and thereon into the hydraulic reservoir.

The fluid flows from the travel pump casing into the vibration pump casing.

The electrovalve control is activated, the power valve deflects the spool of the power cylinder control to its extreme position, and the cylinder tilts the plate of the travel pump.

The pressurized oil flows from the pump to the inputs of the travel hydraulic motors and moves the machine forward.

The brake control valve solenoids are activated and release pressurized oil into the brakes in the travel reduction gears. The brakes of the machine have been released.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

5

THE MULTI-FUNCTION VALVE

3

CI01E504

The multi-function valve contains - Short-circuit valve position 1.

- One-way valve for supplying the closed circuit position 2.

- Safety valve consisting of a control and an excess-flow valve. The excess-flow valve allows for the flow of the superfluous fluid from the pressure circuit into the opposite circuit. The control valve controls the excess-flow valve and equalizes pressures in the pump power cylinder of when the safety pressure has been reached, i.e., it returns the plate to zero position (relieves load on the engine).

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CD01D145

4

CD01D146

5

SV212 - SV216

6

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 THE IDLER-WHEEL LOCK-BLOCK ON THE FLOW DIVIDER

60

1,8

450 450

60

CI01E505

The block contains 1.

Safety valves 450 bar (6527 psi) integrated with a one-way valve for emergency increment of the supply pressure in the circuit between the flow divider and the hydraulic motor on the wheel.

2.

The 1.8 mm (0.07 in) orifice providing the stability of the system of the idler-wheel lock during tight turns.

3.

Two-way flow divider with automatic set-up of control logic in line with the direction of the flow.

SV212 - SV216

6 Situation: the machine is moving forward, the left wheel is sliding though.

Increase of flow through the hydraulics of the left wheel originates changes in control pressures on the faces of the flow divider spool. The spool restricts the increased flow and maintains minimal difference between the speed of both wheels until adhesion conditions have changed and equalized wheel speed.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

7

ASC VALVE

60

B

L

60 A P

CI01E506

ASC is a dual, electrically powered restriction valve.

The operating part is a gate controlled by an electrovalve.

Situation: the left wheel is spinning in forward travel.

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7 The hydraulic motor revolution sensor signals the difference in wheel speed to the Susmik microprocessor.

The Susmik sends signals to the electrovalve, which allows the pressurized fluid to the gate. The gate restricts the flow to the hydraulic motor turning at higher revolutions until both wheel speeds are equal.

SV212 - SV216

8

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 VIBRATION HYDRAULICS

Inside the main closed circuit, the hydraulic oil flows between the axial piston variable hydraulic pump and the fixed speed hydraulic motor.

Value of the hydraulic pump flow is given by its drive speed and displacement. Direction of the pressurized oil flow changes depending on the inclination of the tilting plate from the zero position. The inclination is adjusted by the hydraulically controlled servo-valve.

The hydraulic motor drives the vibration exciters, which turn mutually after the hydraulic motor changes its direction of rotation and this results in a change of the eccentric moment value (amplitude). Simultaneously, flow volume. i.e. frequency changes, too. Hydraulic oil is re-injected into the system by the steering hydraulic pump with the oil coming through the oil filters from the hydraulic reservoir.

VIBRATION WITHOUT ACTIVATION

17bar P

10 6

4,5

P1

400 42 42

40°C °C

5bar 55°C °C

42 400

8 Oil arrives from the steering pump into the filtration block and from there flows to the vibration pump and safety valve, which is not functioning. The 22 bar (319 psi) supply pressure is provided by the pressure valve in the travel pump.

CI0E507

The pressure reaches both lines of the closed circuit via the multi-function valve.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

9

VIBRATION ACTIVATED

17bar P

10 6

4,5

P1

400 42 42

40°C °C

5bar 55°C °C

42 400

CI01E508 9 From the steering pump oil reaches the filtration block and from there goes to the steering pump and the control valve.

The solenoid is powered, slides the control valve over to the extreme position and the pressure reaches one side of the pump power cylinder. The plate is positioned in an extreme position. The pump delivers maximum output to one line of the closed circuit (marked in red) at a pressure which is determined by the load on the hydraulic motor. The opposite return line of the closed circuit is under supply pressure (marked in green), and drains via the drain valve of the hydraulic motor into the hydraulic motor casing and from there to the reservoir (marked in blue).

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10

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 STEERING HYDRAULICS

The steering hydraulics consists of the Rexroth servo steering unit, as controlled by the steering wheel, where the source of pressurized oil is a fixed gear-type hydraulic pump that takes in oil from the hydraulic tank and sends it under pressure into the servo steering.There the oil flow splits depending on the steering wheel turning direction. From the servo steering, the oil flow enters into straight-line hydraulic steering cylinders.

Effect of pressure on the piston results in motion of a piston rod, the heads of which are connected to the linkage. The piston rod gives the reciprocating linear motion and turns the frame with the roller.

The servo steering parts are: • Double shock valve - this is a variably adjustable, double acting linear limiting valve. It operates in conjunction with a suction valve.

• Suction valve - this is a safety valve which protects against the occurrence of pulses. In conditions of unevenness, it compensates with hydraulic liquid in order to avoid development of pressure loss on the opposite side of the hydraulic cylinder in the event of increasing pressure at the shock valve.

1 Q27R gear pump

• Non-return valve - this avoids the effects of pressure pulses on the gear pump.

This converts mechanical energy into pressurized hydraulic oil. The pump features teeth with a special shape for improved efficiency and minimized.

• Pressure control valve - this is a directly controlled, limiting valve variably adjustable from 5 MPa (725 psi) to 16 MPa (2320 psi).

2 Rexroth Parchim servo steering

Quality, performance and reliability are ensured by the high manufacturing tolerances of individual components. Because of the repair quality this entails, repair by replacement of the individual components is considered as uneconomical. In the event of some parts malfunctioning, the entire system (valve block) is to be replaced.

While turning the steering wheel, the volume of the hydraulic supply oil flowing through the servo steering into the linear hydraulic motor in proportional, depending on the steering wheel turning angle. The one-way shock valve built inside the valve block compensates the adverse effect of pressure pulses on the steering wheel during travel.

SV212 - SV216

In the case of overall wear, the steering assembly is to be replaced a the new one.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

11

STEERING WITHOUT ACTIVATION

T R

16bar

200 T 17bar

798 P

150

200

10 6

L

4,5

P1

P

60 bar 27 100 5bar 55°C °C

40°C °C

CI01E509 10 Oil is pumped from the tank by the steering pump and oil under pressure passes through the open center of the power steering into the filtration block.

Devices for feeding closed circuits are connected to the output of the filtration block.

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12

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 STEERING TO THE RIGHT

T R

16bar

200 T 17bar

798 P

150

200

10 6

L

4,5

P1

P

60 bar 27 100 5bar 55°C °C

40°C °C

CI01E510 11 Oil is pumped from the oil reservoir by the steering pump and flows under pressure through the open gate in the power steering, through the hydraulic motor and into the steering cylinders.

Under the effect of the movement of the steering cylinders, oil passes from the opposite openings of the filtration block on to the power steering and feeds the closed circuits.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

13

LIFTING HYDRAULICS Lifting and lowering the hood and the operator’s compartment for access to the engine, the hydraulic and vibration traveling pump and other components for inspection, maintenance and repairs is performed by two linear hydraulic motors for the hood and one for the operator’s compartment.

The power source is a small unit consisting of a 24V electric motor, a pump and a suction filter. In addition, an electrovalve is included in the circuit for varying the pressurized oil flow.

The pump is not repairable. If pump function defects are noticed during operation, resulting in excessive prolongation of the time necessary for lifting the hood and the operator’s platform and insufficient pressure being developed by the pump, the pump has to be replaced by the new one.

The manual hydraulic pump (RC 16), an emergency source of pressure energy for driving the linear hydraulic motors, is of the double acting piston type, with rectilinear reversible motion from the manual lever.

Maintenance of the entire system consits of lubrication of the lever system pins to meet machine operation conditions but at a minimum once per year and of keeping the pins and piston rods in a clean state.

The hydraulic locking device is built into the block fixed on the linear hydraulic motors.

The hydraulic locking device totally seals off the hydraulic circuit under pressure. It ensures the constant position of the lifted hood and operator’s compartment and protection against descending slowly over time or against failure of the hydraulic circuit (sudden leakage of the fluid).

In the event of failure, a manual hydraulic pump can be substituted into the circuit. During its usage, the electrovalve distributor can be controlled mechanically, thereby avoiding dependence on the machines electrical circuit.

The lifted hood and operator’s compartment are locked hydraulically in the raised position, which also protects against accidental oil losses from the system.

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14

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 LIFTING OF THE CAB OR HOOD

1

3

2

A2

B2

A1

B1

P

T

T

P

80 1,9

M

CI01E511

12

The electric pump pumps oil from hydraulic reservoir and sends it the control valves.

By activating the cab (hood) lifting solenoid the gate slides and the pressurized oil flows through the locking device for the cab (hood) lifting cylinder and into the hydraulic cylinder. The cab (hood) lifts up.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

15

LOWERING THE CAB AND HOOD

1

3

2

A2

B2

A1

B1

P

T

T

P

80 1,9

M

CI01E512

13

The electric pumps oil from the hydraulic reservoir and sends it to the control valves.

The cab (hood) solenoid is activated, the spool slides over and pressurized oil flows to the hydraulic cylinder. At the same time, the hydraulic locking device is released and the cab (hood) overrides the restriction valve in the hydraulic locking device to return to its original position.

In case of an emergency, such as a defect in the wiring or battery, it is possible to lower or lift the cab or hood by means of a manual pump and mechanical sliding of control valve spools to the correct position.

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16

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 RESERVOIR HYDRAULICS

The oil reservoir is welded out of the steel plates, and screwed to the upper frame portion.

Inside the reservoir the following parts are to be found: a suction strainer with a cleaning lid, a level indicator and a sight gauge.

In the reservoir bottom are a discharge valve, a hydraulic block, and a component for the operator’s compartment and the hood raising and lowering.

The hydraulic block consists of the safety valve, the thermostatic valve and the oil temperature sensor. The safety valve protects the hydraulic pump cases against high pressure. The thermostatic valve maintains optimum temperature of hydraulic oil in range of 55°C (131°F) to 70°C (158°F). At low hydraulic oil temperature, the cooler is put out of operation.

The hydraulic circuit is supplied from the hydraulic reservoir by the steering hydraulic pump via the suction strainer and the filtering block.

In the return line of the hydraulic system, the reservoir is provided with a siphon to avoid oil leakage during repairs of the machine; only for repair (replacing) of the steering hydraulic pump is it necessary to disconnect the screw coupling of the suction hose on the reservoir.

The discharge valve is opened by turning it to the left; flow can be controlled by manually turning the valve.

The valve end position is locked against falling out. Do not loosen it forcibly across the end position - it can result in damage of the valve and the closing part falling out.

When re-filling the reservoir with oil, it is necessary to use a pressure re-filling station with filters of filtering capacity higher than 20 micron-millimetres (0.0008 in).

The cap on the filler neck is protected by a lead seal; if this is damaged, the machine guarantee time is reduced by 50%.

HYDRAULIC RESERVOIR

100

°C

40°C 55°C5bar °C

CI01E513

The hydraulic reservoir consists of 1.

Suction strainer

2.

Filler neck with venting and air filter

3.

Level indicator

4.

A block mounted to the bottom of the reservoir, with a thermostat, hydraulic oil temperature sensor, and a 5 bar fuse for pump casing overload

5.

A hydraulic oil drain valve oil screwed to the bottom on the other side and an electrical pump for lifting and folding of the cab and hood

SV212 - SV216

14 Oil flows to the reservoir block and through the radiator into the reservoir. As long as the oil temperature is lower than 40°C (104°F), the thermostat lets the fluid flow into the reservoir without cooling. With increased temperature the thermostat restricts gradually the flow and at 55°C (131°F) the entire flow of the return line goes through the radiator.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

17

DISCHARGING OF CLOSED CIRCUITS

CI01E514

15

Situation: The machine is moving forward and the drum vibrates.

Supply pressure arriving from the filtration block is separated into three basic flow passages.

• Flow through the supply pressure safety valve in the travel pump, which discharges the travel pump casing, from there into the vibration pump casing and eventually into the reservoir.

• Discharging of the closed travel circuit - the fluid drains into the drum drive hydraulic motor, from there in parallel into the casing of the wheel drive and eventually into the reservoir.

• Discharging of the closed vibration circuit - the fluid drains into the vibration hydraulic motor casing and eventually into the reservoir.

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18

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 BRAKE RELEASE - EMERGENCY TOWING

16bar

60

T 17bar

10 6

4,5

60

T

P

80 1,9 40°C

M

5bar 55°C

°C

°C

60

CI01E515

Pressure produced by the manual pump reaches the filtration block, the 11 bar (159 psi) safety valve and the electrovalve.

When the electrovalve spool moves the pressure reaches the individual brakes of the Transmital gearboxes .

SV212 - SV216

16 By disconnecting the quick-couplers and connecting them to drain, the circuit is isolated from the machine brake release function and returns to its original function as a feedback circuit.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

19

TEST POINTS In order to allow easy diagnostics of the hydraulic circuits, the test points are grouped in a bank and provided with quick couplers for easy and drip-free connection of the measuring instruments (M16x2 thread).

Maximum pressure Pressure in the reverse travel circuit (1): 420 bar* (6091 psi) Pressure in the forward travel circuit (2): 420 bar* (6091 psi) Pressure in the vibration circuit I (3): 400 bar (5801 psi) Pressure in the vibration circuit II (4): 400 bar (5801 psi) Pressure in the steering circuit (5): 190 bar** (2756 psi) Pressure feed pump (6): 22 bar*** (319 psi) Pilot pressure (7)

3 4 5 6 17

CD01E008

* This value will be raised by the forced feed pressure, i.e. by up to 30 bar (435 psi). ** Total pressure in the steering circuit (forced feed pressure + flow-through losses) *** Value at idle speed - at higher speed, it is higher, max. 30 bar (435 psi).

M7

CD01E009

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1

2

18

SV212 - SV216

20

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 RELEASING TRANSMISSION AND WHEEL HYDRAULIC MOTOR BRAKES

Release the hose (4) and quick-coupling (3) from the clamp (5).

5 3

4

19

CD01D151

Disconnect the quick-coupling (2) from the hose (1) from the pressure filter to the hydraulic reservoir.

2 1

20

CD01D152

Connect the hose (4) to the manual hydraulic pump using the quick-coupling (2) on the hose (1).

4 1 CD01D153

SV212 - SV216

2

3 21

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

21

Next, s/c the hydraulic travel circuit. The travel hydraulic pump has two multi-purpose main relief valves.

Unscrew middle portions (1) of the valves (hex 27 mm (1.06 in)) three turns cc/w.

Then the starter switch key to position I. Insert the control lever into the manual hydraulic pump and pump until the brake warning light goes off.

The machine now has its brakes released for towing.

Because of leakage, the pressure in the brake line may drop during towing. Should the brake warning light come on during towing, pressure should be renewed.

During towing check that the brakes do not heat up due to insufficient release. When the hydraulic motor brakes have been released and the travel hydraulic circuit has been short-circuited, the working, emergency, or parking brakes cannot be applied. All brakes are out of service.

1 CD01D150

1 22

When towing has ended, return the machine to its original condition.

Use cables of sufficient strength.

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SV212 - SV216

22

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 HYDRAULIC DIAGRAM

Designation 1 1A 1B 1C 2

Travel pump Pilot circuit relief valve: 22 bar (319 psi) Relief valve (forward): 420 bar (6091 psi) Relief valve (reverse): 420 bar (6091 psi) Vibration pump * SV212 (42cc) ** SV216 (55cc) 2A Pilot relief valve: 28/42 bar (406/609 psi) 2B Relief valve (vibration II): 400 bar (5801 psi) 2C Relief valve (vibration I): 400 bar (5801 psi) 3 Drum drive hydraulic motor: * SV212 (60cc) ** SV216 (80cc) 4 Vibration hydraulic motor * SV212 (42cc) ** SV216 (55cc) 5 Wheel drive hydraulic motor 8 Steering pump: 27 bar (391 psi) 9 Power steering unit 9A Steering main relief valve: 150 bar (2175 psi) 9B Relief valve (left): 200 bar (2900 psi) 9C Relief valve (right): 200 bar (2900 psi) 10 ASC Valve 11 Hydraulic steering cylinder 12 Divider block 12A Relief valve (right reverse travel): 453 bar (6570 psi) 12B Relief valve (left reverse travel): 543 bar (6570 psi) 13 Pressure switch 60 bar (870 psi) 14 Suction strainer 15 Filtration block 16 Filling filter 17 Oil level gauge 18 Combined cooler 19 Non-return valve 20 Thermoregulator

SV212 - SV216

22 23 24 25 26 27 28 29 30 31

Quick coupler Quick coupler Quick coupler Thermometer sensor Power lift group Manual pump Lifting block Hydraulic locking device Hydraulic motor for lifting the cab Hydraulic motor for lifting the hood

M1: Reserve travel test point M2: Forward travel test point M3: Vibration I test point M4: Vibration II test point M5: Steering test point M6: Pressure feed pump test point M7: Pilot pressure test point HF Hand forward HR Hand reverse LHR Left-hand reverse LHF Left-hand forward RHR Right-hand reverse RHF Right-hand forward

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

11

9C

9

23

3

5 10 9A

9B

15 31

12 13

12A

10 24 29

12B

28 22 27 13

1C 2C 25

8

CI01E501

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16 17

19

26 14

1

1A 1B

2

2A

2B

4

20

18 4

SV212 - SV216

24

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

This page is intentionally left blank

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

1

SECTION 35 - HYDRAULIC SYSTEM Chapter 4 - Hydraulic pump CONTENTS Section

82021

Description

Page

Specifications ................................................................................................. 1 Torque specifications ..................................................................................... 1 Description ..................................................................................................... 2 Disassembly ................................................................................................... 3 Reconditioning and replacement of parts ................................................... 8 Assembly ...................................................................................................... 14 Inspection and adjustments ........................................................................ 25

SPECIFICATIONS SV212 SV216 SV212 - SV216 Vibration pump Vibration pump Travel pump (042PV) (055PV) (075PV) Displacement (maximum) ................................42 cm3 (2.56 in3) ...........55 cm3 (3.35 in3) ......... 75 cm3 (4.57 in3) Minimum speed............................................................500 tr/mn ...................... 500 tr/mn ..................... 500 tr/mn Rated speed...............................................................4200 tr/mn .................... 3900 tr/mn ................... 3600 tr/mn Maximum speed.........................................................4600 tr/mn .................... 4250 tr/mn ................... 3950 tr/mn Maximum attainable speed at max. disp....................5000 tr/mn .................... 4700 tr/mn ................... 4300 tr/mn Theoretical torque at max. disp............................... 0.67 Nm/bar ..................0.88 Nm/bar ................ 1.19 Nm/bar Weight.....................................................................34 kg (75 Ib) ................. 40 kg (88 Ib) .............. 49 kg (108 Ib)

!

WARNING

!

1

Be sure to fill the pump housing with clean hydraulic fluid prior to start up. Fill the housing by pouring filtered oil into the upper case drain port (1).

CS01D530

5

TORQUE SPECIFICATIONS 042PV 055PV 075PV Swashplate ..................................................13.5 Nm (9.96 Ib.ft) .......13.5 Nm (9.96 Ib.ft) ..... 13.5 Nm (9.96 Ib.ft) Servo cylinder ...................................................9 Nm (6.63 Ib.ft) .......13.5 Nm (9.96 Ib.ft) ....... 24 Nm (17.7 Ibf.ft) Leveler guide .....................................................23 Nm (17 Ib.ft) .............23 Nm (17 Ib.ft) ........... 23 Nm (17 Ib.ft) Side cover ....................................................13.5 Nm (9.96 Ib.ft) ..........32.5 Nm (24 Ib.ft) ........ 32.5 Nm (24 Ib.ft) Swashplate guide.........................................13.5 Nm (9.96 Ib.ft) ..........32 Nm (23.6 Ib.ft) ........ 32 Nm (23.6 Ib.ft) Side cover screws installed in “Blind” holes.13.5 Nm (9.96 Ib.ft) ..........32.5 Nm (24 Ib.ft) ........ 32.5 Nm (24 Ib.ft) Side cover screws installed in “Thru” holes ...10.5 Nm (7.7 Ib.ft) ..........25 Nm (18.4 Ib.ft) ........ 25 Nm (18.4 Ib.ft)

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 DESCRIPTION

25 26 23 22

49

21 24 15

17

48

47 33 34

30

31

37 39 31

40

17

18 17

38

35

35

32

36 34

33

14 28 46

13 27 29

12 20 5 2

6

8

9

11

19

16 41 45 42

44 43 10

3

50 51 52

7 1 4 2

CS01D586

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Cover Bolt O-ring Bolt Adapter O-ring Plate Spacer Spacer O-ring Coupling Plug Relief valve Relief valve Adjusting screw Screw Plug Screw Gasket End cover Cylinder block

SV212 - SV216

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

Piston Slipper guide Guide Bolt Spacer Swashplate Leveler, complete Bearing Piston Plug Housing Bolt O-ring O-ring Shaft Bearing Plate Shaft packing O-ring Swashplate leveler Cover

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

Plug Spring O-ring Pin Gasket Adapter plate Solenoid Orifice plate Spring Spring retainer cup

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

3

DISASSEMBLY 055 PUMP 1.

Thoroughly clean all external surfaces prior to removal of the control components.

2.

Using a 4 mm (0.16 in) internal hex wrench, remove the four electrovalve mounting screws.

Remove the electrovalve (with O-rings and orifice) from the adapter plate.

3.

Using a 5 mm (0.2 in) internal hex wrench, remove the eight adapter plate mounting screws. Remove the adapter plate and gasket from the housing.

!

WARNING

!

Protect exposed surfaces and cavities from damage and foreign material.

4.

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

CD01D134

3

CD01D135

4

CD01D136

5

042 OR 075 PUMPS 5.

Thoroughly clean the external surfaces of the control components.

6.

Using a 4 mm (0.16 in) internal hex wrench, remove the four screws and remove the PCP.

7.

Check all surfaces for nicks or damage. Clean the internal screens.

8.

Thoroughly clean all external surfaces prior to removal of the control components.

9.

Using a 5 mm (0.2 in) internal hex wrench, remove the eight control mounting screws. Remove the control assembly (with orifice check valve and spring) and control gasket from housing.

!

WARNING

!

Protect exposed surfaces and cavities from damage and foreign material.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

10. Remove the multi-function valve cartridge with a 32 mm ( 1.26 in) hex wrench on the largest hex on the cartridge.

CD01D137

6

CD01D138

7

CD01D129

8

CD01D130

9

11. Remove the shim adjustable pressure relief valve plug with a 25 mm (1 in) hex wrench.

12. Position the pump with the shaft facing up.

13. Remove the three or four screws holding the retainer plate and seal carrier to the housing using a 10 mm (0.4 in) hex wrench (042 units) 5 mm (0.2 in) internal hex wrench.

NOTE: Certain early production units use a single piece retainer plate and seal carrier.

14. After removing the screws, the spring force on the shaft may move the seal carrier out of its bore by approximately 5 mm (0.2 in). If the seal carrier does not move from its bore after removing the screws, pry it from its bore as shown and/or lightly tap the end of the shaft with a soft mallet.

15. Remove the O-ring from the seal carrier.

16. Place the seal carrier and seal in an arbor press and press out old seal.

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5

17. After removal of these components, place the pump on a work surface with the shaft up.

18. Remove the shaft and bearing assembly from the housing. The bearing outside diameter is a slip fit in the housing bore.

NOTE: If the shaft and bearing stick in the housing, lightly tap the end of the shaft with a soft mallet to free the bearing.

19. Remove the retaining ring and press the shaft out of the bearing.

NOTE: If the pump is equipped with an auxiliary mounting pad, temporarily reinstall two of the large screws which fasten the end cover to the housing. These screws will hold the end cover against internal spring pressure while the small screws are removed.

CD01D054

10

CD01D055

11

CD01D057

12

20. Using a 5 mm (0.2 in) or 6 mm (0.24 in) internal hex wrench or a 10 mm (0.4 in) hex wrench, remove the two or three small screws which fasten the end cover to the pump housing.

21. Using an 8 mm (0.31 in) internal hex wrench for 042 pumps, a 19 mm (0.75 in) hex wrench for 055 pumps or a 24 mm (0.94 in) hex wrench for 075 pumps, remove the large screws which fasten the end cap to pump housing.

22. Remove the end cover from the housing. The alignment pins and valve plate will normally remain with the housing. Remove the end cover gasket.

Remove the swashplate leveler spring shims (if installed) from the spring housings in the end cover.

23. Remove the three springs from the pump: the two long swashplate leveler (“T-Bar”) springs and the short swashplate hold down spring.

NOTE: Certain units are equipped with dual swashplate leveler springs (an inner spring “nested” inside each of the standard springs).

24. Remove the alignment pins and distribution plate, noting the direction of the arrows on the distribution plate.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

25. Straighten the locking tabs (used on early production units) and remove the six side cover screws (with flat washers on later production units) using a 10 mm (0.4 in) hex wrench for 042 pumps or a 13 mm ( 0.51 in) hex wrench for 055 and 075 pumps.

26. Remove the side cover and the swashplate leveler (“T-Bar”) assembly from housing.

CD01D058

13

CD01D060

14

CD01D061

15

CD01D063

16

27. Remove spring seats from swashplate leveler.

NOTE: Early production pumps do not have removable (hardened) spring seats.

28. For units with leveler guide posts, remove the two guide posts and sealing nuts holding the leveler to the side cover. Use a 17 mm (0.67 in) open end wrench or a 10 mm (0.4 in) hex wrench on 042 frame size pumps. Use a 3/4 in open end wrench and a 13 mm (0.51 in) hex wrench on 055 and 075 frame size pumps. Remove the swash plate leveler from the side cover. Remove the side cover O-ring.

29. Mark the servo cylinders and housing to relate each servo cylinder with its respective side of the housing.

30. Remove the three or four screws retaining each servo cylinder to the housing, using a 10 mm or 13 mm (0.51 in) hex wrench.

31. For early production units, carefully pry each cylinder from the housing by using a screwdriver in the notches in the cylinder. For later production units, install an 8 mm (0.31 in) or 10 mm (0.4 in) screw in the threaded hole in the center of each cylinder, and pull the cylinders from the housing. The servo piston will remain in the housing.

NOTE: For later production units with displacement limiters, remove the limiter screw from each servo cylinder and install an 8 mm (0.31 in) or 10 mm (0.4 in) screw in its place to act as a puller screw.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

7

32. Remove the cylinder block through the housing end cover opening. The swashplate and piston assembly will remain in the housing.

CD01D064

17

CD01D065

18

CD01D066

19

CD01D067

20

33. Remove the swashplate bearing cage link pin from the housing through the control opening.

NOTE: A flat head screw is used as the link pin in 042 frame size pumps. If may be removed with a 3 mm (0.11 in) internal hex wrench.

34. Remove the bearing cage locator link from the swashplate through the control opening.

35. Remove the swashplate and pistons through the housing side cover opening. Disengage the servo arm from the slider block located in the servo piston as the assembly is removed.

36. Remove the servo piston and slider block from housing.

NOTE: Units equipped with an automotive control have a threaded hole in one end of the servo piston for the centering assistance spring assembly. For these units, note the orientation of the servo piston in the housing.

37. Remove the swashplate cradle bearing cage.

Remove the bearing races. The bearing races are a loose fit on two locating pins in the housing.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

38. Remove the feedback link from the head of the special screw on the swashplate assembly.

CD01D068

21

CD01D069

22

39. Using a 10 mm (0.4 in) or 13 mm (0.51 in) hex wrench, remove the four screws holding the slipper guide hold down mechanism to the swashplate.

40. Remove the piston assemblies from the slipper guide.

RECONDITIONING AND REPLACEMENT OF PARTS 1.

After disassembly all parts should be thoroughly cleaned in a suitable solvent. Replace all O-rings, gaskets and the shaft seal.

2.

Inspect all parts for damage, nicks, or unusual wear patterns. Replace all parts having unusual or excessive wear or discoloration.

3.

If the end cover journal bearing needs replacement (as manifested by large amounts of the metal back of the bearing being visible through the plastic bearing material), remove the bearing with a suitable puller. Do not damage the valve plate surface of the end cover.

CD01D070

SV212 - SV216

23

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 4.

Lightly lubricate the steel backing of a new journal bearing. Press the journal bearing into the end cover using a suitable driver.

5.

When installed correctly, the bearing will be flush to 0.5 mm below the distribution plate surface of the end cover.

9

CD01D071

24

CD01D072

25

CD01D073

26

NOTE: For 042 frame size pumps, the bearing is located 21 to 21.5 mm (0.82 to 0.84 in) from the front surface of the supply pump recess in the end cover.

6.

If a new journal bearing is installed, the bearing must be sized with the appropriate arbor to assure the minimum bore diameter is met. Carefully press the sizing arbor into the bearing to size it.

!

WARNING

!

The arbors are precision finished to size the journal bearings without damaging them. Damaged arbors must be replaced. Do not attempt to use the drive shaft in place of an arbor. Inadequate clearance between the shaft and bearing will result in inadequate lubrication and shortened bearing life.

NOTE: The charge pump shaft bushing in the end cover may be replaced in a similar manner to the drive shaft journal bearing.

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10 7.

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 Certain frame size pumps with twin port end covers may have the servo relief valves and rotation plugs located in a removable rotation block. Remove the rotation block screws with a 5 mm (0.2 in) internal hex wrench and remove the block and gasket.

For pumps with a pressure limiter function (except units with automotive control), remove the servo relief valves from the end covers or rotation block with a screw driver.

For pumps with the pressure limiter eliminated and/ or automotive control, remove the servo relief passage plug(s) from the end cover or rotation block with a 3/16 in. internal hex wrench.

042 pump twin port end cover 27

CS01D533

Note the position of the rotation pipe plugs and remove them from the end cover or rotation block with a 1/8 in. internal hex wrench.

8.

Install the servo relief valves or relief valve passage plugs into the end cap or rotation block as shown in the accompanying illustrations and chart.

NOTE: Pumps with a pressure limiter function (except those units with automotive control) MUST have servo relief valves installed in the end cover or rotation block to limit servo pressures.

055 pump side port end cover 28

CS01D534

9.

Install the rotation pipe plugs into the end cover or rotation block as shown in the accompanying illustrations and chart.

055 pump twin port end cover 29

CS01D536

075 pump side port end cover CS01D536

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

11

075 pump twin port end cover rotation 31

CS01D537

Pressure limiter Pipe plugs in holes

Servo relief valves (0-ring plugs for automotive control in hole)

O-ring plugs in holes

Open holes

Port “A”

Port “B”

Pump rotation

YES

YES

R (CW)

1, 3

6, 7

None

2, 4, 5

YES

YES

L (CCW)

2, 4

6, 7

None

1, 3, 5

NO

NO

EITHER

1, 2, 5

None

6

3, 4, 7

!

WARNING

!

Uncontrollable movement of the vehicle/machine and its attachments can result from installing the pressure limiter logic plugs in the incorrect ports for the pump rotation. Correct pressure limiter function MUST be verified. This can be accomplished by testing the pump before it is installed, or by defining and performing a test in the vehicle/machine before it is released from repair.

Torque the servo relief valves or relief valve passage plugs to 12 Nm (8.85 Ib.ft). Torque the rotation pipe plugs to 5.4 Nm (4 Ib.ft).

When reinstalling the rotation block and gasket, torque the screws to 16 Nm (11.8 Ib.ft).

10. The threaded holes in the swashplate (for the hold down screws) must be cleaned of old locking compound prior to reassembly. A 6 mm (0.24 in) thread tap may be used for this purpose.

11. Inspect the swashplate guide for wear. The guide may be removed by removing the special locking screw with a 5 mm (0.2 in) (042 pumps) or 6 mm (0.24 in) (055 and 075 pump) internal hex wrench.

12. Servo arm alignment is critical to proper pump operation. For this reason, removal of the servo arm from the swashplate is not recommended.

CD01D074

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

13. If the servo arm must be removed from the swashplate, remove the locking screw with a 13 mm (0.51 in) hex wrench.

14. “Keystone” design servo arms must be parallel (within 0.25 mm (0.98 in) total) to the wide surface of the slot in the swashplate when installed. “Press fit” design servo arms must be carefully aligned with the slot and threaded holes in the swashplate while installing, and must be pressed completely into the swashplate slot.

NOTE: “Keystone” design servo arms and swashplates are no longer available for servicing 055 and 075 frame size pumps. A swashplate/servo arm kit is available to service these units. Refer to the appropriate Service Parts Manual for more information.

15. Torque the servo arm to swashplate locking screw to 32 Nm (23.6 Ib.ft).

16. Assemble the swashplate guide to the swashplate with the special locking screw. Torque the screw to 13.5 Nm (9.95 Ib.ft) for 042 pump and 32 Nm (23 Ib.ft) for 055 and 075 pumps.

CD01D075

33

CD01D076

34

17. If the headed roll pin and flat washer for the bearing cage locator link must be installed on the swashplate, the distance between the washer and the side of the swashplate must be as indicated below: Pump frame size

Distance “H” ±0.010 in (±0.25 mm)

042

0.140 (3.60)

055

0.21 (5.33)

075

0.240 (9.45)

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

Swashplate

13

Headed pin

Flat washer “H” CS01D538

35

CD01D077

36

CS01D539

37

18. Inspect the servo piston and seal rings for wear. If worn, remove the seal rings and expander O-rings from the piston.

19. Install new expander O-rings into the seal grooves in the servo piston.

20. Carefully install the piston seal rings in the piston grooves, over the expander O-rings. Do not stretch the seal rings any more than necessary when installing.

21. Lubricate the seal rings and carefully slide the servo piston into the servo cylinders. Allow the assembly to settle for at least 5 minutes to allow the seal rings to return to their original “unstretched” size. The remove the servo cylinders.

22. Compress the cylinder block spring and remove the spiral retaining ring, retainer, spring, and spring seat. Reassemble in the reverse order.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 ASSEMBLY

1.

Clean and lightly oil all parts prior to assembly of the pump. Be sure to torque all threaded parts to the recommended torque specifications.

!

WARNING

!

Most parts have critical, high tolerance surfaces.

Caution must be exercised to prevent damage to these surfaces during assembly. Protect exposed surfaces, openings, and ports from damage and foreign material.

2.

Assemble the piston assemblies into the slipper guide.

3.

Lubricate the slipper running surfaces. Center the pistons and guide on the swashplate.

NOTE: Later production pumps use a fixed-clearance hold down mechanism. Early production 055 and 075 frame size pumps use a spring-loaded hold down mechanism. Service parts for the spring-loaded hold down mechanism are no longer available. If hold down parts require replacement on these earlier production units, the fixed-clearance hold down mechanism must be installed. Refer to the appropriate Service Parts Manual for more information.

4.

Assemble one-half of the fixed-clearance hold down mechanism as follows:

-

Position two spacers over the threaded holes in the swashplate as shown.

-

Position the slipper guide bearing on top of the spacers and the slipper guide.

!

WARNING

CD01D078

38

!

The “split” between the slipper guide bearing plates must be located in line with the swashplate arm.

The bearing surface of the bearing plates must be located next to the guide.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 5.

15

Install two new screws (with locking compound) and flat washers through the slipper guide bearing, and spacers. Finger tighten the screws into the swashplate.

NOTE: Inspect the flat washers for raised edges or “burrs”. The smooth side of the flat washers must be installed next to the slipper guide bearing.

!

WARNING

!

Always use new screws with proper locking compound.

6.

Assemble the other half of the fixed-clearance hold down mechanism in a similar manner.

7.

Assemble one-half of the spring-loaded hold down mechanism as follow:

CD01D079

39

CD01D080

40

Lubricate the slipper guide bearing and position it on top of the slipper guide.

!

WARNING

!

The “Split” between the slipper guide bearing plates must be located in line with the swashplate arm.

The bearing surface of the bearing plates must be located next to the slipper guide.

8.

Position two spacers in the holes of the guide bearing and over the threaded holes in the swashplate as shown.

Position two flat washers on top of the spacers.

Position two leaf springs on top of the washers.

Position two spring aligners on top of the leaf springs.

9.

Install two new screws (with locking compound) through the spring aligners, leaf springs, flat washers, and spacers. Finger tighten the screws into the swashplate.

!

WARNING

!

Always use new screws with proper locking compound.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

10. Assemble the other half of the spring-loaded hold down mechanism in a similar manner. Torque the hold down screws to 13.5 Nm (9.95 Ib.ft). The slipper guide and piston slippers must be able to slide freely on the swashplate.

CD01D081

41

CD01D082

42

CD01D067

43

CD01D163

44

11. Lubricate the pistons and cylinder block bores.

Install the assembled swashplate and pistons into the cylinder block by inserting the pistons into the cylinder block bores. The pistons and bores are not selectively matched, therefore no specific piston and bore matching is required.

12. Check that the swashplate bearing race locating pins are secure in the housing.

13. Install the swashplate bearing races into the housing, positioning the races on the locating pins.

Retain the races in position with petroleum jelly.

The locating pins are offset in the housing to assure proper assembly.

14. Assemble and lubricate the bearing cage, and install it on the bearing races.

15. Install the bronze slider block on the swashplate servo arm.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

17

16. Install the feedback link on the head of the special screw on the swashplate assembly.

!

WARNING

!

To avoid the possibility of the pump sticking in stroke, the feedback link must NOT be installed in pumps equipped with non-feedback controls (cover plate, 3-position solenoid, and automotive control type pumps).

CD01D083

45

CD01D084

46

CD01D085

47

17. Position the servo piston in the housing.

NOTE: For units equipped with automotive control, the machined end of the servo piston (with the tapped hole) must be located on the side of the housing where the centering assistance spring sleeve will be installed.

18. Carefully lower the cylinder block and swashplate assembly into the housing through the end cap opening.

NOTE: A tool to assist in holding and installing the assembled cylinder block and swashplate may be made from a positive lock, quick release pin and a large flat washer (1 inch inside diameter with clearance flats ground on the outside diameter). Insert the pin through the cylinder block and swashplate, and lock in place with the flat washer under the swashplate.

19. Hold the cylinder block and swashplate assembly approximately 12 mm ( 0.47 in) above the cradle bearings.

20. Properly position the feedback link in the control opening.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

21. Position the servo piston on the slider block, taking care not to wedge the block. The parts should slide freely.

CD01D086

48

CD01D087

49

CD01D088

50

22. Lower the cylinder block and swashplate assembly until the swashplate is properly located on the cradle bearings.

NOTE: If an assembly tool was used to install the cylinder block and swashplate, release and remove the pin.

The flat washer should fall through the shaft opening of the housing.

23. Hold the servo piston in position and install the servo cylinders.

NOTE: Be sure to assemble the correct servo cylinder on each side of the housing. For units equipped with an automotive control, a special servo cylinder is installed on the centering assist spring side of the housing.

24. Install the three or four screws in each servo cylinder. Torque to 13.5 Nm (9.95 Ib.ft) for 042 and 055 pumps or 24 Nm (17.7 Ib.ft) for 075 pumps.

NOTE: For units equipped with automotive control, the servo cylinder screws on the centering assistance spring side of the housing will be installed later.

25. Align the slot in the swashplate bearing cage with the headed spring pin in the swashplate and the pin hole in the housing. Hook the cage locator link over the spring pin, between the washer and the swashplate. Rotate the link into the slot in the bearing cage.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

19

26. Align the hole in the locator link with the hole in the housing and install the link anchor pin through the link and into the housing.

51

CD01D089

For 042 pump A flat head screw is used as the link pin in 042 frame size pumps. Install a new screw (with locking comprund) through the locator link and into the housing.

Tighten the screw into the housing until the head of the screw is positioned at a height (distance “H”) of 4.53 to 4.79 mm (0.18 to 0.19 in), from the machined surface of the pump housing.

!

WARNING

Cage locator Pump housing

Link

Screw

!

“H”

Always use a new screw with proper locking compound. Do NOT torque this screw against the locator link. The link MUST rotate freely.

CS01D540

52

CD01D090

53

27. Push the swashplate assembly toward the control side of the housing until the swashplate guide contacts the bearing race. Check for clearance between the servo arm and the slider block. If no clearance is present, recheck the assembly of the bearing cage and races.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

28. Position the swashplate leveler (“T-bar”) on the side cover. Note the orientation of the leveler and the cover.

CD01D060

54

CD01D091

55

CD01D092

56

CD01D093

57

29. For units with leveler guide posts, install the two guide posts and sealing nuts. Torque to 9 Nm (6.63 Ib.ft) for 042 pumps or 23 Nm (17 Ib.ft) for 055 and 075 pumps.

NOTE: If the screw holes in the side cover are “thru” holes, the threads of the screws must be coated with sealing compound.

30. Install the leveler spring seats.

NOTE: Early production pumps do not have removable (hardened) swashplate leveler spring seats.

31. Install the inner spring spacer washers (if used).

Install a new side cover O-ring.

32. Hold the swashplate leveler toward the end cover end of the housing so the leveler clears the side of the swashplate during side cover installation. Install the side cover and swashplate leveler.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

21

33. Install two side cover screws (with flat washers) finger tight into the blind holes in the housing, to hold the cover while checking the “zero angle” position of the swashplate.

34. If all the parts which affect the zero angle setting are being reused, rotate the side cover to align the marks on the cover and housing that were made during disassembly.

35. Apply a force 22 to 44 Nm (16.2 to 32.4 Ib.ft) to the swashplate leveler to ensure both arms are in contact with the swashplate. Make sure the swashplate is properly located on its bearings. Use a depth micrometer to measure the distance from the end cover face of the housing to the outer edge of the swashplate surface. Take a second measurement at a point 180° from the first point of measurement (at the opposite edge of swashplate surface). these measurements must not vary by more than 0.025 mm (0.001 in).

CD01D094

58

CD01D095

59

36. Rotate the side cover (which will also rotate the leveler and swashplate) until the zero angle position is established, as determined by the depth measurement.

37. After the zero angle position has been established, tighten the two screws to hold the side cover.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

38. Install the remaining four screws with flat washers.

NOTE: The threads of the two side cover screws installed in “thru” holes in the housing must be coated with a sealing compound to prevent leaks. New screws have sealant pre-applied.

39. First, torque the four side cover screws installed in “blind” holes to 13.5 Nm (9.95 Ib.ft) for 042 pumps or 32.5 Nm (24 Ib.ft) for 055 and 075 pumps. Then, torque the two side cover screws installed in “thru” holes to 10.4 Nm (7.67 Ib.ft) for 042 pumps or 25 Nm (18.4 Ib.ft) for 055 and 075 pumps.

CD01D096

60

CD01D057

61

CD01D098

62

40. Install the end cover alignment pins into the housing. Lubricate the running surface of the cylinder block and install the distribution plate on the alignment pins.

NOTE: Note the direction of the arrow cut-outs in the valve plate. The arrows must point in the direction of pump rotation. For example, a right hand (clockwise) rotation pump must have the arrows pointing in the clockwise direction (when viewed from the shaft end).

(The photo on this page shows a valve plate installed for clockwise (CW) rotation).

41. Install the two long springs (with inner springs, if used) on the swashplate leveler spring seats.

Install the short spring on the servo arm link. Place new end cap gasket on the housing (located by the alignment pins). Take care not to bend or damage the end cap gasket during installation.

42. Lubricate the end cover journal bearing. Install the hardened shims in the end cover pockets for the swashplate leveler springs. Retain the shims with petroleum jelly.

43. Lower the end cover onto the housing, while positioning the three springs in their pockets in the end cover.

When properly installed, the end cover will engage on the alignment pins, but the springs will hold the end cover 3 to 8 mm (0.11 to 0.31 in) away from the housing.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

23

44. Install the four large end cover screws.

NOTE: If the pump is equipped with an auxiliary mounting pad, temporarily install two of the large screws which fasten the end cover to the housing. These screws will hold the end cover against internal spring pressure while the small screws are installed.

Tighten the large end cover screws evenly to the torque indicated in the accompanying table.

Frame size

Torque Nm (Ib.ft)

042

75 (55)

055

122 (90)

075

256 (189)

CD01D099

63

45. Install the two or three smaller screws holding the end cover to the housing. Torque the 6 mm (0.23 in) screws to 13.5 Nm (9.95 Ib.ft) and the 8 mm (0.31 in) screws to 38 Nm (28 Ib.ft).

NOTE: A lifting bracket is installed on one of the smaller end cover screws.

46. Position the pump on its end cover.

Using caution to prevent damage to the sealing surface, press the roller bearing onto the drive shaft. (For units with a 3-piece bearing, press the inner race onto the shaft, then install the outer race/cage assembly and the special washer).

Install the bearing retaining ring onto the shaft.

47. Install the screws and torque to 16 Nm (11.8 Ib.ft).

48. Install the shaft and bearing assembly through front of housing, aligning the shaft spline with the cylinder block spline. Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cover journal bearing. Then lower the shaft and bearing assembly into position.

49. Rotate the shaft by hand. The rotating assembly should turn freely. If it does not rotate freely, the pump must be disassembled and the problem corrected.

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SV212 - SV216

24

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

50. Rotate the pump shaft with a torque wrench to assure correct assembly.When properly assembled, the torque required to turn the shaft (after “break-away”) should be within the ranges shown in the accompanying table.

Torque to turn shaft (variable pump at 0°) Ib.ft (Nm) Frame size

Minimum

Maximum

042

2 (37)

7.5 (10.2)

055

4 (5.4)

9 (12.2)

075

5 (6.71)

10 (13.6)

!

WARNING

!

Always test the pump prior to putting it into service to check for correct pressure limiter and control functioning. Improper functioning of these systems can result in uncontrollable movement of the vehicle/machine.

055 pump 51. In preparation for installing the adapter plate, place a new gasket on the housing. Place the adapter plate into position and install the screws. Torque the screws to 16 Nm. NOTE: A sealing washer must be installed under the head of any mounting screws that are installed into “thru” holes in the housing.

52. Install new O-rings and the orifice onto the electrovalve assembly and install the electrovalve onto the adapter plate. Install the screws and torque to 5.4 Nm (4 Ib.ft).

042 and 075 pump 53. In preparation for installing the control, place a new gasket on the housing. Inspect to ensure that the control orifice check valve and spring are in their proper position in the control.

SV212 - SV216

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

25

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

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

56. Align the control gasket and install the screws.

Torque the screws to 16 Nm (11.8 Ib.ft).

CD01D136

64

CD01D139

65

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

57. Install new O-rings in the PCP housing. Place the PCP against the EDC housing and install the screws. Torque to 5.4 Nm (4 Ib.ft).

NOTE: Do not remove the black plastic cover from the aluminium plate. This is not a serviceable item and will void the product warranty.

042, 055 and 075 pumps 58. Install the cartridge in the multi-function valve cavity and torque to 89 Nm (65.6 Ib.ft). Do not over torque the multi-function valve cartridge.

59. Install the shim adjustable pressure relief valve, torque to 68 Nm (50 Ib.ft).

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SV212 - SV216

26

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 INSPECTION AND ADJUSTMENTS

INSPECTION OF THE SUPPLY PRESSURE SAFETY VALVE Mark the position of the valve in relation to the cylinder body. Loosen the 27 mm (1.01 in) locknut and remove the safety valve. Check the valve cone and seat. On reassembling observe the correct position of the valve in relation to the mark. Tighten the locknut to a torque of 46-55 Nm (34-40.7 Ib.ft).

CD01D147

66

CD01D148

67

CD01D149

68

ADJUSTMENT OF THE SUPPLY PRESSURE SAFETY VALVE Loosen 27 mm (1.01 in) locknut and turn the adjustment plug. By turning c/w the pressure increases, cc/w decreases. Thereafter tighten the locknut to a torque of 46-55 Nm (34-40.7 Ib.ft).

ADJUSTMENT OF SAFETY PRESSURE Turn the screw by the internal hexagonal socket while holding the middle hexagonal head. Turning c/w the pressure increases, cc/w decreases. One turn changes pressure by 9.3 MPa (1349 psi). Once in the set position, hold the adjustment screw using key and tighten the locknut to a torque of 16 Nm (11.8 Ib.ft). Follow the same procedure for the second multi-functional valve.

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SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

27

ADJUSTMENT OF THE BY-PASS VALVES The by-pass valve is part of the multi-function valve.

Opening and closing of the valves is carried out with the motors shut down. For the middle screw of the multifunction valve use a 27 mm (1.06 in) key and for the large screw us a 1-1/4” key. Turn the middle screw 3 turns cc/w to open the by-pass valve. Do not turn by more than 3.5 turns - a considerable amount of oil would leak out.

CD01D150

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69

SV212 - SV216

28

SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

NOTES

SV212 - SV216

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SECTION 39 - FRAMES - CHAPTER 1

1

SECTION 39 - FRAMES Chapter 1 - Drum CONTENTS Section

92013

Description

Page

Description ..................................................................................................... 2 Specifications ................................................................................................. 4 Torque specifications ..................................................................................... 4 Special tools ................................................................................................... 4 Drum removal ................................................................................................. 7 Vibrator plate assembly .............................................................................. 14 Removal of the right side of the drum ....................................................... 16 Inspection and adjustment of vibration frequency ................................... 19 Troubleshooting............................................................................................ 20

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2

SECTION 39 - FRAMES - CHAPTER 1 DESCRIPTION

The vibrating drum, together with the driving lugs is fixed to both sides of the front frame using rubberized metal pieces of the prescribed rigidity. The vibration effect is generated by means of two cams located on both sides of the drum. The cams are joined by a shaft and actuated by a hydraulic motor that is located on the left side of the drum.

The drum is driven by a hydraulic motor located on the right side of the drum.

1 24

45

21 46

14 17

12 10

8

18

57 40

40

3

38 30

57

10

23 38 9 39

7

22 33

18

44

6

31

15 28

21 28

44

16 37

13 26 42

17 4

11a

2 15 16

20

11

1

CS01D552

1. Console 2. Console 3. Carrier 4. Vibrator plate 6. Nuts 7. Left cover 8. Right cover 9. Hub 10. Cover 11. Hydraulic motor 11a.Guide pin 12. Cover SV212 - SV216

13.

14.

15.

16.

17.

18.

20.

21.

22.

23.

24.

26.

Ring Screw M14 Spacers Spacers Support Retaining plate Screw Rubber mounting Ring Collar Hydraulic motor O-ring

28.

30.

31.

33.

37.

38.

39.

40.

42.

44.

45.

57.

Bearing Nut Pad Drain plug Screw M20x120 Screw M20x70 Screw M16x130 Screw M16x50 Screw M14x25 Screw M12x40 Screw M12x40 O-ring 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1

3

46 47 49 50 53

51 46

54

52 55

46 54 48 5

53 55

51 52

46 49

50

54

56

CS01D541

5.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

2

Connecting shaft Bearing Right shaft Left shaft Cam Cam Ring Key Bushing Snap ring Pin Connecting shaft

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4

SECTION 39 - FRAMES - CHAPTER 1 SPECIFICATIONS

SV212 SV216 Drum diameter .............................................................................. 1500 mm (59 in) .................... 1500 mm (59 in) Drum width................................................................................. 2200 mm (86.6 in) ................. 2200 mm (86.6 in) Drum thickness .................................................................................. 25 m (984 in) .................... 40 m (1574.8 in) Fluid capacity of vibrating rollers.........................................................8 L (2.11 gal) ......................... 8 L (2.11 gal)

TORQUE SPECIFICATIONS Fastening hardware Screws, nuts Thread Tightening torque Rubberized metal pieces (21) left, right side............. 44, 45, 52.......................M12 ..................... 75 Nm (55 lb-ft) Covers (12) ........................................................................... 46.......................M12 ..................... 75 Nm (55 lb-ft) Inside covers (10) ................................................................. 40.......................M16 ................. 165 Nm (122 lb-ft) Vibration hydraulic motor ...................................................... 14.......................M14 ................ 120 Nm (88.5 lb-ft) Drum (1) to frame (50) mounting .......................................... 37.......................M20 ................. 315 Nm (232 lb-ft) Left cover (7), right cover (8)................................................. 38.......................M20 ................. 315 Nm (232 lb-ft) Hub (9) left cover (7) ............................................................. 39.......................M16 ................. 165 Nm (122 lb-ft) Driving lug (3) hydraulic motor (24) - right side..................... 20.......................M20 ................. 314 Nm (231 lb-ft) Bracket (1), hydraulic motor (24) - right side......................... 19.......................M16 ................. 165 Nm (122 lb-ft) Bearings (28) ........................................................................... -............................ - ...........75-80 Nm (55-59 lb-ft)

SPECIAL TOOLS No1. Installation ND080073 (Bolts for clamping rubberized metal pieces)

ND080073

3

ND090535

4

ND080149

5

No2. Handling ND090535 (Wedge for drums)

No3. Handling ND080149 (For consoles pos.2 and 30-1)

SV212 - SV216

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SECTION 39 - FRAMES - CHAPTER 1

5

No4. Installation ND080229 (For tightening nut KM26 (30))

ND080229

6

ND101781

7

ND101776

8

ND101777

9

ND080148

10

No5. Installation ND101781 (Disassembly of hub (9), vibration plate (3) and bearings (28))

No6. Installation ND101776 (Seal ring driver (22))

No7. Control ND101777 (For checking on conical bearing pre-load in hub (9)).

No8. Installation ND080148 (For covers (7), (8) and (10); and vibrators)

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6

SECTION 39 - FRAMES - CHAPTER 1

No9. Installation ND080213 (Cam support (49))

ND080213

11

ND080145

12

ND080146

13

ND080147

14

CD01D161

15

No10.Installation ND080145 (For driving and calibration of bushing (53))

No11.Installation ND080146 (For setting up position pin (55)

No12.Control ND080147 (Axial bearing play)

No13.For frequency measurement ND103942

SV212 - SV216

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SECTION 39 - FRAMES - CHAPTER 1

7

DRUM REMOVAL 1.

Raise the drum frame until the drum is just touching the ground. Support firmly on both sides.

2.

Remove the cover from the vibration hydraulic motor.

3.

Remove the vibration hydraulic motor hose clamps.

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CD01C040

16

CD01C041

17

CD01C042

18

SV212 - SV216

8

SECTION 39 - FRAMES - CHAPTER 1

4.

Remove the four screws from the vibration hydraulic motor.

5.

Slide out the hydraulic motor and set it to one side of the frame.

6.

Remove the hose clamps on the rear cross member of the frame.

7.

Remove the travel hydraulic motor hose clamps.

SV212 - SV216

CD01C043

19

CD01C044

20

CD01C045

21

CD01C046

22 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1 8.

Place a suitable receptacle underneath the travel hydraulic motor.

9.

Remove the travel hydraulic motor hoses.

9

10. Plug the hoses and the hydraulic motor ports.

CD01C047

23

CD01C048

24

CD01C049

25

CD01C050

26

11. Attach the hoses to the mirror on the cab.

12. Disconnect the wires from the travel hydraulic motor (sensor, solenoid).

13. Unscrew the plugs in the front cross member and install the hooks.

14. Use a suitable lifting device to suspend the cross member.

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10

SECTION 39 - FRAMES - CHAPTER 1

15. Remove the screws (17) and (16) on both sides and set the cross member to one side.

27

CD01C051

16. Loosen the frame/bracket connecting screws (37) on the left side, and (9) on the right side.

9

37

28

CD01C052

17. Insert the tool No.1 clamping bolts.

No.1

29

CD01C053

18. Tighten the rubberized metal pieces an extra 810 mm (0.31-0.4 in).

8-10 mm

CD01C054

SV212 - SV216

1

30 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1

11

19. Following removal of the screws (37) remove the spacers (15, 16).

15

16

31

CD01C055

20. Roll the drum from the frame. Install the drain plug (33) in the left cover in lower position.

33

32

CD01C056

21. Use chock No.2 to prevent any machine movement.

22. Unscrew the drain plug (33) from the vibrator cover and drain the oil into a receptacle.

No.2

33

CD01C057

23. By turning the console (2), remove the screws (39) stepwise. The two screws placed horizontally are to be removed first after the tool has been attached.

39

CD01C058

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2

34 SV212 - SV216

12

SECTION 39 - FRAMES - CHAPTER 1

24. Position the console (2) vertically and using tool No.3 attach it to a suitable lifting device.

No.3

25. Remove the remaining two screws (39).

2

39

39

35

CD01C059

26. Remove the console together with the vibrator plate from the drum and set it to one side. Remove the tool No.1 screws one after the other.

No.1

No.1

36

CD01C060

27. Remove the screws and (44), remove the console (2) from the rubberized metal pieces.

2

44

37

CD01C061

28. The vibrator plate is to be rotated and placed on the rubberized metal pieces.

29. Remove the safety pad (31).

31

CD01C062

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38 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1

13

30. Place tool No.4 on the nut (30).

No.4

39

CD01C063

31. Remove the nut (30) and pad (31).

30

31 40

CD01C061

32. Rotate the vibrator plate - support.

33. Remove the screws (42).

42

41

CD01C065

34. Insert the screws in the holes, (tool No.5) and by tightening evenly remove hub (9). If necessary use screw tool No.5.

No.5

CD01C066

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42 SV212 - SV216

14

SECTION 39 - FRAMES - CHAPTER 1

35. Press out the bearing (28) from the hub, the seal ring (22) and the collar (23).

23 22 28

43

CD01C067

VIBRATOR PLATE ASSEMBLY For assembly, follow removal procedure in reverse order.

1.

28

Press the outer race of the bearing (28) into position and install the seal ring (22) using tool No.6.

22

28

44

CD01C067

2.

Install the “O” ring (26) and ring (13) on the vibrator plate bearing, preheated to 90°C (194°F) (when replacing). Insert the inner part of the bearing (28) preheat to between 90 and 100°C (194 and 212°F).

28

13

CD01C068

SV212 - SV216

26

45

7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1 3.

Fill the bearings with grease and insert the hub (9).

4.

Insert the inner part of bearing (28) - preheat to between 90 and100°C (194 and 212°F).

15

28

9 46

CD01C069

5.

Insert the pad (31), nut (30) and tighten with tool No.4 (tap slightly on the tool while tightening).

6.

Tighten the nut to a torque between 75 and 80 Nm (55.3 and 59 Ib.ft), using tool No.7.

No.7

CD01C070

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47

SV212 - SV216

16

SECTION 39 - FRAMES - CHAPTER 1 REMOVAL OF THE RIGHT SIDE OF THE DRUM

1.

Turn the drum to the position shown.

2.

Use tool No.3 to suspend console (1) with a suitable lifting device.

3.

Remove the screws (45).

4.

Set the console with the driving lug to one side.

12

45 No.3

03

1

48

CD01C071

5.

To remove the cover (12), remove the screws (38), suspending the cover on tool No.8 and using three M16 screws in service holes “A” to press the cover from the front of the drum.

6.

Set the cover to one side.

A A No.8

A 38 49

CD01C072

7.

Using the same tool, remove the vibrator.

No.8

CD01C073

SV212 - SV216

50

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SECTION 39 - FRAMES - CHAPTER 1 8.

9.

17

Remove the screws (40), retaining plate (18) and cover (10) and press out the outside races of the bearings (46) from covers (8 and 10) and remove the connecting shaft (5).

10 40

Follow the same procedure for removing the covers and vibrator on the left side of the drum.

18

5

46

51

CD01C074

10. Warm up the bearing races (46) to between 90 and 100°C (194 and 212°F) and slide then off the shafts.

46

46

52

CD01C075

11. Take out the ring half-segments (51) and the loose cam (50). The rigid cam may be removed by milling the cam body (49) in its weakest point, or by using a new shaft (47), (48) complete with cam (49).

47 48 49

51 50 53

CD01C076

12. When assembling the cam using new parts, shaft (47, 48) along with key (52) must be pressed first into a preheated cam (49) (250-350°C) (482662°F). The cam must be placed on tool No.9.

47 48 52 49

No.9

CD01C077

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54 SV212 - SV216

18

SECTION 39 - FRAMES - CHAPTER 1

13. Press the bushing (53) into the cam (50) using tool No.10.

14. Calibrate the bushing using tool No.10.

53

50

No.10

55

CD01C078

15. Further operations are identical for both sides of the drum and for assembly the procedure may be followed in reverse. When installing the outer bearing races (46) in the covers (7, 8 and 10), match with the internal bearing races.

46

7

8

56

CD01C079

16. Install the snap ring (54). For installation of the connecting shaft (5), the vibrators must be synchronized - this is done by aligning groove “A” on both ends of the shaft with the pins (55) in cam (47) and (48).

A

54

5 57

CD01C080

17. Press the pins (55) into both shafts (47) and (48), positioning with tool No.11.

55 47 48

CD01C081

SV212 - SV216

58 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 1

19

18. After installing the covers (7 and 8), check out the assembly using tool No.12. Axial play of the bearings of both vibrators should be 1.5-2.5 mm (0.0590.098 in).

No.12 59

CD01C082

19. For replacement of the vibration hydraulic motors (11), guide pin (11A) must be heated up to 200°C (392°F), and slid on the output shaft of the hydraulic motor. The guide pin on the spline must bottom freely and must not be forced.

11

11A

20. Coat the hydraulic motor (20) screws with loctite.

20

CD01C083

60

INSPECTION AND ADJUSTMENT OF VIBRATION FREQUENCY 1.

Measure the frequency while running and vibrating the drum vibrator. Place the sensor of the instrument against the plate and measure the frequency.

2.

If the frequency differs from that specified in this manual, adjust it by means of the adjusting screws on the vibration pump.

Frequency adjustment valve in Hz Machine

SV212

SV216

High amplitude Hz

32

29

Low amplitude Hz

35

35

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CD01D161

61

SV212 - SV216

20 3.

SECTION 39 - FRAMES - CHAPTER 1 Loosen the lock nut (2) and use a screw driver to turn the adjusting screws (1) (unscrewing gives higher frequency, tightening gives lower frequency).

The upper screw “A” adjusts frequency for high amplitude. The lower screw “B” adjusts frequency for low amplitude.

Do not adjust to a higher frequency than that specified by the manufacturer. Do not switch the frequencies, the lower frequency must work in conjunction with the higher amplitude and viceversa. Both low and high frequencies are factory adjusted.

3

2 B 1 CD01D162

SV212 - SV216

A

62

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SECTION 39 - FRAMES - CHAPTER 2

1

SECTION 39 - FRAMES Chapter 2 - Articulation CONTENTS Section

92020

Description

Page

Specifications ................................................................................................. 1 Torque specifications ..................................................................................... 1 Description ..................................................................................................... 2 Special tools ................................................................................................... 3 Disassembly ................................................................................................... 4

SPECIFICATIONS Max. vertical frame swing ................................................................................................................................±10° Max. horizontal steering angle .........................................................................................................................±36°

TORQUE SPECIFICATIONS Screws Thread size Screw item No. Torque Drum frame, plate (2)......................................................... M24..........................40 ................. 549 Nm (405 Ib.ft) Rear frame, plate (1).......................................................... M20..........................39 .............. 314 Nm (231.6 Ib.ft) Plate (2), bearing (23) ........................................................ M16..........................38 .............. 165 Nm (121.7 Ib.ft) Bearing (23), hub (3).......................................................... M14..........................37 ................... 118 Nm (87 Ib.ft) Hose clamp (6), plate (1) ................................................... M12..........................36 .................. 75 Nm (55.3 Ib.ft) Cover (11), hub (3)............................................................. M12..........................34 .................. 75 Nm (55.3 Ib.ft) Steering cylinder pin packing (17)...................................... M12..........................35 .................. 75 Nm (55.3 Ib.ft)

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SV212 - SV216

2

SECTION 39 - FRAMES - CHAPTER 2 DESCRIPTION

The articulation connecting the drum frame to the rear frame is equipped with a large-size bearing with cross rollers allowing for the frame to swing vertically, and two vertical pins allowing side movement for steering.

36 39 17 12

10 34

11 25

24 3 13

34

17 35

11 9

37

5

18

40

21

10 9 34 4

2 38

1

CS01C505

2.

3.

4.

5.

9.

10.

11.

12.

13.

17.

18.

21.

24.

Frame plate Hub Pin Shim Ring Cover Cover Pin Spacer Pad Pad Ring Bearing

SV212 - SV216

25.

34.

35.

36.

37.

38.

39.

40.

Nut Screw M12x25 Screw M12x30 Screw M12x40 Screw M14x90 Screw M16x60 Screw M20x16 Screw M24x90

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SECTION 39 - FRAMES - CHAPTER 2

3

SPECIAL TOOLS No1. Installation ND084425 (Front member under towing unit frame)

ND084425

1

ND080324

2

ND101782

3

ND090586

4

ND090610

5

ND90480

6

No2. Installation ND080324 (Rear member under towing unit frame)

No3. Installation ND101782 (For pressing out pin 4)

No4. Handling ND090586 (14t double-hook chain for the drum)

No5. Installation ND090610 (Wrench for nut KM 14, pos.25)

No6. Installation ND90480 (For bearing 24)

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SV212 - SV216

4

SECTION 39 - FRAMES - CHAPTER 2

No7. Handling ND103875 (suspension hook)

ND103875

7

ND080148

8

No8. Handling ND080148

DISASSEMBLY 1.

Place the machine on firm ground and support the frame in front using special tool No.1.

No.1

9

CD01C084

2.

Support the frame at the rear using special tool No.2.

No.2

CD01C085

SV212 - SV216

10

7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 2 3.

Remove the shims (5).

4.

Using special tool No.3, remove the pins (4) from the ends of the hydraulic cylinder rods, along with the rings (9) and seal rings (21).

5

4

9

21

No.3 5.

Remove the hose clamps on the drum frame.

6.

Remove the hose clamps on the articulation and the rear frame.

7.

Remove the vibration hydraulic motor cover.

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CD01C086

11

CD01C045

12

CD01C088

13

CD01C041

14 SV212 - SV216

6

SECTION 39 - FRAMES - CHAPTER 2

8.

Remove the vibration hydraulic motor screws.

9.

Slide the hydraulic motor from the drum and place it to one side.

15

CD01C043

10. Attach the drum to a lifting device using special tool No.4.

11. Remove the bolts (40) and the pad (18).

12. Place the drum to one side with the front frame to the right of the machine.

18

40 16

CD01C089

13. Attach a lifting device to the frame (2). Remove the screws (38). Place the plate (2) to one side.

2

38

17

CD01C090

14. Loosen the screws (37).

37

CD01C091

SV212 - SV216

18 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 2

7

15. Place special tool No.7 under the upper screw and attach a lifting device using special tool No.8. Place the bearing to one side.

No.7

No.8

19

CD01C092

16. Loosen and remove the nut (25) using wrench No.5.

No.5

CD01C093

20

CD01C094

21

17. Remove the pads (17) and press the pins (12) out of the bearings using a hydraulic press.

18. Use a lifting device to place the hub assembly (3) on one side.

3

CD01C095

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22 SV212 - SV216

8

SECTION 39 - FRAMES - CHAPTER 2

19. Remove the covers (10, 11) and the spacers (13).

20. Press out the bearings (24) using special tool No.6.

11 24

10 13

CD01C096

SV212 - SV216

23

7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 3

1

SECTION 39 - FRAMES Chapter 3 - Drum Segments and Scrapers CONTENTS Section

92013

Description

Page

Specifications ................................................................................................. 1 Hardware torque ............................................................................................ 1 Special tools ................................................................................................... 1 Description ..................................................................................................... 2 Segment installation ...................................................................................... 3

SPECIFICATIONS

HARDWARE TORQUE Screws and nuts for segments................................................................................................ 314 Nm (231.6 Ib.ft)

SPECIAL TOOLS No1. Clamps ND054304

CS01D542

7-29530 - 04-2001

1

SV212 - SV216

2

SECTION 39 - FRAMES - CHAPTER 3 DESCRIPTION

5 9 12 16

21 7

11

CS01D547

5.

6.

7.

9.

11.

12.

16.

21.

6

11

1

Plugs Rear scraper Front scraper Screws Screws Screws Nut Washer

SV212 - SV216

7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 3

3

SEGMENT INSTALLATION 1.

Place the machine on firm and flat ground.

2.

Use a suitable lifting device to suspend the front scraper with clamps for smooth drums.

3.

Remove the scraper screws (9).

2

CD01C141

9

4.

CD01C142

3

CD01C143

4

Lower the scraper to ground and set it to one side.

7-29530 - 04-2001

SV212 - SV216

4

SECTION 39 - FRAMES - CHAPTER 3

5.

Follow the same procedure for removal of the rear scraper.

6.

Remove the plugs (5) in the drum frame.

7.

Clean the surface of the drum thoroughly.

8.

Lift the first segment using the holes provided.

9.

Place it on the drum.

SV212 - SV216

CD01C144

5

CD01C145

6

CD01C146

7

CD01C147

8 7-29530 - 04-2001

SECTION 39 - FRAMES - CHAPTER 3

5

10. Fasten with the four No.1 clamps (two on each side). Before tightening, even up the segment edges with the edge of the drum.

No.1

CD01C148

9

CD01C149

10

CD01C150

11

CD01C151

12

11. Drive slowly forward for about 1.6 metres (63 in), while checking that the clamps do not interfere with the drum frame.

12. Position the second segment, leaving a gap of about 26 mm (1.02 in) between the segments.

Connect the segments using hardware items 12, 16 and 21.

13. Move forward again, place the third segment in position and proceed as before with the second segment.

Tighten the screws, move the machine so that the segments settle down on the drum, check the screws and then tighten fully to a torque of 314 Nm (231.6 Ib.ft).

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SV212 - SV216

6

SECTION 39 - FRAMES - CHAPTER 3

14. Install the segment scrapers (6, 7) supplied with the segments on the front member and the rear cross-member of the drum frame. Adjust the gap between scraper and the drum to 30 mm (1.18 in).

Previously removed screws (11) and pads may be used if required. Tighten to a torque of 314 Nm (231.6 Ib.ft).

11

7 6

CD01C152

SV212 - SV216

13

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SECTION 41 - STEERING - CHAPTER 1

1

SECTION 41 - STEERING Chapter 1 - Control CONTENTS Section

50110

Description

Page

Specifications ................................................................................................. 1 Special tools ................................................................................................... 1 Description ..................................................................................................... 2 Fault finding - steering .................................................................................. 3 Disassembly and assembly of steering wheel ............................................ 3

SPECIFICATIONS

SPECIAL TOOLS No.1 Assembly (Washer for steering wheel removal)

ND080755

1

7-29530 - 04-2001

SV212 - SV216

2

SECTION 41 - STEERING - CHAPTER 1 DESCRIPTION

3

5

3

2 1

4 2

CS01C508

1 2 3 4 5

Steering pump Steering control valve Steering cylinders Hydraulic reservoir Filtration block

STEERING WITHOUT ACTIVATION

ACTIVATION OF STEERING TO THE RIGHT

Oil is pumped from the tank by the steering pump and oil under pressure passes through the open center of the power steering into the filtration block.

Oil is pumped by the steering pump from the oil tank and passes under pressure through the open port of the power steering, over the steering hydraulic motor into the steering cylinders.

Devices for supplying closed circuits are connected to the output of the filtration block.

SV212 - SV216

By the effect of the movement of the steering cylinders, oil passes from opposite openings to the filtration block through the power steering, and to supply the closed circuits.

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SECTION 41 - STEERING - CHAPTER 1

3

FAULT FINDING - STEERING PROBLEM

POSSIBLE CAUSES

CORRECTION

Steering is defective, the wheel gets stuck

1- Steering control valve

1- Inspect and repair

Steering does not work in difficult terrain

1- Low pressure

1- Adjust pressure

2- Worn pump

2- Replace pump

Steering goes to one side

1- Defective servo reverse valve

1- Inspect and repair

DISASSEMBLY AND ASSEMBLY OF STEERING WHEEL Remove the steering wheel cup (6) and the nut (21) and insert tool No.1 under the steering wheel. Remove the steering wheel using a steering wheel spanner, dismantle the steering wheel bracket (1) and slide it with the steering rod (2) out from the steering column.

Remove the snap rings (30), (31) and press shaft (2) out together with the bearing. Remove the bearing (9) from the shaft.

7 21 25 31

Press the bearing on the shaft (the bearing must be degreased and fresh grease must be applied), secure it with the snap ring (31), press it into bracket (1), secure with the snap ring (30) and mount it to the steering column. Check that no clearance can be detected between bracket (1) and the steering column after the shaft has been set in steering. Mount the steering wheel.

30

1

9 18 26

2

CS01C507

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6

3

SV212 - SV216

4

SECTION 41 - STEERING - CHAPTER 1

NOTES

SV212 - SV216

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SECTION 41 - STEERING - CHAPTER 2

1

SECTION 41 - STEERING Chapter 2 - Steering cylinders CONTENTS Section

50761

Description

Page

Specifications ................................................................................................. 1 Special torques .............................................................................................. 1 Special tools ................................................................................................... 2 Removal of steering cylinders ...................................................................... 3 Replacing the seals ....................................................................................... 4

SPECIFICATIONS

SPECIAL TORQUES Piston rod/piston/nut assembly (M42x2).................................................................................... 430 Nm (317 Ib.ft) Cylinder body/cover assembly (M115x2) ................................................................................ 660 Nm (486.8 Ib.ft)

7-29530 - 04-2001

SV212 - SV216

2

SECTION 41 - STEERING - CHAPTER 2 SPECIAL TOOLS

No.1 Assembly ND101784 (Spanner for disassembly of cover 10)

ND101784

1

ND101785

2

ND101783

3

ND101782

4

Assembly ND101785 (Spanner for disassembly of cover 10)

No.2 Assembly ND101783 (For installation of piston in hydraulic cylinder)

No.3 Assembly ND101782 (For removing pin 10)

SV212 - SV216

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 2

3

REMOVAL OF STEERING CYLINDERS

16

11 10 11

10 16 CS01C510

5

Place the machine on firm flat ground. Turn the steering wheel as far as it will go and lift the cab for easier access.

Place a tray under the dismounted hydraulic cylinder. Disconnect the hoses and plug them up. Remove the shims (11) and screws (16), and extract the pins (10) from the ends using special tool No.3. Push the piston rod in after the piston rod pin has been pressed out. Remove the hydraulic cylinder from the machine using a suitable lifting device, sliding it out through the rear frame opening towards the drum.

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SV212 - SV216

4

SECTION 41 - STEERING - CHAPTER 2 REPLACING THE SEALS

Place a tray under the hydraulic cylinder and plug the ports. Drill the safety pin out from the front cover face (10) (or remove the locking device employed, depending on the type of the hydraulic cylinder. Remove the cover (10) using wrench No.1 (depending on the type of the hydraulic cylinder), slide the piston rod (4) with the piston (5) out and remove the nut (8) and the piston.

Remove the cover (10).

8

5

4

10

6

CS01C509

Dip all new seals in oil before installation.

Grease all sliding surfaces and watch out for damage to sliding surfaces. Install parts with new seals only after straightening out the seals. At least 15 minutes should elapse between the installation of new seals and the completion of the hydraulic cylinder assembly. Use special tool No.2 for the installation of the piston rod with the piston in the cylinder body.Tighten threaded assemblies to the torque specified.

1

6

5 CS01C509

2

3

4 7

ASSEMBLY SEALING MATERIAL KITS ITEM NO.

DESCRIPTION

PCS

1

T19 Packing

1

2

T20 Collar

1

3

Wiper ring

1

4

Guide band

2

5

Ring

1

6

Ring

2

SV212 - SV216

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3

1

SECTION 41 - STEERING Chapter 3 - Steering control valve CONTENTS Section

50743

Description

Page

Specifications ................................................................................................. 1 Tightening torques ......................................................................................... 1 Description ..................................................................................................... 2 Special tools ................................................................................................... 3 Disassembly ................................................................................................... 4 Reassembly .................................................................................................... 7 Functional check .......................................................................................... 12

SPECIFICATIONS Technical data and set values for assembly Setting for valve piston in housing (hydraulic center) ........................................................................ 2.3±0.01 mm recess provided in gauge holder 7470798101 Setting tolerance for hydraulic center ± 0.05 mm Disks (42) - distance gauge - valve piston ................................................................... Thicknesses 1.5 to 2.1 mm Gradations from 0.05 to 0.05 mm Axial play of drive shaft (8)..........................................................................0.03 mm, setting tolerance ± 0.02 mm Disk (3) - axial play of drive shaft....................................................................... Gradations from 0.05 to 0.05 mm Steering spindle - slip torque .................................................................................................................max. 8 Nm

TIGHTENING TORQUES Hexagon bolts (1) - cover (2) .............................. 32 ± 3 Nm (for servostats with nominal pressure up to 150 bar) 40 ± 3 Nm (for servostats with nominal pressure up to 180 bar) Pressure relief valve (19) ....................................................................................................................... 30 ± 3 Nm Bolts securing the steering system in its bracket .......................................................20 ± 3 Nm - 4 bolts M8, 10.9 Filter insert (29)...................................................................................................................................... 12 ± 3 Nm Hexagon nut - steering wheel ..............................................................................................................35 to 45 Nm

7-29530 - 04-2001

SV212 - SV216

2

SECTION 41 - STEERING - CHAPTER 3 DESCRIPTION

5

7

5

49

6 5 2

4

3 21 20

1 45

29 10

19

11

39 12

43 18

16 9

15

34

40 37

35 36

17

SV212 - SV216

5

23 27 28

31 32 23 25

23 28 22

24

30

33 23 1

CS01E526

Bolts Cover Spacer Compensating disk O-ring Rotor-set Cover disk Drive shaft Housing O-ring Plug Pressure spring Pressure relief valve Poppet Seal disk Cover disk Pressure spring Valve guide bearing Valve insert/plug O-ring Check valve Plug O-ring Popper Seal disk Cover disk

48

14 24 25 26

36 26

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

44

41

38

13

46

8

42 47

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

Plug Pressure spring Filter Valve seal Valve seal Ball Canical plug Stop bush Spring washer Spacer Spring carrier Coupling piece Steering spindle Pin Axial needle Compensating disk Back-up ring O-ring Name plate Round head grooved pin O-ring Seal ring Flange

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3

3

SPECIAL TOOLS No1. Assembly device N° 8470 798 651

Not illustrated

2

XXXXXXX

No2. Tool for removing pressure relief valve (19) N° 8440 798 201 Not illustrated

3

XXXXXXX

No3. Mandrel with aligning bush for seal ring (42) flange N° 8470 798 001 Not illustrated

4

XXXXXXX

No4. Guide bolts for assembling the steering element N° 8470 798 051 Not illustrated

5

XXXXXXX

No5. Gauge holder for measuring the valve piston and drive shaft N° 8470 798 101 Not illustrated

6

XXXXXXX

No6. For motor widths 8.5, 9.5, 11.1 to 106 mm, gauge insert 13 mm diameter N° 8470 798 552 Not illustrated

XXXXXXX

7-29530 - 04-2001

7 SV212 - SV216

4

SECTION 41 - STEERING - CHAPTER 3

No7. Torque meter (without insert) N° 7470 798 703

Not illustrated

8

XXXXXXX

No8. Insert for torque meter N° 8470 798 551

Not illustrated

9

XXXXXXX

DISASSEMBLY In order to ensure reliable functioning of the servostat within the overall steering system, absolute cleanliness must be ensured during removal, storage of the parts and assembly.

1.

Clamp assembly device 1 in the vice and mount the steering system in this device with the hand pump side upper most. Remove the bolts (1).

2.

Remove the following parts in succession: Cover (2), Compensating disk (4) (for steering system designs with motor width above 15.9 mm), additional spacer (3), rotor set (6) and cover disk (7).

4

3

2

5 7 5

1

6 5 10

CS01E517

3.

Draw a diagonal line from the housing (9) to the flange (49).

4.

Remove the housing (19) from the flange (49).

5.

Take up the released pressure spring (12) with combined shutoll and pressure relief valve.

6.

47 12

43 44

48

13

Take up the released short-circuit valve comprising the plastic valve guide (18) with pressure spring (17), poppet (14), seal disk (15) and cover disk (16).

42

5 49

41 18 38 39 14 15 16 17 CS01E518

SV212 - SV216

11

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3 7.

Remove the coupling piece (38).

8.

Remove the steering spindle (39) with axial needle bearing (41) and compensating disk (42) from the flange.

9.

Remove the valve piston complete with stop bush (34), spring carrier (37) and drive shaft (8) from the housing.

10. Separate the valve piston, stop bush, spring carrier, drive shaft and pins (40). Only remove the plug (11) with O-ring (10) if necessary. If wear or damage is not visible, the spacer disk (36) and spring washers (35) should not be separated from the spring holder.

5

11

40

37

36

10

34

8

9 35

36 12

CS01E519

11.

!

WARNING

!

Since the hose safety valves are prescribed by law for closed designs and are subject to the acceptance conditions of the technical control boards (TUV), these may only be removed if an appropriate test bench is available for realignment, permitting a flow rate of approx. 1.5 to max 4 dm3/min and producting the pressure required for the test.

Remove the plug (33) and valve seats (30) from the housing. Tip out the balls (32) and valve seats (31).

31

23 32

30 23

9 CS01E520

7-29530 - 04-2001

33 13

SV212 - SV216

6

SECTION 41 - STEERING - CHAPTER 3

12. Using a hook, press the plug on the hand-pump side through the R-connection from the housing port. Tip out the poppet (24) with seal disk (25) and cover disk (26).

25 26 9

24

13. Press the cylinder replenishing valve, comprising the poppet (24), seal disk (25), cover disk (26), pressure spring (28) and plug (27) out of the housing on the flange side, using a mandrel.

28

23 27

23 22 28 26 25 24 14

CS01E521

14. Unscrew the check (21) from the “P” connection.

21

9 15

CS01E522

15. Unscrew the filter insert (29) from the housing.

NOTE: The valve insert model up to 50 dm3/min volumetric flow may only be dismantled for cleaning. In the case of wear or pressure deviations, the entire valve must be replaced. Since the valve setting cannot be corrected, the valve must be re-assembled using the same components. Valve insert up to 80 dm3/min volumetric cannot be dismantled.

29

9 16

CS01E523

16. Remove valve insert (19).

17. Screw the hexagon nut, tool 2 (port “b”) onto the threaded part of the pressure relief valve. Place the spacer, tool 2 (port “a”) onto the valve shaft and engage the hexagon nut with the spacer.

20 19

18. Clamp a hexagon socket screw wrench vertically into the vice and place the valve insert with the hexagon socket on the wrench.

9 CS01E524

SV212 - SV216

17 7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3

7

19. Using a fork wrench, width across flats 27, turn the hexagon nut against the spacer, until screw plug (201) and sleeve (202) separate.

!

WARNING

!

The valve is spring-pretensioned.

20. Remove the valve piston (203), pressure spring (205), washer (206), spring plate (207) and valve body (208). Remove the washer (20) and pressure pin (210) from the valve body (208). Draw the Oring (204) from the valve piston.

201

208 209

210

205

207

206

203 18

CS01E516

REASSEMBLY 1.

Install cylinder replenishing valves.

2.

Place a greased O-ring (23) on the plug (22) with projection on the face. Assemble the poppet (24) with seal disk (25), cover disk (26), pressure spring (28) and plug (22), and place this in the handpump side bore on the housing.The plug should be flush with the housing surface.

3.

Place a greased O-ring (23) on the plug (27) without projection on the face. Assemble the poppet (24) with seal disk (25), cover disk (26) pressure spring (28) and plug (27) and place this in the flange-side bore on the housing. The plug should be flush with the housing surface.

4.

Install dummy plug (11).

5.

Press the dummy plug with greased O-ring (10) into the housing bore flush with the flange.

6.

In the vice, compress the spring assembly, comprising the two external spacers (36) with the punched hole on the inside, and the two internal spring washer (35), with the spring recess in the middle facing one another. Install this assembly in relation to the carrier. Center the spring assembly in the relation to the carrier. Combine the spring carrier (37) and stop bush (34), the shorter drive cams on the stop bush should relate with the shorter driver grooves on the spring carrier.

7-29530 - 04-2001

25 26 24 23 26 27 22

9

23

28 26 25 24 19

CS01E521

11

40

37

36

10

34

9

8 35 CS01E519

36 20

SV212 - SV216

8

SECTION 41 - STEERING - CHAPTER 3

7.

Screw the stop bush with spring carrier into the valve piston so that it still turns easily; align the spiral spline of the stop bush with the 3 drive cams on the valve piston. Screw the stop bush in until the two drives on the opposite side overlop over the full length.

8.

First place the drive shaft (8) with pin (40) in the valve piston assembly; the drive shaft pin should be aligned with a common longitudinal groove in the stop bush and/or valve piston. The position of the stop bush in relation to the valve piston described in paragraph 6, above should be maintained.

9.

Slide the valve piston assembly into the housing with the two drive cams on the flange side.

10. Place the gauge (large model, 1/100 mm scale, at least 15 mm total stroke) into the eccentric clamp hole of the gauge holder 0.5. The gauge holder has a recess with precise tolerance (refer to the technical data). On an even surface, such as the cover (2), clamp the gauge in the holder so that the stroke is roughly halved. Set the gauge to “zero”.

11. Secure the gauge holder with 3 bolts on the flange side of the housing and turn one driver cam on the stop bush to the traver pin. Position the valve piston and drive shaft facing this set-up. Note the valve on the gauge in this position. Record the measured valve obtained, e.g 7.15 mm. Remove the gauge holder from the housing; do not change the setting.

12. Place the axial needle bearing (41) and compensating disk (42) removed during disassembly onto the steering spindle (39) in succession. Insert the steering spindle (39) in the flange (without the built in seal rings). Place the gauge holder on the flange and read off the valve facing the polished face of the steering spindle turn the steering to contact the axial bearing. Measured valve obtained, for example, 7.20 mm. Correct the difference of 0.05 mm by fitting a thicker compensating disk (42), refer to the technical data. Remove the valve piston assembly and steering spindle from the housing and flange.

17 12

18

13 42

5 49

41 18 38 39 14 15 16 17 CS01E518

SV212 - SV216

43 44

21

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3

9

PRE-ASSEMBLE FLANGE 13. Lightly grease the O-ring (44) and place it in the external radial groove of the flange bore.

14. Compress the back-up ring (43) to form a heart and place it on the O-ring (44). Ensure that the back-up ring contacts the O-ring all round.

15. Place the flange on the work bench with the parting plane up wards. Place tool 3 (port “a”) with the conical opening upwards into the flange. place the lightly greased O-ring (47) over the seal ring (48) and place both parts in the tool. Using tool 3 (port “b”), press the seal ring into the flange.

16. Place the axial needle bearing (41) and compensating disk (42) removed during dismantling onto the steering spondle (39) in succession. Press the steering spindle into the flange, being careful of the seal elements. The steering spindle should not be repeatedly pushed in and taken out once the seal elements have been fitted.

17. Clamp assembly mechanism 1 into the vice. Place the flange (49) into the assembly device and secure by means of 2 hexagon bolts. Place the coupling piece (38) on the steering spindle with the flat tang of the coupling piece in the driver groove of the steering spindle. Place the O-ring (5) into the flange. Screw one guide bolt 4 into two opposite flange screw threads.

18. Assemble the poppet (14) with seal disk (15), cover disk (16) pressure spring (17) and valve guide (18) in succession, and place the assembly in the flange-side housing bore.

19. Place the combined shutoff and pressure relief valve (13) into the flange-side housing bore with the locating spring on the outside, together with the pressure spring (12).

20. Clamp the assembly device into the vice so that the two guide bolts are horizontal. Slide the housing (9) over the guide bolts in the position marked during dismantling and place it on the flange. The shortcircuit valve (23) matches the unmachined cost recess of the flange exactly. Engage the driver cams of the stop bush with the coupling piece by turning the steering spindle.

7-29530 - 04-2001

SV212 - SV216

10

SECTION 41 - STEERING - CHAPTER 3

21. Place O-ring (5) on the housing. Place the cover disk (7) with the visible oil chambers facing the housing, but otherwise as desired.

4

22. Turn the drive shaft until the two face-side markings are parallel to the vertical housing connection side.

23. Place one O-ring (5) into each groove of the external rotor of the rotor set (6). Position the rotor set; the open rotor chamber must point towards the housing connection side.

24. Place the compensating disk (4) removed during dismantling onto the drive shaft. For steering models with rotor width over 15.9 mm: First place the spacer (3) with reduced diameter on the drive shaft.

3

2

5 7 5

1

6 5

CS01E517

22

25. Place a gauge in the center bore of the gauge holder 4 (large model 1/100 mm scale). Unscrew the base of the gauge’s tracer pin, replacing it with a base with a plane surface diameter of 13 mm, tool 6. Place the gauge on a plane surface of the cover (2), and set to “zero”.

26. Unscrew guide bolt 4. Tightly screw the gauge holder with 2 cover bolts (1) and washers onto the rotor set (refer to the technical data). Turn the steering spindle using tool 8, and note the position reaching the highest valve on the gauge. Stop turning the steering spindle at this point, lightly pressing the base of the tracer pin so that the internal steering elements are moved down.

27. Note the measured valve. Deduct the drive shaft play from the measured result (refer to the techincal data). The difference can be corrected by installing a thicker washer (53) (refer to the technical data for gradations).

28. Remove the gauge holder. Position the cover (2) and screw in the hexagon bolts (1). Only bolts of the length and type specified in the spare parts list may be used. Refer to the technical data for tightening torques.

29. Check the slip torque of the internal steering elements. For this purpose, place the torque meter 7 with insert 8 onto the steering spindle and measure the idling torque, as per technical data. If this check reveals a higher torque than specified in the technical data, the cover bolts must be removed again and the housing aligned in relation to the cover by repeatedly turning the steering spindle. Then retighten the cover bolts with the prescribed torque.

SV212 - SV216

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3 30. Tightly screw the filter insert (43) into the central threaded hole on the housing connection side.

Refer to the technical data for tightening torques.

11

13

9 23

CS01E523

31. Screw the check valve (21) into the P-connection and tighten using a hexagon socket screw wrench.

Refer to the technical data for tightening torques.

21

32. Clean the parts thoroughly; rubber and plastic parts must not be cleaned using trichloroethylene.

Blow through holes.

9 24

CS01E522

33. Place the O-ring (204) in the groove of the valve piston (203). Being careful of the O-ring, press the valve piston into the sleeve (202).

201

208 209

205

206

34. Place pressure pin (210) in the valve body (208).

Close the valve body with the plastic washer (209).

Place the plate spring (207) and pressure spring (205) onto the valve body.

35. Place washer (206) in the valve piston. This washer has been selected by the manufacturer. If no washer was fitted, the valve must be reassembled without a washer.

36. Place the pre-assembled part into the valve piston and then fit the screw plug (201). Clamp the assembly and press the sleeve (202) onto the snug fit of the screw plug (201).

210 CS01E516

207

203 25

37. Tightly screw in the valve insert with O-ring (20) fitted. Refer to the technical data for tightening torques.

7-29530 - 04-2001

SV212 - SV216

12

SECTION 41 - STEERING - CHAPTER 3

38. Clamp the assembly device into the vice so that the two lateral housing bores are uppermost. Then place a valve guide (31), with locating ball on the outside, and a ball (32) into each hole.

31

39. Screw the valve guides with fitted greased O-rings (23) into the housing bores. So that the hose safety valves can later be set on the test bench, only screw the valve guides in until the outside O-rings are just inside the gauge bores.

23 32

30 23

9 CS01E520

33 26

FUNCTIONAL CHECK Clamp the completely assembled steering system on the test bench.

Connect the pressure and return lines.

Connect each cylinder via one high pressure hose. The cylinder used should leak as little oil as possible so as to ensure that subsequent measurements are not distorted. The quantity of oil leaked must be measured in all cases and deducted from the valves determined in accordance with 14.5, below. Bleed the steering system and raise the oil temperature to approx 65°C. Set the flow rate and test bench pressure in accordance with the specifications in the spare parts lists (nominal pressure +30 bar).

SETTING THE HOSE SAFETY VALVE

Turn the steering system as far as possible to the right and then pull on the steering wheel with a force of approx. 30 to 40 N. The breakaway pressure of the hose safety valve at the R. connection must build up.

The adjustment should be made after releasing the steering wheel by screwing the valve seat (30) in or out.

The valve specified in the spare parts list (tolerance ± 10 bar) must be obtained. One revolution of the valve seat corresponds to approx. 130 bar.

The second hose safety valve is adjusted in the same way by turning the steering wheel to the left. The hexagon socket of the valve guides should be closed using the plug (33).

Remove plug 8440 030 106 and replace it with the pressure relief cartridge (19).

NOTE: Before commencing adjustments, unscrew the hose safety valves as described in section “38”, above, until they are flush with the housing, thus ensuring that the outer O-rings are tight.

Remove the pressure relief cartridge (29) from the steering system and replace it by a plug 8440 030 106.

Set the test bench to a volumetric flow of 4 dm3/min and a pressure of +30 bar in accordance with the spare parts list.

SV212 - SV216

7-29530 - 04-2001

SECTION 41 - STEERING - CHAPTER 3 CHECK THE MAXIMUM PRESSURE

13

SLIPPING OF POWER ASSISTED STEERING WHEEL

Pression (bar)

With the pump running, turn the steering wheel clockwise as far as possible and pull on the steering wheel, diameter 500 mm, with a force of 35 N (corresponds to a torque of 8.25 Nm). The test pressure must correspond to the nominal pressure specified in the spare parts list or on the nameplate, but must not exceed 100 bar.

The slip is within the permitted range if no more revolutions are required to turn the steering wheel than listed in the table below for the given rotor width.

Courant volumique (dm3/min)

27 Adjust the flow rate and test bench pressure in accordance with the specifications on the spare parts list (nominal pressure + 30 bar).

CS01E525

Turn the steering system as far as possible and then pull on the steering wheel with a force of approx. 30 to 40 N. The maximum steering pressure must be built up.

The valve of the maximum pressure must correspond to the specifications in the diagram or to the nominal pressure on the nameplate and in the spare parts list.

Tolerance ± 5%. Repeat the measurement in the opposite direction. If the maximum pressure is not obtained within the specified tolerance, the pressure relief valve is wrongly set.

CHECK VALVE RETURN

Permissible slip new Rotor with mm Rev per Rev per 30 sec 1 min

Permissible slip when worn Rev per 30 sec

Rev per 1 min

8.5

2.3

4.5

3.4

6.7

9.5

2.0

4.0

3.0

5.9

11.1

1.8

3.5

2.5

5.0

12.7

1.5

3.0

2.3

4.5

15.9

1.2

2.4

2.0

4.0

19.0*

1.0

2.0

1.8

3.6

* Over Repeat the test turning the steering wheel in the other direction.

Build up the maximum pressure in the terminal position.

After slowly releasing the steering wheel, the maximum pressure must drop at a rate of 10 bar per second to the operating pressure.

CHECK FOR STICKING Once the maximum pressure has fallen and the steering wheel been released slowly, no noticeable sticking may occur when turning the steering wheel in the other direction.

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14

SECTION 41 - STEERING - CHAPTER 3

CHECK OIL LEAKAGE When turning the steering system as far as possible with the pump running, the oil leaked must not exceed the maximum valves listed in the table below for the given test pressure and oil leakage.

Normal pressure (bar)

Test pressure (bar)

Oil leaked in dm3/min

50

40

0.44

80

64

0.64

100

80

0.77

120

96

0.90

130

104

0.97

150

120

1.10

180

144

1.27

The oil leaked from the cylinder must be subtracted from the mensured valve.

Repeat this check for oil leakage, turning in the other direction.

CHECK HYDRAULIC CENTER When the pump is running and the steering wheel turned as far as possible in either direction, the difference in torque between clockwise rotation must not exceed 20%, referred to the lower valve. In each case, a pressure of 20 bar above the operating pressure should be obtained.

CHECK FOR EXTERNAL TIGHTNESS Set a return pressure of 10 bar on the test-bench. After running for two minutes with the steering valve in idle position, no leakages may be visible in the power assisted steering system. The protective cover or steering column jacket should be removed from the steering system.

Tightness at high pressure should be checked during the tests in accordance with paragraphs “Check the maximum pressure” and “Check valve return” above.

FUNCTIONAL CHECK OF REPLENISHING VALVES Cavitation must not occur when the steering wheel is turned 2 or 3 times from one end position, to the other without power assistance. This test must be carried out with an unbalanced cylinder, because in this case the missing wheel volume required to fill the larger cylinder chamber must be obtained via the replenishing valve.

SV212 - SV216

7-29530 - 04-2001

SECTION 50 - AIRCONDITIONING - CHAPTER 1

1

SECTION 50 - HEATER - AIRCONDITIONING Chapter 1 - Removal and installation CONTENTS Section

90310

Description

Page

Specifications ................................................................................................. 1 Removal .......................................................................................................... 2 Defects in the airconditioning system ......................................................... 4 Replacing (tightening) the belt ..................................................................... 5

SPECIFICATIONS Cooling power ..................................................................................................................................3 kW (4.02 hp) Voltage .............................................................................................................................................................24 V Current ...............................................................................................................................................................6 A Coolant..........................................................................................................................................................R134a Quantity of coolant ...................................................................................................................................... 0.95 kg High-pressure protection..........................................................................................................2.7 MPa (391.6 psi) Low-pressure protection ...............................................................................................................0.2 MPa (29 psi)

7-29530 - 04-2001

SV212 - SV216

2

SECTION 50 - AIRCONDITIONING - CHAPTER 1 REMOVAL

1.

Loosen the filler cap (33).

33

2.

Open the drain valve on the radiator.

3.

Drain the coolant into a suitable container.

4.

Raise the cab.

SV212 - SV216

CD01C131

1

CD01C018

2

CD01C117

3

7-29530 - 04-2001

SECTION 50 - AIRCONDITIONING - CHAPTER 1 5.

Remove the heater cover.

6.

Disconnect the air pipes, wiring, and remove the heater control valve from the cab frame.

7.

Disconnect the heater supply and return hoses.

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3

CD01C132

4

CD01D133

5

CD01D133

6

SV212 - SV216

4

SECTION 50 - AIRCONDITIONING - CHAPTER 1

8.

Remove the screws that attach the heater return hose on the cover.

9.

Remove the heat exchanger.

CD01C135

7

CD01C136

8

DEFECTS IN THE AIRCONDITIONING SYSTEM Always call service for repairs DEFECT

CAUSES

The unit doesn’t cool

Check compressor belt Check evaporator fan. NG. Check fuses F6 in the fuse box See Operator’s manual Check coolant level in inspection orifice of the dryer filter. Leakage receiver - (bubbles, fogging up, etc...)

Check solenoid switch, with engine running with A/C on the switch doesn’t react (no click in compressor) 1. Faulty fuse F6, 2. Faulty thermostat 3. Faulty pressure protection

SV212 - SV216

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SECTION 50 - AIRCONDITIONING - CHAPTER 1

5

REPLACING (TIGHTENING) THE BELT Loosen the screws (16, 17) and the belt (13) (remove) by swinging compressor 12 in (-) direction.

17

Tighten using a suitable lever by swinging the compressor in (+) direction.

12 16 17 CS01D587

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13 9

SV212 - SV216

6

SECTION 50 - AIRCONDITIONING - CHAPTER 1

NOTES

SV212 - SV216

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SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

1

SECTION 55 - ELECTRICAL CIRCUIT Chapter 1 - Wiring diagram CONTENTS Section

40000

Description

Page

Electrical installation ..................................................................................... 1 Functional description ................................................................................... 2 Electrical legend ............................................................................................ 4

ELECTRICAL INSTALLATION OVERALL FUNCTION The electrical installation consists of two accumulator batteries, an alternator and other control and indicating devices.

Operating voltage is 24 V. The negative pole of the accu-batteries is connected to the machine frame through a battery master switch. The battery master switch connects or disconnects the supply to the machine electrical system.

In addition to the conventional automotive type circuits in the machine, a number of electronic components are used, for example, some circuits are protected by diodes, some instruments use thyristors, etc.

A hydraulic control block (ASC) is controlled by a computer (SUSMIK) located below the instrument panel. Therefore all welding work on the machine is prohibited, without disconnecting all sensitive components from the power supply and/or dismantling them, if possible, in advance. For example, data stored inside the SUSMIK equipment can be erased by welding close to it. In the following section, you will find circuit diagrams of the machine electrical system and interconnections of the individual circuits.

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2

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 FUNCTIONAL DESCRIPTION

PLACING THE STARTER SWITCH KEY IN POSITION 1 ON After placing the starter switch key in position 1, the engine and the machine are in rest position. The battery master switch is ON. - a 24 V current runs to the F3 fuse - this current flows through S10, S11 to the UB contact of a brake timer.

- In addition, the H6 indicator lamp is supplied from F3; thereafter the current passes through the S21 brake pressure switch to the ground. The indicator lamp is ON - the machine is braked.

- The current continues through the S13 neutral position switch, current runs to K5 that goes ON, thereby, connecting contacts 3 and 5 and this supplies the H5 neutral position indicator lamp and the E16, E17 brake lamps.

- In addition, the current flows to A4; after passing through the F4 and F5 fuses the other measuring instruments and indicator lamps are supplied.

- The H9 engine oil pressure warning lamp is ON. - The engine hourmeter is not functioning, because 0 Volts (ground) is coming from the D+ output on the alternator.

STARTING THE ENGINE - On starting up - green color.

Current is arriving at K1 and activating a coil; it is connected to a starter motor, simultaneously activating the Y5 solenoid (engine stop). It will be held switched-on also after starting completion, being held by current from K3.

Solenoid conductors - Switching conductor - white color Holding conductor - red color Ground - black color

SITUATION AFTER SHIFTING THE TRAVEL LEVER FROM ITS NEUTRAL POSITION FORWARD (WORKING SPEED) - The S13 switch goes OFF, the K4, K5 relays release, the H5 neutral position indicator lamp goes OFF. - From K5, current flows to INP - the A2 timer. It switches the ground to Y6 (a solenoid switch comes ON); the machine brakes are released.

- The S21 brake pressure switch disconnects, the H6 brake indicator goes OFF and supply of the travel circuits through K5, K6 to S17 and simultaneously of S16 (fast speed) begins.

FAST TRAVEL SPEED By switching S16 ON, current reaches solenoid valves Y7, Y14 inside the wheels, and through the A4 Susmik it reaches the Y8 solenoid valve.

- Supply for the A3 travel lever comes through the S16 “Turtle/Hare” switch (contacts 6-2).

- Because the S16 terminal (contact 8) is deprived of current, the K7 cannot switch ON and vibration cannot operate.

STOPPING THE MACHINE - Shifting the travel lever into middle position results in switching the S13 switch ON; the K5 relay is activated, connecting contacts 3-5. The A2 brake timer input (INP contact) is deprived of current, and timing begins. 3 seconds later, the circuit in A2 is broken (loss of ground on the AUT contact), the Y6 magnet loses its supply and disconnects the pressure circuit to the brakes. This results in the machine brakes being applied.

- After loss of pressure in the brake circuit, the S21 pressure switch is ON and the H6, H5 indicator lamps come ON, along with the E16 and E17.

- On the D+ terminal of the G3 alternator, current increases to 24 V and begins to supply the P5 hourmeter; the H10 battery charge indicator lamp goes OFF. Pulses are coming from the alternator (W terminal) through the B line, putting the P4 engine tachometer into operation.

- After working oil pressure is reached in the engine, the S26 pressure switch goes OFF and the H9 engine oil pressure lamp as well.

SV212 - SV216

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SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

3

STEERING ACTIVATION WITH THE MACHINE IN HALTED (BRAKED) POSITION When the steering wheel of the machine is turned, the steering circuit is pressurized; this results in switching the S15 steering pressure switch ON, current flows to the input INP of the A2 timer and the timer will connect Y6 to the ground. The machine brakes are released (green indicator).

- When the steering system is no longer sollicited, the S15 steering pressure switch goes OFF and the A2 timer is started again. Three seconds later this results in the brakes being applied once more.

- The S35 push-button serves to cancel the A2 timing function. It is used when climbing a gradient, for example, where a danger exists of backward motion within the timer delay (blue indicator) after shifting the travel lever into position 0.

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4

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 ELECTRICAL LEGEND

A1 A2 A3 A4 A5 B1 B2 B3 E1 E2, 3 E4, 5 E6, 7 E8, 9 E10, 11 E12, 13 E14 E15 E16, 17 E18 E19, 20 F1-7 G1, 2 G3 H1 H2 H3 H4 H5 H6 H7 H9 H10 H11 H12 K1 K2-8 M1 M2 M3 M4 M5 M6 M7 M8 P1 P2 P3 P4 P5 Q1 R1, 2 S1 S2 S3 S4 S5 S6

- Turn indicator control (optional) - Brake timer - Travel control - Differential lock control block(optional) - Longitudinal inclination detector (optional) - Engine oil temperature detector - Hydraulic oil temperature detector - Fuel level detector - Instrument panel lighting - Front marker lights (optional) - Tail lights (optional) - Front headlights - Rear headlights - Left turn indicator lights (optional) - Right turn indicator lights (optional) - Cab lighting - Safety beacon (optional) - Brake lamps - Car type lighting - Front auxiliary headlamp - Fuses - Batteries - Alternator - Indicator lamp for turn indicators (optional) - Horn - Back-up alarm (optional) - Hydraulic oil level indicator - Travel control neutral position indicator - Brake indicator - Vibration preselection indicator - Engine lubrication indicator - Battery charge indicator - Air filter restriction indicator - Hydraulic filter restriction indicator - Contactor - Auxiliary relay - Starter - Electric motor for hood & cab lifting system - Cab ventilation van - Front windshield wiper - Rear windshield wiper - Front windshield washer - Rear windshield washer - Heating fan - Engine temperature detector - Hydraulic oil temperature detector - Fuel gauge - Speedometer - Hourmeter - Battery master switch - Resistors - Push button for cab lifting system - Push button for hood lifting system - Switch box - Front headlight switch - Rear headlight switch - Hazard light switch (optional)

SV212 - SV216

S7 S8 S9 S10 S11 S12 S13 S14 S15 S16 S17 S18 S19 S20 S21 S22 S23 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33 S35 V1, 5 X1 X2-24 X25 X26 X27 X28 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13 Y14

- Turn indicator change-over switch (optional) - Rotating beacon switch (optional) - Horn push button - Right-hand control arm switch - Emergency brake push button - Back-up alarm switch (optional) - Neutral position switch (on travel control) - Hydraulic oil reservoir float - Steering pressure switch - Fast travel switch - Speed preselector switch - Vibration change-over switch - Vibration switch (on travel control) - Gas lever terminal switch - Brake pressure switch - Differential lock switch (optional) - Drum speed sensor (optional) - Left wheel speed sensor (optional) - Right wheel speed sensor (optional) - Engine lubrication pressure switch - Air filter restriction - Hydraulic filter depression switch - Cab ventilation selector - Front windshield wiper - Rear windshield wiper - Windshield washer push button - Heating fan selector - Parking brake push button - Blocking diode - Hand lamp socket - Connectors - Diagnostic socket (optional) - Car radio reception socket - Rotating beacon socket - Connector - Cab lifting electrovalve - Cab lowering electrovalve - Hood lifting electrovalve - Hood lowering electrovalve - Engine STOP electrovalve - Brake electrovalve - Fast travel speed (left wheel) electrovalve - Fast travel speed (drum) electrovalve - Vibration I. electrovalve - Vibration II. electrovalve - Differential lock- electrovalve LH wheel (optional) - Differential lock- electrovalve RH wheel (optional) - Travel servo-valve - Fast travel speed (right wheel) electrovalve

7-29530 - 04-2001

CS01E501

7-29530 - 04-2001 STEERING PRESSURE SWITCH

BRAKE

BRAKE LAMPS

ENGINE STOP

HYDRAULIC OIL TANK FLOAT

BACK-UP ALARM

HORN

SAFETY BEACON

RIGHT FRONT TURN INDICATOR LIGHT

RIGHT REAR TURN INDICATOR LIGHT

LEFT REAR TURN INDICATOR LIGHT

LEFT FRONT TURN INDICATOR LIGHT

CAB LIGHTING

FRONT AUXILIARY HEADLAMP

REAR HEADLIGHTS

FRONT HEADLIGHTS

CAR TYPE LIGHTING

TAIL LIGHTS

FRONT MARKER LIGHTS

HOOD LOWERING

HOOD LIFTING

CAB LOWERING

CAB LIFTING

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 5

1

SV212 - SV216

6

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

This page is intentionally left blank

SV212 - SV216

7-29530 - 04-2001

CS01E502

7-29530 - 04-2001 HYDRAULIC OIL FILTER

AIR CLEANER / CHARGING / HOURMETER

ENGINE LUBRICATION

FUEL GAUGE / SPEEDOMETER

HYDRAULIC OIL TEMPERATURE

ENGINE TEMPERATURE

SERVO-VALVE

RIGHT WHEEL SPEED SENSOR

LEFT WHEEL SPEED SENSOR

DRUM SPEED SENSOR

LONGITUDINAL INCLINATION DETECTOR

RIGHT WHEEL VALVE

DIFFERENTIEL LOCK LEHFT VALVE

FAST TRAVEL SPEED (DRUM)

BRAKE PRESSURE SWITCH

VIBRATION II

VIBRATION I

FAST TRAVEL SPEEDRIGHT WHEEL

FAST TRAVEL SPEEDLEFT WHEEL

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 7

2

SV212 - SV216

8

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

This page is intentionally left blank

SV212 - SV216

7-29530 - 04-2001

CS01E503

7-29530 - 04-2001

FAST TRAVEL SPEED (DRUM)

FAST TRAVEL SPEED RIGHT WHEEL

FAST TRAVEL SPEED LEFT WHEEL

HEATING FAN

WINDSHIELD WASHER, REAR

WINDSHIELD WASHER, FRONT

REAR WINDSHIELD WIPER

FRONT WINDSHIELD WIPER

CAB VENTILATION VAN

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 9

3

SV212 - SV216

10

SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

NOTES

SV212 - SV216

7-29530 - 04-2001

1

SECTION 90 - PLATFORM, CAB - CHAPTER 1

SECTION 90 - PLATFORM, CAB Chapter 1 - Operator’s compartment CONTENTS Section

90310

Description

Page

torque specifications ..................................................................................... 1 Operator’s compartment ............................................................................... 2 Travel brake control adjustment ................................................................... 8

TORQUE SPECIFICATIONS M8 nut on the wiper arm ..................................................................................................9-10 Nm (6.63-7.37 Ib.ft) M10 nut on the wiper arm ........................................................................................................... 25 Nm (18.4 Ib.ft)

SV212 - SV216

7-29530 - 04-2001

2

SECTION 90 - PLATFORM, CAB - CHAPTER 1 OPERATOR’S COMPARTMENT

OPERATOR’S COMPARTMENT ASSEMBLY Removal 1.

2.

Loosen the operator’s compartment retaining nuts.

CD01C115

1

CD01C116

2

CD01C117

3

Tilt the compartment using the hydraulic tilting cylinder.

SV212 - SV216

7-29530 - 04-2001

SECTION 90 - PLATFORM, CAB - CHAPTER 1 3.

Disconnect the cable on the injection pump (3), drain the coolant partially and disconnect the heater hoses (1), (2) and electrical cables. Remove the power steering assembly underneath the cab, disconnect the anchor chain and lower the cab.

Connect a suitable lifting device to the eye bolts on the cab roof and place it to one side.

3

2

1

3

4

CD01C118

Installation For installation, follow the removal procedure in reverse order and add coolant.

CAB Removal 1.

Rear the window wiper removal - remove the cover (6), wiper, nut on the wiper shaft (1), screws (9) and clamps with the wiper motor.

6

5

CD01C119

1 9

CD01C120

7-29530 - 04-2001

9

6

SV212 - SV216

4 2.

SECTION 90 - PLATFORM, CAB - CHAPTER 1 Front wiper removal - remove the screws (75) from the upper cover (14).

75 75

14

7

CD01C121

3.

Disconnect the cables, remove the drive nut (2) and the drive (1). Disconnect the cables and remove the clamp (6) with the fan (14).

2

14 6

2

2 1

8

CD01C122

4.

Remove the wiper nut (1) and drive shaft nut (2).

1

CD01C123

SV212 - SV216

2

9

7-29530 - 04-2001

5

SECTION 90 - PLATFORM, CAB - CHAPTER 1

DOOR LOCKS 1.

Remove the lower cover (10).

10

10

CD01C124

2.

Remove the nut (63), disconnect the rods (64, 65) and remove rod (64).

65

63

64 11

CD01C125

3.

Remove the flange (103), loosen the screws (75) and remove the handle with the push-button and washers.

75 103

64 75 CD01C126

SV212 - SV216

12

7-29530 - 04-2001

SECTION 90 - PLATFORM, CAB - CHAPTER 1 4.

6

Remove the screws (81) and the left and right locks (8, 9).

81 8

13

CD01C127

Installation For installation, follow the same procedure in reverse order. Set up the push-button and the lock by adjusting nut (63).

SEAT 1.

Tilt the control panel (1) on the right side of the seat, remove the cover (2) below, disconnect the cables, free and fold.

1

2 14

CD01C128

2.

Remove the cover bellows, remove the nuts and lift out the seat. Remove the screws (20) and the grid (8) on both sides.

20 CD01C129

7-29530 - 04-2001

8 15

SV212 - SV216

7 3.

SECTION 90 - PLATFORM, CAB - CHAPTER 1 Remove the cover (6) and the seat plate (1).

1

6

16

CD01C130

4.

Remove the ball (13) from the seat plate, free the snap ring (26) and pull out the pin (8), and the spring (11).

13

1

26 11 9

8

10

6

22 24 5 CS01C520

SV212 - SV216

17 17

7-29530 - 04-2001

SECTION 90 - PLATFORM, CAB - CHAPTER 1

8

TRAVEL BRAKE CONTROL ADJUSTMENT Remove the screws (1), the instrument panel with the control and the cabling.

Remove the screws (2) and the control. Unscrew the control plastic cover and set the brakes on the control lever.

2 1 CD01D157

18

CD01D154

19

The control may be fixed in position using an adjustable clamp. The travel control operates also as a service and parking brake. The vibrator push button is located in the lever to be ready to interrupt of vibrations any time.

7-29530 - 04-2001

SV212 - SV216